The Door Building Bible
1. Read work order. (Make door parts first)
2. Check angle for correct measurement and Plunger Holes
3. Make parts Lock Mount and Plungers and (dead bolts if needed) check for right hinge.
4. Weld parts to angle Guide pipe and Dead Bolts if needed
5. Put angle frame together check for length width, then square weld
6. 14 gauge back panel, lay on table, put frame on top flat side down guide pipe away from you. Check for(right hinge) top would be to your right. Otherwise to your left. Puyt in spreader rod. Line up edge and top and bottom. Inside swing will be flush with angle on side with guide pipe.
7. Drill Holes, 21/65 weld on nuts. Stamp Number top end of angle
8. Remove angle frame oversize holes except top hole 25/64 stamp number in panel above top hole remove panel
9. Outer door panel LVD 3/16”, VD. ¼” HVD. 3/8”, MVD. ½”, MVDE 1” Safe Doors check work order best side down on table check for right hinge top is right of you. Get your center line. Put angle frame on panel flat side up. Safe doors and out swing Vault Doors ¾”, top 13/16” guide pipeside mark top and bottom corners, set I beams on top and clamp down. Recheck alignment inside swing doors ¾”, top ½” guide pipe side Mark top and bottom corners. Put cross tensioner in place snug it up. Leave gap roller rod 2” and 2-2 ½” L3”6” L3” and 7” no weld. Make sure spreader rod remains in place, weld frame to panel.
10. Clean plungers, buff stainless after cleaning with thinner.
11. Cut roller rod 2” less than length of frame. 2” and 2 ½” angle get 9/16” hot roll rod, 3” angle get ¾” hot roll rod. 4 pcs. Pipe per rod, debur edges, take out tensioner and spreader. Unclamp I beams (ream guide pipe)
12. Rod will be placed from inside edge of angle out 4 ¾” on 2” and 2 1/2” angle out 5” on 3” angle. Put pipe in place and tack weld. Make sure straight align rod up and down weld on stop pipe, finish weld top and bottom pipe. Hold off on carrier pipe for handle measurement.
13. Lay out handle and lock mount, measurements from bottom of angle up 39” (outside handle) 49” (center hole of lock mount) on VD. HVD. MVDE. Lock mount on VD.HVD. MVD. MVDE. LVD. And safe doors up 37” –Handle 47” center hole of lock mount align bypass lock 10” above center of lock mount hole carrier pipe allow room for handle tabs weld door to skin. (CUSTOM DOORS MAY VARY) Make sure guide pipe reamed or buffed.
14. Insert plungers. Weld on tabs straight up. (MVD and MVDE tabs are 1 3/8”) in line with plungers. Roll tabs away from you. 3” from edge of angle to nearest edge of tab (top) weld tabs for inside handle. (Lock mount in line) and (handle 2 ½” up from line) close to outside handle. All tabs straight up. Double roller rods 1 ½” up opening side, 1 ½” up opening side, 1 ½” down hinge side down. LYNCH PINS FOR INSIDE HANDLE DOORS 1 TAB LOCK MOUNT 2 TAB OUTSIDE HANDLE
15. Connect 3” linkage pieces so plungers are all the same jamb nut and tighten.
16. Align lock mount with center line, check for S.S. backing and/or random lock weld in place. Retract plunger to flush, make linkage rod for lock.
17. Drill holes for handle and lock center hole of lock mount all the way through top and bottom holes, lock mount only.
18. VAULT DOOR WITH INSIDE HANDLE- Place 14GA. Back panel number side down on top of angle frame, line up bolt holes, mark top of panel and side nearest you on angle, slide panel to side, lay out holes to bottom of lynch pins and just past edge of angle, use round template. Remove 14 GA. Panel.
19. Put inside handle together, align lever and linkage to roller rod or butterfly weld lever to stud, lever should be stopped on angle base and handle should be straight before welding.
20. Hook inside handle linkage to roller rod or butterfly plungers should be retracted and handle straight, weld base to door skin in line with edge of angle frame.
21. Lay out handle hole in 14GA panel down from top line halfway from top of base to top of handle. Put stop in if needed.
22. Remove 3” straps from table. Round corners, primer bottom, and remove from table. Weld 2 ½” stops.
NEXT!!! 