Alcoa Alumax Bath Enclosures STIKSTALL 792 Series User manual

INSTALLATION
INSTRUCTIONS
792 SERIES
STIKSTALLTM
SHOWER ENCLOSURE
Copyright © Alumax Bath Enclosures 1997. All rights reserved.
BATH ENCLOSURES
a product of Alcoa
Tel:
Fax: [phone]
www.alumaxbath.com
G03711074
8-1-06

Page 2 of 11G03711074
8-1-06
LIMITED WARRANTY AND REMEDY
ALUMAX BATH ENCLOSURES warrants to its dealers, customers, and all subsequent purchasers
and users, that the products supplied by it shall be free from material defects in material
and workmanship for a period of one (1) year after shipment, provided they are installed and
maintained according to ALUMAX BATH ENCLOSURE's recommended practices and installation
instructions. This warranty shall apply only to defects appearing within one (1) year from
the date of shipment, and provided that ALUMAX BATH ENCLOSURES is promptly notified in
writing of such defects. The sole and exclusive remedy with respect to the above warranty
or with respect to any other claim relating to defects or any other condition or use of the
products supplied by ALUMAX BATH ENCLOSURES, however caused, and whether such claim
is based upon warranty contract, negligence, strict liability, or any other theory, is limited
to repair or supply of such products, or repayment by ALUMAX BATH ENCLOSURES of the
purchase price paid for it, at ALUMAX BATH ENCLOSURE's option.
ALUMAX BATH ENCLOSURES does not make any other representations or warranties, express or
implied, including, but not limited to, any implied warranty of merchantability and any
implied warranty of fitness for a particular purpose. In no event shall ALUMAX BATH
ENCLOSURES be liable for special, direct, indirect, or consequential damages, including, but
not limited to, loss or use of profits.
Dealers agree to pass on to its customers and users in writing ALUMAX BATH ENCLOSURE's
Warranty and Remedy as set forth above.
Laws and building and safety codes governing the design and use of bath enclosures vary
widely. ALUMAX BATH ENCLOSURES does not control the selection of product configurations,
operating hardware or glazing materials, and assumes no responsibility therefor.
INSTALLATION NOTES
Unpack your unit carefully and inspect for freight damage. Lay out and identify all parts
using the instruction sheets as a reference. Before discarding the carton, check for small
hardware bags that tend to fall to the bottom of the box. If any parts are damaged or
missing, refer to the descriptions noted in the instructions when contacting your dealer for
replacements.
Handle the glass panels carefully and protect the edges. Safety tempered glass is very
resistant to breakage, but it can be broken by banging the edges against a hard surface. The
sharp corners of the panels can damage tile and floor surfaces, so do not remove any
protective devices until you are ready to install the glass.
Please wear safety glasses whenever drilling or cutting. When drilling holes in ceramic tile
or marble, use a center punch and hammer to carefully break the surface glaze so the drill
can start without skidding.
To install your ALUMAX STIKSTALL Shower Enclosure you will need the following: tape
measure, level, #2 Phillips screwdriver, drill, 1/8" and 3/16" drill bits, 3/16" wrench,
hacksaw, mallet or hammer, wood block, razor or sharp knife, pencil, glass cleaner, and
caulking (clear silicone recommended). Optional tools include a miter box for cutting parts
to length, files, center punch and masking tape.

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A. 2 Curb Sections (with weep slots)
B. 2 90° Anchor Plates
C. 24 #8 x 1/4" Truss Head Screws
D. 2 Header Sections
E. 2 Wall Jambs
F. 6 Plastic Wall Anchors
G. 6 #8 x 1 1/2" Truss Head Screws
H. 2 Plastic Setting Blocks
J. 1 Fixed Glass Panel
K. 1 90° Post
L. 2 Clear Vinyl Jamb Seals
M. 1 Glazed Door Panel
N. 1 Pivot Jamb
P. 1 Strike Jamb (Magnetic)
R. 2 Snap-in Fillers
S. 1 Drip Rail
T. 2 Drip Plugs
U. 1 Tapered Drip Vinyl
W. 1 Roll Double Stick Tape
X. 2 #10 x 7/16" Sq. Head Set Screws
Y. 1 Nylon Spacer
AA. 2 Nylon Pivot Bushings
BB. 1 Security Washer
CC. 1 Interior Door Handle
DD. 1 Exterior Door Handle
EE. 2 #6 x 1 1/4" Round Head Screws
FF. 4 Pcs. Vert. Glazing Vinyl (72")
GG. 2 Pcs. Horiz. Glazing Vinyl (48")
792 STIKSTALL PARTS LIST
BA
R
R
D
M
L
T
S
U
W
C
C
X
X
Y
B
C
F
G
C
GF
D
E
J
K
N
E
H
AC
C
P
AA
BB
CC
EE
DD
AA
GG
FF

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1- ALL DOORS
The ALUMAX 792 STIKSTALL Shower Enclosure is
completely reversible and may be installed pivot-left or
pivot-right(hinge-leftorhinge-right). Thedoormaypivot
from the wall or from the center post. Using the diagram,
determinethecorrectpositionforthedoorinyourparticular
STIKSTALL installation. This instruction sheet depicts a
pivot-right(hinge-right)installation.
NOTE: Fixed glass panel size should be determined by
formulas shown on ALUMAX detail sheets.
CAUTION: For safety reasons, the door panel must
always open outward.
The ALUMAX STIKSTALL framework has been designed to work with a variety
of different door types. To ensure correct installation, this 792 Instruction Sheet
is designed to be used by itself with a 790 Framed Pivot Door or with an instruction
supplement packed with a 390 Frameless Pivot Door, a 790i Intre-Hinge Door or
a 1090 Heavy Frameless Pivot Door.
Each step in this primary instruction sheet will indicate whether it applies to
all door types or if a supplement should be used. If your door panel kit does not
have an instruction supplement, then contact your dealer for the proper instructions.
790 door panel kits are covered in this instruction, therefore will not come with a
separate instruction supplement.
2- ALL DOORS
Assemble the two curb sections [A] (with
weep slots) by sliding a 90° anchor plate [B] into
the mitered ends and forcing the sections together.
The weep slots in the curb must be to the inside.
Using the slotted holes in the anchor plate as a
guide, drill matching 1/8" holes into the curbs.
Secure the anchor plate to the curb with four #8 x
1/4" truss head screws [C]. As you tighten the
screws, be sure the mitered ends are forced tightly
together. To increase the rigidity of the mitered
joint, drill and install two more screws through
the round holes in the bracket.
Assemble the two header sections [D] in the same
manner and set the assembly aside.

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3- ALL DOORS
5- ALL DOORS EXCEPT 1090
Measure the opening at the bottom of the
shower stall and trim the ends of the curb assembly
[A] (with weep slots) to fit the shower sill. The
curb should sit near the centerline of the sill. If
required, use a file to round the lower ends of the
curb assembly to fit the shower sill properly.
Using a 3/16" drill bit, drill the interior face of the
curb assembly on both ends as shown.
Reposition the curb assembly on the shower sill
and mark its position with a pencil line along the
interior and exterior base.
Wipe the shower walls and sill, curb assembly
[A] and wall jambs [E] with a clean, dry cloth to
remove any dust or debris. Apply a 1/4" bead of
caulk along the inside of both of the pencil lines
marked in Step #3. Carefully replace the curb in
the exact position marked. Caulk the inside of the
curb ends where they meet the wall. Caulk
generously around the anchor plate [B], screws
[C], and the inside of the mitered joint.
Replace both wall jambs and attach to the walls
with six #8 x 1 1/2" truss head screws [G].
4- ALL DOORS
Place the two wall jambs [E] into the ends of
the curb assembly [A]. Masking tape may be used
to hold the curb in place during this operation.
Plumb the jambs and mark the hole locations on
the wall. Remove all parts and drill the walls for
mounting hardware.
For tile or marble walls, drill six 3/16" diameter
holes and insert the plastic wall anchors [F].
Attachments to fiberglass or acrylic units can be
made in two ways. If a reinforcement is built into
the wall of the unit, drill six 1/8" holes to install
mounting screws directly into the reinforcement.
If walls are not reinforced, drill six 3/16" holes and
install plastic wall anchors or toggle bolts (toggle
bolts not supplied by ALUMAX).

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6- ALL DOORS
Place two setting blocks [H] into the curb
assembly [A] as shown to support the fixed glass
panel [J]. The setting blocks should be positioned
approximately 3" from each corner of the glass
panel. Remove any protective strips from the
glass panel and set it into place on the setting
blocks approximately 1/2" into the wall jamb [E].
A strip of masking tape 1/2" from each vertical
edge of the glass will aid alignment.
NOTE: Obscure glass panels should be installed
with the rough surface of the glass to the exterior
of the unit. Deco or etched glass panels should
have the patterned surface to the inside.
Press the 90° post [K] into the curb assembly. It
should overlap the glass panel by 1/2". Use masking
tape to hold the post in position temporarily.
Press the header assembly [D] over the wall
jambs [E] and the 90° post [K]. Check the post for
plumb. Adjust as required by varying the overlap
of the header over the wall jambs. You may need
to trim the ends of the header where it meets the
wall. The minimum horizontal dimension for the
door opening is the door panel width (see the
graphic in Step #9) plus 3/4", maximum is the door
panel width plus 1 3/4".
Using the holes in the ends of the header and curb
as a guide, drill four 1/8" holes into the wall jambs.
Drill two 1/8" holes thru the header and curb into
the 90° post as shown, then enlarge the two outer
holes with a 3/16" drill for clearance on the self-
tapping screws. Secure the header and curb to the
wall jambs and post with six #8 x 1/4" truss head
screws [C].
CAUTION: Slide the glass panel away from the
wall jamb before drilling to prevent breakage.
8- ALL DOORS
7- ALL DOORS
Hold the 90° post [K] plumb and carefully
measure horizontally from the top of each wall
jamb [E] to the outside edge of the post. Add 3/16"
to each measurement to find the corresponding
dimension on the header assembly [D] (from the
outside mitered edge to the squared ends) and
trim the header assembly to fit.
NOTE: To facilitate out of plumb walls, the 1/2"
glass bite may be varied from 1/4" to 3/4".
Using a 3/16" drill bit, drill the interior face of the
header assembly on both ends as shown.

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9- 790 DOORS ONLY
Strip two clear vinyl jamb seals [L] into the
door panel [M] splash guard and the pivot jamb
[N] and trim flush at the ends. Both vinyls should
be turned to trap water from the shower head.
Secure the vinyls with a small quantity of glue or
caulk at each end or by carefully crimping the
vinyl pocket. Set the door panel aside.
Press the pivot jamb and strike jamb [p] (with
magnetic strip) over the wall jamb [E] and 90°
post [K]. Refer to Step #1 for the proper handing
of the door.
NOTE: The magnetic strip on the strike jamb
must face the exterior and the clear vinyl jamb
seal on the pivot jamb must face inward.
10- 790 DOORS ONLY
Snap the fillers [R] into the curb assembly
[A] and header assembly [D] between the door
jambs with the raised lip to the exterior and the
pivot holes toward the pivot jamb. Center the curb
filler in the curb between the pivot and strike
jamb (use masking tape to hold in position).
NOTE: The snap-in fillers should be exactly 3/8"
longer than the door panel width.
11- 790 DOORS ONLY
Pull the bottom end of the pivot jamb [N]
tight to the curb filler [R] and plumb the jamb.
Drill two 1/8" holes thru the pivot jamb and into
the wall jamb [E] 3/8" to 3/4" from the wall and
approximately 1/4" vertically from the ends of the
jamb. Drill a third hole centered between the first
two and enlarge the outer holes with a 3/16" drill
for clearance on the self-tapping screws. Attach
the pivot jamb permanently with three #8 x 1/4"
truss head screws [C].
Slide the header filler [R] tight against the pivot
jamb. Push the strike jamb [P] tight against the
fillers top and bottom. With the pivot jamb plumb
and both fillers tight between the two door jambs,
the strike jamb also will be plumb and parallel to
the pivot jamb. Attach the strike jamb to the 90°
post [G] in the same manner as the pivot jamb.

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12- 790 DOORS ONLY
13- 790 DOORS ONLY
14- 790 DOORS ONLY
Insert the two #10-24 x 7/16" square head
set screws [X] into the threaded holes in the pivot
blocks in the top and bottom rails of the glazed
door panel [M]. Position the pivot pins 1 1/2" from
the pivot side of the door (the side opposite the
magnetic strip). Tighten the set screws just enough
to prevent the pivot blocks from moving (finger
tight plus a quarter turn). A 3/16" wrench (not
supplied by ALUMAX) will fit the set screw heads.
Press the white nylon spacer [Y] over the bottom
pivot pin on the door panel.
Insert the two nylon pivot bushings [AA] into
the pivot holes in the head and curb fillers [R].
Lift the door panel [M] and insert the top pivot pin
into the pivot bushing in the header filler. Hold
the door vertical and insert the bottom pivot pin
into the pivot bushing in the curb filler. It may be
necessary to remove the header retaining screws
and raise the header slightly to install the door.
When the door has been set into place, snap the
security washer [BB] over the top pivot pin to hold
the upper pivot bushing in place and prevent
accidental dislodging of the door.
Cut the drip rail [S] to the length of the bottom
rail minus 11/16". Clean the bottom door rail and the
drip rail thoroughly to ensure proper adhesion. Unroll
the double stick tape [W] and carefully apply it to the
back of the drip rail (do not peel the tape backing yet).
Insert the tapered drip vinyl [U] into the drip rail.
Position the drip rail flush with the bottom and pivot
side of the door panel [M], then raise the strike side
until the bottom edge of the drip vinyl is parallel to the
curb [A]. Mark the location of each end of the drip rail.

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15- 790 DOORS ONLY
Inspect the pieces of black glazing vinyl,
and note the two different profiles. The smaller
shape [FF] is installed vertically and the larger
shape [GG] is installed horizontally. For structural
strength and maximum water resistance, these
vinyls are designed to fit tightly between the glass
and framing. To speed installation, use glass
cleaner for lubrication and a small block of wood to
press the vinyl into place.
17- ALL DOORS
16- 790 DOORS ONLY
Attach the interior door handle [CC] and
the exterior door handle [DD] to the door panel
[M] with two #6-32 x 1 1/4" round head screws
[EE].
Close the door and check the clearance with the
strike jamb [P]. If necessary, loosen the set
screws [X] on the top and bottom slide bars and
adjust the door panel to align the strike magnets.
When the door panel is properly aligned, tighten
the set screws securely.
Adjust the drip vinyl [U] by sliding it left or
right until it just touches the curb. Trim the vinyl
(flush with the pivot end and notch 1/4" longer
than the drip rail as shown on the strike end).
The drip plug [T] is supplied with a left and right
hand plug together. Break the right and left drip
plug apart and insert the appropriate plug into
the high (strike) side of the drip rail. Discard the
unused drip plug. Peel off the tape backing and
carefully press the drip rail [S] to the door in the
marked position.
1/4" GLASS
REQUIRES: V-219 V-220
3/16" GLASS
REQUIRES: V-226 V-225

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18- ALL DOORS
19- ALL DOORS
20- ALL DOORS
Carefully caulk the interior jamb-to-wall
and curb-to-base joints. For appearance, you may
wish to caulk the exterior joints as well. We
recommend you wait twenty-four hours before the
first shower to allow the caulking to cure properly.
Cut four pieces of the larger vinyl [GG] 1/2"
longer than the horizontal opening and trim the
ends on a 45° angle. Install the top exterior vinyl
starting at both ends and working toward the
middle. Be careful not to stretch the vinyl.
Install the top interior vinyl and the two bottom
vinyls in the same way.
Cut four pieces of the smaller vinyl [FF] 1"
longer than the vertical opening (to prevent
gapping from shrinkage) and trim the ends on a
45° angle. Using the masking tape guides, center
the glass panel [J] in the frame. Cut four short (1"
- 2") pieces of the small vinyl and press into both
jambs on each side to hold the glass temporarily.
Take one of the long pieces of vinyl, and starting
on the outside exterior jamb, press each end into
the frame and work toward the middle. Be careful
not to stretch the vinyl. Install the other three
pieces in a similar fashion.

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To keep your Alumax Bath Enclosure looking like new we recommend the Alumax
ShowerBrightConsumerMaintenanceKit.TheConsumerMaintenanceKitsurfaceshouldbe
applied every 45 to 60 days. To purchase or for more information contact your dealer. Our
dealers have the materials to do a professional ShowerBright restoration. For best results
professionalrestorationsshouldbeperformedamaximumofonceeverythreemonths.Contact
yourdealerformoreinformation.NewunitswithfactorysuppliedShowerBrightcoatinghave
alimitedlifetimewarranty.Fordailycleaningthesimplestandpreferredmethodistowashthe
unit with clean water and dry with a soft cloth. Do not use scouring pads, sharp instruments,
or acid-based cleansers to clean the unit.
Consumer kits will be sold direct, consumers will need to go to dealers for professional
restoration and new units can be purchased with the permanent coating. Consumer kit
materialsneedtobeappliedevery45to60days,promaterialstobeappliedoncequarterlymax
and factory has limited lifetime.