Hy-Lite block inserts install in about an hour. Each insert is packaged with a full-size template with
step-by-step installation instructions.
|
Please make sure you read and understand all instructions before beginning installation. |
| 1) Unpack the Hy-Lite block insert panel. The unit ships completely assembled with both sides of the frame screwed in place. |
|
| 2) Remove the vinyl screw covers from the block insert panel. Save the covers for later. |
 |
| 3) Remove the now-exposed screws. Save the screws for later. |
 |
| 4) Remove the keeper frame pieces from the main frame. |
 |
| 5) Remove the pins from the hinges of the door in which you will install the block insert. Using a hinge pin or a center punch, tap out the pins from the door hinges. |
 |
| 6) Once the pins are removed, carefully remove the door. Place the door on sawhorses, making sure the door is protected from scratching. |
 |
| 7) If you are installing the insert into a panel door, find and mark the center point of the panels from side-to-side at the top of the panels. |
 |
| 8) Align the top of the template with the top of the upper-most panel of your door. |
 |
| 9) Align the top of the template with the line you drew, aligning the center line on the template with the center line you marked on the door. |
 |
| 10) While holding the template in place at the top, center the bottom of the template between the panels at the bottom of the door. In some cases the template will be narrower than your panels. |
 |
| 11) Mark the outline of the template on the door with a pencil. |
 |
| 12) Drill a 3/8" hole in each corner of the outline, being sure that you drill within the line. |
 |
| 13) To protect the door while cutting, you may want to apply a low-tack masking tape outside of the cut line you have drawn. You may need more than one strip, depending on the width of your saw base. |
 |
| 14) Starting from one of the holes you have drilled, cut along the marked line with a jigsaw. Make sure that you use the appropriate saw blade and that it is long enough to cut all the way through the door. |
 |
| 15) Remove the material that you have cut out from the door. If you have applied masking tape, remove it at this time. |
 |
| 16) Set the block insert on the sawhorses with the side with the removed frame facing up. Place the door over the panel so that the panel fits in the cutout opening. Align the door so that the panel is centered in the opening side-to-side and top-to-bottom. |
 |
| 17) Reinstall the keeper frame pieces. Make sure to align the holes in the keeper frame with the holes in the block insert panel. The frame pieces must go on the same side from which they were removed. |
 |
| 18) Reinstall the screws. |
 |
| 19) Reinstall the vinyl screw covers. |
 |
| 20) Replace the door and insert the pins in the hinges. Now you have a beautiful door that brings light and style into your room. |
 |
