Pella Door 81CM0100 User Manual

© 2011 Pella Corporation  
Part Number: 81CM0100  
INSTALLATION INSTRUCTIONS - INSTRUCCIONES DE INSTALACION  
ALUMINUM-CLAD SLIDING PATIO DOORS WITH  
FLUSH FLANGE  
Lea las instrucciones en español en el reverso  
Installation Instructions for Replacement of Aluminum Sliding Doors in Hard Coat Stucco  
Applications in arid climates.  
These instructions are designed for typical hard coat stucco exterior applications in arid climates.  
The installation must leave the existing aluminum door frame and weep system in place. These  
instructions are not to be used with any other construction method and rely on the integrity  
of the existing aluminum sliding door and flashing system. Building designs, construction  
methods, building materials, and site conditions unique to your project may require an installation  
method different from these instructions and additional care. Determining the appropriate  
installation method is the responsibility of you, your architect, or construction professional. If you  
have questions, please contact your local Pella retailer.  
REMEMBER TO USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT.  
Wood  
Blocking  
Flush  
Flange  
Existing Aluminum  
Door Frame  
Sill Pan  
Optional Sill Nose  
Always read the Pella® Limited Warranty before purchasing or installing Pella  
products. By installing this product, you are acknowledging that this Limited  
Warranty is part of the terms of the sale. Failure to comply with all Pella installation and  
maintenance instructions may void your Pella product warranty.  
See Limited Warranty for complete details at http://warranty.pella.com.  
 
OPENING PREPARATION  
2
A. Prepare the door opening by removing the venting  
panel and the glass from the existing fixed side of the  
aluminum door frame.  
Note: It may be necessary to cut the divider  
between the venting panel and fixed glass areas  
with a reciprocating saw. The existing aluminum  
frame is left in place so as not to disturb the existing  
exterior stucco flashing or drainage system.  
2A  
2B  
2B  
B. Cut the existing door sill out of the opening. Using a  
reciprocating saw or side grinder, cut the existing sill as  
close to the longest leg of the jamb extrusion as possible.  
Note: Be careful to avoid damage to the interior  
flooring materials. Drilling holes in the sill prior  
to cutting may make the removal of the existing  
sill easier. If existing sill has a stainless steel cap  
on the sill, removing the cap prior to cutting will  
make cutting easier.  
C. Clean old sealant and other debris from the  
door opening.  
2B NOTE  
D. Remove the door lock strike from the lock  
jamb of the existing door frame.  
E. Place a bead of sealant at each joint where the  
existing door frame jambs meet the existing  
door sill pieces. Fill any holes in the jamb and  
head with sealant.  
2F  
INTERIOR  
F. If the weep holes of the existing sill have been  
cut away, drill new weep holes in the existing  
door jambs. Be sure to drill weep holes in all  
vertical jamb legs, except the most interior leg.  
2E  
Note: Ensure all new or existing weep holes are  
open before proceeding with the installation.  
G. Cut wood blocking to fill the vent and fixed panel  
cavities in the head and jamb of the existing door  
frame. The depth of the blocking should be the  
same height as the tallest leg of the existing jamb  
extrusion. Cut the head blocking to fill the entire  
length of the head in both channels. Cut the  
jamb blocking to fill both jamb channels to within  
approximately 1" of the bottom of the jamb.  
2G  
H. Set the wood blocking in sealant in the existing door frame. Make sure the blocking is  
flush with the furthest protruding part of the existing jamb. Place a 3/16" bead of sealant  
in the door panel cavities, then insert the wood blocking into the head cavities followed  
by the jamb cavities. Next insert the wood blocking into the jamb panel cavities of the  
existing door frame. Secure the blocking by pre-drilling and inserting #8 x 2-1/2" screws.  
 
OPENING PREPARATION (CONTINUED)  
2
I. Construct a sill pan for the door. Measure the rough opening width and add 2". Measure  
1" up from each end and cut through the vertical leg of the pan material. If there is a step  
down at the exterior of the door opening, make the sill pan depth equal to the door frame  
depth - 2-1/8". If there is NO step down, make the sill pan depth equal to the frame depth.  
Bend the bottom (side) flaps of the pan material up, then bend the back leg around the  
end of the pan.  
Dry fit the sill pan and the door into the opening.  
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J. If there is a step down at the exterior of the door opening, cut the sill nosing to the  
rough opening width plus two times the flange width. Notch the sill nosing. If there is  
NO step down, skip to step K.  
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Note: If the new door frame is deeper than the existing door frame, it will be necessary  
to cut the interior flooring material back to allow the door flush flanges to contact the  
existing aluminum door frame.  
 
OPENING PREPARATION (CONTINUED)  
2
K. Apply five lines of 3/8" diameter sealant across the rough opening sill in the  
location shown. Make sure the lines of the sealant covers the area between the  
stucco and rough opening.  
Sealant lines and sill pan if there  
is a step down.  
Sealant lines and sill pan if there  
is NO step down.  
Flashing  
Flashing  
Tape #2  
Tape #2  
2O  
Flashing  
Tape #1  
Flashing  
Tape #1  
Sill Pan  
6"  
6"  
2M  
2O  
Sill Pan  
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Five  
Sealant Lines  
2K  
O
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Stucco  
Sill Nosing  
2N  
L. Place a 3/8" bead of sealant at each corner of  
the rough opening from the stucco along the  
edge of the rough opening as shown.  
Note: It is important to avoid letting the sealant  
skin over prior to applying the sill pan.  
2L  
M. If using sill nosing with a step down, Install the  
sill pan and sill nosing into the opening. Press down  
to seal them into the opening. DO NOT overlap.  
2N  
2M  
Sill Nose  
Sill Pan  
2N  
N. Apply sealant at nosing ends continuing from the front of the sill pan  
around the exterior surface of the wall where the sill nosing will end.  
 
OPENING PREPARATION (CONTINUED)  
2
O. Cut two pieces of flashing  
2O  
tape 12" longer than the  
rough opening width. Place  
tape #1 across the sill nosing  
just up to where the nosing  
begins to slope down and  
extending 6" up each jamb.  
Apply the second piece of  
flashing tape over-lapping  
the first piece and the exterior  
edge of the sill pan and 6" up  
each jamb.  
SILL TAPES  
#2  
Sill Pan  
#1  
2O  
Sill Nose  
PREPARE THE DOOR FOR INSTALLATION  
3
TWO OR MORE PEOPLE WILL BE REQUIRED TO HANDLE THE PANEL AND FRAME SAFELY.  
A. Remove the plastic wrap and cardboard packaging from the door.  
Note: If screens, grilles or hardware are removed from the door at this time, label them  
and store them in a protected area.  
B. Remove the shipping spacers. Carefully slide the movable panel halfway open and  
remove the spacers from both the top and bottom of the movable panel.  
C. Remove the venting panel by lifting it off of the lower track and tilting the bottom of the  
panel away from the door frame. Then, lower the panel out of the top track. Carefully set  
the panel aside.  
D. Drill 13/64" diameter clearance holes through the frame at a 45° angle, on the room side  
of the door lock jamb and fixed jamb in the locations shown. Space the holes a maximum  
of 6" from each end and a maximum of 10" on center.  
EXTERIOR  
3D  
FIXED JAMB  
VENT JAMB  
6" MAX  
Drill 13/64" clearance holes  
through frame at 45° angle  
10" MAX  
10" MAX  
10" MAX  
10" MAX  
INTERIOR  
E. Drill a 13/64" clearance hole through the door  
frame at each indentation in the extrusion at the  
top (head) of the door frame.  
10" MAX  
10" MAX  
10" MAX  
6" MAX  
 
PREPARE THE DOOR FOR INSTALLATION (CONTINUED)  
3
Pella  
SmartFlash  
Tape  
F. Doors using Installation Clips: Install  
installation clips. Place the clip so that the  
lip is facing up and against the flush flange,  
at the locations shown in the placement  
diagram. Secure the clip by driving #6 x  
5/8" corrosion resistant screws through the  
outer two holes of the three holes shown.  
#6 x 5/8” corrosion  
resistant screws  
3F  
6“ from end  
Lip  
3G  
6"  
6"  
Pella SmartFlash Tape  
G. Apply Pella SmartFlash  
tape across the head of  
the door extending 6"  
down each jamb. Place  
the tape starting on  
the aluminum cladding  
and extending onto the  
wood frame.  
SETTING AND FASTENING THE DOOR  
A. Dry fit the door into the opening.  
4
Note: If the new door frame is deeper than the existing door frame, it will be  
necessary to cut the interior flooring material back to allow the door flush flanges to  
contact the existing aluminum door frame.  
B. From the exterior, set the door into the opening. Set the sill of the door on the sill  
panel and tilt the door into position.  
C. Insert shims around the door temporarily while you verify that the door will fit into the  
opening and that the door flanges will overlap the stucco or existing aluminum door  
frame by a minimum of 1/2" on all sides.  
REMOVE THE DOOR FROM THE OPENING  
D. Place three 3/8" beads of sealant. Place the first beads sealant 1/2" in front of the base  
of the interior sill pan lip. This bead should also continue up the corner of the sill pan  
at each end, sealing the vertical joints of the sill pan and up 6" onto each jamb side of  
the rough opening. The second bead should be approximately 1/2" from the exterior  
edge of the frame wall, running from jamb to jamb with a 2" break in the middle of the  
opening. Place a third sealant bead 1/4" from the exterior edge of the flat portion of the  
sill nose or the sill pan. Start and stop this sealant line 1" from each jamb.  
Application without  
sill pan  
1/2"  
1st Bead  
1st Bead  
2nd Bead  
2nd Bead  
6
"
3rd Bead  
6"  
3rd Bead  
Leave a 2"  
break in  
Leave a 2"  
break in  
center of pan  
INTERIOR SILL P  
center of pan  
AN LIP  
1
"
1
"
SILL NOSE  
4D  
 
SETTING AND FASTENING THE DOOR (CONTINUED)  
4
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E. Place a 3/8" diameter continuous bead of sealant on  
the face of the existing door frame jambs and head.  
TWO OR MORE PEOPLE ARE REQUIRED FOR  
THE FOLLOWING STEPS  
4E  
F. From the exterior, set the door into the opening. Set  
the sill of the door onto the sill pan and tilt the door into  
position, centering it in the opening. DO NOT slide the  
door on the sill pan.  
G. Insert the door from the exterior of the building. DO  
NOT slide the bottom of the door into the opening.  
Sliding will damage the sealant lines. Place the bottom  
of the door at the bottom of the opening, then tilt the  
top into position. Center the door between the sides  
of the opening to allow equal clearance for shimming.  
Frame Screw Method: Insert one #8 x 3" screw into  
the top anchor hole on each side of the frame.  
Installation Clip Method: Insert one screw into one  
hole in each of the top clips.  
Exterior View  
4F  
H. Insert shims between the door and the sides of  
the opening at the top two anchor hole locations in  
the door. Keep shims back 1/2" from interior face  
of the door frame.  
Note: Keep the exterior of  
the door pressed against the  
Interior  
existing door frame to ensure  
a good sealant line.  
4H  
I. Plumb and square door. Insert  
shims, as necessary, between  
the door and the sides of the  
rough opening starting up 6"  
from the bottom of the door.  
Keep shims back 1/2" from  
4J  
1
INCHES  
0
m  
2
0
2
3
3
4
0
interior face of the door frame.  
5
0
6
0
7
0
Note: DO NOT OVER SHIM.  
J. Check the interior reveal. Make sure the measurement from the interior face of the door  
to the interior face of the wall is equal at several points around the door.  
Note: If the dimensions are not equal, check to make sure the fins are folded out to 90°  
at all points.  
K. Secure the frame. Insert a 1" wide  
shim behind the pilot hole at the lock  
strike(s). Insert a #8 x 2-1/2" screw  
4K  
4K  
(included in the panel retainer and  
screw package) into the pilot hole  
making sure it passes through the  
shim and into the rough opening.  
Shim  
Shim  
Note: The weather-strip must be  
pushed aside to reveal the pilot  
hole. Be careful not to damage the  
weather-strip.  
 
SETTING AND FASTENING THE DOOR (CONTINUED)  
4
Frame Screw Method:  
Note: If using installation clips, proceed to step 4N.  
4L  
Interior  
Fixed Panel  
Threshold  
4M  
Exterior  
L. Apply sealant and insert a #8 x 2-1/2" pan head (provided) or 3/16" x 1-3/4"  
concrete screw into each hole in the bottom of the door frame, as indicated above.  
M. Position and secure the panel retainers by drilling pilot holes through the remaining  
holes in the retainer into the sill support or wood blocking, then apply sealant to the  
holes and insert a screw into each hole as specified below.  
Aluminum sill support: 9/64" pilot holes, #10 x 3/4" thread cutting screws (provided).  
Wood blocking: 1/8" pilot holes, #10 x 2-1/2" flat head corrosion resistant wood  
screws (provided).  
Masonry floor: 3/16” x 1-3/4” concrete screws. Pilot drill per screw manufacturer’s  
recommendations.  
Installation Clip Method:  
N. Fasten the door to the opening by driving two #8 x 1-1/4" corrosion resistant screws into  
the pre-punched holes in the clips. If the clips are bent and fastened to the interior stud/  
block, install the screws as close to the bend as possible.  
Note: DO NOT shim above the door. For masonry openings use two 3/16" x 1-1/2"  
masonry screws per clip. Pre-drill the masonry before attempting to drive the screws in.  
4N  
O. Drive #10 x 3-1/2" corrosion resistant wood screws through the holes in the  
threshold in to the floor.  
Note: For concrete floors, use masonry screws a minimum size of 3/16" x 3-1/2".  
 
INSTALLING THE INTERIOR INSTALLATION SCREWS  
5
A. Drill 1/8" x 1" deep pilot holes into the rough framing through the clearance holes in  
the top (head) and sides (jambs) of the unit frame.  
B. On the sides of the door, drive #10 x 3-1/2" corrosion resistant wood screws through  
the door frame into the rough framing. Drive the screws until snug, DO NOT over-  
tighten the screws. DO NOT bend or bow the unit frame.  
EXTERIOR  
STUCCO  
EXTERIOR  
STUCCO  
FIXED JAMB  
VENT JAMB  
INTERIOR  
INTERIOR  
R I O R  
Drill 1/8" diameter pilot  
hole through the clearance  
hole in the frame.  
5A  
5B  
#10 x 3-1/2"  
corrosion resistant wood screw  
13/16" Pilot  
C. Apply sealant to each  
pilot hole drilled in the  
top (head) of the door  
frame, then insert a #10 x  
3-1/2" corrosion resistant  
screw into each hole.  
Sealant  
goes here  
5C  
REINSTALL THE SLIDING PANEL  
6
TWO OR MORE PEOPLE WILL BE REQUIRED TO HANDLE THE PANEL SAFELY.  
A. Insert door panel. From the exterior of the building, tilt the  
top of the panel toward the door frame and insert the top  
of the door panel into the top track. Move the bottom of the  
panel toward the door frame until it is vertical. Gently set the  
panel down into the bottom track. Adjust the panel clip and  
tighten the panel clip screw.  
6A  
Note: Be careful not to pinch your fingers between the  
two panels. DO NOT close the sliding panel until you have  
installed the hardware. The door may lock when closed.  
B. Install the handles and panel retainer. Follow the instructions included in the hardware  
package. If the panel is not square to the door frame, adjust the bottom rollers by  
removing the adjusting hole cover and inserting an 8" long #2 Phillips screwdriver into  
the hole. Turn clockwise to raise the panel and counter-clockwise to lower the panel.  
C. Install screen. Instructions for installing the screen are found in the screen door package.  
 
APPLY EXTERIOR PERIMETER SEALANT  
7
A. Place a corner bead of sealant on the edge of the door flush flange on top and  
sides. DO NOT seal the sill of the door frame to the opening.  
JAMB CROSS SECTION  
Exterior View  
7A  
E R I O R  
INTERIOR  
7A  
FIXED JAMB  
EXTERIOR  
STUCCO  
Flush flange  
8INTERIOR SEAL  
Caution: Ensure use of low pressure polyurethane window and door installation foams  
and strictly follow the foam manufacturer’s recommendations for application. Use of  
high pressure foams or improper application of the foam may cause the door to bow  
and hinder operation.  
A. Apply insulating foam. From the interior,  
8A  
insert the nozzle of the applicator  
approximately 1" deep into the space  
between the door and the rough opening  
and apply a 1" deep bead of foam. This  
will allow room for expansion of the foam  
and will minimize squeeze out. Apply  
sealant across the interior surface of shims  
to create a continuous seal. For doors with  
jamb extensions installed, ensure the foam  
is placed between the door frame and  
the rough opening, not between the jamb  
extension and the rough opening. Follow  
foam manufacturer's instructions.  
Interior  
Note: It may be necessary to squeeze the  
end of the tube with pliers to insert it into  
the space between the door frame and the  
rough opening. DO NOT completely fill the  
space from the back of the brickmould to  
the interior face of the opening.  
8C  
6"  
B. Check the door operation by opening and closing the door.  
Note: If the door does not operate correctly, check to make sure it is still plumb, level,  
square and that the sides are not bowed. If adjustments are required, remove the foam  
with a serrated knife. Adjust the shims and reapply the insulating foam sealant.  
C. Add a sealant bead across the inner sill and 6" up each jamb between the frame and  
rough opening.  
 
FINISHING INSTRUCTIONS  
Paint or finish immediately after installation.  
Note: DO NOT paint, stain or finish weather strip or vinyl parts! If paint, stain or finish gets on  
the weather stripping, wipe it off immediately with a damp cloth. To maintain proper product  
performance, do not remove weather strip, foam corner seal wedges or gaskets. Air and water  
leakage may result if these factory-installed items are removed. After finishing, allow doors to  
dry completely before closing them. Pella will not be responsible for finishing imperfections.  
The use of unapproved finishes, solvents or cleaning chemicals may cause adverse reactions  
with door materials. Pella will not be responsible for problems caused by the use of  
unapproved materials. If in doubt, contact your local retailer or representative.  
Use of inappropriate finishes, solvents, brickwash or cleaning chemicals will cause adverse actions  
with window and door materials and voids the Limited Warranty.  
Care and maintenance information is available in the Pella Owner's Manual. You can obtain an  
owner's manual by contacting your local Pella retailer. This information is also available on  
Factory Prefinished Panels:  
A door panel that has been prefinished with stain or paint from the factory requires no additional  
finishing. Clean the surface with mild soap and water. DO NOT use a brasives. DO NOT scrape or  
use tools that might damage the surface.  
FINISHING INSTRUCTIONS (CONTINUED)  
Clad Exterior Frame:  
The exterior frame is protected by aluminum cladding with our tough EnduraClad baked-an-factory finish that  
needs no painting. Clean this surface with mild soap and water. DO NOT use abrasives. DO NOT scrape or use  
tools that might damage the surface.  
Panel Cleaning and Prep Instructions for Unfinished or Primed Panels:  
Dry wipe dust from doors gently. Examine door for possible smudges or fingerprints made from normal handling  
or construction. To remove smudges, lightly wipe surface with warm water. DO NOT sand surface of fiberglass  
panel. Scuff sand with light grade sand paper or abrasive pad (220 grit or higher). Rinse surface with mineral  
spirits for fiberglass panels and warm water for steel panels. Let door and side light surfaces dry completely  
before applying finish. Finish the door panels as soon as possible after installation.  
Failure to use the correct type of finish may result in a door that sticks shut. Ask a qualified paint professional to  
specify a product with good blocking resistance.  
EXTERIOR FINISH OF ALUMINUM CLAD DOORS  
The exterior frame and sash are protected by aluminum cladding with our tough EnduraClad® or EnduraClad  
Plus baked-on factory finish that requires no painting. Clean this surface with mild soap and water. Stubborn  
strains and deposits may be removed with mineral spirits. DO NOT use abrasives. DO NOT scrape or use tools  
that might damage the surface.  
Use of inappropriate solvents, brickwash or cleaning chemicals will cause adverse reactions with window and  
door materials and voids the Limited Warranty.  
 
INTERIOR FINISH  
If products cannot be finished immediately, cover with clear plastic to protect from dirt, damage and moisture.  
Remove any construction residue before finishing. Sand all wood surfaces lightly with 180 grit or finer sandpaper.  
DO NOT use steel wool. BE CAREFUL NOT TO SCRATCH THE GLASS. Remove sanding dust.  
Pella products must be finished per the below instructions; failure to follow these instructions voids the Limited  
Warranty.  
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Note: To maintain proper product performance do not paint, finish or remove the weather-stripping, mohair  
dust pads, gaskets or vinyl parts. Air and water leakage will result if these parts are removed. After finishing,  
allow venting windows and doors to dry completely before closing them.  
Pella Corporation is not responsible for interior paint and stain finish imperfections for any product that is not  
factory-applied by Pella Corporation. Use of inappropriate finishes, solvents, brickwash, or cleaning chemicals will  
cause adverse reactions with the window and door materials and voids the Limited Warranty.  
For additional information on finishing see Pella Owner’s Manual or go to www.pella.com.  
CARE AND MAINTENANCE  
Care and maintenance information is available by contacting your local Pella retailer. This  
information is also available at www.pella.com.  
IMPORTANT NOTICE  
Because all construction must anticipate some water infiltration, it is important that the wall system be designed  
and constructed to properly manage moisture. Pella Corporation is not responsible for claims or damages  
caused by anticipated and unanticipated water infiltration; deficiencies in building design, construction and  
maintenance; failure to install Pella® products in accordance with Pella installation instructions; or the use of Pella  
products in wall systems which do not allow for proper management of moisture within the wall systems. The  
determination of the suitability of all building components, including the use of Pella products, as well as the  
design and installation of flashing and sealing systems are the responsibility of the Buyer or User, the architect,  
contractor, installer, or other construction professional and are not the responsibility of Pella.  
Pella products should not be used in barrier wall systems which do not allow for proper management of moisture  
within the wall systems, such as barrier Exterior Insulation and Finish Systems, (EIFS) (also known as synthetic  
stucco) or other non-water managed systems. Except in the states of California, New Mexico, Arizona, Nevada,  
Utah, and Colorado, Pella makes no warranty of any kind and assumes no responsibility for Pella windows  
and doors installed in barrier wall systems. In the states listed above, the installation of Pella products in  
barrier wall or similar systems must be in accordance with Pella installation instructions.  
Product modifications that not approved by Pella Corporation will void the Limited Warranty.  
 

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