Build the tall lined sliding wooden enclosure

1. Qualify full support and the actual load

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Choose a level, rigid, continuously supporting surface at least 48.092 in (1221.54 mm) wide × 24.092 in (611.94 mm) deep. It must support the complete veneered underside and every floor edge. Feet or two end rails do not satisfy this design.
2. The conservative bed-volume envelope is 6.74 cubic feet (191 L), before wood support displacement. At an assumed wet bulk density of 100 lb/ft³ (1602 kg/m³), the bed alone is 674 lb (306 kg). Weigh the actual wet mix; add the shell, water, furnishings and equipment when qualifying the furniture and floor.

Check before continuing: The full-footprint support and total-load review are recorded before assembly or loading.

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2. Plan transport and maintenance access

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Keep room above for complete roof/rib removal, in front for a helper supporting each pane, and beside both vents for airflow and cleaning. Allow the scheduled external capture width 48.811 in (1239.8 mm) plus working space. Rehearse the transport path while empty.
2. Do not stack enclosures, hang this box, climb on it or move it loaded. Plan separate furniture restraint to the actual wall structure if tipping is possible; this guide does not rate a stand or wall anchorage.

Check before continuing: The empty enclosure has a continuous support plan and a clear route for removing both glass leaves and the roof.

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3. Resolve the product and veneer holds

Parts: Actual product samples and supplier replies

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Read H01–H10 before dependent purchases or cuts. Obtain CRL acceptance for this matched D2203A48 closure, vinyl, uncapped shoes, modified right jamb, thin-web screws and removal/anti-lift design. Save the supplier response; rejected details need redesign.
2. Choose ONE exterior species: maple, white oak or walnut. The schedule needs three 48 in (1219.2 mm) × 96 in (2438.4 mm) sheets with the approved PSA backer. Confirm panel balance, cured coating compatibility, humidity/heat/cleaner exposure, acclimation, pressure and dwell. A changed backing or balancing layer needs new geometry and quantities.
3. Approve the exact liner/underlay application and coating/cushion-bond samples. No received product or physical trial has yet been supplied. The open holds distinguish this digital candidate from construction acceptance.

Check before continuing: Required written answers are recorded before proceeding; rejected or unresolved substitutions stay on hold.

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4. Inventory wood and the nylon-wheel track kit

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Measure the actual thickness of the nominal 3/4 in (19.05 mm) plywood at several points. Reject delaminated sheets and warped stock. Check solid wood supports are 1 1/2 in (38.1 mm) square and the frame pine is 3/4 in (19.05 mm) thick.
2. Receive the complete CRL D2203A48 kit, separately selected glazing vinyl, separate 144 in (3657.6 mm) D603A jamb stock, 963L lock and FP86 pulls. The precut kit uses four D650 nylon wheels and four D652 guides. Confirm actual inventory and the usable length of both overlapping shoe blanks. Cosmetic caps are omitted subject to accepted wheel retention and smooth uncapped ends.

Check before continuing: Received wood gauges and matched D2203A48 kit contents are recorded; no glass has been ordered.

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5. Measure the lining and transfer height marks

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place the underlay and 45 mil (0.045 in / 1.14 mm) EPDM liner together on a smooth offcut. Measure the actual compressed stack without a corner fold. The reference is 0.08 in (2.03 mm) underlay plus 0.045 in (1.14 mm) liner, totaling 1/8 in (3.18 mm). These separate values are planning allowances, not measured delivery. Record the actual result on a marked measuring strip.
2. On the measuring strip, mark the floor underside. Above it, mark the actual plywood thickness plus compressed lining to locate the finished floor. From that mark, measure up 12 in (304.8 mm) for the maximum total bed, 14 in (355.6 mm) for the retaining-panel top and 15 in (381 mm) for the vent bottom. Transfer these marks to the build.

Check before continuing: The actual compressed lining and all shared height marks are recorded on the measuring strip.

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6. Cut this build’s plywood blanks

Parts: P01 — Floor; P02 — Removable roof; P03L — L wall; P03R — R wall; P04 — Back; RB1 — Laminated substrate retaining board; RB2 — Laminated substrate retaining board; RB3 — Laminated substrate retaining board

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use all three PLY layouts and matching exact stock tables. Square a reference edge, support both cut sides and allow the scheduled 1/8 in (3.18 mm) kerf. Start with labeled rough blanks; floor and roof finish at 48 in (1219.2 mm) × 24 in (609.6 mm). Keep their grain along the 48 in (1219.2 mm) dimension and the long back/retainer span. This trim-tolerant layout uses three sheets; it does not depend on a perfect factory 48 in (1219.2 mm) edge.
2. For the 45/64 in (17.86 mm) reference plywood, side panels finish at 24 in (609.6 mm) × 34 19/32 in (878.68 mm); the back at 46 19/32 in (1183.48 mm) × 34 19/32 in (878.68 mm); and all three retainer layers at 46 19/32 in (1183.48 mm) × 14 1/8 in (358.78 mm). Fit sides between floor and roof within the 36 in (914.4 mm) core height, and back/retainer between sides. A changed received gauge requires coordinated recalculation before final cutting.

Check before continuing: Opposite sides match; all three retainer boards have the same height and square edges.

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7. Label, pair and fit the plywood

Parts: P01 — Floor; P02 — Removable roof; P03L — L wall; P03R — R wall; P04 — Back; RB1 — Laminated substrate retaining board; RB2 — Laminated substrate retaining board; RB3 — Laminated substrate retaining board

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Mark every part ID, front edge, inside face and grain direction in pencil. Keep the long grain across the back and retainer span. Stack matching parts and check them with a straightedge; correct discrepancies before holes.
2. Use one imperial measuring system and a shared marked strip. Metric values are equivalents. Exact mating decimals in the workshop tables are intentional. Mark the final line from the actual mating pieces, leave it during the rough cut, then fit matching pairs together.

Check before continuing: Opposite sides match; all three retainer boards have the same height and square edges.

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8. Mark the two roof openings

Parts: P02 — removable roof

Tools / setup: Measuring tape, square, pencil and the tools named below

1. On the roof, mark two 18 in (457.2 mm) × 16 in (406.4 mm) openings. Their front edges are 4 in (101.6 mm) from the front; left edges are 4 in (101.6 mm) and 26 in (660.4 mm) from the left. Keep the centre strip intact.

Check before continuing: Both roof-opening outlines have the scheduled borders and intact centre strip.

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9. Mark both raised wall vents

Parts: P03L / P03R — left and right walls

Tools / setup: Measuring tape, square, pencil and the tools named below

1. On each side, mark a 12 in (304.8 mm) × 3 in (76.2 mm) opening starting 6 in (152.4 mm) behind the front edge. Its lower edge is 15 in (381 mm) above the finished-floor mark, not the floor underside.

Check before continuing: Both side-vent outlines start 3 in (76.2 mm) above the maximum bed line measured from the actual finished floor.

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10. Cut supported openings and check borders

Parts: P02 — Removable roof; P03L — L wall; P03R — R wall

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Drill starter holes entirely inside the waste. Cut with a guided router or supported jigsaw; do not cross the marked corner lines. Ease sharp reveals and remove every splinter.
2. Mark the scheduled capture-strip footprints over the opening margins, using full-size paper templates while the strips are still uncut. Each mesh edge must fit beneath a strip, and no fastener station may land in an opening. Leave the rest of the roof solid; equipment penetrations are a later, separately fitted operation.

Check before continuing: Both vents start 3 in (76.2 mm) above the maximum total bed; all roof borders and the centre strip remain intact.

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11. Prepare safe wide frame and strip stock

Parts: F0L, F0R, F0T, F1L, F1R, F1T, CLB, CLU, CLT, CRB, CRU, CRT, CF, CB, CT, CR, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, RTLF, RTLA, RTLL, RTLR, RTRF, RTRA, RTRL, RTRR, LCL, LCR, LCF, LCBL, LCBR, LCM, LCQL, LCQR, LCPL, LCPR, CFL, CFR, CM; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the labeled PINE-FRAME layouts, not a guessed board number. Rip the 2 1/2 in (63.5 mm) frame strips with guards, featherboards and push sticks; crosscut the named jamb/header layers. Reserve the separate trial board for hardware, screen and finish samples.
2. Prepare safe full-width PINE-THIN stock to 3/8 in (9.53 mm) thickness before ripping the new 1 in (25.4 mm) screen captures and 1/2 in (12.7 mm) liner clamps. Route screen recesses while blanks are wide and supported. Follow machine minimum feed lengths; never thickness or route a loose narrow strip by hand near a cutter.

Check before continuing: Frame and strip stock is identified, sound and safely prepared for the next cuts.

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12. Cut and dress the solid supports

Parts: F0L, F0R, F0T, F1L, F1R, F1T, CLB, CLU, CLT, CRB, CRU, CRT, CF, CB, CT, CR, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, RTLF, RTLA, RTLL, RTLR, RTRF, RTRA, RTRL, RTRR, LCL, LCR, LCF, LCBL, LCBR, LCM, LCQL, LCQR, LCPL, LCPR, CFL, CFR, CM; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the five labeled SOLID-stock layouts for the four bottom cleats, three rear uprights, two front posts, three upper supports and one roof rib. The nominal 2-by-2 lumber designation means a reference section of 1 1/2 in (38.1 mm) square. Measure the full received section; these are solid supports, not laminated strips.
2. Lightly ease exposed corners and especially the wood supports beneath the liner. Keep joint faces square and bare. Label the underside of each roof capture so it returns to its own holes.

Check before continuing: Each solid member and thin strip is identified; no cracked or knot-weakened wood support is used.

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13. Trial and machine the screen pockets

Parts: Trial board; eight V and eight RT capture strips; mesh offcut

Tools / setup: Caliper, guarded router, fixed guide, clamps, wide sacrificial stock, eye/hearing/dust protection

1. Measure the largest welded-wire crossing and the actual cured film on both bearing faces. Reference wire is 0.041 in (1.04 mm), crossing 0.082 in (2.08 mm), and two 0.003 in (0.08 mm) films give a 0.088 in (2.24 mm) pocket. These are model inputs, not delivered tolerances.
2. On a wide clamped trial blank, use a guided router and shallow passes to form the rebate: a shallow edge pocket. Leave a full outer bearing land. The nominal 1/2 in (12.7 mm) land loses 0.006 in (0.15 mm) to perimeter fitting relief, leaving 0.494 in (12.55 mm). It must sit flat while all wire ends remain buried.
3. Do not exceed 1/8 in (3.18 mm) pocket depth without redesign. Trial with the received mesh and finish, then machine safely wide blanks before final ripping/crosscutting. Record depths and labels on all sixteen capture strips.

Check before continuing: Pocket fits the actual crossing; lands sit flat and wire cannot peel or rattle.

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14. Laminate the retainer and staggered front frame

Parts: RB1, RB2, RB3, F0L, F0R, F0T, F1L, F1R, F1T; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Dry-stack RB1, RB2 and RB3 face to face, flush at their top and ends. Their combined depth matches three layers of the actual plywood. Dry-lay the front frame above them: outer layer jambs run full height, inner layer header runs full width.
2. Spread Titebond III on the two retainer bond interfaces and between the two frame layers. Keep a consistent film across bare wood; use padded straight clamping pads and enough clamps to close the joints without bowing the long members.
3. Compare both frame diagonals and check the track-bearing faces with a straightedge. Wipe away squeeze-out before it hardens. Do not glue the frame to the retainer; these remain separate assemblies for finishing and removal.
4. Follow the glue label for temperature and clamping. Leave these unstressed glue-ups for at least 24 hours before drilling or loading, extending the wait when the manufacturer requires it.

Check before continuing: The laminated retainer is flat and the 1 1/2 in (38.1 mm) deep frame has staggered, closed joints.

Required wait: Glue cure: at least 24 hours; follow the received label

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15. Trial the received track and glass system

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Make a rigid gauge matching the actual square dry frame. The reference clear opening is 41 19/32 in (1056.48 mm) × 17 31/32 in (456.41 mm). Use a smooth disposable 6 mm thickness sample for initial fit; it is not a substitute door. Final approval includes a fabricator-provided glass sample of the accepted thickness.
2. Seat the sample in a D610 offcut with supplier-confirmed vinyl. Fit a D650 wheel assembly and a D652 guide according to the received instructions. Compare the D602 bulb rail, D603 upper channel and guide engagement with the catalogue/DWG reference; resolve discrepancies before final cuts.
3. Check the nominal 1 1/8 in (28.58 mm) glass-height deduction with the complete received assembly. Trial uncapped, fully deburred shoe ends, wheel retention, closing cushions, right-jamb divider relief and sufficient removal lift. Do not cut a supplier-rejected profile or force a tight glazing channel.

Check before continuing: The sample rolls, lifts out with retention removed, and seats securely with the guide inside the upper channel.

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16. Trial uncut liner folds around a post

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fold actual liner and underlay offcuts over a dressed cleat and around representative front and rear post corners. Keep the central floor mark distinct from the raised shelf. Test uncut corner pleats and the clamp grip. The nominal 1/8 in (3.18 mm) wall allowance may not accommodate folded bulk; change clamp offsets and all dependent checks before proceeding if the real stack requires more space.

Check before continuing: Actual folded stack fits without a stretched membrane, sharp contact or unsupported clamp.

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17. Position and drill the bottom cleats

Parts: P01 — Floor; CLB — L bottom cleat; CRB — R bottom cleat; CF — Front floor cleat; CB — Back floor cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place P01 on a flat sacrificial board. Set the left and right bottom supports inward by the actual side-panel thickness, using an offcut as a spacer. Set their front ends behind the three-layer retaining panel. Fit CF between them against the back of that panel; fit CB between them against the inside face of the back panel.
2. Clamp each wood support. Transfer the bottom-support stations through the floor: #8 clearance holes are 11/64 in (4.37 mm) through P01 only; start 7/64 in (2.78 mm) pilots into pine and confirm grip on an offcut. Set a stop so no drill or screw can emerge.

Check before continuing: Cleats are clamped in their scheduled positions; front and rear panel recesses fit; pilot and clearance paths remain within their receivers.

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18. Glue and fasten the floor from underneath

Parts: P01 — Floor; CLB — L bottom cleat; CRB — R bottom cleat; CF — Front floor cleat; CB — Back floor cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply Titebond III only to the floor/wood support bond faces. Drive the #8 × 1 1/4 in (31.75 mm) screws from below, leaving their heads flush with the floor underside. Wipe all squeeze-out and keep the four corner beds smooth.
2. Check the retainer and back-panel recesses before the glue sets. Let the floor assembly remain flat and unstressed during cure.

Check before continuing: The floor underside sits completely flat, with no projecting head; the front recess fits the three-layer retaining panel.

Required wait: Do not stress glued wood supports for at least 24 hours

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19. Fit the two walls and upper supports

Parts: P03L — L wall; P03R — R wall; CLU — L rear upright; CRU — R rear upright; CLT — L upper cleat; CRT — R upper cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Clamp CLU and CLT to the inside of the left wall; repeat with CRU and CRT on the right. Upper wood supports end at the back-panel face and start 1 1/2 in (38.1 mm) behind the front. The rear uprights fit between lower and upper wood supports.
2. Stand each wall on P01, flush with its outer edge and front. Clamp it to the bottom wood support. Use a helper while the box is open.
3. Transfer the listed stations through each wall into the matching solid receiver. Drill the #8 clearance through the plywood, then a stopped pilot into pine. Keep the rear-upright back screws offset from the side screws as shown in the station schedule.
4. Fasten with #8 × 1 1/4 in (31.75 mm) screws, tightening by hand for the last turn. These wall joints stay dry during fitting so the panels can be removed for finishing.

Check before continuing: Walls are upright and parallel; all screw points terminate in solid wood supports, and no screw projects into the room.

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20. Close and square the back

Parts: P04 — Back; CT — Back upper cleat

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit P04 between the side panels, resting on the floor with its outside face flush to the side-panel rear edges. Clamp to CB, CT and both rear uprights.
2. Compare the two diagonals across the front and across the back. Adjust until each pair differs by no more than 1/16 in (1.59 mm). Recheck on the final supporting surface if it differs from the bench.
3. Drill clearance through P04 and stopped pilots into the named receivers at the close and square the back operation stations. Use the offset upright positions so a back screw does not meet a side screw.
4. Fit the #8 × 1 1/4 in (31.75 mm) screws and check that the full back edge sits flush. Do not pull a twisted box square by overdriving a screw.

Check before continuing: The shell remains square without clamp pressure; the back and both walls bear on the floor.

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21. Fit the centre rear upright

Parts: CM — centre rear upright; P04 — back; CB / CT — lower and upper rear cleats

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Fit CM centrally against P04 at X = 24 in (609.6 mm), between the lower rear cleat CB and upper support CT. Its reference length is 31 19/32 in (802.48 mm). Keep the ends square and in full bearing.
2. Clamp CM square without bowing P04. Transfer its six rear-facing stations using the matching drawing and exact table. Drill clearance through P04 and stopped pilots into CM.
3. Fit six #8 × 1 1/4 in (31.75 mm) screws flush from the back. Keep the entire screw point buried; check the reference pilot and countersink in matching offcuts first.
4. Recheck the back diagonals and support bearing. Ease the liner-facing corners while preserving the full load-bearing section. The two front posts are fitted in the following pictured operations.

Check before continuing: CM is square, in full end bearing and fixed by six buried-point rear screws; the back stays square.

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22. Seat the three-layer retaining front

Parts: RB1 — Laminated substrate retaining board; RB2 — Laminated substrate retaining board; RB3 — Laminated substrate retaining board

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Seat the cured three-layer retainer on P01 in front of CF. Its ends fit between the side panels and its front face is flush with the front of the floor.
2. Set the wood retaining-panel top 14 in (355.6 mm) above the finished floor, before adding the track. A 12 in (304.8 mm) total bed leaves 2 in (50.8 mm) to the wood top.

Check before continuing: The retaining top is level at the marked height and the cured laminate bears fully on the floor.

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23. Fasten the retainer with offset screw rows

Parts: RB1 — Laminated substrate retaining board; RB2 — Laminated substrate retaining board; RB3 — Laminated substrate retaining board

Tools / setup: Measuring tape, square, pencil and the tools named below

1. At the end stations, drill #8 clearance through each side and pilots into the retainer ends. At the front stations, drill clearance through RB1 and RB2 and pilots into RB3; keep the 2 in (50.8 mm) screws within the laminate.
2. From inside, drill clearance through CF and pilots into RB3 for the separate rear-facing 2 in (50.8 mm) screws. Offset these stations 3/8 in (9.53 mm) to the right of the front-facing stations so opposing screws cannot meet. Tighten all screws flush; these low fasteners will be isolated behind the uncut liner.

Check before continuing: The retaining top is level, continuous and at the marked reference mark; no screw point projects through its inner face.

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24. Position and secure both front posts

Parts: CFL / CFR — front posts; CLB / CRB — bottom side cleats; RB3 — inner retainer layer

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Stand CFL and CFR behind the retainer, bearing on CLB and CRB respectively. Their reference length is 12 5/8 in (320.68 mm). Clamp each square with its front face against RB3 and top flush with the retainer.
2. Fit four side screws per post at 2 1/2 in (63.5 mm), 5 1/2 in (139.7 mm), 8 1/2 in (215.9 mm) and 11 1/2 in (292.1 mm) above the finished floor, using clearance through each side and stopped pilots into its clamped post. Keep both posts square and bearing on their lower cleats.

Check before continuing: Both posts bear on their named cleats and are square, with four side screws each and six through-connections still to fit.

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25. Trial the flush retainer connection and nut recess

Parts: BTL1 — Flush retainer machine screw, recessed interior washer and locknut; BTL2 — Flush retainer machine screw, recessed interior washer and locknut; BTL3 — Flush retainer machine screw, recessed interior washer and locknut; BTR1 — Flush retainer machine screw, recessed interior washer and locknut; BTR2 — Flush retainer machine screw, recessed interior washer and locknut; BTR3 — Flush retainer machine screw, recessed interior washer and locknut

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Before touching a finished part, trial the exact Bolt Depot 24910 1/4-20 × 3 1/2 in (88.9 mm) flat-head screw, 16019 washer and 16008 nylon locknut in matching offcuts. Length includes the head. Use a 5/32 in (3.97 mm) hex driver and the received nut’s 7/16 in (11.11 mm) wrench. Hand-tighten slowly; stainless can seize, so stop rather than force binding threads.
2. Reference rear recess is 1 in (25.4 mm) diameter and 5/8 in (15.88 mm) deep, leaving 7/8 in (22.23 mm) of the 1 1/2 in (38.1 mm) post at its washer seat. Hold the loose post square under a stopped flat-bottom bit with backing and clamps. Confirm the actual socket outside diameter is no more than 7/8 in (22.23 mm) and can enter with clearance. Do not deepen the recess to make a wrong bolt fit.

Check before continuing: Actual hardware and held sample satisfy socket, wood-bearing, thread and tip-clearance limits.

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26. Bore and fit all six flush retainer screws

Parts: BTL1 — Flush retainer machine screw, recessed interior washer and locknut; BTL2 — Flush retainer machine screw, recessed interior washer and locknut; BTL3 — Flush retainer machine screw, recessed interior washer and locknut; BTR1 — Flush retainer machine screw, recessed interior washer and locknut; BTR2 — Flush retainer machine screw, recessed interior washer and locknut; BTR3 — Flush retainer machine screw, recessed interior washer and locknut

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Mark three centres per post at 3 1/4 in (82.55 mm), 7 in (177.8 mm) and 10 1/2 in (266.7 mm) above the finished floor. Their X coordinates are 1 29/64 in (36.91 mm) and 46 35/64 in (1182.29 mm) from outside left. These revised centres avoid N02’s own four side screw paths. Clamp the stack and drill 9/32 in (7.14 mm) clearance square through RB1/RB2/RB3 and the post. Use the tested 82-degree front countersink only deep enough for the flat head to sit flush.
2. Insert the screw from outside. Inside its rear post recess, install one washer and the complete nylon locknut. Received washer must be at most 1/16 in (1.59 mm) thick for this reference stack. Require at least two full threads beyond the nylon and at least 1/16 in (1.59 mm) tip clearance below the post face. Tighten only to close the joint; do not crush wood or assign a torque from this drawing.

Check before continuing: Six joints close flat, threads fully engage and all tails remain safely recessed.

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27. Inspect and protect the recessed hardware

Parts: BTL1 — Flush retainer machine screw, recessed interior washer and locknut; BTL2 — Flush retainer machine screw, recessed interior washer and locknut; BTL3 — Flush retainer machine screw, recessed interior washer and locknut; BTR1 — Flush retainer machine screw, recessed interior washer and locknut; BTR2 — Flush retainer machine screw, recessed interior washer and locknut; BTR3 — Flush retainer machine screw, recessed interior washer and locknut

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Bolt and hardware dimensions are receiving checks; never infer structural capacity from bolt count.

1. Check the post is flat, remaining wood intact and no metal edge can catch the liner. Keep a 0.55 in (13.97 mm) veneer service opening around each exterior flat head. Finish and fully cure the recess before reassembly; place supplementary loose underlay pads over the recessed hardware. No fastener pierces the membrane. Connection capacity and actual sample acceptance remain open holds.

Check before continuing: Reference bearing remains intact; surfaces are smooth and the accepted padding arrangement can be fitted.

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28. Fit the laminated jambs and header

Parts: F0L — L jamb layer; F0R — R jamb layer; F0T — Header layer; F1L — L jamb layer; F1R — R jamb layer; F1T — Header layer

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Set the laminated front frame on the retaining top. Align its front face with the retainer and sides. Both jambs must bear fully on the retainer; do not suspend them on screws.
2. Clamp the frame square. Drill #8 clearance through the side panels into stopped pilots in the jamb ends at the scheduled heights. Fit #8 × 2 in (50.8 mm) screws.
3. Measure the clear opening at the top, middle and bottom and its clear height at three positions. The reference width is 41 19/32 in (1056.48 mm) and height 17 31/32 in (456.41 mm). Record the smallest values and both diagonals.
4. Lay a straightedge beneath the header and over the retainer. Correct any bow now. The detachable roof will later screw into the header and wood supports, further closing the box.

Check before continuing: The opening is square within 1/16 in (1.59 mm) and its upper/lower track faces are straight and parallel.

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29. Check receivers, stopped pilots and flush heads

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Compare the assembled shell with the part list and inspect every joint from both sides. Use the fastener-stations download to check that no receiver, through-member or screw is missing.
2. Make pilot tests in matching offcuts. The starting pilots are 7/64 in (2.78 mm) for #8, 3/32 in (2.38 mm) for #6 and 1/16 in (1.59 mm) for #4. Adjust for the actual wood and screw root; a split or spinning test means the setup is wrong.
3. Set the clearance depth separately from the receiver pilot. Use 11/64 in (4.37 mm), 9/64 in (3.57 mm) and 1/8 in (3.18 mm) starting clearance bits for #8, #6 and #4 respectively. Confirm head shape in a scrap countersink.
4. Keep at least 1/16 in (1.59 mm) undrilled wood beyond a screw point. Do not substitute a longer screw to repair a stripped hole; repair or replace its receiver and repeat the trial.

Check before continuing: No point, burr, split, hollow screw path or proud floor screw remains.

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30. Cut, deburr and label the four mesh pieces

Parts: ML — L ventilation mesh; MR — R ventilation mesh; MTL — Roof mesh; MTR — Roof mesh

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Cut two roof pieces 19 in (482.6 mm) × 17 in (431.8 mm), and two side pieces 13 in (330.2 mm) × 4 in (101.6 mm), from the hardware-cloth roll. Wear eye protection and cut-resistant gloves while handling the cut edges.
2. Remove projecting wire ends and burrs. Keep a minimum 1/2 in (12.7 mm) mesh margin beyond each opening, fully under the capture strips. Do not leave a sharp wire end exposed to the room.
3. Check the mesh opening against the future occupant and feeder plan. This 1/2 in (12.7 mm) construction mesh will require a securely retained finer barrier for many occupants; do not treat it as universal animal containment.
4. Label the two roof pieces and two side pieces. Store them flat until their capture strips are ready.

Check before continuing: All edges are smooth and will be enclosed; none of the four pieces is stretched, rusted or damaged.

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31. Capture both side screens on solid lands

Parts: ML, MR, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Centre ML/MR over their own wall openings. Dry-seat all four widened captures with their routed pockets facing the wire. The outer solid lands must touch the wall; every wire crossing and cut end must fit inside its pocket.
2. Clamp the strips flat without bowing wire. Transfer the revised stations on the solid outer lands, outside the wire perimeter. Drill #6 clearance through each strip only, then a stopped pilot into the wall. Do not drill through a wire crossing.
3. Drive the #6 × 1 in (25.4 mm) screws until the strips hold the mesh firmly. With 3/8 in (9.53 mm) captures and the reference plywood, the points must stay buried; verify from inside after every group.
4. Run a cloth along the entire interior reveal and gently press the mesh perimeter. Fix any snag or loose edge. Remove the assemblies again during the finishing step, preserving the labels.

Check before continuing: There is no accessible cut wire or loose mesh edge; the opening remains above the fill line.

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32. Build the removable screened roof

Parts: P02, CR, MTL, MTR, RTLF, RTLA, RTLL, RTLR, RTRF, RTRA, RTRL, RTRR; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place the roof underside up on padded supports. Fit CR between the front frame position and rear upper wood support, centred across the roof width. Transfer its top-down #8 screw stations through the roof into the rib.
2. Centre MTL/MTR under the roof openings. Seat their eight 1 in (25.4 mm) captures with routed pockets toward the wire and solid lands flat against the roof. Transfer the revised outer-land stations, drill clearance through strips and stopped pilots in P02, then fit #6 × 1 in (25.4 mm) screws flush.
3. Turn the roof with a helper and check every point remains beneath the outer face. The centre rib sits between the openings and ends against the rear wood support; the vent borders stay fully supported.
4. Dry-seat the roof on the shell and transfer the final roof screw holes. Leave them unfastened until the later access work is complete. The roof and mesh are not shelves; heat and light fixtures require separately supported, specifically qualified equipment.

Check before continuing: The roof sits flat, its wire edges are enclosed and it can lift off without catching the frame.

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33. Cut and deburr the accepted profiles

Parts: TRACK-B — D602 lower rail; TRACK-T — D603 upper channel; JAMBL — D603 vertical jamb receiver; JAMBR — D603 vertical jamb receiver; STOPLF — Bond-retained neoprene jamb cushion; STOPLB — Bond-retained neoprene jamb cushion; STOPRF — Bond-retained neoprene jamb cushion; STOPRB — Bond-retained neoprene jamb cushion

Tools / setup: Measuring tape, square, pencil and the tools named below

1. After H01 acceptance, cut two vertical D603A jambs from the separate D603A stock to fit between the lower rail and upper channel. The reference jamb length is 17.16375 in (435.96 mm). Clamp the extrusion with protected jaws, use a square guided metal cut and file every burr. Keep swarf out of channels.
2. Cut the horizontal D602 and D603 from their designated kit lengths to the accepted cushion-to-cushion fit. Both reference lengths are 41.36275 in (1050.61 mm). Cut each D610 shoe from its own supplied overlapping kit blank after confirming received usable length and shipping cuts, wheel retention and the glass-order allowance. Do not rip a profile to the schematic lane width in a stock drawing.

Check before continuing: Each labeled profile has its accepted fitted length, square ends and no sharp burrs; factory sections and wheel retention are intact.

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34. Fit the jambs and approved divider relief

Parts: TRACK-B — D602 lower rail; TRACK-T — D603 upper channel; JAMBL — D603 vertical jamb receiver; JAMBR — D603 vertical jamb receiver; STOPLF — Bond-retained neoprene jamb cushion; STOPLB — Bond-retained neoprene jamb cushion; STOPRF — Bond-retained neoprene jamb cushion; STOPRB — Bond-retained neoprene jamb cushion

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Only after supplier approval, remove the right-jamb central divider over the specified full jamb height, preserving its web and outer legs. Smooth the cut completely. This lets the rear-leaf lock clip approach the closing cushion. Trial the exact clip; if CRL rejects the change, redesign the closure before purchase/construction.
2. Secure the vertical jamb webs flush: left screws in the front lane, right screws in the rear lane. Use the exact stations. Keep track seats bare and unchanged; veneer and finish must stop at traced bearing footprints.

Check before continuing: Accepted jamb relief is smooth, webs and outer legs are intact, and flush jamb screws leave the guide and closing paths clear.

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35. Align and fasten the rolling tracks

Parts: TRACK-B — D602 lower rail; TRACK-T — D603 upper channel; JAMBL — D603 vertical jamb receiver; JAMBR — D603 vertical jamb receiver; STOPLF — Bond-retained neoprene jamb cushion; STOPLB — Bond-retained neoprene jamb cushion; STOPRF — Bond-retained neoprene jamb cushion; STOPRB — Bond-retained neoprene jamb cushion

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Align D602 with the corresponding D603 lanes using the complete gauge, plumb strip and straightedge. The published lane spacings differ slightly. Transfer the lower-web row at Y = 0.6 in (15.24 mm) and the upper row at Y = 0.38425 in (9.76 mm); upper screws must clear the centre divider. These are assembly distances from the outside front.
2. Use only supplier-approved thin-web countersinks matching the actual #4 flat heads. Drill clearance through metal, then stopped pilots into the named wood receiver. Fit #4 × 3/4 in (19.05 mm) screws by hand. Eight lower, eight upper and six jamb screws are installed at this stage. Roll both gauge leaves end to end; no head may meet a wheel, guide or glass.

Check before continuing: Both gauge leaves move freely with consistent engagement; mounting heads never touch the wheels or guides.

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36. Predrill the removable anti-lift inserts

Parts: ALF1 / ALF2 / ALF3 / ALB1 / ALB2 / ALB3 — six HDPE strips; twelve #4 × 3/4-inch screws; upper track and header

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With the accepted closure gauge and received guide fully seated, measure the free space above each D652 guide. Machine the HDPE strips from broad safely held stock to fit each upper-channel lane, leaving at most 1/16 in (1.59 mm) upward movement. The reference thickness is illustrative; the received guide and extrusion govern.
2. Use three strips per lane, with two closed internal butt joints. The outside ends stop 1/8 in (3.18 mm) short of the former full-lane ends, leaving 0.122 in (3.1 mm) reference clearance to the cured cushions. End-strip length is 13.663 in (347.04 mm); middle length is 13.788 in (350.22 mm). Trial both guides throughout full travel: no guide may escape through a service gap.
3. Remove glass before transferring the twelve insert stations from the current table. The original eight positions are retained and four inner-end positions are added. Drill clearance through each supported HDPE strip and the accepted upper-track web, then stopped pilots in the named header layer. Countersink the strip heads flush. Mark each ID and orientation; trial the actual driver with panes parked opposite each screw.

Check before continuing: Gauge confirms continuous upper capture; all holes are prepared before coating.

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37. Disassemble, sand and mask the wood

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Photograph and label the complete hardware dry fit, including all anti-lift holes, lock and pull positions, and the supported removal trial with the accepted closure gauge and sample. Final panes are ordered only after the cured assembly is measured. Remove hardware, captures, roof, walls, frame and retainer for finishing. Keep the glued floor/cleat and laminated frame/retainer assemblies intact.
2. Sand from 120 to 220 grit along the grain. Ease all liner-contact edges; vacuum dust and wipe with a clean lint-free cloth. Fill no structural defect with finish; replace damaged material.
3. Keep glass, rollers, mesh and liner away from sanding and coating. Mask bare glue faces and all actual track/bond/bearing footprints. Use the supplier-approved substrate preparation beneath veneer. No glue joint may rely on an unapproved cured coating.
4. The calculated one-coat planning area is 219.3 square feet (20.37 square metres), including conservative rectangular wood faces, veneer topcoat, samples and contingency. It needs 5 US quart cans (0.946 L each); buy 3 two-can packs. Extra coats or balancing layers need new quantities.

Check before continuing: Wood is clean and dry, the liner path is smooth and all fittings are labelled for reinstatement.

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38. Apply the accepted wood sealer

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check the can is Varathane Triple Thick clear satin water-based polyurethane, manufacturer 284473. The selected Lowe’s pack contains two quart cans. Stir; do not shake. Follow the received label and use a quality synthetic-bristle brush.
2. Apply the manufacturer-approved sealer/topcoat sequence to the exposed wood, edges and reveals, while keeping all marked bare bearing and bond seats masked. The label application range is 60–90°F (16–32°C) below 85% relative humidity. Use ventilation and label protective equipment. The veneer supplier must accept the actual cured substrate.

Check before continuing: Correct product and conditions; every required face and reveal coated, masked seats preserved.

Required wait: Follow the received application and recoat directions; the full cure is recorded in the next operation.

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39. Record and complete the wood coating’s full cure

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Record the time and conditions of the final applied coat. Full cure is seven days at 70°F (21°C) and 50% relative humidity (RH) with ventilation; adverse conditions need longer under the manufacturer’s directions. Two-hour recoat and 48-hour light-use times are not full cure.
2. If repair coverage is needed, follow the 220-grit intercoat preparation and recoat instructions; add its coat area to the quantity record and restart the final-coat cure clock. Inspect the dry film for missed end grain, runs, tackiness and damage.
3. This coating protects an ordinary indoor wood shell. The separate liner takes the damp bed; do not rely on polyurethane or wood glue as an immersed joint seal.

Check before continuing: The recorded full-cure period has passed under suitable conditions and every coated surface is intact.

Required wait: Full cure: seven days at 70°F (21°C), 50% relative humidity (RH); longer when required

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40. Approve the complete veneer sample

Parts: Veneer trial piece and complete finishing system

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the actual substrate, sealer, selected veneer/backer/PSA and topcoat on a spare piece. PSA means pressure-sensitive adhesive. Supplier instructions control cleaning, acclimation, application pressure and dwell; no unsupported dwell time is substituted.
2. Measure the whole cured layer. The reference is 0.0305 in (0.77 mm); maximum 0.046 in (1.17 mm) before this design must be recalculated. Confirm one-sided panel balance and inspect after the intended humidity, heat and cleaning exposure.
3. Keep metal and cushion-bond footprints bare. The sample must remain flat and well bonded, with no lifting corners, bubbles or coating damage. Record the supplier-approved wait and the completed result.

Check before continuing: Approved sample is flat, secure and within the coordinated stack limit.

Required wait: Complete supplier-confirmed acclimation and adhesive dwell plus the received topcoat full cure.

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41. Cut and apply the matching edge strips

Parts: All scheduled edge and reveal V-pieces

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the VENEER layouts and labeled V-pieces. Put grain along each scheduled grain axis. Cover the floor/roof edges, exposed wall edges, roof-opening reveals, vent lips and external capture edges before their broad faces.
2. Cut oversized blanks on a sacrificial board with a sharp knife and straightedge. Use repeated shallow passes; keep fingers behind the cut. Transfer actual traced bearing footprints before peeling backing.
3. Apply the accepted PSA system with the specified firm scraper/pressure. Support fibers while trimming flush, then ease edges lightly. Do not bend veneer around a sharp plywood edge or bridge a removable seam. Stop vent edge bands at bare fitted butt joints; keep wall skins 1/64 in (0.4 mm) outside the finished capture-frame outline.

Check before continuing: Exposed plywood layers are covered; hardware seats and service seams remain usable.

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42. Veneer the complete outside faces

Parts: All face V-pieces; separate roof, body and captures

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Apply the scheduled roof top, floor underside, sides, back, front frame, retainer front and external capture faces. Face veneers cover the ends of their matching edge strips. Keep roof grain straight and widthwise, including the front edge.
2. Trace openings from the actual parts, cut from the supported side and preserve all margins. Keep separate skins on the removable roof and each capture. Do not cover an assembly screw or the bare track footprint.
3. Open the scheduled full-depth screw-head access holes with supported tooling after the dry trial. Heads remain flush on their original wood datum. Inspect all outside corners and reveals before the final topcoat.

Check before continuing: Uniform chosen species covers faces, roof and edges without blocking removal or rolling hardware.

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43. Topcoat veneer and finish the full cure

Parts: Finished exterior and coating record

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use the supplier-approved topcoat on the accepted veneer system. Protect marked track, cushion-bond and bare bearing seats; keep all service holes clear. Record application conditions and final coat time.
2. The selected coating’s reference full cure is seven days at 70°F (21°C) and 50% relative humidity. Follow the received label if conditions require longer. Recoat/light-use times do not establish full cure.
3. Inspect for bubbles, lifted edges, runs, tackiness and warp. Repair using an approved method and restart the affected cure clock. Recheck total layer thickness and flatness before final assembly.

Check before continuing: All affected surfaces are fully cured, flat and intact.

Required wait: Seven-day reference full cure after the final coat; longer when actual conditions or the received label require.

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44. Reassemble the cured body and tracks

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Reference glass dimensions are not a blind ordering instruction.

1. Reassemble the labelled shell, two front posts, six complete flush machine-screw sets, frame, captures and tracks in their matched holes. Reach interior nuts before underlay and liner cover them. Recheck threads and recessed tips without crushing cured wood or finish. Confirm full support, diagonals, flat bearing lands, alignment and the accepted closure-gauge removal trial.

Check before continuing: The cured shell is square and supported, captures bear flat, and reinstalled tracks pass the accepted gauge and removal trials.

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45. Bond the four accepted jamb cushions

Parts: STOPLF/STOPLB/STOPRF/STOPRB and accepted contact bond

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Use DAP Weldwood Original 00271 only after CRL/DAP approval of the received anodized aluminium and plain neoprene. Trial cleaning and two-face coating on matching offcuts. Never use this bond on EPDM, glass or HDPE.
2. Cut four 17.16375 in (435.96 mm) × 0.28 in (7.11 mm) × 1/16 in (1.59 mm) strips. They fit between the horizontal tracks, with no tabs across the rails. Mask adjacent channels and apply the accepted thin contact-bond film by its label.
3. Fit each strip on its named jamb lane, press as specified and leave it undisturbed. The model film is 0.003 in (0.08 mm); measure the actual cured stack before glass sizing. Reject lifting edges or movement during repeated sample closing/service trials.

Check before continuing: Four cushions are secure, correctly placed and clear of track/guide paths.

Required wait: Seven days to the published maximum-strength reference; follow actual label and supplier requirements.

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46. Measure and release the final glass order

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

Before you begin: Reference glass dimensions are not a blind ordering instruction.

1. Install the four accepted bond-retained cushions between the horizontal tracks and complete their full cure. Then measure the smallest width between their cured contact faces and the bare seat-to-seat opening height. Give the glass fabricator the actual track, shoe, vinyl, guide and lock samples with those measurements.
2. Reference pane size is 21.428375 in (544.28 mm) wide × 16 27/32 in (427.83 mm) high × 6 mm thick, approximately 7.7 lb (3.49 kg) per pane. These are NOT order dimensions. Width starts from (measured cushion-to-cushion width + accepted overlap) ÷ two; height starts from measured bare opening minus the accepted profile deduction. The fabricator confirms all final allowances.
3. Resolve the GC728C listing conflict before glazing: the kit recommends it for 6 mm glass while the current vinyl page lists a different glass-thickness range. CRL must identify the exact received vinyl and fit. Confirm polished edges, corner treatment, tolerances and monolithic tempered glass. All fabrication happens before tempering; never drill, trim or grind a tempered pane on site.
4. Record both accepted final pane cuts and revise the coordinated specification if they differ. The complete D2203A48 kit suggests no more than 36 in (914.4 mm) × 48 in (1219.2 mm) per panel. No numerical mass capacity was established for these two-wheel reference panes. This smaller two-roller reference pane is about 2.506 square feet (0.233 square metres). That comparison is not a load rating or approval of the altered closure.

Check before continuing: The final measured opening, exact profiles and supplier-confirmed glass cuts are recorded; the panes are within the kit’s stated size guidance.

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47. Lay protective underlay and the one-piece liner

Parts: LINER, LCL, LCR, LCF, LCBL, LCBR, LCM, LCQL, LCQR, LCPL, LCPR; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With roof and doors off, cut one 84 in (2133.6 mm) × 58 in (1473.2 mm) underlay blank and one matching EPDM blank. Keep their centers marked and corners intact. Vacuum the clean floor and dress every sharp support edge. The larger rough blank allows folding and handling; it is not the installed basin size.
2. Lay the soft underlay over every contact face, including the central floor, four cleat shelves and all five front/rear posts. Place supplementary loose protective pads over each recessed nut pocket; actual bulk must fit without pulling the liner tight. Place the liner above it with slack. Work from the floor center outward; do not stretch it between supports or hang it from clamps. The model separately shows the reference protective layer.

Check before continuing: Underlay covers every hard contact and the intact liner lies slack over all five post returns.

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48. Fold corners and mark the actual liner heights

Parts: LINER, LCL, LCR, LCF, LCBL, LCBR, LCM, LCQL, LCQR, LCPL, LCPR; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. At each corner, raise an uncut diagonal ear. Dress the liner over the cleats and around both front posts and all three rear uprights on their room-facing surfaces; never force it through or behind a fixed post. Fold surplus into upright pleats; do not slit, staple or splice below the upper dry clamping band. Use the actual-material trial to decide the fold direction and bulk.
2. Check the actual central finished-floor elevation with a straightedge and depth gauge. Mark maximum total bed 12 in (304.8 mm) above it, clamp screw centers 13 3/8 in (339.73 mm) above it and final liner top 13 3/4 in (349.25 mm) above it. If the compressed/folded stack changes those positions or clamp bearing, stop and revise the dimensions. Keep liner below the retainer top and clear of tracks.

Check before continuing: Uncut folds fit without tension; bed, clamp and top lines are transferred from the measured central liner floor.

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49. Fasten the ten removable liner clamps

Parts: LINER, LCL, LCR, LCF, LCBL, LCBR, LCM, LCQL, LCQR, LCPL, LCPR; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Install all five short rounded post clamps LCQL/LCQR and LCPL/LCM/LCPR first while the long side clamps are absent; this preserves straight driver access. Then fit LCBL/LCBR and LCF, followed by LCL/LCR. Dry-fit the actual folds beneath each strip before holes. Transfer the exact screw centers halfway across each 1/2 in (12.7 mm) strip; only the scheduled screws pierce the upper dry band, from 13 1/8 in (333.38 mm) to 13 5/8 in (346.08 mm) above the actual central liner floor; their centers are 13 3/8 in (339.73 mm) above that floor. The basin below 13 1/8 in (333.38 mm) remains uncut and unpunctured.
2. Pre-drill clearance through each held wood clamp and a stopped #6 pilot in its wood receiver with the liner lifted away. Return the liner and underlay, then make only the scheduled small screw punctures by hand under the clamp. Never drill loose membrane around a rotating bit. Fit the listed #6 × 1 in (25.4 mm) screws without crushing or cutting the liner. Round clamp edges, keep corners smooth and check buried tips. Trim excess only above the final top line after the entire dry fit is accepted.

Check before continuing: All ten clamps are secure in the stated order; only scheduled dry-band screws pierce the lining and the basin below stays intact.

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50. Complete the 24-hour shallow liner check

Parts: LINER, LCL, LCR, LCF, LCBL, LCBR, LCM, LCQL, LCQR, LCPL, LCPR; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. On qualified continuous support, add 1 in (25.4 mm) of water above the central floor for 24 hours before substrate. Mark the level and inspect the shell/accessible underside for dampness. The rectangular upper water estimate is 4.23 US gallons (16.0 L); cleats displace some water. This is a shallow leak check, not aquarium approval.
2. Siphon or wet-vacuum the water out; never tip the box. Dry it and investigate any moisture, tears, stressed folds or moved clamps. Repair or replace the membrane using an accepted method, then repeat the full check. Do not cover a failed test with substrate.

Check before continuing: The recorded 24-hour shallow test shows no leak or shell dampness; water is removed and the liner and shell are dry.

Required wait: Inspect a 24-hour shallow water test before filling

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51. Glaze each shoe and fit its wheels and guides

Parts: GL, GR, HL, HR, WHL1, WHL2, WHR1, WHR2, TGL1, TGL2, TGR1, TGR2; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Inspect the fabricator-supplied tempered panes for chips and cracks on a clean padded bench with a helper. Fit the supplier-confirmed glazing vinyl in each D610 shoe and seat the glass evenly using received instructions. Do not force a disputed vinyl or let bare metal touch a polished glass edge.
2. Install two D650 wheel assemblies and two D652 guides per pane at the accepted gauge positions. Wheel centers reference 1 1/2 in (38.1 mm) from each glass end. Deburr uncapped shoe ends and check the assemblies cannot shift or work out; the optional D332A cosmetic caps are not part of this candidate.

Check before continuing: Each supported pane is undamaged; accepted vinyl separates glass from metal, and both wheels and guides are securely retained.

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52. Seat the rear leaf, then the front leaf

Parts: GL, GR, HL, HR, WHL1, WHL2, WHR1, WHR2, TGL1, TGL2, TGR1, TGR2; use labeled picture and schedules

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Insert the left closing leaf into the rear upper channel first, lift it, bring the roller shoe over the corresponding lower rail and lower gently. Install the right closing leaf in the front lane in the same way. Do not let the pane twist.
2. Move each leaf through its entire path and check the 1 1/2 in (38.1 mm) closed overlap. Inspect the guide engagement at both ends and the middle. The panes must not rub one another, a mounting head or a wood edge.

Check before continuing: Both doors roll without binding and remain seated throughout their travel; there is no glass-edge damage.

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53. Install anti-lift inserts around the parked panes

Parts: ALF1/ALF2/ALF3 and ALB1/ALB2/ALB3; twelve #4 × 3/4-inch screws

Tools / setup: Measuring tape, square, pencil and the tools named below

1. With the lock removed and a helper controlling both seated panes, park both panes to the RIGHT. Bring the middle strip into the vacant LEFT opening 2 in (50.8 mm) below its channel and 1 in (25.4 mm) in from the jamb; move it toward the jamb, then raise it into the empty LEFT end of its lane and slide it into the middle above the guides. Hold it while fitting its left screw. Park panes LEFT to reach the right screw; retain positive support throughout.
2. Fit the left end strip with both panes RIGHT, then the right end strip with both panes LEFT. Repeat for the other lane. Keep both internal joints closed and leave only the specified outer service gaps. Use the twelve exact stations and accepted driver; never force a strip against a guide or glass.
3. For removal, support the panes and remove the left and right end strips first, parking both panes opposite the end being worked on. Release both middle screws from their accessible pane positions. Park panes RIGHT, slide the supported middle into the empty LEFT end, lower it 2 in (50.8 mm), move it 1 in (25.4 mm) inward away from the jamb, then withdraw it toward the room. Use the same lower-and-move-inward route for each end strip. Remove all strips before lifting a pane.

Check before continuing: Both lanes retain the guides through full travel; joints, outer gaps, driver access and supported strip removal pass the actual dry trial.

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54. Prove cushion and anti-lift retention

Parts: ALF1 / ALF2 / ALF3 / ALB1 / ALB2 / ALB3; STOPLF / STOPLB / STOPRF / STOPRB

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check all four cured bond-retained jamb cushions. They end between the horizontal tracks and have no screw tabs. Each closing glass edge must meet soft rubber without striking a head or sharp lip. A detached cushion requires repair, full cure and renewed fitting checks.
2. At both ends and the middle of travel, gently lift each pane. It must remain positively engaged on the lower rail, with the top guide retained. Remove the inserts to demonstrate safe service removal, then reinstall them. If the pane can clear its lower rail with the inserts fitted, correct the profile fit before proceeding.

Check before continuing: Neither pane can be lifted off its rail in any operating position; both remain removable after the inserts are unscrewed.

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55. Fit and test the ratchet lock

Parts: LOCK — CRL 963L removable anti-spread housing; LOCKBAR — CRL 963L ratchet bar and rear-leaf clip; PULLL — CRL FP86 finger pull; PULLR — CRL FP86 finger pull

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Close both doors on their cushioned jamb stops. Fit the 963L ratchet bar to the rear leaf and its anti-spread housing across the overlap following the supplied orientation. Protect the polished edge; no improvised metal packing may touch glass.
2. Adjust the ratchet to secure both leaves without forcing or bowing them. With the key removed, gently test each door separately for sliding, spreading and lifting. The anti-lift inserts remain installed independently of the lock.

Check before continuing: The lock holds both closed leaves and releases predictably without forcing the glass; independent anti-lift inserts remain fitted.

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56. Fit the pulls and measure service access

Parts: LOCK — CRL 963L removable anti-spread housing; LOCKBAR — CRL 963L ratchet bar and rear-leaf clip; PULLL — CRL FP86 finger pull; PULLR — CRL FP86 finger pull

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Clean the pull locations using the pull maker’s instructions. Place each FP86 near its closing edge, away from the lock and shoe, and confirm the complete bypass path before bonding. Follow the adhesive preparation and dwell time on the received product.
2. Unlock and remove the lock body before moving a pane. The reference single-leaf access is 19.367875 in (491.94 mm) wide × 17.16375 in (435.96 mm) high. Plan at least 18 in (457.2 mm) width for service; larger objects require both panes or roof removed. The rear-leaf ratchet clip stops against the opposite rear-lane cushion, before the metal jamb. Measure this with the received clip; never force travel beyond the stop.

Check before continuing: The lock holds both closed leaves and releases predictably; pulls do not collide and service access is documented.

Required wait: Complete the received pull adhesive preparation and dwell before using the handles.

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57. Secure the removable roof

Parts: P02 — Removable roof

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check that mesh, liner clamps and track hardware are complete before setting the roof down. Seat it without trapping the liner, glass guides or future cables.
2. Use the transferred roof stations: three screws along each side wood support, four across the front header and four across the rear upper wood support. Drill clearance through P02 and stopped pilots into the receivers.
3. Fit #8 × 1 1/4 in (31.75 mm) screws, tightening evenly by hand. Do not glue the roof and do not use the mesh as a handle. Check the doors again with the roof secured.
4. Keep the roof screw locations accessible in the final equipment arrangement. Remove equipment and disconnect power before roof service; support equipment independently of the screen.

Check before continuing: The roof cannot shift or lift unintentionally, and both doors still operate without binding.

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58. Inspect construction and rehearse maintenance

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Check every scheduled screw, all six recessed retainer nut stacks, complete thread engagement, screen captures, polished glass, roof perimeter, lock and anti-lift inserts. Repair splits, burrs, loose fittings and stripped receivers. Keep exterior retainer drives accessible. Inside access requires removal of the empty liner and underlay.
2. Measure the closed gaps at the jambs, between the glass leaves, below the shoes, around the roof and at the mesh. Record actual values; the construction clearances alone do not establish containment for an animal or feeder.
3. Verify the cured finish and dry shell after the liner test. Check that no below-fill screw or cable has penetrated the basin and that the removable liner clamps are accessible.
4. Rehearse removing and reinstalling the lock, anti-lift inserts, both panes and roof with the enclosure empty. Confirm that the cleaning tools can reach the rear corners and that the full bed can be removed without tipping the box.

Check before continuing: The completed construction record has no unresolved defect. Animal and equipment commissioning remains a separate step.

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59. Remove and refit glass for service

Parts: Both glazed leaves, lock and removable inserts

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Empty the enclosure and disconnect/remove equipment. With a helper supporting the glass, remove the lock body and both lanes of anti-lift inserts. Support the front leaf first, then the rear; never use the edge as a lifting handle.
2. Move the front leaf 2 in (50.8 mm) away from its closing jamb. The reference path lifts 1/4 in (6.35 mm), tilts the bottom toward the room and lowers onto padding. Actual accepted profile clearance controls; never force glass. Repeat for the rear leaf after the front one is safely removed.
3. Vacuum and wipe tracks without flooding; dry them immediately. Refit rear pane first, then front. Reinstall all inserts and lock and repeat full travel, closed-gap and anti-lift tests before returning an occupant.

Check before continuing: The complete empty service route is clear and retention passes after reassembly.

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60. Remove and inspect the liner for maintenance

Parts: Ten liner clamps, empty EPDM sheet and underlay

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Remove animals and equipment, then scoop the full bed into containers without tipping the box. Remove the panes or roof as needed for reach. Never pull a liner loaded with substrate or water.
2. Remove long side clamps first to reach the short front and rear post clamps. Label all ten strips and screws. Release the folds gently, lift the empty liner and underlay and inspect the floor, cleat edges and every membrane fold.
3. Dry and repair the cause of dampness or abrasion. Replace damaged material or use a manufacturer-accepted repair, complete all cure waits and refit with short post clamps first. Repeat the 24-hour shallow liner check and closure checks before refilling.

Check before continuing: All surfaces are sound and dry; repaired/reinstalled liner passes the repeated shallow check.

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61. Place and measure the total bed

Parts: SUBSTRATE — 12-inch total bed

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Place the enclosure permanently on its qualified full-footprint support before filling. Add smooth protective pads under hard decorations, spreading their loads without puncturing the liner. Do not place a sharp rock directly on the membrane.
2. Measure the entire bed from the finished central liner floor. A drainage layer, separator and substrate all count toward 12 in (304.8 mm); for example, 2 in (50.8 mm) drainage leaves at most 10 in (254 mm) for the remaining layers.
3. The reference uninterrupted floor rectangle between lined supports is 43 11/32 in (1100.93 mm) × 17 15/16 in (455.61 mm), about 5.4 square feet (0.5 square metres). Above the maximum 12 in (304.8 mm) total bed, the clear height below upper supports is 20 31/32 in (532.61 mm), before equipment or furnishing deductions. Measure the received construction.
4. Weigh the delivered damp mix and record the total installed load. Check support deflection, doors and liner after filling; remove the bed if anything shifts or binds. The density scenarios are planning arithmetic, not a structural rating.
5. The picture omits the roof to show the bed. If removed for loading, refit all fourteen roof attachments and repeat door, lock, anti-lift and perimeter checks before commissioning.

Check before continuing: The total bed stays at or below its line, with 2 in (50.8 mm) retaining-wall space above the bed and documented remaining usable space.

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62. Qualify the actual occupant and equipment

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Select the intended species, life stage and number of occupants against current care requirements using the finished usable interior, not the nominal 48 in (1219.2 mm) × 24 in (609.6 mm) × 36 in (914.4 mm) shell. This generic guide assigns no species suitability.
2. Qualify every gap and the mesh opening for the occupant and feeders. Add a mechanically retained finer barrier when needed, then reassess ventilation, visibility, cleaning and equipment performance.
3. Choose heat, light, ultraviolet and control equipment for the actual habitat. Follow their exact mounting, separation and combustible-clearance instructions; use an independent support for fixtures. Keep hot parts away from wood, liner, glass and animal contact, and do not load the mesh.

Check before continuing: The intended species, life stage, usable space, equipment supports and cable routes are recorded before commissioning.

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63. Commission the configured habitat before entry

Parts: Named parts shown in the picture

Tools / setup: Measuring tape, square, pencil and the tools named below

1. Plan any cable penetration against the exact connector and strain relief before cutting. Put it above the liner, seal and finish its wood reveal, then fit a retained closure that cannot be pushed open. Do not trap a cord in the roof joint or make a new hole through the wet basin. Complete the affected coating’s full cure after sealing a new opening before equipment testing or animal entry.
2. Run the complete configured habitat unoccupied through its planned day/night and wet/dry cycles. Measure the relevant temperatures, humidity, ventilation and light exposure; verify thermostat control, safe surfaces, door retention and cleaning access. Record passing results before animal entry.

Check before continuing: Animal entry follows a separate, documented species/equipment commissioning review; a finished wooden shell is not that approval.

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