R40 cut-down garage door set Assembly manual 'Georgian'
R40 cut down 'Georgian' Item Length Height Qty R40 cut Track set 2400x2270 UM 1 set 35000 'Georgian' panel 500mm 2450 500 3 pc. 35001R 'Georgian' panel 610mm with raised cassette 2450 610 1 pc. 24004 ALU profile 60mm 6000 60 2x2.5m 25005 Endcaps 500 500 3 pr 25006 Endcaps 610 610 1 pr 13003 Bottom weatherseal 2.5 m 13005 Top weatherseal 2.5 m 27022 Rivets 3.2x8, aluminium 30 pc. 27023 Rivets 3.2x8, white 10 pc. 27014 Bolt M8x60 10 pc. 27015 PVC anchor A10 10 pc. Additional options upon request 22006 Shut bolt 22009 Lock knob 22002 Handle knob 001 Top weatherseal profile on lintel 002 Top brackets with rollers Technical specifications Min W Max W Min H Max H Headroom manual/operator Headroom with option 001 manual/operator Headroom with option 001+002 manual/operator Sideroom Fitting depth mm 1925 2425 1981 2155 110/140 80/120 70/110 75 2900 2
Necessary tools Jig saw Power drill Angle grinder Riveter Right angle ruler Ruler Ø3.4mm, Ø8mm drills Step drill Wrench socket M10 M13 Knife Pencil Silicone spray 3
Site survey form SL Ceiling HR W H SR Aperture view (mm) min max W Width H Height HR Headroom SL Sideroom left SR Sideroom right For fitting Behind wall W and H must be measured on the inner side of wall.for fitting In between - W and H must be measured in fitting place. Roof Floor INSIDE D Side view (mm)** min max D* Depth CH** Ceiling height AW Wall thickness * D must be measured on top of lintel ** CH must be measured on left and right sides of the garage AW Aperture CH Fitting Behind the front wall In between the opening H+1000mm IMPORTANT! Check for windows and doors on side walls (position, height, opening direction) Check for additional lintels on ceiling, columns/pillars on side walls, pipes and cables on HR, SL, SR wall Take in to account if floor is missing or existing floor level will be changed Comments and additional drawings: Company name / Name Post code / Address Phone / e-mail sales@ryterna.co.uk fax: 014 4234 5001 www.ryternagaragedoors.co.uk 4
measuring Cutting tracks to height Vertical angle must be 50mm higher than the opening H+50mm Measure from top end downwards H+50mm and mark cutting line Do this on both vertical angles Vertical angle comes assembled together with vertical track (yellow colour) e.g. opening is 2023mm high Cutting line must be: 2023+50=2073mm from the top end Cutting line 5
Cutting options 1. Less than 140mm from the bottom Cut down. At the bottom adjust distance between vertical angle and vertical track to be 35mm. 2. More than 140mm from the bottom Cut down. At the bottom adjust distance between vertical angle and vertical track to be 35mm. Drill 8mm hole 5-15cm from bottom. Replace bolt from cut off part. 6
Mark distance H+50mm Cut off Adjust distance 35mm Drill Ø8mm hole Replace and tighten bolt 7
Cutting panels to width Garage door panels must be 25mm wider than the opening. Garage door width range: 1925-2425 mm For 'Georgian' panels it is necessary to cut from both sides evenly. C = W + 25mm e.g. opening (W) is 2170mm, so panel cutting width 2170 + 25 = 2195 mm Check for a=b Check for the right angle between the cutting line and the panel edge 8
Make cutting width measuring W+25mm Check for a=b and mark cutting line Cut panel to width For 'Georgian' design panels it is necessary to make two symetric cuts from both ends All other designs requires only one cut from one side 9
Fixing end-caps There are 3 pairs 500mm high end-caps for 2, 3 and 4th panel and 1 pair 610mm high end-caps for 1st - bottom panel. Put on end-caps and align with the panel Riveting places: middle of end-cap, 50mm from the end-cap's ends Do not rivet top of 4th (top) panel and bottom of 1st (bottom) panel. Do it after cutting to the opening height if necessary (see on next page). Use Ø3.4mm drill to make holes for riveting Rivet on end-caps 10
Cutting panels to height Fitted garage door must be 10mm higher than the opening to have overlap between door and lintel. Garage door height range: 1981-2155 mm Panels must be cut in way to keep proportions between cassettes and aluminium profiles on bottom and top panels. Set of Georgian doors consists of 4 panels. 3 standard panels 500mm high 1 panel 610mm high with raised cassette 610mm panel is used only for bottom panel Extended part - 186mm is mainly used to get the right garage door height Please choose option according to the opening height Opening height 1981-2006 go to page 12 Opening height 2007-2038 go to page 13 Opening height 2039-2140 go to page 14 Opening height 2140-2155 go to page 15 N.B. Completely assembled door panels must be 10mm higher than the structural opening to get 10mm overlap between lintel and top panel. 11
Opening height 1981-2006 Cut off the top of top panel to leave 475mm Cut off the part of bottom panel The cutting part height X can be calculated Opening height according to formula (for this option only): Min Max X=2115-H Top alu profile 10 10 Top panel 4 475 475 Intermediade panel 3 500 500 Intermediade panel 2 500 500 Bottom panel 1 476 501 Bottom alu profile 10 10 Bottom weatherseal 20 20 Top overlap door-lintel -10-10 1981 2006 12
Opening height 2007-2038 Cut off the top of top panel to leave 492mm Cut off the part of bottom panel The cutting part height X can be calculated Opening height according to formula (for this option only): Min Max X=2132-H Top alu profile 10 10 Top panel 4 492 492 Intermediade panel 3 500 500 Intermediade panel 2 500 500 Bottom panel 1 485 516 Bottom alu profile 10 10 Bottom weatherseal 20 20 Top overlap door-lintel -10-10 2007 2038 13
Opening height 2039-2140 Cut off the part of bottom panel The cutting part height X can be calculated Opening height according to formula (for this option only): Min Max X=2140-H Top alu profile 0 0 Top panel 4 510 510 Intermediade panel 3 500 500 Intermediade panel 2 500 500 Bottom panel 1 509 610 Bottom alu profile 10 10 Bottom weatherseal 20 20 Top overlap door-lintel -10-10 2039 2140 14
Opening height 2140-2155 Opening height Min Max Top alu profile 0 15 Top panel 4 510 510 Intermediade panel 3 500 500 Intermediade panel 2 500 500 Bottom panel 1 610 610 Bottom alu profile 10 10 Bottom weatherseal 20 20 Top overlap door-lintel -10-10 2140 2155 Put on top alu profile in raised position to reach required height 15
Bottom panel Measure bottom panel cut off part according to the garage door opening height Check your option on page 11 Cut paralelly the bottom part of the bottom panel End-caps must be on and riveted before cutting 16
Cut aluminium profile to fit panel length (W+25mm) Put on aluminium profile 17
Bottom panel (upside down) + end-cap + alu profile Assemble alu profile in the way shown on picture below: Outside: end-cap,profile, panel Inside: alu profile, end-cap, panel Panels in picture are placed upside-down. 18
Put rivet on outside in the corners to connect panel, alu profile and end-cap Put rivets along alu profile in 40-50cm intervals on both panel sides 19
Thread in bottom watherseal. Spray some silicone lubricant in advance. Distribute rubber evenly and leave some excess rubber outside the panel. From inside in the corner of alu profile drill the hole through aluminium and rubber. Do it on both sides. Rivet to fix rubber in alu profile and cut off excess rubber. 20
Top panel Measure top panel cut off part according to the garage door opening height Check your option on page 11 Cut aluminium profile to fit panel length (W+25mm) Put on alu profile Panel, end-cap and alu profile must be combined the same way as on bottom panel - page 18 21
Put rivet on outside in the corners to connect panel, alu profile and end-cap Put rivets along alu profile in 40-50cm intervals on both panel sides 22
Thread in top watherseal. Spray some silicone lubricant in advance. Distribute rubber evenly and leave some excess rubber outside the panel. From outside in the corner of alu profile drill the hole through aluminium and rubber and fit rubber with rivet. Cut rubber excess. Do it on both sides. 23
The door is ready for fitting Please follow R40-UM fitting manual: Important! To fix brackets and hinges please drill Ø3.4mm holes before screwing self tappers 24