Prepare the New Overlay Panel
NOTICE
The overlay door panel must not weigh more than 20 lbs. The thickness of the door panel must be 3/4".
1.Place a towel, or similar, soft
2.Lay the wood panel out with the front side of the wood facing down.
3.Cut the foam tape in to four pieces, two pieces the width of the overlay and two pieces the height of the overlay.
4.Remove adhesive protection strip from one piece of the cut foam and align the edge of the foam tape to the inside edge of the overlay as shown, adhering the foam tape to the overlay. See below.
5.Trim each piece of tape immediately after applying it to the overlay. Do not allow any overlapping of the foam tape. Damage to the overlay can occur is the foam tape is not trimmed correctly.
6.If required, attach any optional cabinet hardware to the wood panel at this time. If an optional cabinet handle is installed, make sure the mounting screw heads are below (countersunk) the back surface of the overlay.
Note: After attaching the optional cabinet hardware, additional supports may be needed to keep panel flat for next steps.
Attaching the Overlay Panel
1.Remove the top hinge pivot pin with a Phillips screwdriver and lift the door off bottom hinge pin. Be careful not to lose the door closer insert sets. Save pivot pin for use later. See figure in next column.
2.Carefully lay the door over the wood panel, making sure door is oriented correctly (top of door with top of wood overlay).
3.Pull door gasket out of the groove completely. Start in the middle and pull outward, moving towards the corners (see below). This may take some force, but be careful not to cut or rip the gasket.
4.After the gasket has been removed, place it on a clean, flat surface.
5.Secure the door to the back of the wood overlay using tape on all four corners. Make sure all four edges are aligned. (See figure on next page)
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