REALCRAFT Carriage Garage Doors and Custom Barn Doors Instruction Manual
- June 3, 2024
- REALCRAFT
Table of Contents
REALCRAFT Carriage Garage Doors and Custom Barn Doors
INTRODUCTION
Dear customer,
Your RealCraft door has arrived! You are now the proud owner of one-of-a-kind,
handcrafted, solid-wood carriage doors! Take a moment to breathe in the earthy
scent, rich tones, and natural grain patterns.
To ensure that your experience with our doors is enjoyable, please use your order receipt to verify all purchased items and quantities are present. If you are missing any items, please let us know within 30 days from the date of delivery. Unfortunately, after 30 days, we will not be able to re-ship missing items without incurring additional charges.
IMPORTANT DOOR CARE
As with other high-quality items, our solid wood handcrafted doors require special care and attention upon arrival. We will not be able to guarantee our doors if the following precautionary procedures are not followed carefully. Thank you for your business, and enjoy this beautiful new addition to your home.
- DO NOT STORE DOORS IN THE CRATE!!**
- Doors must be finished and sealed within 7 days of delivery to assure quality and integrity.
- If the doors are unable to be hung within one week of arrival, take the doors out of the crate, apply sealant, and store them lying down on a flat surface.
- Do not store doors leaning against a wall.
- Do not store them outdoors or in an uncovered, damp location.
- For doors facing direct sun/weather for long periods of time, it is best to consider additional protection such as an overhang.
Doors will retain their shape if appropriately stored indoors. If stored under any of the conditions mentioned above, the doors are subject to warping and will not stay square and flat. Doors will remain square and in good condition when hung and sealed immediately. Your doors are made of the highest quality wood and superb craftsmanship; however, wood is naturally prone to swelling, and the door assembly could leak or sag when these precautions are not taken.
GETTING STARTED
WHAT YOU HAVE
- Carriage and/or Entry Door
- Standard or Specialty Hinges
- Jambs and/or Trim (Casing)
- Door Bottom – Sweep or Seal
- Astragal
- Manual Hardware (cane bolts, lockset)
- Automatic Opener & Accessories
- Threshold
WHAT YOU WILL NEED
- An extra person (for installation assistance)
- Tape Measure
- Carpenter’s Level
- Power Drill & Bits
- Finish Nail Gun & Nails
- Philips & Slotted Screwdrivers
- Hammer
- Utility Knife
- Sandpaper
- Waterproof Wood Glue
- Wood Shims
- Wood Blocks (for propping up the door in position)
- Painters Tape (to reduce “tear-out”)
- Circular Saw (if adjusting height)
FINISHING
Although RealCraft does not finish the doors in the house, below are some basic guidelines to navigate the process:
We recommend a sealant be applied to the doors and trim within 7 days of receipt in order to resist the elements/changing climate, i.e., humidity, sun, rain, etc.) as much as possible. Polyurethane has been applied to the top and bottom edge (end grain) of the door as a sealant. If you trim the door height, be sure to re-seal the surfaces as they are especially vulnerable to water infiltration. Each region of the country has unique climate considerations that must be taken into consideration. For further guidance, we recommend consulting with your local wood finishing shop.
TWO FINISH TYPES
-
SURFACE FINISHES:
Surface-type finishes such as paints, varnishes, or polyurethanes, are often the best choice when the overhang or roof protects a door well. This type of finish needs little maintenance and sheds water easily. When a new coat is needed, it will require extra time sanding and scraping to remove the previous finish before applying the new topcoat. -
PENETRATING FINISHES:
Usually oil-based, a penetrating finish will soak into the wood to repel water. This finish will require recoating ‘maintenance’ more often than a surface-type finish; however, it is much easier to reapply, taking only a fraction of the time in prep work with a little light sanding. The nicks and scratches that come with time will accent the ambiance and heritage of the doors. When the doors begin to look ‘thirsty and dry,’ then it is time to reapply the penetrating finish.
There are many brands and products from which to choose for finishing. We
recommend a high-quality brand such as Osmo for finishing our doors.
realcraft.com/pages/osmo.
NOTE:
- Before applying the seal coat, always hand sand the doors’ surface in the direction of the grain and remove any dust with compressed air or a tack cloth. Silicone “squeeze out” at the glass is normal and ensures a watertight seal. To remove, carefully run a razor blade along the edge of the glass and lift off. Be sure the blade is unused to limit the possibility of scratching.
- In an ideal situation, the doors should be trimmed/planned to fit before applying the seal coat (this is especially true of surface finishes). This process will eliminate the chance that a finish will need to be touched up after hanging.
NOTE:
If using a drivable threshold (rubber or aluminum) wait until everything is
properly shimmed to ensure a proper fit.
JAMB ASSEMBLY INSTALL
Each Jamb Assembly Kit has been mortised for the hinges. Please take care to match the proper kit with each door set to avoid hinge misalignment.
-
Check your Rough Opening. The opening should be 3” greater in width and 2” greater in height than the nominal door size, i.e., a 9×8 set would be framed 9’ -3” wide by 8’ -2” high.
-
Trim the side jamb legs to fit your sill condition. The jamb should extend beyond the door by 1/2” if using the drivable rubber, or no threshold.
For cutting Aluminum thresholds that are .5” (a half-inch) thick:- Measure from the bottom hinge to the bottom of the door
- Determine how big of a gap you want between the threshold and the bottom of the door. Min. of 3/16” and Max. of 11/16”.
- Add 0.5” (a half-inch) thickness to the gap you chose and write it down.
- Pull a tape measure from the bottom hinge on the jamb leg, mark your measurement, and then make the cut. Note: the legs are hand-mortised, and their appearance may slightly vary.
The Jamb legs should sit on the floor, and the threshold will need to be cut to fit inside the jamb.
-
Assemble the side jambs to the head jamb, and to the wooden threshold, if applicable. Spread silicone between the threshold and the jamb leg to prevent water seepage.
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Test fit the assembly. Lay several thick beads of adhesive silicone below the threshold before installing.
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Securely shim & square the Assembly Kit by measuring it diagonally, corner to corner. When the measurements are equal, the frame is square.
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With a nail gun, tack the kit in place with 2.5” finish nails. Be sure to nail near the shims, not through them. This will help you adjust the shims later on.
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Hang the doors and close them to check the fit. It may be necessary to adjust the shims in or out to achieve the best fit and even gapping.
IMPORTANT:
Finish the installation by removing one to two of the factory screws from the
jamb side of each hinge, and replacing them with a 3” screw. Choose screws
most likely to penetrate the structural framing.
FOR OUTSWING DOORS:
At least two of the hinges on each door have a non-removable pin (NRP). Locate
these hinges by opening the door. The NRP hinges have a small Allen set screw.
Tighten the screw to secure the doors.
FINISHING TOUCHES
Installation of these hardware and accessory items will complete our carriage or entry door installation.
ASTRAGAL
To minimize thermal/moisture transfer in the vertical gap between the door
slabs, the astragal is the best when installed to the exterior of the active
door. However, it can be mounted on the passive door on the interior – To
install: cut to the desired length, apply water-proof wood glue, finish the
nail or clap the piece to dry. Allow the glue to dry fully before closing the
doors completely.
CANE BOLTS
The cane bolts secure the passive door leaf from the interior when closed.
They may also secure the door from blowing in the wind when open. Depending on
the application, we typically recommend an offset can bolt for the top (to
clear the weather-stripped jamb.) and a straight cane bolt for the bottom.
Alternatively, a straight bolt at the top with a mounting block will
accommodate the weather stripping.
LOCKSET
Your door may have been predrilled for lockset hardware. To install: Follow
the instructions included with your hardware. You will notice that the strike
plates and/or the jamb drilling have not been done in the factory. This is to
ensure you get a professional and proper installation of your doors and
hardware. Jobsite eccentricities can cause a strike plate to need adjustment
in the field, and this job is best suited for the installer.
DRIVEABLE RUBBER THRESHOLD
A rubber threshold is best installed on a clean, dry, concrete surface. Before
installing: Remove all loose debris from the floor. Preheat the threshold in a
warm room or in the sun to ensure it is flexible enough to install. Place
under closed doors, so the bump just touches the back of the doors (fig 1).
Mark the location and snap a chalk line the entire length of the opening.
Measure the total width and trim threshold, then test fit. Remove the
threshold and apply three rows of adhesive, as shown (fig 2). Press into place
and ensure uniform contact with the floor. Weight threshold or close doors and
use wedges to keep constant pressure while drying. Allow curing 24 hours
before use.
DOOR SWEEP
Brush sweeps are provided with each set of carriage doors unless specified
otherwise (upgraded or not required). This accessory will help keep out draft
and debris, however, is not intended to be a thermal, moisture, or rodent
barrier. To install: Position the sweep to the inside, where it touches the
floor with light pressure. Mark and pre-drill the door, then attach the sweep
with screws. The slotted holes will allow adjustments for an uneven floor.
DRIVABLE ALUMINUM SADDLE THRESHOLD
The ADA Driveable aluminum saddle threshold is used to create a smooth
transition into the interior space. The thickness is 0.5” aluminum; it is
durable, ADA-compliant, and designed for regular vehicular use. We recommend
the aluminum saddle threshold for applications where carts, lawn equipment,
and/or bikes are frequently brought in and out for ease of use.
AUTOMATIC DROP-DOWN BOTTOM
The automatic door bottom is a mechanism that fits into a dado at the bottom
of the door. [ The doors will ship with a spacer to fill the gap for transit
support] Once installed, as the door closes, a pin closes against the jamb and
pushes a silicon fin down to close up to a 0.5” gap. This auto door bottom
used in conjunction with a threshold will make a weather-tight seal for the
bottom of the doors – perfect for conditioned (living) spaces.
PRE-HUNG ENTRY DOORS
Your Pre-hung Entry Door has been crafted and created with care. Take a moment to read through the instructions before proceeding with the installation.
- Check your Rough Opening. The opening should be 2” greater in width, and 3” greater in height than the nominal door size, eg., a 3×7 set would be framed 3’-2” wide by 7’-3” high.
- Lay three heavy beads of silicone under the area that the sill will make solid contact with.
- Set the unit in place, firmly setting it in the silicone.
- Begin shimming the unit, working from the top down, periodically checking for even gaps around the door and square of the frame.
- When the unit is square, use a finish nailer to set the jamb in place. Don’t shoot through the shims; this will help later adjustments.
IMPORTANT:
Finish the installation by removing one to two of the factory screws from the
jamb side of each hinge, and replacing them with a 3” screw. Choose the screws
most likely to penetrate the building framing.
FOR OUTSWING DOORS:
At least two of the hinges on each door have a non-removable pin (NRP). Locate
these hinges by opening the door. The NRP hinges have a small Allen set screw.
Tighten the screw to secure the doors.
ENTRY SET HARDWARE:
The strike plates and/or the jamb drilling have not been done in the factory.
This is to ensure you get a professional and proper installation of your doors
and hardware. Jobsite eccentricities can cause a strike plate to need
adjustment in the field, and this job is best suited for the installer
.
CHECKLIST
- Match parts received with the Final Invoice. Report any missing items within 30 days of delivery.
- Finish doors within 7 days of receipt for protection and warranty.
- Stage/Install according to instructions laid out by RealCraft.
ABOUT US
RealCraft is committed to excellence in creating high-quality products for customers around the world. Built Real in the USA, our original door and hardware designs are visually stunning and structurally robust. We strive to exceed your expectations by combining personalized customer service with the highest quality products. We invite you to Build Real.™
RealCraft is constantly releasing new, innovative, and exclusive products. We always have great things in the works, so swing by our website to stay completely up-to-date on everything we have to offer.
ORDER TODAY
To order, please call us at 800.694.5977. Our experienced designers are ready
to help you find the perfect doors and
hardware for your project’s needs.
P 800.694.5977 F 253.857.9295
WWW.REALCRAFT.COM
[email protected]
WWW.REALCARRIAGEDOORS.COM
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RealCraft
Formerly Real Carriage Door & Sliding Hardware 9803 44th Ave NW Suite Gig
Harbor, WA 98332.
© 2020 RealCraft. All rights reserved.
References
- Osmo Exterior & Interior Wood Finishes | RealCraft
- RealCraft Custom Carriage Garage Doors & Custom Barn Doors
- RealCraft Barn Doors & Barn Door Hardware Made In Washington