Endura All-Aluminum Z-Articulating Cap Sill Series Guide

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
1
1. Flathead Screw Driver or Stiff Scraper:
To remove old Z-Series sill cap.
2. Small Wood Block: To protect
aluminum sill deck when prying off
adjustable sill cap.
3. Measuring Tape: For sizing new sill cap
and door bottom before cutting to proper
length.
Required Tools and Materials
ADDITIONAL TOOLS FOR FRENCH DOORS
1. 7/8” Diameter Drill Bit
All-Aluminum Z-Articulating Cap Sill Field Replacement Instructions
4. Pencil: To mark cap and door bottom.
5. Cutting Tool: Chop /Miter Saw recommended
to trim cap and door bottom to proper length.
6. 1/2" crown Staples: To secure Door bottom
to panel.
(1) 6/0 Z-Articulating Cap
(2) Kerfed Door Bottoms & (2) Staple On Door Bottoms
(1) Right Z-End Base
Mull Stiffener
(1) Right Z-End Base
Mull Stiffeners
(1 )Left Z-End Base
Mull Stiffener
(1) Left Z-End Base
Mull Stiffeners
(1) Left and (1) Right
Active Mull Stiffener
Gaskets
(1) Left and (1) Right Active
Mull Stiffener Gaskets
Astragal Lower Trim Cap
(1) White & (1) Bronze
1 pair of (2)
Corner Pads
(3) Corner Pads
(1) Bottom Pad for
Astragal Boot
(1) 3/0 Z-Articulating Cap
(1) Kerfed Door Bottom & (1) Staple On Door Bottom
French (Double Door) Replacement Kit Contents
Standard Door (Single) Replacement Kit Contents
1S
1F
2R
2R
6
6
8 9
2L
2L
4
4
5
3
35
7
(2) 3/0 Mylar Strip
7
(1) 3/0 Mylar Strip
(2) Z-AC Door Bottom Gasket
(1) Z-AC Door Bottom Gasket
Rev Date 5.11.16

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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Identifying Your Sill System
ZAI-AA-AA to ZAC-AA SEE PAGE 4
Z-Series Adjustable Sill (ZAI-AA-AA )
ZAI-AA-AA Features
• Flat Cap
• Screw Covers
ZAI-AA-AA Sill
Screw Hole
Cover
Bolt Receiver Cup
(French Doors Only)
• Receiver Cup Under Cap
Use the boxes below to Identify your current sill system. Once your sill system has been properly identied, proceed to the appropriate section.
ZAC-AA to ZAC-AA SEE PAGE 17
ZAC-AA Features
Z-Series Articulating Sill AA (ZAC-AA )
Z-End Base
ZAC-AA Sill
• Slanted Cap
• Z-End Bases with Weatherstrip Locater
• Pin Capture Under Cap

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
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Z-Articulating Cap Sill Field Replacement Instructions
Table of Contents
1. Remove Corner Pads Page 5
2. Remove OLD Adjustable Cap Page 6
3. Install Mylar Strip(s) Page 6
4. Install Z-End Base Mull Stiffeners Page 6
5. Cut NEW Z-Articulating Sill Cap to Length Page 7
6. Apply Spring-Loaded Cap Bases 8
7. Insert NEW Sill Cap Page 9
8. Replace Astragal Bottom Sealing Pad and Corner Pad Page 10
9. Replace Door Bottom Sweep Page 11
10. Stapling Door Bottom to Panel Page 12
11. Replace Corner Pads Page 13
12. Check the Operation of the Door Page 13
ZAI-AA to ZAC-AA PAGE 4
1. Remove Corner Pads Page 15
2. Remove ZAC-AA (Single and French) Page 16
3. Remove ZAC-AA (Sidelite, Hinged Patio and Previously Retrotted Units) Page 17
4. Cut NEW Z-Articulating Sill Cap to Length Page 18
5. Check Cap Assembly Page 19
6. Insert NEW Sill Cap Page 20
7. Replace Astragal Bottom Sealing Pad and Corner Pad Page 21
8. Replace Door Bottom Sweep Page 22
9. Stapling Door Bottom to Panel Page 23
10. Replace Corner Pads Page 24
11. Check the Operation of the Door Page 24
ZAC-AA to ZAC-AA PAGE 14

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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Z-Series Adjustable All-Aluminum Sill (ZAI-AA )
ZAI-AA-AA Features
• Flat Cap
• Screw Covers
ZAI-AA-AA Sill
Screw Hole Cover
• Receiver Cup Under Cap
ZAI-AA-AA Receiver Cup
(French Doors)

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
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(If Present) Remove Simple Solution
Corner Pad from each jamb by peeling
it off.
Clean any residual debris and dirt from
the jamb.
Proceed to Step 2.
Remove the weatherstrip by pulling it
out of the kerf slot
1. Remove Corner Pads (ZAI-AA to ZAC-AA)
b)
c)
d)
b)
TOP DOWN
VIEW
of Simple
Solution
Corner Pad
Weather-
stripping
*
a)
a)
*Corner Pad may be look
different.

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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2. Remove OLD Adjustable Cap (ZAI-AA to ZAC-AA)
4. Install Z-End Base Mull Stiffeners (ZAI-AA to ZAC-AA)
3. Install Mylar Strip(s) (ZAI-AA to ZAC-AA)
Protect aluminum sill deck with a
small wood block to prevent damage
when prying off sill cap.
a)
b)
c)
d)
a)
b)
Place a athead screwdriver under
front leg of sill cap at one end.Then pry
sill cap up with screwdriver, working
from one end to the other.
Pull sill cap out of channel.
Clean any debris out of sill channel and
on the jambs.
Proceed to step 3.
Insert Z-End Base Mull Stiffeners 2L & 2R into each side of the
channel against the jambs
Proceed to step 4.
NOTE: The Z-End Base Mull Stiffeners are handed and can only
be inserted one way. The back of the Z-End Base Mull Stiffener
should be ush with the face of the jamb.
a)
NOTE: Do not caulk or staple the Z-End Base Mull Stiffeners in
place.
NOTE: Do not remove the orange protective gasket label until
cap is fully installed into the door unit.
a)
b)
Jamb
Z-End Base Mull Stiffeners
2L
22
2R
Align the Mylar Strip 7 with the inside
edge of the Dam of the Sill, and apply by
rmly pressing into place.
a)
Mylar Strip should contact the lip of the
Dam.
For French Applications two Mylar strips
should be used along the full length of the
sill channel.
Contacting Dam
lip
7

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
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X/2 X/2
Cut 1/8"from each endCut 1/8"from each end
3. Install Mylar Strip(s) (ZAI-AA to ZAC-AA)
c)
d)
Proceed to step 5
Proceed to step 5
Measure the length of the sill (X).
Measure the length of the sill (X). Measure and mark the centerline of the Cap
CAUTION: Measure carefully
and cut precisely within
1/32” to ensure proper
operation. A cap cut too
short will not seal correctly.
CAUTION: Measure carefully and cut precisely within 1/32” to ensure
proper operation. A cap cut too short will not seal correctly.
5. Cut NEW Z-Articulating Cap to Length (ZAI-AA to ZAC-AA)
a)
a) b)
b)
x
x
Measure and cut new cap 1s to match length of the sill minus 1/4".
Sill Length (x) 1/4"
c) Measure and cut new cap 1F to match length of the sill minus
1/8" on each side. Cut from both ends of the cap to ensure caps
Centerline remains centered.
FOR FRENCH (DOUBLE) DOOR APPLICATIONS
FOR SINGLE, SIDELITE AND HINGED PATIO DOOR APPLICATIONS
Cut Here
If needed, move the bases at the end of the caps to the inside (1/2”from the end)
1S
1F
Cap Centerline

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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a)
a)
b)
b)
6. Apply Spring-Loaded Cap Bases (ZAI-AA to ZAC-AA)
SINGLE, SIDELITE AND HINGED PATIO DOORS ONLY
Ensure that all 6 spring-loaded bases are used and properly positioned.
Ensure that all 3 spring-loaded bases are used
and properly positioned.
Proceed to step 6
Proceed to step 6
FRENCH (DOUBLE) OPENING DOORS ONLY
1” to 1-1/2” Y Y 1” to 1-1/2”
1"to 1-1/2"
Bases
1"to 1-1/2"
YY Y YY
1S
1F
The spring-loaded bases at the ends of the cap should be 1"to 1-1/2"from the cap’s edge.The 4
center spring-loaded bases should be evenly spaced between the 2 spring-loaded bases at the
ends of the cap, approximately 12"- 13"inches apart (Y).
The spring-loaded bases at the ends of the cap
should be 1"to 1-1/2"from the cap’s edge.The
spring-loaded center base should be evenly
spaced between the 2 spring-loaded bases
at the ends of the cap, approximately 12"-15"
inches apart (Y).

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
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7. Insert NEW Sill Cap (ZAI-AA to ZAC-AA)
a)
b)
c)
Press one end of cap 1 into channel and
against Z-End Base/ Mull Stiffeners 2 .
Depress the cap 1 , to gain access to the orange
protective labels on each Z-End base/ Mull Stiffener
(If present) and remove.
Proceed to step 8
Install the opposite end of the cap 1 into the sill by
bringing it straight down into the sill channel and
against Z-End Base/ Z-End Base Mull Stiffener 2 .
Apply Pressure to the cap 1 to fully seat cap into
place along entire length of sill.
b)
d)
FOR SINGLE, SIDELITE, HINGED PATIO AND FRENCH DOOR UNITS
d)
e)
a)
c)
Sill Dam should contact the bottom side of the top of
the cap, and the angled leg of the cap should contact
the back side of the Sill Dam
Sill Dam Should
contact cap
e) Grasp Tab Here
f)
Kerf Slot
Weatherstrip
Leg

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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e)
9. Replace Astragal Bottom Sealing Pad and Corner Pad French Door Units Only (ZAI-AA to ZAC-AA)
a) Position astragal to gain access to the Bottom Bolt Sleeve, Corner Pad and Bottom Sealing Gasket.
FOR FRENCH DOOR UNITS
Proceed to step 10
b)
c)
d)
e)
f)
Remove old corner pad and Bottom
Sealing Gasket by peeling down and
away from the astragal. Use a stiff
scraper to remove any remaining
residue.
Use the Trim Cap that matches the
color of the astragals body, and
discard the other.
Reinstall weatherstripping
Install new Astragal Bottom Sealing
Gasket 8 by aligning the ush bolt
with the hole in the pad c1, then
install new Simple Solution Corner
Pad 4 by Pressing into place c2.
The lip of the Bottom Sealing
Gasket should extend out in front
of the astragal, and the Simple
Solution Corner Pad should sit
ush on top of the gasket.
Ensure the edge of the Corner pad
is located behind the weatherstrip
after installing corner pad in place.
Remove Weatherstrip to gain
easy access to the Corner Pad
Remove original Lower Trim Cap
by prying it off of the bottom of the
astragal with a Flat Head Screw
Driver.
Align the new Lower Trim Cap 9
with the astragal’s body, and Insert
the Trim cap into the bottom of the
astragal.
Corner Pad should
contact the top of the
Bottom Sealing Pad
New Corner Pad
Old Trim
Cap
New
Trim
Cap
New
Corner
Pad
New
Corner
Pad
New
Bottom
Sealing Pad
Bottom Sealing Pad
Side View
b)a) c)
e) f)
Bottom Sealing Gasket Bottom Sealing Gasket Lip
extends past Bolt Sleeve Face
Reinstall Weatherstrip
Uninstall
Weatherstrip
Old
Corner
Pad
d)
New Lower
Trim Cap
Peel Off
Press into
place
Press
into
place
c1. Install Bottom Pad
Side View
3
8
2
9
4
4
9
98
8
c2.

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
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10. Replace Door Bottom Sweep (ZAI-AA to ZAC-AA)
Remove old door bottom from panel by prying it off with a athead screwdriver.
Align the Door Bottom 5 with the panel and mark cut line within 1/32". Cut line should
match length of panel (X).
REMOVE DOOR FROM HINGES
*Remove any caulk from the panel and kerf slots using a scraping tool .
Cut down the Door Bottom 5 to match the length of the panel (X).
a)
b)
c)
i)
j)
c)
Align Door Bottom ush with the lock side of the panel and insert
kerfs into slots on door.
Proceed to step 11.
i)
b)
Cut Line
X
Cut Line
X
a)
FOR SINGLE, SIDELITE, HINGED PATIO AND FRENCH DOOR UNITS
Z-AC Door Bottom Gasket
Kerf Relief Slits
Solid Edge
1-1/4” or greater
1-1/4” or
greater
d) e) f)
1-1/4"
Cut Lines
1.
Cut Lines
2.
Using a stiff scraping tool, remove the existing Door Bottom Gasket from the end of the
door bottom. If no Gasket is present or has been cut off completely, skip to step 2.
Measure the location of the Kerf Legs. Kerf legs should be trimmed back 1-1/4" or more
from the edge of the door bottom. If 1-1/4" or greater notch is present, proceed to step 4,
If not proceed to step 3.
Be sure to completely remove all residue from the old gasket to assure the new
pad adheres properly.
1.
d)
e)
f)
2.
If less than a 1-1/4" notch is present, re-notch the Kerf Legs to at least 1-1/4" by
clipping the Kerf Legs.
Measure and mark the Kerf Legs at 1-1/4" from the edge of the Door Bottom. Cut
the Kerf Legs down with a cutting tool to the base of the Door Bottom.
From the edge of the Door Bottom, trim the Kerf Legs at the base back to the cut
made in the previous step and remove.
BE CAREFUL NOT TO CUT INTO THE DOOR BOTTOM.
h)
g)
Align and Apply New Door Bottom Gasket to Z-AC Door Bottom
• Align the Solid Edge of the Door Bottom Gasket with the outer edge of the Z-AC
Door Bottom as shown. Once aligned, tip and press Gasket rmly into place,
ensuring that the Door Bottom Kerf Legs protrude through the Gasket Relief Slits,
while the Gasket Solid Edge remains aligned ush with the Door Bottom Edge.
Remove paper backing from the Door Bottom Gasket.
• Peel the protective paper layer covering the adhesive on the back of the Door
Bottom Gasket off and discard.
g)
Flush
Flush
Door Bottom
Kerf Legs
h)

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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11. Stapling Door Bottom to Panel (ZAI-AA to ZAC-AA)
Attach Door Bottom with two 1/2" crown staples and 80 PSI of
air pressure at ends between the rigid ramp and ex ns.
STAPLE ON SWEEP- If using a staple-on door sweep, staple on both
sides approximately every 6"along the length of the door.
Proceed to step 12
a)
b)
c)
1/4" Crown Staple 1/2" Crown Staple
Incorrect Size Staple Correct Size Staple
When stapling the Z-AC Door bottom to the panel, staples should
be inserted between the Rigid Ramp and Flex Fins. Staples should
be aimed away from the kerf slots in the bottom of the panel to
prevent cracking of the door bottom, or damage to the kerfs.
The insertion of staples at an angle or in the wrong location will
result in damage to the door bottom
Only 1/2" crown staples should be used to secure the door bottom to the
panel. The use of staples with a shorter crown such as crown 1/4"staples
will result in cracking and damage to the door bottom.
a)
Rigid
Ramp
Rigid
Ramp
Flex Fins
Staples
b)
Wrong staple
location
Wrong staple
location
Angled into
kerf
Use 80 PSI of air pressure to insert
staples. Endura suggest using an air
pressure regulator for best results.
Staple position Along the Length of Panel
6”
6”
6”
6”
6”
6”
1/4"1/2"
PSI
Required Air Pressure
FOR SINGLE, SIDELITE, HINGED PATIO AND FRENCH DOOR UNITS

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
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NOTE: For best performance, Do not reapply
old/used corner pad. Replace with a new
Simple Solution Corner Pad for this step.
Ensure that the old corner pad has been
removed from each jamb. a)
a) b)
c)
Jamb Jamb
Weatherstrip
Corner Pad
Corner Pad ush with interior side
of jamb
For Strike Margins greater than 5/32"For Strike Margins less than 5/32"
Corner Pad Flush with the
weatherstrip kerf
Weatherstrip
Corner Pad
12. Replace Corner Pads (ZAI-AA to ZAC-AA)
If you have any questions, please contact your Endura Sales Representative or call Customer Service: 1-800-334-2006
13. Check the Operation of the Door
Ensure that the door opens and closes smoothly.
Ensure the cap operates properly up and down as the door is opened and closed.
Ensure that Door Bottom makes contact with the Z-AC as the door is closed.
Ensure the Panel makes contact with the Corner Pad and Z-End Bases.
Close and open the door several times
a)
b)
c)
d)
8817 W. Market St., Colfax, NC 27235
1.800.334.2006 www.enduraproducts.com
The information contained in this document is the condential and proprietary information and trade secrets of Endura Products, Inc. Any disclosure, use or dissemination of
such information without the express written permission of Endura Products, Inc. is strictly prohibited. Endura Products, Inc. also owns any and all intellectual property rights
embodied in such information, including patent rights, copyrights, and trademark rights, and no license of any intellectual property right is intended, nor should any license
be implied, as a result of the receipt of this document.
US Patents: 6,789,358; 7,350,336; 8,522,483; 8,991,100; 8,991,101; D722,388; D638,958; D722,387; D722,388; D713,976 and Patents Pending.
Canadian Patents: 2,771,705; D139,250 and Canadian Patents Pending.
FOR SINGLE, SIDELITE, HINGED PATIO AND FRENCH DOOR UNITS
Remove backing paper from Simple Solution
Corner Pad 4 to expose adhesive.
a)
b)
d)
e)
c)
Align Simple Solution Corner Pad with the
top of Z-End Base.For margins less or equal
to than 5/32", apply the corner pad with the
locator edge ush against the weatherstrip
kerf, and for margins greater than 5/32",
apply the corner pad with the locator edge
ush against the interior jamb.
Repeat Steps a - c for the second jamb
Proceed to step 13
Ensure the Simple Solution Corner Pad
contacts the top surface of the Z-End Base
and press rmly into place on to jamb.
4

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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ZAC-AA Features
Z-Series Articulating Cap All-Aluminum Sill (ZAC-AA )
Z-End Base
• Slanted Cap
• Z-End Bases with Weatherstrip Locator
ZAC-AA Sill
• Pin Capture Under Cap

15
(If Present) Remove Simple Solution
Corner Pad from each jamb by peeling
it off.
Clean any residual debris and dirt from
the jamb.
Proceed to Step 2.
Remove the weatherstrip by pulling it
out of the kerf slot
1. Remove Corner Pads (ZAC-AA to ZAC-AA)
b)
c)
d)
b)
TOP DOWN
VIEW
of Simple
Solution
Corner Pad
Weather-
stripping
a)
a)

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
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2. Remove ZAC-AA (ZAC-AA to ZAC-AA)
a)
b)
c)
d)
e)
f)
g)
h)
j)
a) b) c)
e1)
g)
f)
Starting at the end of the sill, depress
the cap to its downward position.
Grasp the front of the cap near the sill’s
dam and rotate it backwards towards
the interior side of the sill.
Once the end of the cap is no longer
attached to the sill, simply pull the cap
up and out of the sill.
Gasket refers to the foam sealing
pad attached to the Z-End Base.
DO NOT ATTEMPT TO REMOVE
THE Z-END BASE
Clean any debris out of sill channel
Remove the weatherstrip (e1) and using
a scraping tool, remove visible portion
of the foam sealing pad (gasket) from
the Z-End Base (e2). Do no remove the
plastic Z-End Base, just the foam pad.
Carefully apply Silicon on the dam of
the sill to ll in any gaps that will be
created when installing Active Mull
Stiffener Gasket 3 in place of the
damaged Z-End Base’s Gasket
Apply new Active Mull Stiffener Gasket
3 to the Z-End Base in place of the old
gasket pad.
Reinstall weatherstrip.
Proceed to step 3
Orientation of Active Mull Stiffener Gasket
Active Mull Stiffener Gasket
Exterior
e2)
3
3
3
h)
Weatherstrip
SINGLE AND FRENCH DOOR UNITS
Grasp Cap
here.
Rotate

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
17
3. Remove ZAC-AA (ZAC-AA to ZAC-AA)
d)
e)
f)
g)
h)
i)
e) f)
Clean any debris out of sill channel
Remove the weatherstrip
Reinstall weatherstrip.
Proceed to step 4
Remove the installed Z-End Base Mull
Stiffener and discard it.
Weatherstrip
Insert new Z-End Base Mull Stiffeners
2L & 2R into each side of the channel
against the jambs
NOTE: The Z-End based are handed and
can only be inserted one way. The back
of the Z-End Base Mull Stiffener should
be ush with the face of the jamb.
h)
NOTE: Do not remove the orange
protective gasket label until cap is
fully installed into the door unit.
Jamb
Z-End Base Mull Stiffeners
2L 2R
FOR SIDELITE, HINGED PATIO AND PREVIOUSLY RETROFITTED UNITS
g)22
a)
b)
c)
a) b) c)
Starting at the end of the sill, depress
the cap to its downward position.
Grasp the front of the cap near the sills
dam and rotate it backwards towards
the interior side of the sill.
Once the end of the cap is no longer
attached to the sill, simply pull the cap
up and out of the sill.
Rotate
Grasp Cap
here.

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
18
Measure the length of the sill without black Z-End Base Assemblies (X).
Measure the length of the sill without black Z-End Base Assemblies (X). Measure and mark the centerline of the Cap
CAUTION: Measure carefully and cut precisely within 1/32” to ensure proper operation. A cap
cut too short will not seal correctly.
CAUTION: Measure carefully and cut precisely within 1/32” to ensure proper operation. A
cap cut too short will not seal correctly.
4. Cut NEW Z-Articulating Cap to Length (ZAC-AA to ZAC-AA)
a)
a) b)
c)
d)
x
x
Proceed to step 5
Proceed to step 5
Sill Length w/o Z-End Bases (x)
X/2 X/2
Cap Centerline
FOR FRENCH (DOUBLE) DOOR APPLICATIONS
FOR SINGLE, SIDELITE & HINGED PATIO DOOR APPLICATIONS
Cut Here
If needed, move the bases at the end of the caps to the inside (1/2”from the end)
Note: With Field Replacement of Existing ZAC-AA Sill, sill length has been cut down to accommodate
Z-End Bases. New ZAC-AA Cap Should be the same length as the old ZAC-AA cap.
Note: With Field Replacement of Existing ZAC-AA Sill, sill length has been cut down to accommodate
Z-End Bases. New ZAC-AA Cap Should be the same length as the old ZAC-AA cap.
1S
1F
b) Measure and cut new cap 1s to match length of the sill minus 1/4".
c) Measure and cut new cap 1F to match length of the sill minus 1/8" on each side.
Cut from both ends of the cap to ensure centerline remains in the center of the cap.

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™FIELD REPLACEMENT INSTRUCTIONS
19
5. Apply Spring Loaded Cap Bases (ZAC-AA to ZAC-AA)
a)
a)
b)
b)
SINGLE, SIDELITE AND HINGED PATIO DOORS ONLY
Ensure that all 6 spring-loaded bases are used and properly positioned.
Ensure that all 3 spring-loaded bases are used
and properly positioned.
Proceed to step 6
Proceed to step 6
FRENCH (DOUBLE) OPENING DOORS ONLY
1” to 1-1/2” Y Y 1” to 1-1/2”
1"to 1-1/2"
Bases
YY Y YY
1S
1F
The spring-loaded bases at the ends of the cap should be 1"to 1-1/2"from the cap’s edge.The 4
center spring-loaded bases should be evenly spaced between the 2 spring-loaded bases at the
ends of the cap, approximately 12"- 13"inches apart (Y).
The spring-loaded bases at the ends of the cap
should be 1"to 1-1/2"from the cap’s edge.The
spring-loaded center base should be evenly
spaced between the 2 spring-loaded bases
at the ends of the cap, approximately 12"-15"
inches apart (Y).

ENDURA PRODUCTS >INSTRUCTIONS> ALL-ALUMINUM Z-AC™ FIELD REPLACEMENT INSTRUCTIONS
20
Proceed to step 7.
6. Insert NEW Sill Cap (ZAC-AA to ZAC-AA)
FOR SINGLE, SIDELITE, HINGED PATIO AND FRENCH DOOR UNITS
a)
b)
c)
Press one end of cap 1 into channel and
against Z-End Base/ Mull Stiffeners 2 .
Depress the cap 1 , to gain access to the orange
protective labels on each Z-End base/ Mull Stiffener
(If Present) and remove.
Install the opposite end of the cap 1 into the sill by
bringing it straight down into the Sill channel and
against Z-End Base/ Z-End Base Mull Stiffener 2 .
Apply Pressure to the cap 1 to fully seat cap into
place along entire length of sill.
b)
d)
d)
a)
c)
Sill Dam should contact the bottom side of the top of
the cap, and the angled leg of the cap should contact
the back side of the Sill Dam
Sill Dam Should
contact cap