40684 Talbot Line, St. Thomas, Ont., N5P 3T2
Phone: (519) 637-7899
Toll Free: (800) 265-5701
Fax: (519) 637-3403
Web Site: www.northstarwindows.com
NORTH STAR
2-PANEL PATIO DOOR
ASSEMBLY INSTRUCTIONS
I:\PDAssembly\2Panel\CovPg.doc - 12/7/06
TWO PANEL PATIO DOOR HARDWARE LIST
QTY. DESCRIPTION
2
QTY. DESCRIPTION
645.2090
ROLLER
ASSEMBLY
2
580.6145 #10 x 2-1/2" P. H. ZINC
QTY. DESCRIPTION
645.3010
ROLLER SHIMS
4
1
645.5200
INTERIOR HANDLE,
SCREWS & LEVER
16
580.1386 #8 x 2-1/2" R. H. W. ZINC
2
580.6115 #10 x 3/4" F. H. ZINC
5
580.1090 #6 x 3/4" F. H. WHITE
645.3000
OPERATING
PANEL SEAL
1
580.1310 #8 x 1/2" P. H CAMTAP ZINC
1
645.5435
INTERLOCK
END CAP L
1
580.0930 #5 x 1/2" F. H. ZINC
1
645.5430
INTERLOCK
END CAP R
4
950.1090
HOLE PLUG
645.3030
HEAD GASKET
(LH & RH)
2
645.3020
SILL GASKET
(LH & RH)
2
1
1
645.5220
EXTERIOR HANDLE
1
645.5260
SINGLE POINT LOCK
& KEEPER
1
1
645. 5640
SILL INTERLOCK DUST
PLUG 1" x 3"
1
575.1036
HEAD INTERLOCK DUST
PLUG 1/2" x 1-1/2"
1 645.2085
HEAD DUST PLUG
12/21/04
1
645.5460
SASH BUMPER (HEAD)
645. 5550
SASH BUMPER (SILL)
2-PANEL PATIO DOOR ASSEMBLY INSTRUCTIONS
STEP 1
SLIDE FIXED SASH SUPPORT
INTO SILL AS INDICATED
A
STEP 2
REMOVE PROTECTIVE FILM FROM HEAD
GASKETS AND APPLY TO BOTH SIDE JAMBS.
APPLY SILICONE TO THE LEG LOCATION
SHOW N ON EACH SIDE JAMB AND FASTEN
USING #8 x2-1/2”R. S. W . SCREW S.
DETAIL A
B
STEP 3
DETAIL B
REMOVE PROTECTIVE FILM FROM
SILL GASKETS AND APPLY TO BOTH
SIDE JAMBS AND FASTEN SIDE JAMB
TO SILL USING #8 x2-1/2”R. S. W .
SCREW S.
P. 1
11/01/04
FIXED PANEL INSTALLATION
IF ASSEMBLED AT JOB SITE, TEMPORARILY
PIN FRAME IN OPENING.
STEP 5
STEP 4
DETERMINE OPERATION OF DOOR (XO OR OX).
IF OPPOSITE OPERATION IS REQUIRED SLIDE
FIXED PANEL SUPPORT TO OPPOSITE SIDE.
FOR PANEL ORIENTATION READ LABEL ON
EDGE OF PANEL, ENSURING GLASS STOPS
ARE TO UNIT INTERIOR.
INSERT FIXED PANEL AS INDICATED AND
PLACE IT ON FIXED PANEL SUPPORT AND
SLIDE INTO SIDE JAMB POCKET
APPLY SILICONE ON BOTTOM AND SIDES OF 1" x 3"
DUST PLUG PLATE AND PLACE ON SILL FLUSH WITH
FIXED PANEL SUPPORT AS INDICATED IN DETAIL A.
FASTEN WITH #6 x 3/4 F. H. SCREW THRU CENTER OF
PLUG
USING RUBBER MALLET INSTALL INTERLOCK BEFORE
SECURING FIXED PANEL WITH 4 - #6 x 3/4" F. H.
SCREWS THRU FRAME WEATHER STRIP
GROOVE AS INDICATED.
MAKE SURE HEAD JAMB IS TIGHT AGAINST THE TOP
OF THE INTERLOCK, THAT THE FIXED PANEL AND
FRAME ARE SQUARE BEFORE FASTENING.
COMPLETE ANCHORING OF UNIT FRAME ENSURING
UNIT IS SQUARE, PLUMB AND LEVEL.
PANEL
ORIENTATION
LABEL
B
A
DETAIL B
DETAIL A
11/01/04
P. 2
STEP 7
AFTER FRAME IS INSTALLED IN
OPENING, INSTALL LATCH KEEPER
USING 2 #10 x 2-1/2" P. H. SCREWS
AT MARKED LOCATIONS INTO STUD.
IF USING MULTI-POINT HARDWARE
FASTEN KEEPER WITH 2 #10 x 3/4"
AND 2 #10 x 2-1/2" P. H. SCREWS.
DETAIL B
STEP 6
B
STEP 8
APPLY 1/2" x 1-1/2" INTERLOCK SEAL
ON UNDERSIDE OF HEAD JAMB
AS INDICATED.
INSTALL SCREEN LATCH KEEPER
USING 2 #5 x 3/4" P. H. SCREWS
ON MARKED LOCATIONS.
C
DETAIL C
STEP 9
APPLY OPERATING
PANEL FOAM SEAL
P. 3
12/21/04
B
STEP 11
INSTALL OPERATING PANEL
INTO FRAME.
STEP 10
A
PEEL AND STICK ROLLER SUPPORT FOAM PADS
INSIDE OF BOTTOM RAIL AND INSERT ROLLER
ASSEMBLIES (NO SCREWS REQUIRED). APPLY
BEAD OF SILICONE FULL LENGTH TO UNDERSIDE
EXTERIOR EDGE WHERE WEATHER-STRIP
ADAPTOR SNAP IN LEG CONTACTS SASH. SILICONE
BOTTOM RAIL ACROSS ENDS TO COMPLETELY
SEAL OFF EACH END BETWEEN SASH AND
WEATHER-STRIP ADAPTER. NEXT SNAP SASH
WEATHER STRIP ADAPTOR INTO PLACE TO
SECURE ROLLER ASSEMBLIES AND FASTEN WITH
#5 x 1/2" F. H. SCREW AT MIDPOINT OUTSIDE EDGE
ON 45 DEGREE ANGLE AS SHOWN.
(NOT IN ROLLER TRACK PATH)
LATCH ADJUSTMENT
SCREW
SILICONE
#5 x 1/2" F. H. SCREW
DETAIL A
STEP 12
DETAIL B
INSERT LOCK WITH LATCH ENGAGEMENT
UPWARD AND FASTEN WITH 2 #10 x 3/4" F. H.
SCREWS. INSERT THUMB LEVER AS INDICATED,
AND INSTALL HANDLES ENSURING SCREWS ARE
ON THE INTERIOR OF DOOR PANEL.(STANDARD
SINGLE POINT HARDWARE SHOWN)
P. 4
12/21/04
STEP 13
SLIDE OPERATING PANEL TO THE CLOSED POSITION.
INSERT DUST PLUG INTO HEAD JAMB POCKET WITH
SCREW HOLE TOWARDS INTERIOR AND SLIDE
INTO POSITION SO WOOL PILE IS FLUSH WITH EDGE.
OF DOOR PANEL. FASTEN WITH #8 x 1/2" P. H.
SCREW.
DUST PLUG
A
STEP 14
PLACE SMALL BEAD OF SILICONE IN
BOTTOM INTERLOCK OPENING.
INSERT END CAP AS SHOWN.
INSTALL INTERLOCK ON OPERATING
PANEL AS INDICATED. ENSURE
INTERLOCK IS FLUSH WITH BOTTOM
OF WEATHERSTRIP ADAPTOR.
(1 RIGHT AND 1 LEFT END CAP IS
PROVIDED FOR REVERSIBILITY OF
DOOR)
STEP 15
ADJUST ROLLERS, ENSURING PANEL IS
SQUARE TO JAMB AND CLEAR OF TRACK,
PRIOR TO INSERTING HOLE PLUGS.
AFTER LOCK AND KEEPER ARE ALIGNED, IN
AND OUT ADJUSTMENT MAY BE MADE BY
TURNING LATCH SCREW AS SHOWN IN
STEP 13.
DETAIL A
P. 5
11/01/04
STEP 16
INSERT SCREEN PANEL INTO HEAD
TRACK, AND BOTTOM ONTO SCREEN
SILL TRACK.
A
STEP 17
SECURE SCREEN BY ADJUSTING TOP AND
BOTTOM ROLLERS WITH ADJUSTMENT
SCREWS FOR SMOOTH OPERATION.
DETAIL A
P. 6
11/01/04
STEP 18
INSTALL OPERATING PANEL STOP
INTERIOR AND EXTERIOR TRIM
INTERIOR
VIEW
EXTERIOR
VIEW
A
STEP 19
INSERT POCKET COVER IN SIDE
JAMB AS INDICATED. (OPTIONAL
ON WHITE DOORS)
STEP 20
INSERT HEAD JAMB POCKET
COVER AND THEN SIDE JAMB
POCKET COVER AS INDICATED.
(OPTIONAL ON WHITE DOORS)
STEP 21
DETAIL A
INSERT SASH BUMPER (SILL)
AS SHOWN.
P. 7
06/28/05
NAILING FIN INSTALLATION INSTRUCTIONS
PRIOR TO INSTALLING NAILING FIN
APPLY 1/8" BEAD OF SILICONE AT
THIS LOCATION. FULL LENGTH OF
HEAD & SIDE JAMBS
DETAIL A
APPLY SILICONE TO END JOINT
ON EACH NAILING FIN.
DETAIL B
A
B
APPLY SILICONE ON JOINT
11/11/04
PATIO DOOR INSTALLATION INSTRUCTIONS
STEP 1
A LEVEL BASE AND SQUARE OPENING IS CRITICAL FOR
THE PERFORMANCE OF THE DOOR. APPLY TWO BEADS
OF SILICONE ON BASE, 1" IN FROM INTERIOR AND
EXTERIOR EDGE OF SILL BEFORE INSTALLING DOOR.
11/11/04
STEP 2
PLACE DOOR FRAME INTO OPENING AS SHOWN,
ENSURING SILICONE FORMS A GOOD SEAL
BETWEEN FLOOR AND DOOR SILL. (DOOR MAY
ALSO BE INSTALLED FULLY ASSEMBLED)
P. 1
STEP 3
SHIM SIDE JAMBS IN THREE PLACES AS SHOWN AND
FASTEN TOP AND BOTTOM WITH #10 x 2-1/2" P. H.
SCREWS IN V GROOVE AS SHOWN IN DETAIL "B".
PLACE MIDDLE SHIM IN LINE WITH MARKED
LOCATIONS FOR LOCK KEEPER. FASTEN SIDE JAMB
AND KEEPER USING #10 x 2-1/2" P. H. SCREWS AS
SHOWN IN DETAIL "A". FASTEN HEAD JAMB AFTER
FIXED PANEL AND INTERLOCK ARE INSTALLED. (REFER
TO DOOR ASSEMBLY INSTRUCTIONS FOR DETAILS)
STEP 4
TRIM EXCESS WOOD SHIMS AND LOOSELY FILL
CAVITY BETWEEN JAMBS AND OPENING WITH
FIBER INSULATION. APPLY A QUALITY EXTERIOR
GRADE CAULKING TO THE EXTERIOR FRAME
CAVITY BETWEEN DOOR FRAME AND OPENING
SINGLE POINT LOCK KEEPER
A
DETAIL A
B
DETAIL B
11/11/04
P. 2