Kohler STERLING 6500 Series User manual

Installation Guide
Hinge Shower Door
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6500 Series
1034028-2-F

Tools and Materials
Thank You For Choosing Sterling
We appreciate your commitment to Sterling value. Please take a few minutes to review this manual before
you start installation. If you encounter any installation or performance problems, please don’t hesitate to
contact us. Our phone numbers are listed within this manual. Thanks again for choosing Sterling.
Before You Begin
WARNING: Risk of personal injury. Do not cut the tempered glass. If the glass is cut, the glass
will shatter and may cause personal injury.
Your new Sterling door can be installed with the door opening to either the right or left. Install the
door with the pivot side away from the showerhead for best results.
Before starting the installation, lay out and identify all of the parts. Inspect them for damage.
Closely follow the instructions pertaining to the sealant application on the door. Sealing areas other
than those shown may cause leaking.
Two people should perform this installation.
Sterling reserves the right to make revisions to the design of products without notice, as specified in
the Price Book.
Determine the Door Configuration
IMPORTANT! Install the pivot side of the door on the side opposite the showerhead.
Determine whether the door will pivot on the right or left side.
Make sure the door can swing freely in the chosen configuration.
Safety Glasses
Level
Caulk Gun
File
Knife Miter Box
Plus:
Drop Cloth
Pencil & Felt
Tip Marker
Claw
Hammer
Tape
Measure
Masking
Tape
Silicone
Sealant
Center
Punch
Drill and
Assorted
Drill Bits
Miter Saw or Hacksaw with
32 Teeth per Inch Blade
Assorted
Screwdrivers
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Parts Identification
Filler Jamb
Wall Jamb
Hinge Jamb
Hinge
Door Panel Assembly
Strike Jamb
Strike Side Wall Jamb
Wall Jamb
Towel Bar
Bottom Seal
Bottom Track
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1. Measure and Cut the Bottom Track
IMPORTANT! Risk of product damage. If your shower has a curve in the corners where they meet the
sidewalls, be sure to measure from wall to wall above the curves. Failure to measure above the curve or
angle could result in the bottom track being cut too short.
Carefully measure the width (distance D) of the finished opening.
Consult the chart below to determine whether or not your installation will need a filler jamb.
Model # Dimension D Filler Jamb Required?
65**-30 27-1/2″(69.9 cm) - 29-1/2″(74.9 cm) Not needed
65**-30 29-1/2″(74.9 cm) - 30-1/2″(76.2 cm) Needed
65**-33 30-1/2″(76.2 cm) - 32-1/2″(82.6 cm) Not needed
65**-33 32-1/2″(82.6 cm) - 33-1/2″(85.1 cm) Needed
65**-36 33″(83.8 cm) - 35″(88.9 cm) Not needed
65**-36 35″(88.9 cm) - 36″(91.4 cm) Needed
65**-39 36-1/2″(92.7 cm) - 38-1/2″(97.8 cm) Not needed
65**-39 38-1/2″(97.8 cm) - 39-1/2″(100.3 cm) Needed
NOTE: If dimension ″D″falls in a range that can be either with or without the filler jamb, use the filler
jamb in your installation.
If your installation does not require a filler jamb, subtract 2-3/4″(7 cm) from dimension ″D″and cut
the bottom track to this dimension. For best results, use a 32-teeth hacksaw blade and a miter box.
If your installation does require a filler jamb, subtract 3-3/4″(9.5 cm) from ″D″and cut the bottom
track to this dimension. For best results, use a 32-teeth hacksaw blade and a miter box.
Measure carefully. If your walls
are curved or angled, measure above the curve or
angle. Failure to do so can result in an improperly cut
bottom track and can void the warranty.
Warning:
Measure
here.
Measure
here. Measure distance
"D" above curves
in the corners.
Angled
Base
Curved
Base
D
Bottom Track
Shower Ledge
Front Edge
Inside of Shower
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Measure and Cut the Bottom Track (cont.)
File the rough edges smooth where the bottom track was cut, taking care to avoid damaging
finished surfaces.
NOTE: If there are curves where the sidewalls meet the threshold, contour the wall jamb edges to match
the curves.
Locate the bottom track on the shower ledge. It should be located on the flattest part of the ledge.
Position the bottom track so the gaps between the track and the wall are identical at both ends.
Make sure the bottom track is placed so it is an equal distance from the front edge of the shower
ledge at all points.
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2. Install the Adjustment Clamps
Insert four adjustment clamps into each wall jamb as shown (eight total).
Partially thread the provided panhead screws through the pre-drilled holes in the wall jambs and
into each adjustment clamp using a Phillips screwdriver. Do not tighten the screws at this time.
Note:
Do not fully
tighten screw.
Adjustment Clamp
#8-18 x 3/4" Screw
Wall Jamb
Wall Jamb
Top View
Wall Jamb
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3. Install the Wall Jambs and Optional Filler Jamb
With a pencil, mark the location of the wall jamb on the shower wall. Measure evenly on both sides.
Place the wall jamb against the wall and check for plumb with a level. The adjustment clamps will
be located closer to the inside of the shower.
Make a pencil mark at each of the four pre-drilled holes in the wall jamb and remove the wall jamb.
Lightly center punch the four hole locations on each wall.
When the installation is on ceramic tile, use the center punch to nick the surface glaze. Tap the
punch lightly with the hammer to avoid cracking the ceramic tile.
Drill each hole with a 5/16″drill bit (use a masonry bit for ceramic tile).
Press and hold the legs of each wall anchor (provided) together and insert the wall anchor legs into
the pre-drilled mounting holes.
Repeat for all the wall anchors.
If your installation requires a filler jamb, position the filler jamb over the holes.
Secure a wall jamb in place (over the filler jamb if needed) using four provided panhead screws.
Repeat for the other wall jamb, skipping filler jamb procedures.
Remove the bottom track and thoroughly clean the shower ledge.
Wall Jamb
Wall Jamb
Top View
Wall Jamb
#8-18 x 2"
Panhead Screw
Filler Jamb
Filler Jamb
With Filler Jamb
Without Filler Jamb
Anchor
Drill holes.
Press and hold legs together.
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4. Caulk and Install Bottom Track
Insert the bottom track and check for proper fit. The lip of the bottom track should face toward the
outside of the shower. The ends of the bottom track should fit snugly against the front protrusions
in the wall jambs.
Remove the bottom track and apply silicone sealant in the groove at the bottom front edge of the
bottom track.
Install the bottom track.
5. Assemble the Hinge Jamb
Lay the hinge jamb on the floor or on a workbench. Use a drop cloth to protect the product finish.
Insert the front side of the hinge into the slot on the hinge jamb.
Secure the hinge to the hinge jamb using four provided flathead screws. Make sure the top edge of
the hinge is flush with the top edge of the hinge jamb before tightening the screws.
Align the slotted holes on the hinge with the channel in the door panel. Make sure the top edge of
the hinge assembly is flush with the top of the channel.
Apply sealant.
Note:
Use silicone
tub & tile type caulk.
Bottom Track
Bottom Track
Wall
Jamb
Flathead Screw
#8-18 x 1/2"
Hinge
Hinge
Hinge Jamb
Hinge Jamb
Hinge Jamb
Insert the hinge
into the slot
making sure the
top edges are flush.
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6. Install the Hinge to the Door Panel
Secure the hinge to the door panel using four of the provided panhead screws.
Install the hinge jamb cap on the top of the hinge jamb where it aligns with edge of door.
NOTE: Leave a small gap on the handle side of the door for clearance from the strike jamb. The door will
not close properly without this gap.
Bottom Seal
Bottom View
Hinge Jamb Cap
Door Panel
Door Panel Hinge Assembly
Hinge Jamb Cap
#8-18 x 3/8" Panhead Screw
Hinge Jamb Cap
Assemble, making sure
top edges are flush.
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7. Install the Flat Seal
Slide the seal into the door panel seal holder with the fabric edge out.
Install the seal holder to the base of the door panel with the four screws provided.
Trim off any excess seal using a utility knife.
Pull out any fabric threads that jut out horizontally from the seal.
Fabric Seal
Seal Channel
Fabric Seal
Seal Channel #8-18 x 3/8"
Panhead Screw
Pull out horizontal
threads.
Note:
Cut off excess
fabric seal length.
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