ROCKET FLUSH HINGED DOOR FRAME Finished Floor Level Don t waste time scratching your head If there is something that is not 100% clear give our fantastic customer service team a call on 0330 9980617 www.rocketdoorframes.com
CAUTION If you follow carefully these instructions for the assembly and installation process your life will be easier A pair of tressles are very useful when assembling the frames. Some parts may have sharp edges so use gloves and be careful when handling the parts. All products are fully inspected and tested before they leave the factory. TOOLS REQUIRED 3 mm Allen key Ø 27 mm Bush PH 2 PZ 2 Ø 3 Ø 16 2
CONTENTS EACH KIT CONTAINS: a b c d x2 e p x4 4.5 X 35 f x2 q Door seal g SX - Left r Hinge with cover x2 h DX - Right s Jig i x2 t Jig insert l 4 4.2 X 9.5 u Jig insert m x4 5.0 X 40 v Strike plate adaptor for tubolar latch n 3.5 X 25 w Strike plate adaptor for euro profile sashlock x72 o x4 M5 X 12 z Strike plate adaptor for din sashlock 3
POSITIONING OF COMPONENTS e i c i d d a f b f g Please note the pull left opening is shown, see pg 6 for pull right opening. h 4
Width Height Finished Floor Level 88-102 mm Finished Wall Thickness Door Panel Door Thickness Finished Wall OPENING REQUIRED IN WALL SINGLE DOOR Width Height 686 x 1981 44 88 to 102 720 2001 762 x 1981 44 88 to 102 796 2001 838 x 1981 44 88 to 102 872 2001 726 x 2040 44 88 to 102 760 2060 826 x 2040 44 88 to 102 860 2060 926 x 2040 44 88 to 102 960 2060 dimensions in mm The standard system is adaptable for wall thickness from 88 to 102 mm (including plasterboard). However extensions are available for wider finished wall thicknesses from 113 to 127 mm and on request even wider walls. If using metal studwork then the opening for the frame needs to be lined with wood (min 40 mm) to allow for the hinge cutouts (see page 8). 5
FRAME ASSEMBLY PULL LEFT PULL RIGHT a b a b g h g h g i i h 6
FRAME ASSEMBLY i l c l i c l l IMPORTANT It is absolutely essential that after installing the distance pieces the dimension X is 8 mm wider than your door and dimension Y 8 mm higher than your door. Dimensions +/- 1 mm. f f X l Y f Y X Finished Floor Level 7
15 mm 40 mm INSTALLING IN STUD WORK Be careful to position the assembled part of the frame on the flush side of the wall at finished floor level. = = Finished Floor Level Cut outs required in stud work. = = 120 mm 135 mm 40 mm 15 mm 8
INSTALLING IN STUD WORK Please note the assembled part of the frame is inserted into the side you want to be flush with the wall with the secondary parts (ref d and e on the other side). Finished Floor Level Two people are needed to perform this task to avoid the risk that the frame will fall. 9
INSTALLING IN STUD WORK d d e d d e Ensure the frame is pushed flush up against the hinge side of the wall HINGE SIDE LOCK SIDE FIXING THE FRAME TO THE WALL It is very important that the frame is perfectly plumb and so please check a number of times BEFORE fixing the frame and during the operation. 90 90 90 90 Finished Floor Level 10
FIXING THE FRAME TO THE WALL It is essential you measure the dimensions x and y BEFORE AND AFTER installation of the frame and they MUST be your door width + 8 mm and your door height + 8 mm. Dimensions +/- 1 mm. X Y Y Finished Floor Level X Finished Floor Level First screw the flush side of the frame to the wall then the opposite side using the screws (n) at 200 mm intervals. Use QUADRUPLE SCREWS at the hinge and corner points. Then double check the frame is still plumb and true, if not adjust until it is. n n n n n 11
FIXING THE FRAME TO THE WALL After installing the frame insert the screws (m) above and below the hinge positions being careful not to tighten too much, the frame should not be bent or warp by this action. Ø 3 m m REMOVE the distance pieces l f f l 12
FIXING THE FRAME TO THE WALL Use PVA or equivalent on the metal edges that are to be plastered, fit fibre plastering tape all around the frame doubling up over corners and the hinge points and, when the PVA is tacky apply the plaster up to the stop bead. Use metal primer on the remaining metal surface return and when dry it is paint ready. PLASTERING AND PAINTING 13
PLASTERING AND PAINTING Very carefully clean the metal surfaces making sure it is completely free of dirt and especially traces of oil which will inhibit the adherence of the door seals. APPLYING THE DOOR SEALS (q) TO THE FRAME 45 45 A A A 45 45 B B B B q q q q 14
INSTALL THE HINGES TO THE FRAME O door r O door Route the door to accept the hinges using the jig (ref s, t and u) and a 16mm dia router cutter and a 27 mm template guide. s s s s Flush to wall side of door t 218 15
Making the first routing on your door Ø 16 not supplied Greater than Ø 16 not supplied Ø 27 7 Making the second routing on your door t u Ø 16 30 16
REMOVING the jig u s Repeat for the other hinge s t 218 17
INSTALLING THE DOOR door p p 18
INSTALLING THE DOOR Use the correct strike plate adaptor for your strike plate, either v, w or z. ADAPTOR FOR DIN SASHLOCK PLATE not supplied not supplied ADAPTOR FOR EURO EURO PROFILE SASHLOCK STRIKE PLATE w z not supplied ADAPTOR FOR TUBOLAR LATCH OR ROLLER BOLT STRIKE PLATE v INSTALLING YOUR LOCK AND HANDLE It is most important that you install your lock into the door at the exact height to suit your strike plate. REMEMBER, the adjustment on the hinges is there to adjust slight irregularities of the frame installation and will not compensate for any lock mis-positioning. You are responsible to ensure the lock is installed at the correct position, the adjustable hinges are there only to adjust the door panel relative to the frame. 19
ADJUSTING THE HINGES 03/2018 0357.01 Z Y X Adjusting the X axis - door panel right/left X ± 1 mm 3 mm Allen Key Adjusting the Y axis - door panel in/out Y ± 1 mm 3 mm Allen Key 3 mm Allen Key Adjusting the Z axis - door panel up/down Z ± 2 mm