(3) Fabrication of Overlay Panel
Fabricate the overlay panel as outlined in the applicable specification on the previous pages and the instructions below.
1)Rout a channel at the bottom of the overlay panel to the proper dimensions. See "(C) Routed Area" in the specification diagram and Fig. 1.
2)Drill six 1/4" diameter (hardwood may require slightly larger diameter) holes 3/8"
(10 mm) deep in the locations designated. See "(A) Threaded Inserts" and "(B) Threaded Inserts" in the specification diagram and Fig. 2.
CAUTION
Use care when drilling holes for mounting hardware. All drilled holes must be straight and drilled to the correct diameter and depth.
Routed Channel |
Fig. 1
Holes
Fig. 2
Holes
3)Screw the 6 threaded wood inserts into the 1/4" holes drilled in the previous step. Make sure that the inserts are threaded straight and that the tops of the inserts are flush to the overlay panel surface. Otherwise, the overlay panel cannot be properly fastened to the door.
4)Mount the door handle hardware. Perlick recommends that the door handle hardware be mounted on the edge opposite of the door hinge side (optional hinge reversal is covered in step 6). Countersunk screw heads are required to ensure that the hardware fasteners do not interfere with the overlay panel fitting flush with the door.
5)While maintaining a hold on the door, remove the hinge stop pin from hinge (B). Pull out the bottom of the door slightly and gently remove the door from hinge (A). See Fig. 3.
If you are leaving the door
Fig. 3
Hinge (B)
Hinge (A)
Hinge Stop Pin
15
