I was invited to the retrofit of the door lock hardware for a standalone employee bathroom in vandal-prone area where there were no public restrooms. The existing lock hardware was a keyed, storeroom function mortise lock with lever handles. An LCN 4041 surface-mount door closer completed the...
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Step 11. Drill a pilot hole through the rim cylinder center mark from the interior side of the door through the exterior side of the door. Make sure the drill bit is level and straight. Look through the mortised opening in the edge of the door to check for level. For this installation, a #7 drill bit was used for the pilot. This hole must be level and straight as the interconnection between the trim and exit device determine the ease of operation.
Step 12. Draw a horizontal line from the hole on the exterior side of the door to the edge. Draw a vertical line down from the hole. These lines will be used to locate the rim cylinder and the push/pull handle on the exterior of the door.
Step 13. Remove the mounting plate.
Step 14. Position the kick plate onto the interior side of the door, making sure the plate aligns with the upper and lower mounting plate marks. Position the kick plate in the center of the door so the edges of the plate are centered in the jamb.
Step 15. Use one flange head TEK screw to attach the kick plate onto the interior side of the door.
Step 16. Place the level on top of the kick plate to level the plate.
Step 17. Install the remaining 11 flange head screws.
Step 18. From the exterior side of the door, drill the rim cylinder center pilot hole through the kick plate.
Step 19. Use a 1-3/16" diameter hole saw to drill out an opening in the kick plate, providing access to the door face. Drill through the kick plate only. DO NOT drill through the door. Cutting out only the kick plate allows the rim cylinder screws to be flush with the top of the kick plate. This enables the exit device's mounting plate to be mounted flush.
Step 20. Draw a vertical centerline at the base of the push/pull handle.
Step 21. Place the Push/Pull Handle onto the exterior side of the door. Align the center of the handle with the vertical centerline on the door. Position the handle with the horizontal line, making sure there is sufficient space for the rim cylinder.
Step 22. Level the push/pull handle.
Step 23. Use one flange head TEK screw to attach the push/pull handle onto the exterior side of the door.
Step 24. Place a level on top of the push/pull handle to level the handle, making sure the handle's centerline aligns with the door's centerline.
Step 25. Install the remaining five flange head screws.
Step 26. From the interior side of the door, drill the rim cylinder center pilot hole through the push/pull handle.
Step 27. Use a 1-3/16" diameter hole saw to drill through the push/pull plate and the exterior face of the door. The rim cylinder will mount into the door through this opening.
Step 28. Drill the two pilot holes for the rim cylinder screws and the pilot hole for the tailpiece as indicated by the template.
Step 29. Use a step drill to enlarge the holes to accommodate the screws and the tailpiece.
Step 30. Mount the rim cylinder using the escutcheon from the mortise lock trim as the spacer. The mortise lock trim was stainless steel and would spin if rotated.
Step 31. Place the mounting plate onto the interior side of the door using the tailpiece to gauge the location.
Step 32. Use a level to position the mounting plate vertically. Make sure the tailpiece is located in the center of the hole.
Step 33. Mark the location for the upper mounting plate hole.
Step 34. Drill a hole through the kick plate using a number seven drill bit. The drill bit should enter the mounting hole previously drilled for determining the locations for the rim cylinder.
Step 35. Slide the rim cylinder tailpiece through the butterfly cam on the mounting plate while placing the mounting plate onto the door. Use a #1/4-20 x 1" Tek screw and lock washer to attach the mounting plate.
Step 36. Level the mounting plate while making sure the tailpiece will rotate smoothly.
Step 37. Install the second #1/4-20 x 1" Tek screw and lock washer.
Step 38. Use a grinder to remove the portion of the tailpiece that extends beyond the butterfly cam. Test the operation of the rim cylinder.
Step 39. Install the Scalp Filler Plate onto the edge of the door.
Step 40. Depress the push pad and install the rim device onto the mounting plate.
Step 41. Slide the end cap bracket into the rear of the rail.
Step 42. Level the rim device and secure the end cap bracket using three #1/4-20 x 1" TEK screws. Test the operation of the rim cylinder and rim device.
Step 43. Fasten the device to the mounting plate using the two #1/4-20 x 1" TEK screws. Test the operation of the rim cylinder and rim device.
Warranty: 3 Years Time to Install: 45 minutes to one hour Tools: 10-24 tap, 1/4-20 tap, drill bits, tools to adjust door closer, drill motor, 5/64" hex wrench I was invited to...