Kohler 97631-G9 Assembly instructions

Installation and Care Guide
Locker with Wall Panels
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Table of Contents
Tools and Materials ............................................................... 2
Before You Begin ................................................................. 3
Plan the Installation ............................................................... 4
Prepare the Site ................................................................. 5
Measure Components ............................................................. 6
Trim the Locker and Walls .......................................................... 8
Dry Fit the Locker and Walls ........................................................ 9
Install the Corner Joints (Optional) ................................................... 10
Install the First Wall Panel ......................................................... 11
Prepare the Locker Unit ........................................................... 12
Install the Locker Unit ............................................................ 13
Install the Second Wall Panel ....................................................... 14
Check the Locker Unit Fit .......................................................... 15
Prepare the Corner Joints (Optional) .................................................. 16
Install the Sidewall Panels ......................................................... 17
Install the Edge Trim (Optional) ..................................................... 18
Seal the Enclosure ............................................................... 19
Complete the Installation .......................................................... 20
Care and Cleaning ............................................................... 20
Warranty ...................................................................... 20
Tools and Materials
Jigsaw with
Grit Blade and
Fine Toothed Blade
Denatured Alcohol
Rags
Shop Vacuum
Breathing
Protection
Drill & Hole Saw
(size will vary)
Plus:
• Standard Woodworking Tools
• Spring Loaded Braces or Lumber
(to create bracing)
• Sawhorses
• Drop Cloth
Sanding Block
1-2 Tubes Color Matched
100% Silicone Sealant
Caulk Gun
7-1/4" Circular Saw
and Masonry Blade
8+ tubes Non-Solvent
Based Construction Adhesive
(Silicone Adhesive when installing over tile)
Masking
Tape
DENATURED
ALCOHOL
Duct
Tape
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Before You Begin
WARNING: Risk of serious injury. When cutting walls and locker, take appropriate safety
measures including the use of breathing protection.
CAUTION: Risk of serious injury. Always wear safety glasses while cutting and drilling.
CAUTION: Risk of serious injury. If the ceiling will be covered with the wall material, the ceiling
must be installed prior to the wall panels. Allow sufficient time for the ceiling installation to cure
before installing the wall panels or the ceiling can fall during installation, causing injury.
CAUTION: Risk of product damage. The wall panels should be room temperature before cutting. Allow
the temperature to stabilize if the walls were in a cold environment.
IMPORTANT! Dust will be generated when cutting the wall panels and locker unit. Cutting the walls
and locker should be performed outside or in a well ventilated area.
IMPORTANT! For best results, cut the walls using a masonry blade. Do not use a blade with teeth.
IMPORTANT! Leave this manual for the end user.
Read these instructions before installing or using this product:
•The locker unit must only be trimmed in height. Do not cut down the sides.
•The existing rough walls must be within 3/8″(10 mm) of plumb.
•The locker unit must be braced using 2x4’s around the entire unit.
•Use color matched silicone sealant in the joints and around the locker unit.
•Check all joints, walls, and accessories for proper color before beginning installation.
•Cover the shower base with a drop cloth or other protective material to avoid damage.
•Follow the construction adhesive and silicone sealant instructions for application and curing time.
•Inspect all components for damage after unpacking, prior to installation.
•A router may be used to cut the walls and locker. The router bit will dull quickly.
•If the wall panels are being installed over existing tile, scuff the tile using 100 grit sandpaper for
better adhesive contact.
•If installing accessories, install 2x4 backing for handrails, shelves, and hooks.
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Plan the Installation
NOTE: Determine which accessories will be installed and where before installing wallboard backing
material, as accessories may require wood bracing.
Install any required bracing.
2x4 bracing is required for the hook unless it is installed into the studding.
2x4 bracing is required for all handrails and shelves.
Accessories
Shelf
Shelf
Shelf
Hook
24" (610 mm) Handrail
36" (914 mm) Handrail
40" (1016 mm) Handrail
54" (1372 mm) Handrail
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1. Prepare the Site
IMPORTANT! Water resistant wallboard backing material is recommended.
Install the rough plumbing for the bath and shower components.
Check the studs for plumb. Studs should be within 3/8″(10 mm) of plumb, shim if necessary.
The ledge of the locker unit can be used as a footrest. The recommended footrest height is 12” (305
mm) to 16” (406 mm), from the floor of the shower to the ledge of the locker unit.
Determine the height of the enclosure and the locker unit.
Install 2x4 bracing where the locker unit will be placed following the dimensions shown above.
To determine the height of the bottom bracing, subtract 1” (25 mm) from the desired height of the
footrest.
Install backing support for all accessories that require additional support. Refer to the installation
guides packed with each product for specific installation needs.
Install wallboard backing material over the locker unit opening with the same dimensions as the 2x4
bracing cut out.
65"
(1651 mm) K-97630: 9" (229 mm)
K-97631: 14-1/2" (368 mm)
2x4 Bracing
K-97630: 9" (229 mm)
K-97631: 14-1/2" (368 mm)
Wallboard
Backing
65"
(1651 mm)
11" (279 mm) Min
15" (381 mm) Max
11" (279 mm) Min
15" (381 mm) Max
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2. Measure Components
Determine if edge trim will be installed.
Order optional edge trim as needed.
Back Wall Measurement
Measure the installation area to determine the cut dimensions for the wall panels.
Subtract half the total width of the locker unit from the width of each back wall panel.
If corner joints will be installed, subtract 1/16” (2 mm) from the width of the wall panels for each
corner joint.
Mark the cut lines on the back side of the back wall panels.
Sidewall Measurement
If corner joints will be installed, subtract 5/16” (8 mm) from the width of each wall panel before
cutting.
Record the location of the handle, showerhead, bath spout, and other components.
Mark the cut lines on the back side of the sidewall panels.
Optional: Installation with Ceiling Panels
CAUTION: Risk of injury. Install the ceiling panel prior to installing the wall panels. Allow the
adhesive to cure before installing the wall panels.
If the ceiling will be covered with the panel material, measure and cut the ceiling panel to size.
Construct bracing or use commercial bracing to hold the ceiling panel in place while it cures.
NOTE: Polyurethane based adhesive is recommended for the ceiling panel.
Apply construction adhesive to the ceiling material as shown in ″Install the First Wall Panel″
section.
With a partner, carefully lift the ceiling panel into place.
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Measure Components (cont.)
Brace the ceiling panel tight against the ceiling and allow it to cure following the adhesive
instructions.
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3. Trim the Locker and Walls
Cut Wall Placement
IMPORTANT! The cut edges of the wall panels MUST be positioned opposite the locker unit. The vertical
edge of the locker unit MUST mate to an uncut, bevel molded edge on the wall panels.
Cutting the Walls and Locker
IMPORTANT! It is recommended the wall panels be cut using a power saw and abrasive wheel or an
abrasive masonry blade.
IMPORTANT! Do not cut the sides of the locker unit. Only trim the top or bottom to fit your wall length.
IMPORTANT! The locker unit must be placed with the shelf grooves angled upward. If the locker unit is
placed upside down the shelves will fall out.
Position the back wall panel face down on a stand or sawhorses that have a protective material on
them.
Cut the back wall panel to the required dimensions. Use a jigsaw with a grit blade for contour cuts.
Repeat with the sidewall panels.
From the front side of the sidewall panel, use a hole saw to cut the holes for valving and other
shower components.
NOTE: Remove any protective films on the locker unit surface before cutting.
Cut the locker unit to the required height dimensions using a fine toothed blade.
IMPORTANT! It is critical the wall panels and locker unit are clean for a strong bond to be created by the
adhesive.
Remove excess material and sand any rough edges using a sanding block.
Clean the back of the wall panels and locker unit with denatured alcohol.
Back Side
Sanding Block
Cut Edge
Uncut Edge
Sidewall
Panel
Shower Valving
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4. Dry Fit the Locker and Walls
Dry fit the corner joints to the back wall panels if they are being installed. See ″Install the Corner
Joints (Optional)″for correct orientation.
Dry fit the locker unit, back, and sidewall panels with shims to confirm fit. Adjust as needed.
Remove the wall panels and locker unit. Remove the corner joints.
Shim
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5. Install the Corner Joints (Optional)
Measure the height of the back wall panel.
Cut the corner joint to the height of the back wall panel using a small rotary tool with a cutting
wheel.
Apply color matched sealant in the deep channel groove on the corner joint. Apply enough sealant
to fill 1/2 of the groove.
Install the deep channel of the corner joint on the side of the back wall panel.
Do Not apply sealant or install the second corner joint until you are ready to install the second back
wall panel.
Deep Channel
Sealant Shallow
Channel
Top View
Back Wall with Joints
Deep
Channel Shallow
Channel
Top View
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