60 DIRECT-TO-STUD SHOWER WALL SET
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1 60 DIRECT-TO-STUD SHOWER WALL SET 60 X 30 MODEL # DKW6008-XX 60 X 32 MODEL # DKW6028-XX 60 X 36 MODEL # DKW6068-XX Unit consists of Model DB608-XX Backwall, and requires one of the following Side Panel Sets to Complete. 30 Model DE308-XX 32 Model DE328-XX 36 Model DE368-XX ATTACH YOUR RECEIPT HERE Purchase Date Questions, problems, missing parts? Call our customer service department at , 8 a.m. - 8 p.m., EST, Monday - Friday, 9 a.m. - 5 p.m., EST, Saturday, 11 a.m. - 5 p.m., EST, Sunday. 1
2 PACKAGE CONTENTS G E B F C E F D H A I PART DESCRIPTION QUANTITY A Lower Back Panel 1 B Upper Back Panel 1 C Left Hand SIde Panel 1 D Right Hand SIde Panel 1 E Left Hand Shelves 2 F Right Hand Shelves 2 G 22 Slotted Hanging Rail 1 H Quick Dry Panel Adhesive 4 I Silicone Adhesive 2 J Shower Arm 1 J HARDWARE CONTENTS (shown actual size) AA Screw Qty. 15 2
3 SAFETY INFORMATION Please read and understand this entire manual before attempting to assemble or install the product. WARNING Always wear safety glasses or eye protection when using power tools. Use a dust mask or respirator for applications that generate dust. DO NOT proceed if any doubt arises about the correct or safe method of performing anything found in this manual. The installation of this product can require the use of power tools. Do not use power tools without adequate training. If necessary, hire or consult a trained professional for expert assistance before continuing. CAUTION Use care when opening the boxes so you do not damage the panels. Store panels in a flat area to avoid warpage until the time of installation. Do not store the panels outside of the original packaging in a vertical position. Make sure the walls are the correct size and are in good condition. Installation of damaged product will void the warranty. PREPARATION Before beginning assembly of product, make sure all parts are present. Compare parts with package contents list and hardware contents list. If any part is missing or damaged, do not attempt to assemble the product. Estimated Assembly Time: 60 minutes Tools Required for Assembly (not included): Level, Tape Measure, Pencil, Shims, Caulking Gun, Safety Glasses, Dust Mask, Saber Saw, Denatured Alcohol, Clean Shop Towels, Phillips Screwdriver, Heavy-Duty Panel Adhesive Helpful Tools (not included): 2 in. x 4 in. Wood Bracing The stud preparation is critical for the installation of the upper back panel hanging rail, and proper support for gluing of panels to studs. It is essential the stud pocket be constructed square and plumb according to the roughing in information provided. Pockets made out of square or incorrectly sized will result in the inability to utilize the hanging bracket provided with this unit and not allow for proper installation of side wall panels. See INITIAL INSTALLATION INSTRUCTIONS on page 4. 3
4 INITIAL INSTALLATION INSTRUCTIONS NOTE: This unit consists of a upper and lower shower back wall and a left and right side wall. Installation begins with the back wall and proceeds to the side walls. Utilizing the provided hanging rail is helpful, but not critical to the installation of the backwall. If hanging rail is not being used, it should not be removed from the back wall, as it will not interfere with the installation. 1. SITE PREPARATION Shower wall assembly requires a square stud pocket constructed to the dimensions shown. Exact stud placement within the boundaries of these dimensions is not critical when not using the hanging rail. Model # DKW6008-XX (60 x 30 ) 6 in. 6 in. 16 in. 16 in. 16 in. When using hanging rail, any deviation from this layout on the backwall will result in the inability to use this system without adjustments being made to the existing stud pocket. See Modification to Stud Layout on page in. 9 in. 9 in. 12 in. 12 in. 9 in. 9 in. 60 in. Model # DKW6028-XX (60 x 32 ) Model # DKW6068-XX (60 x 36 ) 6 in. 6 in. 16 in. 16 in. 16 in. 6 in. 6 in. 16 in. 16 in. 16 in. 10 in. 10 in. 12 in. 12 in. 32 in. 12 in. 12 in. 36 in. 12 in. 12 in. 10 in. 10 in. 12 in. 12 in. 60 in. 60 in. 4
5 INSTALLATION INSTRUCTIONS 1. MODIFICATION TO STUD LAYOUT If the stud pocket layout does not match the configuration in the INITIAL INSTALLATION INSTRUCTIONS, and you are using the hanging rail, you must fasten 2 in. x 4 in. wood headers (not included) to the existing stud pocket to accommodate the mounting of the hanging rail. Place headers on the back wall of the stud pocket, centered 72-1/2 in. above the shower base between the existing studs /2 in. 2. HANGING RAIL Install the top of the hanging rail (G) 73 in. above the shower base with screws (AA). The hanging rail (G) should be centered on the back wall. Use a level (not included) to ensure the hanging rail (G) is positioned correctly. Hardware Used 2 73 in. 19 in. 22 in. G 19 in. AA Screw x 3 73 in. 3. Lower Back Panel The lower back panel (A) has a aluminum channel along the top edge that the upper panel (B) will fit into. Make sure you have the lower back panel (A) facing the correct way. If necessary, place 1/16 in. thick shims (not included) where the lower back panel (A) will rest on the shower base. Trial fit the lower back panel (A) to ensure the stud pocket from step 1 was properly prepared and that there are no obstructions. Pull the lower back panel (A) back once you confirm the fit, then apply a bead of panel adhesive (H) on the studs behind lower back panel (A). Press firmly to secure the lower back panel (A) to the studs with panel adhesive. 3 Finish Side Top Glue Side A 5
6 INSTALLATION INSTRUCTIONS 4. upper Back Panel The upper back panel (B) has an aluminum tab on the bottom that fits into the lower back panel (A). Make sure you have the preassembled hanging rail at the top on the backside of upper back panel (B) and the tab facing down. Lift the upper back panel (B) and position it on the hanging rail (G) and in the aluminum channel on the lower back panel (A). Confirm correct fit. The vertical aluminum channel on both ends of the back panel should be in alignment to allow for installation of the side panels. Remove the upper back panel (B) and apply a continuous bead of silicone adhesive (I) to the bottom of the upper back panel (B) and the top of lower back panel (A). Apply a bead of panel adhesive (H) to the upper back wall studs. Position the upper back panel (B) onto the hanging rail (G) and set the upper back panel (B) into the aluminum channel of the lower back panel (A). Press firmly to secure, and cleanup excess silicone adhesive (I) with denatured alcohol (not included) while the silicone adhesive (I) is still wet. 4 I B A A B G NOTE: The hanging rail (G) will hold the upper panel tight to the studs. If the hanging rail was not used, see OPTIONAL WOOD BRACING INSTRUCTIONS on page 8. ADDITIONAL BACK WALL SUPPORT You may obtain additional support for back wall panels by drilling 12 evenly spaced 1/8 holes (3 per side/6 per panel) through the vertical aluminum channels on the outsides of the upper back panel (B) and lower back panel (A). Counter sink /2 stainless steel flathead screws through the holes in the channels into the studs. Apply silicone adhesive (I) around the screw heads prior to installation of the end wall panels. Hardware Used B A AA Screw x 12 6
7 INSTALLATION INSTRUCTIONS 5. Side PanelS Locate the location of the plumbing holes; if no plumbing holes exist, proceed to Step 2. Transfer the plumbing hole data to the left side panel (C) or right side panel (D). If a shower arm is placed within the walls of the unit, the hole for the shower arm should be placed 1-1/2 in. from the top of the required side panel. Using a jig saw or standard bi-metal hole saw (neither included), cut out the plumbing holes. Protect the finish surface with masking tape (not included) where the saw will contact the surface. 5 C 1-1/2 in. D 6. If necessary, place 1/16 in. thick shims (not included) where the left side panel (C) and right side panel (D) will rest on the shower base. Trial fit the left side panel (C) and right side panel (D) to ensure the stud pocket was properly prepared and that there are no obstructions, and that the shelf supports on the backwall align with the shelf supports on the side panels. Apply a continuous bead of silicone adhesive (I) to the entire length of the aluminum channel at the open end of the backwall panel. Then apply heavy-duty panel adhesive (H) to the backside of the side panels (C&D) along the upper top edge and the full length of the front edge of the side panels (C&D). Slide the left side panel (C) and right side panel (D) into the aluminum channel of the back wall panel and secure firmly to the wall with the panel adhesive (H). If the left side panel (C) and/or right side panel (D) pull from the wall, see OPTIONAL WOOD BRACING INSTRUCTIONS on page 8. Clean up excess silicone adhesive (I) with denatured alcohol (not included) while silicone adhesive (I) is still wet. 6 7 Tabs C D Finish Side Panel Adhesive Backwall C D Back Side 7. To insure proper fit, slide (4) backwall shelves into place on backwall using installed tabs as a guide. Apply silicone adhesive (I) to shelf support on back wall and sidewall return. Slide shelves into place securing firmly into the shelf pocket. Side wall Shelves slide onto tabs Shelf 7
8 OPTIONAL WOOD BRACING INSTRUCTIONS Note: These steps cannot be completed until both the back wall panels and side wall panels are installed. 1. Optional Wood Bracing To hold the installed panels more securely against the wall, place two wood braces (not included) against the back wall. Place two more braces (not included) against each left and right wall Wedge six horizontal braces (not included) against the left and right wall braces Insert small blocks (not included) between the rear panel braces and the back panel braces. These will apply pressure to the back panel to hold it in place. Remove the braces after 24 hours. 3 8
9 CARE AND MAINTENANCE Wipe the surface with a damp cloth or sponge. For basic stains, clean with mild detergent or general purpose cleaner. For cleaning corners and seams, spray with mildew cleaner. With regular maintenance spraying there should be no need to scrub any silicone caulk joints. TROUBLESHOOTING PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Panels not sticking to wall. 1. Surfaces not properly prepared for silicone adhesive/sealant. 2. Wall surface not flat for proper adhesion. 1. Clean surface thoroughly and reapply adhesive. 2. Use wood bracing support to form panel to wall surface. Panels not fitting properly. Existing wall surfaces out of plumb. Correct stud pocket to required specifications. 9
10 WARRANTY The manufacturer provides a LIMITED TEN (10) YEAR WARRANTY for its solid surface tub and shower surrounds to be free of manufacturing defects in materials and workmanship. If this product is found to be defective in materials or workmanship, after inspection by an authorized representative, we will repair, or at our option, exchange the product for a similar model. This warranty is valid for a period of ten (10) years, so long as it remains in use in its original place of installation. This warranty covers only products installed in accordance with the installation instructions, used as recommended and not damaged due to misuse, abuse or improper installation. It does not apply to any seams or changes made to the product by professional tradesmen or fabricators. The warranty applies only to the original purchaser and installation of these products in residential applications. It does not apply to commercial applications. The manufacturer s option to repair or exchange the products under this warranty does NOT cover any labor or other costs of removal or installations, nor shall the manufacturer be responsible for any other incidental or consequential damages attributable to a product defect or to the repair or exchange of a defective product. REPLACEMENT PARTS LIST For replacement parts, call our customer service dept. at , 8 a.m. - 8 p.m., EST, Monday - Friday, 9 a.m. - 5 p.m., EST, Saturday, 11 a.m. - 5 p.m., EST, Sunday. G H I B E F C E F D A J AA 10
11 REPLACEMENT PARTS LIST (CON T) Model # DKW6008-XX (60 x 30 ) PART DESCRIPTION PART # A Lower Back Panel DB608D-XX B Upper Back Panel DB608U-XX C Left Hand Side Panel DE308L-XX D Right Hand Side Panel DE308R-XX E Left Hand Shelves DS14L-XX F Right Hand Shelves DS14R-XX G 22 Slotted Hanging Rail TSH22HR-00 H Quick Dry Panel Adhesive TSG11PA-00 I Silicone Adhesive TSG11SA-00 J Shower Arm TSH01SA-CH AA Screw TSH01SC-SS Model # DKW6028-XX (60 x 32 ) PART DESCRIPTION PART # A Lower Back Panel DB608D-XX B Upper Back Panel DB608U-XX C Left Hand Side Panel DE328L-XX D Right Hand Side Panel DE328R-XX E Left Hand Shelves DS14L-XX F Right Hand Shelves DS14R-XX G 22 Slotted Hanging Rail TSH22HR-00 H Quick Dry Panel Adhesive TSG11PA-00 I Silicone Adhesive TSG11SA-00 J Shower Arm TSH01SA-CH AA Screw TSH01SC-SS Model # DKW6068-XX (60 x 36 ) PART DESCRIPTION PART # A Lower Back Panel DB608D-XX B Upper Back Panel DB608U-XX C Left Hand Side Panel DE368L-XX D Right Hand Side Panel DE368R-XX E Left Hand Shelves DS14L-XX F Right Hand Shelves DS14R-XX G 22 Slotted Hanging Rail TSH22HR-00 H Quick Dry Panel Adhesive TSG11PA-00 I Silicone Adhesive TSG11SA-00 J Shower Arm TSH01SA-CH AA Screw TSH01SC-SS 11
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