Durabilt Premier Three-Season Sunroom Instruction manual

Assembly and Installation Instructions
for
Premier Three-Season Sunroom
Deluxe Three -Season Sunroom
Under
Dura-Lock or Dura-Therm
Dura-Bilt Products, Inc. P.O. Box 188 Wellsburg, N.Y. 14894
Dealer Service 570-596-2000 E-Mail [email protected]
DURA-BILT RESERVES THE RIGHT TO CHANGE DESIGN AND/OR SPECIFICATIONS WITHOUT NOTICE.
Check the material received.
Match your shipment with the Bill of Materials.
If there is a shortage or wrong material,
call Dealer Service immediately.
Safety is important!
Wear Safety Glasses and Work Gloves.
Follow all safety practices while assembling
and installing this product.
DTSSE-10
Read the instructions before starting the job. They explain the steps required
to produce a finished product that will meet factory specifications.
All references to “Left” and “Right” are while facing the home.

Tools Required
Cordless Drill Tape Measure Metal Saw Level Chalk Line Clamp Hammer
Utility Knife Caulk Gun Silicone Lubricant Spray
Nut Driver Bits with Magnetic Head: 1/4” - 5/16” - 7/16” Drill Bits: 13/64” - 1/4” Masonry
Page 1
Fasteners
Fastener Description
1/4” - 20 X 1-1/2” Bolt & Locking Nut
#12 X 2” Sloted Hex Head Screw
#10 X 1” Hex Head Screw
#12 X 3/4” Self Drilling Screw
#8 X 1/2” Self Drilling Screw
Plastic Lag Shield
#10 X 1-1/2” Flat Head Phillips Screw
(They come with the threshold)

Component Descriptions
Page 2
Gable End Channel Gable End Channel Clamp Floor Channel
Corner Joiner Wall Channel
Wall Channel Trim Angle
1” X 1”
Corner Brace
Gable End Attach Angle
1-1/2” X 1-1/4” X 1/16”
Side Wall Stiffener Angle
1-1/2” X 1-1/4” X 1/8”
Panel Frame
Universal Spacer
The Universal Spacer is used for
1” increment variations in the walls.

Page 3
Room Assembly

Installation Basics
The installation is completed in three stages.
1. Stage One: Layout and install Floor Channel, Mounting Rail and Wall Channel.
2. Stage Two: Install the Wall and Door Panels.
3. Stage Three: Install Roof and Gable Ends.
It is suggested that you read these instructions completely before starting the job. They detail the steps in each
of the three stages of the project.
All references to ‘Left and ‘Right are while you are facing the room from outside the room.
As in all quality construction, key elements are to be kept square, level and plumb. This is especially critical
with the Floor Channel and Wall Channel. Taking the time to install these correctly will help avoid problems
later in the project.
Because of the wide variety of patio, porch and deck floors, it is left to the judgment of the job contractor on
how best to level the Floor Channel.
The length of Front Wall is distance between the outside edge of the Side Floor Channels. Length of the Side
Walls is from the back of the Wall Channel to the front of the Floor Channel. The measurements in your
Project Planner are these outside measurements.
*If you are installing a Dura-Bilt Roof and Deluxe Three-Season Room at the same time, the Mounting Rail
is to be installed in Stage One. Establishing the Mounting Rail location is covered in these instructions.
However, you must follow the Dura-Therm or Dura-Lock instructions for proper Mounting Rail installation
procedures.
If the roof is already installed, it is necessary to raise the front of the roof several inches above the final height
of the room wall. Brace the roof solidly in position. Remove any Roof Post Assemblies not needed. If the
existing Front Header will interfere with the Deluxe Front Header, it must be removed. New screws are
provided for the new Deluxe Front Header.
Because you may encounter out of plumb home walls or some growth in the side walls of the room, the two
Starter Panels will give you the flexiblity to position them within the wall channel or to cut down their width,
if necessary.
Page 4

Page 5
Stage One
Marking Floor Channel Locations
1. Find the previously determined location of the back Right Corner of the room.
Mark that location on the home at the deck level.
Get the length of the Right Side Wall from the Project Planner in your Installation Package. Mark this
dimension on the deck with a chalk line.
Helpful Hint: Use the 3’x 4’x 5’triangle method to make sure your wall is at a right angle to the home. See
Drawing.
2. Determine the location of the back Left Corner of the room. (Use the Front Wall Length given in your
Project Planner as a guide.) Mark the Left Side Wall with a chalk line the same way you marked the Right
Side Wall.
It is important to use the 3’x 4’x 5’triangle method again to be sure your Left Side Wall is at a right angle to
the home.
3. Measure distance between front corners. It must be the same dimension as in your Project Planner. Then
snap a chalk line to mark the Front Wall.
Marking Wall Channel Locations
1. At the Back Right Corner location of the room, use a carpenter’s level and a long straight edge to continue
the line on the deck up the Right side of the home.
2. Refer to your Project Planner for the Mounting Rail height provided when this order was placed. Otherwise
refer to the Mounting Rail Height Chart in the Roof Installation Instruction Book. Then mark the point where
bottom edge of the Mounting Rail will be located. See Drawing at top of Page 6.
3. Move to the Back Left Corner of the room and repeat process used in Step 1 of Marking Wall Channel
Locations.

Mounting Rail Location
1. If you are installing a Dura-Bilt Roof and Deluxe Three-Season Room at the same time, the Mounting Rail
is installed first. Read the appropriate installation instructions (Dura-Therm or Dura-Lock) for the proper
procedure.
Attaching Mounting Rail for Roof
Follow the instructions provided with the Dura-Bilt Roof you are installing.
Install Floor Channel
Measure, cut and miter the Floor Channel sections.
Note: If you are installing a room that Does Not have a solid panel at the home wall, see page 12.
Place Right Side Floor Channel sections on deck with outside of the Floor Channel aligned with Line “A”
established in Step 1, Page 5. High side of the Floor Channel is to be inside room.
Continue laying out the Front and Left Side Floor Channel sections. Then make sure that the Floor Channel
dimensions agree with measurements given in the Project Planner.
Floor Channel Continued on Next page Page 6
Deck or Patio
Line “A”
Home
Deck or Patio
Mounting
Rail
Height
Home

Drill 13/64” holes in Floor Channel every 12 inches.
Wood Deck: Caulk the underside of the Floor Channel covering all of the drilled holes and mitered cor-
ners. You must use the #10 x 1” hex head screws with the Magni 599 coating supplied by Dura-Bilt every 12
inches.
Concrete Patio: 1. Use Floor Channel as a pattern to mark screw
locations on concrete.
2. Remove Channel and use a 1/4” masonry drill bit
and drill holes 1-1/4” deep.
4. Hammer Plastic Lag Shields into holes.
5. Caulk the bottom of the Floor channel then Replace Floor Channel
over the Plastic Lag Shields and Fasten with #10 x 1” screws.
Page 7
All reasonable efforts must be made to make all the Floor Channel level.
Caution: The mitered Corner pieces must match perfectly because the vertical Corner Joiner extrusion will be
a tight fit in both directions in the floor channel.
All Channel joints must butt tightly together.
Helpful Hint: Place a long straight edge against edge of separate sections of Channel to assure perfect
alignment. When the Floor Channel positioning is correct, you are ready to fasten Floor Channel to deck.
The cut out for the swinging door will be made after the door is located.
Left Corner Right Corner
Note: Corner Joiners will install only as
shown with the notch at the top.
(Applicable for Straight Line Roofs.)
Notch Notch

Page 8
Install Wall Channels
Note: If you are installing a room that Does Not
have a solid panel at the home wall, see page 13.
Use the following procedure to install both Left and
Right Wall Channels after Floor Channel has been installed.
1. Cut the Wall Channel so it will fit between
Floor Channel and underside of Mounting Rail.
Note: The Wall Channel fits inside the Floor Channel
2. Drill 13/64” holes starting 2” up from the
bottom and spaced 18” to 24” apart.
Final hole 2” from top.
3. Apply a strip of 1” x 1” foam tape
on the back of the Wall Channel along the
full length of edge. See Drawing.
4. Position outside edge of Wall Channel so
it is on the Line you marked on side of home.
5. Attach to home with #12 x 2” hex screws.
See Drawing below.
OutsideInside
Line “A” marked
earlier for
Wall Channel
Outside Edge.
Wall
Channel
Floor Channel
Example of Right Wall
(Left Wall Opposite)
Short leg of
Floor Channel
is to outside.
1” x 1”
Foam Tape
#12 x 2”
Hex Screw
Wall Channel
Top View
of
Right Wall
1” x 1”
Foam Tape
Floor Channel
Wall of Home
#10 x 1”
Screw
OutsideInside

Page 9
Stage Two
Basics of The Wall and Door PanelAssembly
Wall, Door and Solid Panels have factory installed Panel Frames on each unit. You will be slipping the Panel
Frames of the Panels together and fastening them with screws to build the walls of the room. (Sliding Glass
Door Frames and Panel Frames are assembled at the job site.) Instructions for Sliding Doors are in a seperate
instruction.
Occasionally these instructions will make references to your Right or Left. It is important that you remember
these are based on your being outside facing the room.
Please observe that the Panel Frames have one side or “leg” that has an inset while the other leg is flat. The
Panel Frame leg with the inset will always be on your Right. The inset will slide behind the flat Panel Frame
Leg of the adjacent panel.
Helpful Hint: Your layout sheet provides the measurements of each wall Panel. Before beginning
installation of Wall Panels, take a few moments to mark location of the panel joints on the floor next to
the Floor Channel. This is an easy guide to make sure the wall is not “growing” or “shrinking” as you
proceed with the installation. The Solid Panels in each wall are there to provide the flexibility to correct
any wall growing or shrinking beyond acceptable limits.
Installation of Wall Panels
These instructions are written on the basis of starting the installation with the Right Wall. You may start with
the Left Wall of the room. However, this could cause confusion because the Left and Right references in these
instructions are based on starting with the Right Wall.
Also, the room is designed to be installed working to a swinging door or a corner, depending on the placement
and type of Wall and Door Panels. This “Keystone” concept results in a room that is solidly locked together
when completed.
For most installations you would (1) start at the home and work to the front corner, (2) work across the front
wall to the other corner. (3) Continue from the corner installing the other side wall to a swinging door. (4)
Then move to the home and work back to the door. With a swinging door as the last panel you install, it
provides the flexibility to complete the last wall of the room.
Another option is: (3) Move to the home and install the other side wall to the corner. (4) Slide the Corner
Joiner into position by inserting into Panel Frames about one-half or two-thirds of the way up the wall and
then sliding it down-and-in to its final position.

Page 10
Installing Starter Panel
1. You can begin installing Wall Panels
at either Right or Left Wall Channel.
This instruction starts at the Right
Wall Channel with the Right Starter
Panel. This panel has a Panel Frame
on one edge, start the other edge
(without the Panel Frame) into the
Wall Channel. Seat the Panel in the
Floor Channel. Do not fasten Starter
Panel in Wall Channel at this time.
2. Following your Project Planner, insert
Panel Frame of the next Panel into
the Panel Frame of the first Panel just
installed. Insert to the stops of the Panel
Frame. Fasten Panel Frame at top,
center and bottom of both inside and
outside of Panel Frame using #8 x 1/2”
self-drilling screws. Do not install
screws in Floor Channel at Panel Frame
until Corner Joiner has been installed.
View from
inside
Enclosure
1. Before installation of the Door Panel, the Floor Channel Side Walls must be cut for the Door opening.
As indicated below, the door hinge side of the Floor Channel is cut slightly larger to accommodate the door
swing. Locate Door Panel and mark sides of Floor Channel accordingly. Remove Door Panel and cut side
walls of Floor Channel as marked.
2. Continue installing Panels by positioning each Panel, or Corner Joiner, so its legs will slide over legs of
Panel already in place.
3. Illustration on next page shows Enclosure Side Wall installed. View from top shows Frame overlap. Door
Panel(s) will install in the same way shown for Window Panels.
View from
outside
Enclosure
Wall
Channel
Top View of
Right Wall
Starter Panel
Home Wall
2”
2”
Center of
Panel
Starter Panel
Floor Channel
Wall
Channel
Pa
g
e 1
0

Note: The Door Panel is 3/16” narrower than the equivalent Window Panel. Allow 3/32” spacing on each
side when installing Door Panel. See Drawing Below.
Installing Wall and Door Modules
As you continue to work from outside the room, the basics of installing the Wall and Door Modules uses the
same procedure as you have just used to install the first Panel.
Page 11
4. #8 X 1/2” self-drilling screws
installed inside and outside where legs
on Panel Frames overlap.
Panel Frames
#8 X 1/2” Screw
(Inside and Outside)
#8 X 1/2” Screw (Inside and Outside)

Installing a Room Under a Fixed Roof
(This is a special application)
1. Start by cutting four (4) pieces of 1-1/2” x 1-1/4” x 1/16” thick
angle so it will fit between the Floor and the bottom of
the Mounting Rail.
(You will need (2) pieces for the right wall and (2) for the left wall)
2. Drill (5) 13/64” holes thru the 1-1/4” leg of the angle in all (4) pieces,
2” down from the top and 2” up from the bottom with the
last (3) holes equally spaced between the first two holes.
See drawing.
3. Apply a strip of 1” x 1” foam tape on the back of
1-1/4” side of the angle approx. 1/16” in from the
1-1/2” side of the angle.
(This is to be done to (2) pieces of angle)
Note: Left wall is opposite.
See drawing.
Page 12
Right Wall
Shown
4. Place the inside leg of the 1-1/2” angle against Line “A”
that has been already established on page 6 then use a level
to plumb the angle, then attach to the home with #12 x 2”
screws, compressing the foam. See drawing at right.
(The foam fills in the gaps of siding or shingles etc.)
5. Install the Floor Channel by placing it against the 1-1/2”
leg of the angle you just attached to the wall. Make sure the
Floor Channel is square with the home and fasten with
#10 x 1” screws. See drawings on next page.
6. Install your first Window or Door Panel into the Floor Channel
and slide it to the home wall.
7. Install 1-1/2” x 1-1/4” x 1/16” thick angle against the left side
of the Floor Channel, making sure it’s plumb at the home wall and
fasten with #10 x 1-1/2” hex head white screws.
8. Repeat Steps 4, 5 and 6 for the left side wall.
Note: All other trim angles will be applied when the room is assembeled.
See next page for more assembly examples.
Line “A”
Home Wall
Top View of
Right Wall at Home
1-1/2” Side

Page 13
Top View
of
Right Wall at Home after Room isAssembled.
Installing a Room with no Solid Panel at the Home Wall
(This is a special application)
1. Floor Channel will be used as Wall Channel in this
application.
2. The Wall Channel will be altered at the factory for
you.
This will allow for a proper fit in the Floor Channel.
(See Illustration at Right)
3. Drill 13/64” holes starting 2” up from the bottom and
spaced 18” to 24” apart. Final hole 2” from top.
4. Apply a strip of 1” x 1” foam tape on the back of the
Wall Channel along the full length of edge.
5. Attach Wall Channel to home with #12 x 2” Hex Head Screws.

Floor Channel
Altered Floor Channel
Inside Room Outside Room
1” x 1”
Trim Angle 1” x 1” Trim Angle
#12 x 2”
Hex Head
Screw
#8 x 1/2”
Screw
#8 x 1/2”
Screw

Page 14
When possible, it is best to work in both directions toward the Door location and install the door last.
1. Start at Left Wall Channel and install Panel identified for left Wall Channel only and work toward Door
location. Then go to Right Wall Channel and install Wall Panels, working your way back around to the Door
location.
2. If you are installing a second door, install that door using the same procedure
as you would with a Wall Panel.
3. If you are installing a Dura-Bilt Roof: After all Enclosure Panels have been installed, place Front Header
that you assembled in Step 15 over the Front Enclosure Wall. Note that Corners have been notched at top
to accommodate Front Header.
4. Level Front Header on the Front Enclosure Wall. Then raise center of Header slightly so that water will
flow to downspouts.
Deluxe Front Header Cover
is supplied to cover the
overhang of Deluxe Front
Header. Attach with
#8 X 1/2” Screws. Deluxe Front Header Cover
Deluxe Front Header
End Cap
Note: When Deluxe Front Header End Caps
are used with Deluxe Front Header Cover.
The Legs of the Deluxe Front Header Cover
will have to be altered back 5/8” to allow the
Deluxe Front Header End Caps
to fit into the ends of the Header.
Deluxe Front Header

5. Attach the Deluxe Front Header to the Panel Frames in the front wall with #12 X 3/4” self-drilling screws
inside and outside where Panel Frame Extrusions overlap. See drawing below.
Top view of Panel Frames looking through Deluxe Front Header
Note: If you have an existing roof you can lower it and secure it at this time. If you have a new roof
install the roof panels now according to instructions provided.
Gable Ends
The Gable End Channel is provided in two parts to allow for easier installation of the Gable End when the
Roof Panels have been previously installed.
1. Cut the Gable End Channel to fit from the back of the Deluxe Front Header to the back of the Wall Chan-
nel.
2. Cut two (2) slots 1/8” wide X 1-1/2” deep into the top surface of the Gable End Attach Channel. This is
done so the Gable End Attach Channel fits around the Wall Channel. See drawings on next page.
End view of the
Gable End Channel
for the right
side wallPage 15
#12 x 3/4” screw
#12 x 3/4” screw
1/8”1/8”
1-1/2”
Top view of the
Gable End
Channel Showing
slots

Note: The end of the Gable End Channel with the 1/8” slots is inserted around the Wall Channel above the
Room Side Wall Panels and then pushed down over Panel Frames until it rests on Panel Frames.
With 76-1/2” and 82” wall height, Gable End Channel will not seat fully on Panel Frames at the door.
This may cause a high spot in the Gable End Channel. It can be leveled by raising the ends of the Gable
End Channel. However, as you install #8 x 1/2” self drilling screws where two Panel Frames over lap
and intersect Gable End Channel, be sure to hit the Panel Frames with screws.
3. Install two-piece Gable End Channels with open side facing out. The Gable End Channel Clamp piece is
installed after Gable Ends are in place.
4. Gable Ends material for Straight Roof is one piece and must be cut in half diagonally corner to corner.
Gable Ends must now be cut to fit. See drawings below.
5. Make the following measurements and mark them on the Gable End. Follow this procedure for each End.
Measure distance (A) from inside of Enclosure Wall Channel to back of Front Header. Measure distance (B)
from bottom of Gable End Channel to under side of Roof Panel. Mark these measurements on the Gable
End as shown in drawing.
Cut Notch (C) as shown to fit around Mounting Rail.
6. Cut the Gable End to your measurements. Check final size, it must fit from the back of the Enclosure Wall
Channel to the back side of the Front Header.
7. Follow same measuring procedure for the other Gable End. Page 16
Mounting Rail
Wall Channel
Gable End Channel
View of right side wall with
Gable End Channel pushed
down over the Panel Frames
and inserted around the
Wall Channel.
Outside Room
Gable End
Channel
Gable End
Channel
Clamp
#8 x 1/2”
Screw
End view of
right wall
Top of wall
Panels

Gable Ends for Dura-Therm and Dura-Lock Roofs
Install the Gable End Attach Angles with #8 X 1/2” screws every 12”.
9. After the Gable End has
been installed, if the Side Wall is over
10’install the Side Wall StiffenerAngle
on the Gable End Channel with
#12 X 3/4” self drilling screws
in the pre-punched holes.
Page 17
Gable
End
Wall Channel
Trim Angle
Locate screws 1/2”
from back of Angle.
1/2”
Place Wall Channel Trim against Wall Channel with one leg against home to cover weather stripping and
caulking. Caulk between house and Wall Channel before fastening Wall Channel Trim to Wall Channel with
five (5) #8 X 1/2” self drilling screws.
Wall Channel Trim is furnished in 120” lengths and must be cut to fit for both inside and outside of Wall
Channel.
Roof Panel
Gable End Panel
Gable End Attach Angle Gable End Attach Angle
Left Wall
Gable End
Channel Clamp
Side Wall
Stiffener Angle

Installing Corner Brace on Room with Gable End Channel
1. Install Corner Brace Bracket on back side of Front Header with (2) #12 X 3/4” screws.
2. Attach Corner Brace to Bracket with two (2) 1/4-20 X 1-1/2” bolt with locking nut.
Do not tighten at this time.
3. Swing the free end of Brace to Enclosure Side Wall and position Bracket on Gable End Channel where
holes in Bracket and holes in Brace are aligned.
4. Attach Bracket to Gable End Channel with (2) #12 X 3/4” self drilling screws. Install and tighten all
locking nuts on 1/4-20 X 1- 1/2” bolts.
Use of Corner Braces may be optional.
Consider use of Braces as optional on Side Walls up to 12’in length. Braces are recommended for Side Walls
more than 12’in length. Braces also recommended for all walls in “high wind” areas.
Corner Brace Bracket
Installing Corner Brace on Room with Side Wall StiffenerAngle
1. Install Corner Brace Bracket on back side of Front Header with (2) #12 X 3/4” self drilling screws as
shown above. (Instructions continued on next page)
Drill 5/16” hole in Stiffener
Angle to aligin with lower hole
in Corner Brace Bracket.
Page 18
Deluxe Front Header
Corner Brace
Brackets
Corner Brace

Installing the Threshold
1. Cut Threshold to 35-1/2”. Notch for In-swinging or Out-swinging door, as shown. Install with 1/4” plastic
lag shields and #10 X 1-1/2” flat phillips screws, unless Threshold is installed on a wood deck, in which case,
omit plastic lag shields.
2. Attach Corner Brace to Bracket with (2) 1/4-20 X 1- 1/2” bolts with locking nuts. Do not tighten at this
time.
3. Swing the free end of Brace to Enclosure Side Wall and position Bracket on
Side Wall StiffenerAngle where holes in Bracket and holes in Brace are aligned.
4. Attach Corner Brace Bracket to Stiffener Angle as shown. Use (2) #12 X 3/4” self drilling screws. Drill
one 5/16” hole inside Wall StiffenerAngle to align with hole in Corner Brace Bracket. Place Corner Brace in
position and install and tighten all locking nuts on 1/4-20 X 1-1/2” bolts.
Threshold for Outswinging Door
Both sides of the Threshold are to be notched the same.
Threshold for Inswinging Door
Both sides of the Threshold are to be notched the same.
Page 19
Treads should
always be to the
outside.
End view of
Threshold
3/8”
13/16”
1/2”
1/2”
3/8”
2”