ULTRA WINDOW & DOOR EXPANDERS AND RECEIVERS INSTALLATION INSTRUCTIONS

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1 ULTRA WINDOW & DOOR S AND RECEIVERS INSTALLATION INSTRUCTIONS! CAUTION: *REMEMBER SAFETY FIRST* Proper Eye and! Hearing Protection must always be worn during installation of all window and door products. UTR 1 rev. 1-3/04 Please read and follow the Installation Instructions enclosed with your window or door. Follow all cautions and warranty requirements. These instructions assume the window is installed, and exterior facing has not yet been applied. CAUTION: The unit must be installed, and sealed around the entire perimeter at the wall. The accessory parts shown are not intended to be water tight on the exterior. (Numbers in parenthesis are metric equivalents.) ITEMS REQUIRED Safety Glasses/Goggles Hearing Protection Device Tape Measure Phillips Head Screwdriver Hammer Rubber Mallet Sealant and Caulk Gun Power Drill Drill Bits: 5/32" (4) and 11/64" (4) Closed Cell Foam Backer Rod 1/2" (13) and/or 1" (25) diameter For Projected Sill Nosings: #6 x 1-1/4" (32) or 1-1/2" (38) Phillips Pan Head Stainless Steel Screws For Traditional Sill Nosing, Sill Drip, or Sill Extender: #6 x 5/ (16) Phillips Pan Head Stainless Steel Screws For Flat Profile Trim Receiver or Backband Profile Trim Receiver, fastening Option 1: 1-1/2" (38) or longer Galvanized Roofing Nails For Backband Profile Trim Receiver, fastening Option 2: #8 x 1-1/2" (38) Phillips Flat Head Stainless Steel Screws INTRODUCTION Lineal parts must be cut to length. To determine the exact lengths required, see page UTR 4 for the Head Receiver and Expander, see page UTR 5 for the Side Receivers and Expanders, and see page UTR 6 for the Sill profiles. 1-5/ Projected Sill Nosing 2- Projected Sill Nosing See Figs. 1 to 5. The Flat Profile Trim Receiver is used with Fig. 1, the 1-5/ (41) Projected Sill Nosing; Fig. 2, the 2- (54) Projected Sill Nosing; Fig. 3, the Traditional Sill Nosing; and Fig. 4, the Sill Drip. The Back Band Profile Trim Receiver is used with Fig. 2, the 2- (54) Projected Sill Nosing and Fig. 5, the Sill Extender. WHEN USING END CAPS, SUBTRACT 1/1 Fig. 7 GAP SIDE JAMB RECEIVER OR RECEIVER MEASURE FROM THIS EDGE NOSING STEP #1: SILL DRIP OR NOSING PREPARATION See Figs. 6 and 7. Projecting legs are extruded into the top surface, to attach the sill nosing or drip to the frame nosing. On the area overhanging either side of the sill, these legs will interfere with the side expanders and receivers. The legs must be removed from both ends before installing the drip or nosing. For both projected sill nosings, the distance to be removed equals the width of the side trim used minus the width of the end cap - 1/1 (2). For the traditional sill nosing, the sill drip, and the sill extender, the distance to be removed equals the width of the side trim used. Take measurements from the innermost edge of the accessory groove in the frame nosing. Use tin snips or rotary grinder to remove the legs, then file flush. 9/1 Fig. 1 Fig. 2 Traditional Sill Sill Drip Nosing 9/1 STEP #2: ATTACHING ANY SILL DRIP OR ANY NOSING See Figs. 1 to 5. Apply sealant into the kerf on the underside of the extruded aluminum sill. Center the sill drip or nosing, leaving an equal amount of overhang on each side. Insert the sill drip or nosing front leg into the kerf on the front of the sill frame nosing. Swing the sill drip or nosing up and press the back leg into place. 1/2" 1/2" For the 1-5/ Projected Sill Nosing See Fig. 8. The 1-5/ (41) projected sill nosing requires end caps. Apply sealant around the interior perimeter of each end cap, then snap the end caps into place. Wipe off excess sealant. Fig. 3 Fig. 4 Sill Extender Fig /4" Sill Drip or Nosing LEGS Fig. 6 SHADED AREA TO BE REMOVED See Fig. 1. To assure screw holes line up, temporarily clamp or secure the sill nosing to the sill. Using a 5/32" (4) diameter drill bit, pre-drill screw holes 9/1 (14) from the back edge of the sill nosing, towards the front of the unit. Locate the holes horizontally 3/1 (5) from each end, towards the center of the unit. If the unit width is between 32" (813) and 59" (1499), drill one additional hole at the center of the sill nosing. For larger units, drill additional holes at 2 (686) on center, along the sill nosing. Fasten with #6 x 1-1/4" (32) or 1-1/2" (38) phillips pan head stainless steel screws through the projected sill nosing, the sill nosing end cap, and up into the extruded sill.

2 UTR 2 END CAP FOR 1-5/ PROJECTED SILL NOSING BEFORE APPLYING Fig. 8 END CAP FOR 2- PROJECTED SILL NOSING AFTER APPLYING Fig. 9 For the 2- Projected Sill Nosing See Fig. 9. The 2- (54) projected sill nosing requires end caps. Apply sealant around the interior perimeter of each end cap, then press the end caps into place. Wipe off excess sealant with a damp cloth. See Fig. 2. To assure screw holes line up, temporarily clamp or secure the sill nosing to the sill. Using a 5/32" (4) diameter drill bit, pre-drill screw holes 9/1 (14) from the back edge of the sill nosing, towards the front of the unit. Locate the holes horizontally 9/1 (14) from each end, towards the center of the unit. If the unit width is between 32" (813) and 59" (1499), drill one additional hole at the center of the sill nosing. For larger units, drill additional holes at 2 (686) on center, along the sill nosing. Fasten with #6 x 1-1/4" (32) or 1-1/2" (38) phillips pan head stainless steel screws through the projected sill nosing, the sill nosing end cap, and up into the extruded sill. For the Traditional Sill Nosing See Fig. 3. To assure screw holes line up, temporarily clamp or secure the sill nosing to the sill. Using a 5/32" (4) diameter drill bit, pre-drill screw holes 1/2" (13) from the back edge of the sill nosing, towards the front of the unit. Locate the holes horizontally 2" (51) from each end, towards the center of the unit. If the unit width is between 32" (813) and 59" (1499), drill one additional hole at the center of the sill nosing. For larger units, drill additional holes at 2 (686) on center, along the sill nosing. Fasten with #6 x 5/ (16) phillips pan head stainless steel screws through the traditional sill nosing, up into the extruded sill. Use only aluminum or galvanized nails 1-1/2" (38) or longer, to secure the long back leg of the traditional sill nosing to the building. For the Sill Drip See Fig. 4. To assure screw holes line up, temporarily clamp or secure the sill drip to the sill. Using a 5/32" (4) diameter drill bit, pre-drill screw holes 1/2" (13) from the back edge of the sill drip, towards the front of the unit. Locate the holes horizontally 2" (51) from each end, towards the center of the unit. If the unit width is between 32" (813) and 59" (1499), drill one additional hole at the center of the sill drip. For larger units, drill additional holes at 2 (686) on center, along the sill drip. Fasten with #6 x 5/ (16) phillips pan head stainless steel screws through the sill drip, up into the extruded sill. Use only aluminum or galvanized nails 1-1/2" (38) or longer, to secure the long back leg of the sill drip to the building. For the Sill Extender See Fig. 5. To assure screw holes line up, temporarily clamp or secure the sill extender to the sill. Using a 5/32" (4) diameter drill bit, pre-drill holes 2-1/4" (57) in from the front edge of the sill extender, towards the interior of the opening. Locate the holes horizontally 2" (51) from each end, towards the center of the unit. If the unit width is between 32" (813) and 59" (1499), drill one additional hole at the center of the sill extender. For larger units, drill additional holes at 2 (686) on center, along the sill extender. Fasten with #6 x 5/ (16) phillips pan head stainless steel screws through the sill extender, up into the extruded sill. STEP #3: RECEIVER PREPARATION A trim receiver must be installed first, when using any frame expander. This includes the standard size frame expanders: 1" (25), 2-1/2" (64), 4" (102), (152), and (178), as well as any custom or cut-to-fit expanders.! CAUTION: When the frame expander is pressed into position, there must be a gap between the top of the frame expander and the top of the trim receiver kerf. This gap will allow for expansion and contraction. The side trim receivers must be cut at the bottom to follow the slope of the sill drip or nosing. Cut these pieces at a 5 angle with the back being higher (shorter) than the front. For the frame expander, relieve the leg; it is not necessary to angle the long, flat area of the frame expander. Notch the leg of the head frame expander at both ends, to clear the side frame receivers. STEP #4: ATTACHING RECEIVERS FLAT PROFILE See Figs. 10 and 11. Cut the top corners of the trim receiver at a 45 angle. To draw these corners together tightly, use the supplied aluminum corner angles. Slide the angle down between the two small guide legs and the outermost edge of the trim receiver. Pre-drill holes in both the head and side, using a 5/32" (4) drill bit.locate holes 3/4" (19) from the front edge and 5/ (16) from the side edge. Fasten with #6 x 5/ (16) phillips pan head stainless steel screws. INSERT BETWEEN GUIDE LEGS Fig. 10 RECEIVER - FLAT PROFILE SLIDE UP, THEN SWING OVER CORNER ANGLE RECEIVER - FLAT PROFILE "A" DIMENSION IS 11/1 FOR FLAT RECEIVER AND 7/ FOR RECEIVER A Fig. 11 EXTERIOR FACING BACKER ROD RECEIVER Fig. 12 NOSING Fig. 13 5/ NOSING 5/ FOR BOTH RECEIVERS GAP

3 UTR 3 BACKER ROD EXTERIOR FACING OPTION 1 GALVANIZED OR ALUMINUM NAILS NOTES RECEIVER- PROFILE Fig. 14 GAP SHIM BY OTHERS OPTION 2 #8 x 1-1/2" PHILLIPS FLAT HEAD STAINLESS STEEL SCREWS See Figs. 12 and 13. Fasten the trim receiver to the exterior wall surface using only aluminum or galvanized nails 1-1/2" (38) or longer, to penetrate through the flashing, the exterior sheathing, and into the framing. Nail 4" (102) from each end and 1 (457) on center between. PROFILE See Fig. 11. Cut the top corners of the trim receiver at a 45 angle. Pre-drill holes using a 5/32" (4) drill bit. Locate holes at 7/ (22) from the front edge and 5/ (16) from the side edge. The groove can be used as a guide for hole placement. Drill holes in both the head and the side trim receivers. Fasten with #6 x 1-1/4" (32) or 1-1/2" (38) phillips flat head stainless steel screws. See Fig. 14. Fasten the trim receiver to the exterior wall using Option 1 or Option 2. Option 1 This option requires a nailing fin. If the nailing fin is not already attached, press it firmly into the kerf in the top of the trim receiver. Use only aluminum or galvanized nails, 1-1/2" (38) or longer, to penetrate into the framing. Nail 4" (102) from each end, and 1 (457) on center between. Option 2 Shim between the flashing and the backband trim receiver with standard 1X nominal size lumber - 3/4" (19) actual size. Pre-drill holes using a 11/64" (4) drill bit. Use the V groove in the screw recess area of the backband trim receiver to position the drill bit. Locate the holes 4" (102) from each end and 1 (457) on center between. Fasten with #8 x 1-1/2" (38) or longer phillips flat head stainless steel screws. STEP #5: INSTALLATION OF See Figs. 12 to 14. Apply a generous bead of sealant on the back leg of the trim receiver. Angle the frame expander and slide it up into the slot where the sealant was placed. Swing the bottom into place and press to fit tightly. If necessary, use a rubber mallet to tap into place, protecting the trim with a piece of scrap board. STEP #6: COMPLETING THE EXTERIOR See Figs. 13 and 14. Apply a backer rod between the siding and trim receiver. Apply a generous bead of sealant over the backer rod in the gap as shown. Do not seal the front face of the side frame expander or trim receiver to the sill, to allow moisture to weep out. For further information, contact your distributor or visit Kolbe on the Internet at Visit download_installinfo.shtml to find the installation instructions for each of our products. Kolbe & Kolbe Millwork Co., Inc. reserves the right to change specifications without notice.

4 Trim Receivers and Frame Expanders Head Dimensions UTR 4 RECEIVER MAY BE SECURED AT TOP WITH A NAIL FIN. 1-3/4" "Y" = FACE DIMENSION ("Y" = "X" - 5/) ("Y" = "Z" - 1") "X" = SHIM BLOCK LOCATION FROM EDGE OF ("X" = "Y" + 5/) ("X" = "Z" - ) 3/4" SHIM (STANDARD 1X NOMINAL LUMBER BY OTHERS) --OR-- RECEIVER MAY BE SECURED AT BOTTOM THROUGH PROFILE. "Z" = DISTANCE FROM EDGE OF TO EDGE OF RECEIVER ("Z" = "X" + ) ("Z" = "Y" + 1") LENGTHS FOR HEAD RECEIVER AND PROFILES "X" "Y" "Z" 3-2-1/2" 3-1/2" 4-5/ 4" 5" RECEIVER LENGTH = 2 x (Z) + WIDTH LENGTH = 2 x (Y) + WIDTH - 1/2"

5 Trim Receivers and Frame Expanders Side Dimensions UTR 5 SIZE LENGTHS FOR SIDE RECEIVERS AND S PROFILES "X" "Y" "Z" 3-2-1/2" 3-1/2" 4-5/ 4" 5" 2 9/1 SILL EXTENDER 1/1 RECEIVER LENGTH = Z + HEIGHT + 1/1 LENGTH = HEIGHT - Use this chart for the Traditional Sill Nosing, the Sill Drip, and the Sill Extender SIZE LENGTHS FOR SIDE RECEIVERS AND S PROFILES "X" "Y" "Z" 3-2-1/2" 3-1/2" 4-5/ 4" 5" RECEIVER LENGTH = Z + HEIGHT + LENGTH = HEIGHT - 1/1 2- PROJECTED SILL NOSING Use this chart for the 1-5/ Projected Sill Nosing and the 2- Projected Sill Nosing

6 Trim Receivers and Frame Expanders Sill Dimensions UTR 6 RECOMMENDATIONS RECEIVER WITH 45 CUTS AT ENDS EDGE OF EDGE OF RECEIVER SIZE ON SIZE MINIMUM 3/1 MAXIMUM OVERLAP FOR LENGTH OF HEAD INTO RECEIVER (AT BOTH ENDS) WITH SQUARE CUTS AT ENDS (NOTCH SNAP-ON LEG ON BACKSIDE, TO CLEAR 0RECEIVER) WITH SQUARE CUTS AT TOP END WINDOW WINDOW LENGTHS FOR TRAD. SILL NOSING, SILL DRIP AND SILL EXTENDER PROFILES "X" "Y" "Z" 4-2-1/2" 3-1/2" 4-5/ 4" 5" TRAD. NOSING, DRIP OR EXTENDER LENGTH = 2 x (Z) + FR WIDTH RECEIVER AND ARE CUT TO FOLLOW SLOPE OF SILL NOSING (OR SILL DRIP) AT THE BOTTOM END WINDOW LENGTHS FOR 1-5/ AND 2- PROJECTED SILL NOSING PROFILES "X" "Y" "Z" 4-2-1/2" 3-1/2" 4-5/ 4" 5" 2- PROJ. NOSE LENGTH = 2 x (Z) + WIDTH - WINDOW SILL NOSING (OR SILL DRIP) 1/1 END CAP (ON 1-5/ PROJECTED SILL AND 2- PROJECTED SILL ONLY) M-3/04-SP

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