How to Measure and Install a Welded Aluminium Build-out Frame. Face fitted to a Timber Door Frame

Install a welded aluminium build-out frame to a Queenslander Hinged Wooden Door frame.

OVERVIEW

In this video, we will teach you how to measure and install a welded aluminium build-out frame to a Queenslander Hinged Wooden Door frame.

STEP 1 – VISUALISE and plan

First, visualise where the build-out will be positioned and plan for a neat & tidy look when installed.

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STEP 2 – CHECK LOCK POSITION AND DEPTH

Checking the lock position and depth are important steps as these doors often have large door knobs that can and do stick out a long way.

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STEP 3 – MEASURE DOOR JAMB DEPTH

The door jamb depth must have at least 25 mm more than the door handle. Measuring this particular door handle, we have 60mm. The door jamb depth must be 85 mm or higher to install the security door.

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STEP 4 – CHOOSE BUILD-OUT-FRAME

The existing door jamb depth is only 55mm, so a build-out frame with a minimum projection of at least 30mm is required. At Starline Security, we have different size options for build-out frames. For this job, we have chosen a 50mm square geometric build-out frame.  We felt this size best complimented the current door jamb.

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STEP 5 – MEASURE THE WIDTH

Measure the width from the edge of the door jamb to the opposite side edge. The measurement is 860mm, add 100mm for an OrderingPortal ordering size of 960mm. 

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STEP 6 – MEASURE THE HEIGHT

Measure the height from the door sill to the top edge of the door jamb. The measurement is 2140mm. Deduct 5 mm for a manufactured size of 2135mm.

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STEP 7 – ORDER BUILD-OUT-FRAME

Refer to the build-out section of our OrderingPortal to order a welded build-out frame like this one. 

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STEP 8 – Install the Build-out frame

Place the build-out on the floor. Measure the placement of the holes on the build-out frame, make them centred with the frame.

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STEP 9 – Pre-drill holes

Using pieces of wood to lift the build-out frame where you are drilling holes so you don’t drill into your client’s floor is always a good idea.

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Pre-drill using a 4mm bit all the way through the build-out. Then use the 10 mm bit to make a hole to suit 10mm plugs.  This is good practice, however, in this case, we will use a trim angle to cover these holes. 

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STEP 10 – ALIGN THE BUILD-OUT-FRAME

Align the build-out equally against the door frame. Measure the middle width, to make sure the frame is in the correct place. Drill a hole and fix off the top 2 screws first. Check the alignment and fix off the remaining holes with the screws.

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STEP 11 – INSTALL A TRIM ANGLE

To complete the installation and give a nice frame finish, install a trim angle using pop rivets to cover both sides. We normally don’t install this accessory until after we have installed the security door just in case the jamb needs adjusting. 

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STEP 12 – FIX OFF REMAINING DOOR JAMBS SCREWS AND SEAL GAPS

We often only install a few build out frame screws and position the security door to check all clearances are fine before fixing off the remaining door jamb screws.  Finish the installation by sealing any gaps with silicone.

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