JELD-WEN, a leading manufacturer of exterior doors, provides comprehensive installation instructions for its pre-hung wood, steel, and fiberglass doors. These instructions are designed to ensure proper sealing, structural integrity, and long-term durability of the door unit within a variety of wall conditions. The following guide is based entirely on the official installation manual provided by JELD-WEN, available at their resources page. This article is structured to help U.S. consumers, DIY enthusiasts, and professional contractors understand the complete process, tools, and materials required for a successful installation.
Overview of Installation Process
JELD-WEN recommends that all installation instructions be read thoroughly before beginning the work. These guidelines are intended for most standard applications but may require adjustments based on the specific building conditions. It is important to note that local building codes and weather conditions can affect the installation method and materials used. Therefore, it is advisable to consult with a building professional or local authority having jurisdiction (AHJ) for compliance.
The installation process involves several key phases: preparation of the site and tools, proper installation of the door unit, sealing of joints and seams, and finishing touches. The goal is to achieve a secure, weather-tight fit that ensures both safety and energy efficiency.
Tools and Materials Required
To successfully install a JELD-WEN exterior door, a range of tools and materials are necessary. These are categorized based on their function in the installation process.
Sealing and Flashing Materials
Proper sealing is critical for preventing air and water infiltration. The following materials are recommended:
- Sealant: Polyurethane for painted surfaces or 100% silicone for exposed surfaces.
- Backer rod: Used to backfill gaps before applying sealant.
- Low expansion foam: Such as Dow Great Stuff™ Window and Door or equivalent.
- Self-adhesive flashing: 4–6 inches wide for stud-framed walls; 9 inches if required by local code.
- Liquid-applied flashing: For installations into a buck (e.g., Protecto Wrap LWM 200 or equivalent).
- Pre-formed sill pan or sheet metal flashing: For the base of the door.
- Drip cap: Required in some cases depending on the door location and exposure.
Hardware and Fasteners
The correct hardware ensures the door operates smoothly and securely:
- Lockset hardware: Per manufacturer instructions.
- 10d galvanized casing nails or #8 x 3″ deck screws: Depending on whether the door will be stained or painted.
- Non-compressible or water-degradable shims: For temporary support.
- Plastic drain screen: With a crisscross or woven pattern, used on step-down landings.
- 3/8″ staples: For securing the drain screen.
- Foam wedges: To complete the weatherstrip seal at the bottom corners of the door.
Tools
The following tools are necessary for precise and safe installation:
- Cutting shears: For working with flashing and sill pan materials.
- Tape measure: For accurate measurements.
- Utility knife: For cutting materials.
- Level: A 4-foot minimum is recommended for alignment.
- J-roller: For compacting sealant and flashing.
- Caulking gun: For applying sealant.
- Drill with bits: For installing hardware and fasteners.
- Construction stapler: For securing drain screens and flashing.
- Hammer, screwdrivers, nail set, square, pencil, pry bar, small punch or magnet: For general assembly and adjustments.
Pre-Installation Steps
Before beginning the installation, it is essential to prepare the site and the door unit.
Remove Packaging and Inspect Door
- Remove all shipping materials such as corner covers, shipping blocks, and pads.
- Remove any exposed staples from the frame but leave the protective film on the glass if applicable.
- Inspect the door for any damage or defects. If any issues are found, contact the manufacturer before proceeding.
Prepare the Rough Opening
- For retrofit installations, remove the old door and sufficient siding to expose at least 9 inches of intact building wrap.
- If the building wrap is damaged, replace it using a shiplap method to ensure continuity.
- Verify that the header and trimmer studs are structurally sound.
- Trim the building wrap flush with the edges of the rough opening.
Installation Instructions
The installation process is broken into steps depending on whether the wall is framed with a buck or is a stud-framed wall. Below are the general steps for each type.
Installing into a Buck
- Seal Joints: Apply sealant to any joint wider than 1/16 inch in the buck and between the buck and concrete or masonry.
- Apply Liquid-Applied Flashing: Cover the buck and surrounding concrete/masonry with liquid-applied flashing at the head, jambs, and sill.
- Continue with General Installation Steps.
Installing into a Stud-Framed Wall
- Apply Sealant and Flashing: Use self-adhesive flashing and follow the manufacturer's instructions for application.
- Apply Spray Adhesive/Primer: On the sill pan and surrounding area.
- Cut and Apply Flashing: Cut self-adhesive flashing to the appropriate size and apply it over the sill pan. For step-down landings, fold the flashing down as shown.
Installing the Sill Pan
- Mark a line across the front and back of the sill pan.
- Apply three 3/8-inch beads of sealant between the lines.
- Place the sill pan into the rough opening and press it firmly into the sealant using a J-roller.
Installing the Door Unit
- Use at least two people to install the door to avoid injury and ensure proper support.
- Apply a continuous bead of silicone sealant where the exterior trim meets the door frame on the interior side.
- Carefully place the door into the rough opening and align it with the jamb and threshold.
Weatherstripping and Sealing
Proper weatherstripping is essential for energy efficiency and to prevent air and water infiltration.
Installing Weatherstrip
- Apply a bead of sealant behind the weatherstrip at the intersection of the jambs, brickmoulds, thresholds, and floor.
- Use the included foam wedges to complete the weatherstrip seal at the bottom corners of the door.
- For doors with a metal frame and adjustable T-Strike, adjust the weatherstrip by pushing it inward until the door slightly compresses it. Secure the T-Strike and tighten the screws.
Drip Cap Installation
- If a drip cap is required, install it and fold the building wrap down over it.
- Seal the cut ends of the flashing with self-adhesive tape or building wrap.
Finishing and Casing
After the door is installed and sealed, finish the interior and exterior surfaces.
- Finish all six sides of the door slab and frame as desired.
- Install casing on both sides of the metal frame. Mark the locations of the oval slots and secure the casing with fasteners.
- Apply sealant around the outside of the door unit between the siding and brickmould, between the brickmould and the jamb, and between the jamb sides and the threshold.
Fire Door Requirements
For fire-rated doors, additional steps are necessary to ensure compliance with local codes:
- Verify the correct seal is installed in the frame and conforms to local fire codes.
- Install automatic-closing hinges that close the door from 18 inches and latch securely.
- Adjust the spring tension if the door does not close properly:
- With the door closed, insert the provided hex wrench and rotate it clockwise.
- Hold in place and remove the tension pin with a small punch or magnet.
- Rotate the hex wrench 1/4 turn and reinsert the tension pin loosely.
- Repeat until the closing force is adequate but do not rotate past the specified number of holes.
Post-Installation Maintenance
Once the door is fully installed, it is important to maintain its integrity over time.
- Inspect sealant joints at least once a year and repair as necessary.
- Remove protective film on glass after all construction is complete or within one year.
- Protect the door unit from damage by covering it with plastic during construction.
- Install any interior trim as desired after the door is fully sealed and finished.
Conclusion
JELD-WEN exterior doors offer a durable, energy-efficient solution for homeowners and contractors. The installation process, while requiring attention to detail, is well-documented and designed to accommodate a variety of wall conditions. By following the manufacturer’s instructions and using the recommended tools and materials, users can ensure a secure, long-lasting installation that meets both functional and aesthetic expectations.
Proper sealing, flashing, and finishing are essential to maintaining the door’s performance and longevity. Additionally, adherence to local building codes and the use of appropriate hardware—especially for fire-rated doors—ensures that the installation is both safe and compliant.
For detailed instructions on finishing, warranty, and maintenance, visit the JELD-WEN resources page at jeld-wen.com/resources.