Sapa ALUMAX 1040 Series User manual

INSTALLATION
INSTRUCTIONS
1040 & 1050 SERIES
HEAVY FRAMELESS BYPASS
BATH ENCLOSURE
Copyright © Alumax Bath Enclosures 2014. All rights reserved.
G03711095
11-4-14
www.alumaxshowerdoor.com


January12,2015
!WARNINGS!
INSTALLATION WARNINGS
a) Alumax Bath Enclosures by Sapa are intended to be installed by an experienced installer. If you need assistance with
locating an experienced installer, contact us at 1.800.643.1514 or go to our website www.alumaxshowerdoor.com to access
our “dealer locator”. If a dealer is not listed in your area, call or send us an e-mail and we will find one for you.
b) The enclosure must be properly installed per our published installation instructions. If NOT, the unit will not operate as
designed which will cause hardware failure, glass breakage, leaking, other unidentified issues, and may cause nullification
of warranty.
c) 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 into 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.
d) Before beginning installation, check the tub rim for level and both walls for plumb. If either is off more than ¼” to 3/8”, you
should use a tapered filler which can be used to level the tub track or plumb the wall jambs.
e) Wear safety glasses when drilling or cutting to avoid injury to the eyes.
f) 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. A skidding drill can cause damage to the surface and can be dangerous (risk of personal
injury).
g) Use caution and proper technique whenever using tools to avoid damage to property and/or personal injury.
GENERAL USAGE AND HANDLING WARNINGS
a) Shower doors are not leak-proof. They are designed to direct water to the interior of the tub or shower under normal
conditions. Excessive water pressure or directing the shower head directly at the door can result in leaks.
b) Do not hang on towel bars or handles or use them to support your weight getting in and out of the bathtub or shower.
Towel bars and handles are not intended to be used as grab bars for assistance getting in and out of the shower or bathtub.
They are not intended to support a person’s weight and could break.
c) Do not use excessive force when opening and closing the enclosure. Excessive force can lead to glass breakage or other
damage to the enclosure. Make sure wall jamb bumpers are securely fastened in place per the installation instructions.
GLASS USAGE AND HANDLING WARNINGS
a) TEMPERED GLASS CANNOT BE CUT. Attempting to cut tempered glass will result in the glass breaking or shattering.
b) USE CAUTION WHEN HANDLING GLASS PANELS. Safety tempered glass is very resistant to breakage, but it can still
break if unequal pressure is placed on it during installation (or if cutting of the glass is attempted). In addition, the sharp
corners of the panels can damage tile and floor coverings or cause injury.
c) PROTECT THE EDGES OF THE GLASS. Never let the edge of the glass come in direct contact with concrete, tile, marble
or other hard surfaces that may nick, or damage the glass edge in any way as this damage may cause a delayed blow.
Always check the edge of the glass for nicks, slivers, rough areas, or clam shelling. Do not install the glass if these
conditions are present.
d) Alumax Bath Enclosures by Sapa is not liable for glass breakage of any kind.
CARE AND CLEANING WARNINGS
a) The simplest and preferred method of cleaning your unit is by washing it with clean water and drying with a soft cloth.
b) If soil is still present after drying, a non-abrasive cleanser with a pH of seven to eight may be used. Comet Bathroom
Cleaner® has been tested and is recommended by the Bath Enclosure Manufacturers Association (BEMA).
c) Contact your dealer for more information about glass coatings that will help keep the glass clean.
d) DO NOT USE SCOURING PADS, SHARP INSTRUMENTS, BLEACH OR ACID-BASED CLEANSERS TO CLEAN THE
UNIT AS THEY MAY DAMAGE THE UNIT.
LIMITED WARRANTY
a) Alumax Bath Enclosures by Sapa provides a LIMITED WARRANTY on material and workmanship only. Primary glass and
component suppliers must be included in all warranty claims.
b) Alumax Bath Enclosures by Sapa is not responsible for glass breakage.
c) Products must be handled, installed and maintained per our published Warning and Installation instructions or the warranty
may be nullified.
d) The Limited Warranty applies to the original owner only, and is not transferable.
e) Please visit our website www.alumaxshowerdoor.com or call us at 1.800.643.1514 to get copies of our published warranty,
installation and warranty policies.

Page 3 of 8 G03711095
11-4-14
1040/1050 PARTS LIST
A. 1 Tub Track B. 2 Wall Jambs C. 6 Wall Anchors D. 6 #8 x 1 1/2" Truss Head Screws E. 4 Jamb Bumpers F. 1 Header G. 4 Hanger Brackets H. 2 Glass Door Panels I. 4 Nylon Bushing J. 4 1/4" x 5/8" Flat Head Screws K. 4 Roller Bearings L. 4 #8 x 3/8" Hex Head Screws M. 4 Large Hole Plastic Washers N. 4 End Caps O. 4 Glass Inserts
P. 2 Towel Bars Q. 4 Small Hole Plastic Washers R. 4 Metal Washers S. 1 Wrench (Not Shown) T. 3 Clear Panel Guides U. 3 #6 x 3/8" Pan Head Screws V. 1 Vinyl Silencer

Page 4 of 8G03711095
11-4-14
Use a level to plumb both wall jambs [B], then mark
the pre-drilled hole locations on the wall. Lightly mark
both sides of the tub track [A] with a pencil, and then
remove all the parts.
For tile or marble walls, drill six 7/32” diameter holes and
insert the plastic wall anchors [C]. A center punch helps
locate the holes accurately.
Attachments to fiberglass or acrylic units can be made in
2 ways. If reinforcement is built into the wall of the unit,
drill six 1/8” diameter holes and install the screws directly
into the reinforcement. If the walls are not reinforced, drill
six 7/32” diameter holes and insert the plastic wall an-
chors or molly bolts (molly bolts not supplied by Alumax).
CAUTION: The tub track should never be screwed to
the tub. This will damage the tub and cause leakage.
1
2
Measure the wall-to-wall opening along the center
of the tub rim. Cut the tub track [A] 1/16” short of this
dimension. An inexpensive miter box available at your
local hardware store will help you get clean square cuts.
If the vinyl silencer [V] is separate from the tub track [A]
slide the silencer into the slot in the tub track and trim
to the same length.
Position the tub track in the center of the tub rim with
the tall leg to the exterior. It may be necessary to file
a radius on the ends of the tub track and wall jambs to
match the corners of the tub.
Press both wall jambs [B] into position over the tub track.
Masking tape can be used to hold all the parts in place
temporarily.
3
Before replacing the tub track [A], force a slight
downward bow in the extrusion. This will ensure the
track fits tight to the sill. Run a bead of caulk on both flat
surfaces on the bottom of the tub track. Then replace
the track on the bath sill in the exact position marked in
Step #2and with the tall leg to the exterior of the bath.
Seat the tub track firmly.
NOTE: Improper caulking will result in leaks.
TUB
TRACK

Page 5 of 8 G03711095
11-4-14
4
6
NOTE: Obscure glass doors should be installed with
the rough surface of the glass to the exterior of the unit.
Deco or etched glass doors should be installed with the
patterned surface to the inside. The towel bar mounting
hole closest to to the edge of each glass panel should
be to the outside.
Determine the proper orientation of the door hanger brack-
ets [G] to the glass door panels [H]. Fit four of the nylon
bushings [I] into the 3/8" diameter holes in the top edge
of the door panels. Slide the four hanger brackets onto
the top edge of the panels until the countersunk holes
line up with the bushings. Secure the brackets to the
door panels with four 1/4"-20 x 5/8" [J] flat head screws.
This bath enclosure is equipped with safety tee-
lock wall jambs. When installed properly the header is
permanently locked to the wall jambs and cannot be
accidently dislodged.
Measure the wall-to-wall opening at the top of the wall
jambs [B] and cut the header [F] 1/16” short of this
dimension. Check the header for fit.
Slide the safety tee-lock of the unmounted wall jamb
into the header.
Holding the header [F] at an angle, engage the end
onto the mounted wall jamb. Pivot the header into
place, then slide the loose wall jamb to the wall and
press into position on the tub track. Attach the loose
wall jamb to the wall per the instructions in step 4.
NOTE: If you are using the optional Anti-Jump vinyl, you
need to insert it into the end of the header at this point. It
cannot be installed once the header is mounted.
Replace one wall jamb [A] and attach it to the wall
with three #8 x 1 1/2” truss head screws [D]. The top
and bottom screws should go through a Jamb Bumper
[E]. Check the jamb for plumb and tighten the screws.
Repeat for the other wall jamb.
Note: Do not over tighten the wall jamb screws.
5
FLAT HEAD
SCREW
DOOR
PANEL
NYLON
BUSHING
END
VIEW
HANGER
BRACKET

Page 6 of 8G03711095
11-4-14
7
Attach the four one inch roller bearings [K] to the
door hanger brackets [G] as shown, using #8-32 x 3/8”
hex head screws [L]. The rollers should be in approxi-
mately the top quarter of the diagonal slots in the bracket
fins.
8
Before installing the door panels, the proper orienta-
tion should be determined. For maximum water-proofing,
the interior panel should always be positioned closest to
the shower head, as shown in this illustration.
Lift the interior door panel [H] (exterior surface
closest to fin) into position with the roller bearings [K]
engaging the roller slot in the header [F]. If the door
panel is not parallel to the wall jambs, remove and adjust
the roller bearings up or down to compensate.
Repeat for the exterior door panel (exterior surface away
from the fin).
9

Page 7 of 8 G03711095
11-4-14
12
10
Locate the four, large hole, plastic washers [M]
and place them over the threads and flush with the four
end caps [N]. Next, place the four glass inserts [O] onto
the four end caps [N] and flush with the plastic washers
[M]. In step 6 the interior and exterior panels were deter-
mined by setting the orientation of the hanger brackets
[G]. The towel bars [P] will be installed on the same side
of the panels as the rollers in the hanger brackets [G].
Insert the threaded portion of an end cap [N] through
one of the holes in a glass panel [H], making sure that
it is located on the opposite side from the rollers on the
hanger brackets [G]. Place a, small hole, plastic washer
[Q] and a metal washer [R] on the end cap threads. Now,
loosely, thread the towel bar [P] onto the exposed threads
of the end cap [N]. Make another end cap assembly, and
thread into the other end of the towel bar [P]. Repeat this
process for the other glass panel [H], making sure that
the towel bar is located on the same side as the rollers
in the hanger brackets [G].
Insert the wrench [S] into the small hole on the
edge of an end cap [N] and rotate in a clockwise direc-
tion until tight. Repeat for all remaining end caps.
11
Locate one of the clear panel guides [T] in the
middle of the tub track [A] with the door panels [H] in
the position shown. With a 7/64" bit, drill a hole into the
V-groove through the mounting hole in the guide. Attach
the center panel guide with a #6 x 3/8" pan head screw
[U] through the drilled hole.
OPTION (Recommended): Included in your hardware
kit are two extra panel guides and screws that can be
used in the center of each panel opening if desired.
TUB
TRACK
GLASS
PANELS
CENTER
GUIDE
#6 x 3/8"
SCREW
EXTERIOR

Page 8 of 8G03711095
11-4-14
Neatly caulk each end of the tub track [A] where
it meets the wall jambs [B] and along the interior edge of
the wall jambs as shown. Run a bead of caulking along
the interior edge of the tub track.
NOTE: The caulking should be allowed to cure for twenty-
four hours before using your new bath enclosure.
13