Build the dry-bed sliding enclosure

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Check and prepare · 1 OF 32

1. Check the delivered wood

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Caliper, tape, square, straightedge, moisture meter

Before you start: Do not start cutting from nominal labels.

Check the delivered wood. Picture explains the action; use the linked drawing for exact settings.

1. Measure each sheet at several points. The reference plywood is 0.70312 in (17.86 mm). Enter the actual batch thickness in the source and regenerate the parts before cutting.
2. Each sheet needs at least 96.3125 in (2446.34 mm) ×47.59375 in (1208.88 mm) before the stated squaring cuts. Check the complete layouts, including defects.
3. Select straight, dry untreated boards:2 ×2 means actual 1.5 ×1.5 in;2 ×4 means actual 1.5 ×3.5 in. Reject splits, loose knots, wane and twisted bearing faces. Record dimensions and stable moisture readings for the workshop.

Check before continuing: Receiving record complete; layouts and regenerated dimensions agree with your actual material.

Watch out: A nominal 3/4 in label does not mean 0.750 in.

Keep beside this step: Receiving (p. 103) · Layouts (p. 55)

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Check and prepare · 2 OF 32

2. Check the sliding-door kit

Parts: Delivered kit and trial offcuts

Have ready: Matched track samples, scrap wood, caliper, lock and safety-glass sample

Before you start: Do not order glass before the full finished-frame trial.

Check the sliding-door kit. Picture explains the action; use the linked drawing for exact settings.

1. Check 993 upper channels,999 lower rails,995 shoes and 997 carriers are the same steel Roll-Ezy system. Do not substitute plastic, aluminum or a different profile.
2. Trial the actual shoe and scant 6 mm glass, both running lanes, cushions, removable lift blocks and 963L lock. Use a supplier-handled sample; do not force a pane into a channel.
3. Reserve matching wood/metal offcuts for the glue and coating trials. Record actual lane sizes, lock projections and the removal sequence.

Check before continuing: The receiving worksheet identifies every delivered model and each unresolved measurement.

Watch out: Matching exterior sizes do not prove matching running channels.

Keep beside this step: Track Fit (p. 75) · Receiving (p. 103)

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Check and prepare · 3 OF 32

3. Plan the three sheets

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Full cutting diagrams, measured saw kerf, supported saw setup

Before you start: Inspect defects before accepting the layout.

Plan the three sheets. Picture explains the action; use the linked drawing for exact settings.

1. Lay out all rough blanks with the face-grain arrows. Sheet 1 holds the floor and back. Sheet 2 holds the left roof and side, all screen rings and the backer straps. Sheet 3 holds the right roof and side and the retaining face.
2. Square the long reference edge and one end. The plan reserves 0.125 in (3.17 mm) at each edge and 0.125 in (3.17 mm) between cuts.
3. Rip the listed rows first, then crosscut each row into blanks. Rip means make a piece narrower; crosscut means shorten it. Keep sound trial offcuts.

Check before continuing: Every rough blank fits its marked usable sheet; no grain direction is rotated.

Watch out: Do not subtract saw kerf from the required finished part.

Keep beside this step: Layouts (p. 55) · Cutlist (p. 43)

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Check and prepare · 4 OF 32

4. Cut and label the plywood

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Supported saw, guides, square, pencil

Before you start: Support the full sheet and waste; follow your saw manual and keep hands out of the cut.

Cut and label the plywood. Picture explains the action; use the linked drawing for exact settings.

1. Cut rough blanks in the planned sequence, then finish each to the exact cut schedule. Measure from the same square edges each time.
2. Label the part ID, FRONT, BOTTOM and INSIDE before turning a piece over. Mark the reference face and the two measuring edges shown on its drawing.
3. Match paired sides and roof depths within 0.010 in (0.254 mm). Panel length/width target is±1/64 in (±0.397 mm), subject to the tighter mating-part checks.

Check before continuing: Finished sizes, quantities and orientation agree with the cut list.

Watch out: A rough blank is not a finished cut.

Keep beside this step: Cutlist (p. 43) · Drawing Key (p. 66)

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Check and prepare · 5 OF 32

5. Cut the solid supports

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Crosscut saw with stop/support, square, part labels

Before you start: Use a carrier or stop setup for short blocks; never hold them beside a moving blade.

Cut the solid supports. Picture explains the action; use the linked drawing for exact settings.

1. Use the two 2 ×4 boards for the sill and header. Use the five 2 ×2 boards for posts, cleats, blocks and roof ribs.
2. Follow the linear-stock diagrams, including end squaring and kerf. Crosscut the long members before the small blocks.
3. These supports retain their purchased thickness and width. No planing or resawing is specified. A different actual section requires recalculating the source.

Check before continuing: All members are square and correctly labeled; the bearing faces are sound.

Watch out: Do not buy shorter precut studs in place of 96 in boards.

Keep beside this step: Layouts (p. 55) · Cutlist (p. 43)

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Check and prepare · 6 OF 32

6. Check the square-edged back

Parts: L side P03L · R side P03R · Full back P04

Have ready: Tape, square, flat supported bench, clamps and spacers

Before you start: Keep the rear edges of both sides square. Do not rout a back recess.

Check the square-edged back. Picture explains the action; use the linked drawing for exact settings.

1. Set the sides at the floor edges and support them with clamps. The back fits BETWEEN the sides, with its outer face flush with their rear edges.
2. For the reference plywood batch, the back is 94 19/32 in (2402.68 mm) wide and 22 19/32 in (573.88 mm) high. Confirm the measured clear distance between the sides before assembly; do not force an oversize back.
3. Keep the back bottom level with both side bottoms. The rear posts and rails support the back fastening; screws do not go into the plywood edges.

Check before continuing: Both rear corners meet squarely with no step or recess in either side. All three panel bottoms line up.

Watch out: Measure between the inside side faces, not across their outside edges.

Keep beside this step: Back Joint (p. 71) · P03L (p. 82) · P03R (p. 83) · P04 (p. 84)

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Check and prepare · 7 OF 32

7. Prepare the roof-rib seats

Parts: Front sill S01 · Front header S02 · Upper back rail S50T · Roof rib 1 S601 · Roof rib 2 S602 · Roof rib 3 S603

Have ready: Guided router, square, chisel, stop setup

Before you start: Trial one complete bearing joint before machining the six ends.

Prepare the roof-rib seats. Picture explains the action; use the linked drawing for exact settings.

1. Mark the three rib centers from the left body datum:25,48 and 71 in (635,1219.2 and 1803.4 mm). Use the exact seat positions on the member drawings.
2. Make each rail seat 0.5 in (12.7 mm) into its width and 0.75 in (19.05 mm) down from its top. Remove the lower 0.75 in from the last 0.5 in of each rib end.
3. The remaining upper end rests on the seat floor. Check the rib tops finish level with the supporting rails; drill only after the clamped dry fit.

Check before continuing: All six ends bear fully; none hangs from a screw alone.

Watch out: Do not reverse an end notch or cut the entire rib end away.

Keep beside this step: Rib Seat (p. 72) · S02 (p. 86) · S50T (p. 87) · S601 (p. 88)

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Check and prepare · 8 OF 32

8. Make the roof overlap

Parts: Left roof P02L · Right roof P02R

Have ready: Guided router, depth measurement, offcut coating trial

Before you start: Confirm the left/right labels before removing either face.

Make the roof overlap. Picture explains the action; use the linked drawing for exact settings.

1. At the center seam, leave the LEFT lower tongue and RIGHT upper tongue. The overlap is 0.5 in (12.7 mm). Use the exact face/depth settings in the machining reference.
2. The nominal removal is 0.36156 in (9.18 mm) deep. Its allowance leaves room for finish; trial both coated offcuts first.
3. Keep the outside roof faces level when seated. The roofs remain removable. Do not glue the overlap or drive screws through its thin tongues.

Check before continuing: The cured sample slides together without force and leaves no more than 1/32 in (0.794 mm) local seated gap.

Watch out: Removing the same face from both halves makes a step instead of an overlap.

Keep beside this step: Roof Joint (p. 73) · P02L (p. 80) · P02R (p. 81)

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Check and prepare · 9 OF 32

9. Cut the vent and ring openings

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Guided router/jigsaw, templates, square, support

Before you start: Keep the cutout supported. Cut-wire handling comes later.

Cut the vent and ring openings. Picture explains the action; use the linked drawing for exact settings.

1. Mark the side vent from the wall FRONT edge: 3.75 in (95.25 mm). Mark its bottom 7 in (177.8 mm) above the finished wall bottom. Each side opening is 16.5 in (419.1 mm) ×4 in (101.6 mm).
2. Mark the four 19 ×16 in (482.6 ×406.4 mm) roof openings using the roof drawings. Preserve the center overlap and all webs.
3. Cut matching through-openings in the six one-piece screen rings. Each ring overlaps its opening by 3/4 in (19.05 mm). Smooth and seal every cut edge later.

Check before continuing: Vent/ring pairs match, supports remain intact and no ring crosses a backer strap or roof rib.

Watch out: Do not enlarge openings into the frame or rib lands.

Keep beside this step: Side (p. 68) · P02L (p. 80) · P02R (p. 81) · Screen Section (p. 74)

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Check and prepare · 10 OF 32

10. Trial the screws and mark holes

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Trial screws, stopped drill, clearance/pilot bits, clamps

Before you start: A clearance hole goes through the first piece; a pilot is the smaller hole in the receiving wood.

Trial the screws and mark holes. Picture explains the action; use the linked drawing for exact settings.

1. Use the exact fastener schedule and drawing datums. Transfer receiver holes during the clamped dry fit; do not build a chain of hole-to-hole measurements.
2. For #8 screws, start the receiving trial at 7/64 in (2.778 mm); clearance is 11/64 in (4.366 mm). Confirm with the real screw root and batch. Countersink only enough for a flush head.
3. Limit each pilot to its listed depth. The schedule checks intermediate wood, joint pockets, screw length and at least 1/16 in (1.588 mm) remaining wood beyond the point in this candidate.

Check before continuing: The offcut joint closes without splitting, a buried point or a crushed veneer.

Watch out: A deep countersink can consume the remaining wood at a thin seat.

Keep beside this step: Drilling Key (p. 89) · Receiving (p. 103)

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Build the wooden shell · 11 OF 32

11. Dry-fit the complete wooden shell

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Flat 112 ×36 in bench, square, two≥98 in clamps, four 30 in clamps, protective cauls

Before you start: Have three people for large-piece handling. Keep walls clamped until the back/frame hold them.

Dry-fit the complete wooden shell. Picture explains the action; use the linked drawing for exact settings.

1. Lay the floor on the fully supported bench. Set sides between floor and roof level; place the back between the square side edges, flush at the rear. Rehearse the front frame, blocks, ribs and removable roofs without glue.
2. Use half-inch cauls to protect faces. Keep long clamps supported and move one clamp at a time to clear a drilling station. Rehearse the actual clamp jaws and tool body.
3. Compare both top and front diagonals, measure each opening and check flatness. Project target: diagonal difference no more than 1/16 in (1.588 mm), with every joint fully seated.

Check before continuing: No part requires forcing; actual tool/clamp access and helper roles are rehearsed.

Watch out: Clamps can pull a wrong-sized assembly together while hiding a bad cut.

Keep beside this step: Overall (p. 67) · Front Frame (p. 70) · Workholding (p. 77)

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Build the wooden shell · 12 OF 32

12. Fit the side cleats and rear posts

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Clamps, wood glue, stopped drill, W200 screws

Before you start: Glue only clean bare wood. Do not rely on glue as a certified structural adhesive.

Fit the side cleats and rear posts. Picture explains the action; use the linked drawing for exact settings.

1. Clamp each side flat on the bench. Seat its upper/lower cleats and rear corner post in the locations on the part drawings, leaving the vent clear.
2. Spread Titebond III on the mating faces and drive the listed screws from the outward side into the solid supports. Keep the heads flush.
3. Set the sides on the floor with temporary braces. Keep the floor interface clamped and follow the measured dry-fit positions.

Check before continuing: Both sides have the same finished height and the rear posts leave a clear, square opening for the back.

Watch out: Do not coat glue lands or leave side walls standing unsupported.

Allow time: Manufacturer open assembly 8–10 min; total 20–25 min at 70°F/50%RH. Keep stressed joints clamped 24 h; do not stress a new joint for at least 24 h.

Keep beside this step: P03L (p. 82) · P03R (p. 83) · Drilling Key (p. 89)

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Build the wooden shell · 13 OF 32

13. Fit the back and its rails

Parts: Full back P04 · Lower back rail S50B · Upper back rail S50T · Center back post S51

Have ready: Clamps, wood glue, W200 screws, square

Before you start: Support the back before loosening a wall brace.

Fit the back and its rails. Picture explains the action; use the linked drawing for exact settings.

1. Clamp the two back rails and center back post to the back, using the drawing locations. Keep the rib seats facing upward.
2. Glue the bare mating faces and fasten through the back into those solids. Set the back between the sides and onto the floor, with its inside face against the rear posts and its outside face flush with the side rear edges.
3. Recheck diagonals before driving the screws into the rear corner posts. Use the listed offset stations so side and back screws do not meet.

Check before continuing: Back is flush at both rear corners, case square and all receiver pilots stop inside solid wood.

Watch out: Do not assume a thin removable back would supply this same racking path.

Allow time: Hold stressed glue joints 24 h, longer if actual label/environment requires.

Keep beside this step: P04 (p. 84) · S50B (p. 106) · S50T (p. 87) · Drilling Key (p. 89)

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Build the wooden shell · 14 OF 32

14. Position the five sill blocks

Parts: Sill support block 1 S101 · Sill support block 2 S102 · Sill support block 3 S103 · Sill support block 4 S104 · Sill support block 5 S105 · Floor P01

Have ready: Square, clamps, wood glue, station drawing

Before you start: The floor remains clamped to the walls; underside fixings are installed at step 19.

Position the five sill blocks. Picture explains the action; use the linked drawing for exact settings.

1. Locate the five short blocks from the floor left datum using their exact X coordinates. Their front faces align with the sill/front-frame recess.
2. Glue their bare bottom faces to the floor and clamp them with the full floor supported. Block height is 2.5 in (63.5 mm).
3. Use a straightedge across the tops. They must carry the sill together without rocking.

Check before continuing: All five bearing tops are level and their locations agree with the drawing.

Watch out: A block floating above the floor transfers no bearing load.

Allow time: Do not turn or stress the assembly until the glue hold is complete.

Keep beside this step: Front Frame (p. 70) · Drilling Key (p. 89)

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Build the wooden shell · 15 OF 32

15. Lay out the front frame

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Flat bench, square, clamps, measuring tape

Before you start: Assemble this frame off the case so the backer holes are accessible.

Lay out the front frame. Picture explains the action; use the linked drawing for exact settings.

1. Lay header and sill on their front faces with three posts between them. The header is above; the center post divides two equal openings.
2. Set each opening to 45.04688 in (1144.19 mm) ×13.09375 in (332.58 mm). Check the entire frame length against the exact rail cut.
3. Lay the six plywood backer straps on the exposed rear faces across each post joint. Mark their positions and transfer the four fixing holes per strap.

Check before continuing: Frame is square on the bench and all bearing ends touch.

Watch out: Do not install the frame first and discover the drill cannot reach an end strap.

Keep beside this step: Front Frame (p. 70) · Drilling Key (p. 89)

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Build the wooden shell · 16 OF 32

16. Join the front frame

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Wood glue, clamps, W125 screws, stopped drill

Before you start: Leave the frame flat and clamped while drilling and driving.

Join the front frame. Picture explains the action; use the linked drawing for exact settings.

1. Spread glue on the bare backer/contact faces. Bearing post ends remain seated against sill and header; the straps tie the joints together.
2. Drive four #8 ×1.25 in screws per strap, using the exact schedule: two into the post and two into the rail. Recheck flush heads and pilot depths.
3. Keep both opening diagonals matched as the glue sets. Lift the cured frame with a helper, supporting both bays.

Check before continuing: The cured frame retains two square openings without clamp pressure.

Watch out: Do not treat the glue label or this digital layout as a structural load rating.

Allow time: Keep stressed joints clamped 24 h; do not stress the frame sooner.

Keep beside this step: Front Frame (p. 70) · Drilling Key (p. 89)

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Build the wooden shell · 17 OF 32

17. Fit the frame and retaining face

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Helpers, clamps, glue, W200 screws, square

Before you start: The center post is permanent. Keep all temporary supports until the frame is fixed.

Fit the frame and retaining face. Picture explains the action; use the linked drawing for exact settings.

1. Seat the sill on all five blocks, with the frame ends between the sides. Use the rehearsed side fixing stations to locate the rails and end posts.
2. Fit the retaining face across the floor front. Its reference height is 6 in (152.4 mm); glue the bare mating lands and screw into the sill and five blocks.
3. Recheck body width, diagonals and both openings before glue cures. Side screws into rail ends locate the frame; no end-grain screw capacity is claimed.

Check before continuing: The retaining face has continuous upper support and five supported lower stations; the frame is square.

Watch out: Do not use the retaining board as a step or lifting handle.

Allow time: Keep clamped for the required glue hold before handling.

Keep beside this step: Front Frame (p. 70) · P05 (p. 85) · Drilling Key (p. 89)

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Build the wooden shell · 18 OF 32

18. Seat the three roof ribs

Parts: Roof rib 1 S601 · Roof rib 2 S602 · Roof rib 3 S603 · Front header S02 · Upper back rail S50T

Have ready: Clamps, W125 screws, depth-stopped drill

Before you start: Do not overdrill the thin bearing ends or use the mesh as a support.

Seat the three roof ribs. Picture explains the action; use the linked drawing for exact settings.

1. Place each rib’s notched ends on their matching header/back-rail seats. Tops align with the roof support plane.
2. Drive one #8 ×1.25 in screw at each end, through the remaining 0.75 in rib end into 0.5 in receiving wood. Use the listed pilot depth and countersink trial.
3. Dry-fit both roofs again. Confirm the screen rings clear the ribs and the right roof can lift free before the left.

Check before continuing: Six bearing ends fully seated; roofs lie flat without being forced down.

Watch out: A screw cannot replace a missing bearing seat.

Keep beside this step: Rib Seat (p. 72) · Roof Joint (p. 73) · Drilling Key (p. 89)

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Build the wooden shell · 19 OF 32

19. Fasten the floor from above after turning

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Three helpers, clamped rigid cradle, bench, W200 screws

Before you start: Turn only the empty cured shell. Clamp the floor to the case before the turn.

Fasten the floor from above after turning. Picture explains the action; use the linked drawing for exact settings.

1. Remove loose roofs and fittings. Put padded temporary cross supports on the bench at X13,48 and 83 in (330.2,1219.2 and 2108.2 mm). They span the header-to-back support plane.
2. With three helpers, turn the clamped empty case upside down onto those supports. The fixed rim/ribs bear on the cradle; the floor underside faces upward. Prevent rolling and sliding with stops/clamps.
3. Drive the listed floor screws downward from this exposed face into lower cleats, rear posts and five blocks. Check all buried points, then return the supported empty shell upright.

Check before continuing: Floor fixings are complete without drilling beneath a flat board or an unstable lifted case.

Watch out: Never attempt the turn with substrate, glass or loose roof panels installed.

Keep beside this step: Workholding (p. 77) · Drilling Key (p. 89)

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Finish and fit the doors · 20 OF 32

20. Prepare the wood for coating

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Abrasives 120–220, vacuum, masking, trial pieces

Before you start: Do not dismantle glued structural joints.

Prepare the wood for coating. Picture explains the action; use the linked drawing for exact settings.

1. Remove the loose roofs and screen rings. Sand exposed wood progressively 120 to 220 grit; ease sharp edges lightly and clean dust from corners and holes.
2. Mask the exact bare-wood steel-track bond lands on sill/header/jambs. Keep hardware, running surfaces and future adhesive contact clean.
3. Test the selected coating and sealant on the actual wood and planned cleaner. Reject weak adhesion or incompatibility; record the accepted system.

Check before continuing: All cut edges and holes are accessible; masked bonding lands remain clean bare wood.

Watch out: Silicone contamination can prevent coating or adhesive from bonding.

Keep beside this step: Finishing (p. 102) · Receiving (p. 103)

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Finish and fit the doors · 21 OF 32

21. Coat the shell and let it cure

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Varathane 284473, synthetic brush, ventilation, film check

Before you start: Indoor dry use only. This coating is not a waterproof tank liner.

Coat the shell and let it cure. Picture explains the action; use the linked drawing for exact settings.

1. Apply the selected finish to exposed faces, cut edges, holes and removable pieces. Stir, do not shake. Use the product’s thick even coat; target 9 mil wet to 3 mil dry rather than wiping on an unmeasured thin film.
2. Apply two extra coats to the dry-basin contact faces only after the required recoat interval and 220-grit preparation. Keep masked track lands bare.
3. Record temperature/humidity, last coat time and full-cure end. Keep coated roof samples: they must still fit without forcing.

Check before continuing: Coating is fully cured and the actual trial passes; odor or dry-to-touch alone is not acceptance.

Watch out: Do not substitute a mildew-additive outdoor finish or call low-VOC animal-safe.

Allow time: VAR-35: about 2 h recoat,48 h light handling,7 days full cure at 70°F/50%RH; cooler/damper conditions need longer. Follow the delivered label if it is more restrictive.

Keep beside this step: Finishing (p. 102) · Receiving (p. 103)

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Finish and fit the doors · 22 OF 32

22. Bond the matched tracks

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Deburred profiles, bare-wood bond lands, PL Premium 1390595, spacers, clamps

Before you start: Keep adhesive out of rolling channels. Do not drill fasteners through the anvils.

Bond the matched tracks. Picture explains the action; use the linked drawing for exact settings.

1. Final-size the continuous rails and jamb channels against the finished frame at the named checkpoint. Keep reference end allowances and cured bond-bed thickness in the calculation.
2. Clean wood/galvanized contact surfaces as the adhesive instructions require. Apply a continuous supporting bond; align upper/lower lanes vertically with the actual sample gauge.
3. Brace the profiles without twisting them. Trial lock clearance and any required divider relief on a sample before altering the actual jamb.

Check before continuing: Both bays have straight aligned lanes and a recorded cured outside-face opening.

Watch out: A screw in a rolling path or a crooked lower rail can damage the shoe or glass.

Allow time: PL Premium: brace≥24 h; reserve 48 h at 78°F/50%RH before loading, longer if actual conditions require. Complete the real wood/metal bond trial.

Keep beside this step: Track Fit (p. 75) · Retention Service (p. 76)

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Finish and fit the doors · 23 OF 32

23. Measure the finished bays and order glass

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Actual cushions, tracks, lock, sample glass, caliper, fabricator order sheet

Before you start: Do not order from the reference pane dimensions alone.

Measure the finished bays and order glass. Picture explains the action; use the linked drawing for exact settings.

1. Install/transfer the actual cushion tabs at the two jambs of each bay. Check the 963L clip and bar clear the delivered channels through the whole travel.
2. Measure each cured track outside-face opening and each cushioned closing width. Pane width=(closing width+1 in overlap)/2; pane height=outside-face opening−1.25 in.
3. Ask the fabricator to confirm scant 6 mm fit, tempering, polished edges, quantities and tolerances. Four reference panes are 22.89844 in (581.62 mm) wide ×11.78125 in (299.24 mm) high; no holes. Sign the actual order only after the trial.

Check before continuing: Fabricator-approved final dimensions and trial evidence are recorded for both bays.

Watch out: Tempered panes cannot be cut, drilled or ground to repair a bad order.

Keep beside this step: Track Fit (p. 75) · Receiving (p. 103)

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Finish and fit the doors · 24 OF 32

24. Prepare the shoes and carriers

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Matching profiles, metal-cutting setup, deburring tools

Before you start: Do not substitute another shoe for scant 6 mm glass.

Prepare the shoes and carriers. Picture explains the action; use the linked drawing for exact settings.

1. Cut each shoe to its actual accepted pane width and each carrier to(closing width+pane width)/2. Reference carrier length is 33.84766 in (859.73 mm).
2. Deburr ends without distorting the running surfaces. Clean out metal chips before assembly.
3. Set carriers and shoe seating as the KV instructions and sample trial require. A carrier rolls at half the pane travel; it is not a fixed rail.

Check before continuing: Four shoes and four carriers match the signed bay order and move freely on the trial.

Watch out: Do not trim a carrier to pane length.

Keep beside this step: Track Fit (p. 75) · Layouts (p. 55)

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Finish and fit the doors · 25 OF 32

25. Fit the four glass panes

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Helpers, glazing handling gear, accepted matched profiles

Before you start: Protect glass edges. Keep lift blocks out until panes are safely seated.

Fit the four glass panes. Picture explains the action; use the linked drawing for exact settings.

1. Use the fabricator-approved shoe seating method. Insert the rear leaf into its upper lane, lift only enough to clear the lower retaining lip, and settle it onto its carrier. Repeat for the front leaf.
2. Fit both bays separately. Keep the agreed one-inch overlap and the closing stops; check metal never strikes an exposed glass edge.
3. Slide slowly by hand through the accepted travel. Stop if a shoe catches, a carrier reaches an end or the frame flexes.

Check before continuing: All four panes are correctly supported, overlap at closing and travel without collision.

Watch out: Do not force a pane into a misaligned lane.

Keep beside this step: Track Fit (p. 75) · Retention Service (p. 76)

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Screens and final checks · 26 OF 32

26. Capture the side screens

Parts: L side mesh M01L · R side mesh M01R · L side screen ring V01L · R side screen ring V01R

Have ready: Mesh snips, wire-handling gloves, W125 screws, trial

Before you start: Wire gloves are for handling only; keep gloves away from rotating cutters.

Capture the side screens. Picture explains the action; use the linked drawing for exact settings.

1. Cut the two side screens from the layout. Each is 17.5 in (444.5 mm) ×5 in (127 mm). Flatten the edges; remove loose wires. Predrill wood before placing mesh; snip any fixing-station wire clearance behind the ring, without leaving exposed ends.
2. Lay each screen against the inside side panel, with a half-inch margin around the opening. Place its one-piece ring over it.
3. Fasten the ring at its six scheduled stations. Keep the buried points inside the outer panel and every cut wire end behind the ring.

Check before continuing: No loose mesh, projecting wire, trapped corner or contact with a front backer remains.

Watch out: Do not assume this mesh aperture suits every animal or feeder.

Keep beside this step: Screen Section (p. 74) · V01L (p. 107) · V01R (p. 108)

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Screens and final checks · 27 OF 32

27. Capture the roof screens

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Flat bench, mesh snips, W125 screws

Before you start: Work on each loose roof with its underside facing up.

Capture the roof screens. Picture explains the action; use the linked drawing for exact settings.

1. Cut four 20 ×17 in (508 ×431.8 mm) screens. Position each with half-inch capture margins. Predrill wood before mesh; keep any snipped screw-station wire ends entirely behind the rings.
2. Clamp the matching one-piece ring over each screen. Drive its six scheduled screws through clearance holes into the roof, without breaking the top face.
3. Check the ring positions against rib and lap drawings. Keep equipment weight off the mesh.

Check before continuing: All four screens are flat, replaceable and clear of ribs/roof seams.

Watch out: Do not fasten a screen in place before its coating has fully cured.

Keep beside this step: Screen Section (p. 74) · P02L (p. 80) · P02R (p. 81)

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Screens and final checks · 28 OF 32

28. Fit the lift blocks, locks and pulls

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Delivered profiles, accepted sample, stopped drill, TRACK screws

Before you start: Every transferred hole must clear the glass and roller sweep.

Fit the lift blocks, locks and pulls. Picture explains the action; use the linked drawing for exact settings.

1. Fit the eight HDPE lift blocks to the actual upper lanes. Use their removable web-only fixing stations; recorded trial dimensions govern their width/depth.
2. At every door position, verify no more than 1/16 in lift and positive lower-shoe capture. Check lock clips cannot spread the leaves apart. Fit one 963L lock per bay and fourFP86 pulls by their instructions.
3. Remove each lock body before sliding. Rehearse unlocking, removing lift blocks, lifting each pane out and refitting everything. Do not load the shell until the complete closure trial passes.

Check before continuing: Locks, lift prevention and the complete removal/refit path pass the actual trial.

Watch out: A keyed lock alone does not stop a pane lifting out of the tracks.

Keep beside this step: Retention Service (p. 76) · Receiving (p. 103)

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Screens and final checks · 29 OF 32

29. Fit the removable roofs

Parts: Left roof P02L · Right roof P02R

Have ready: Helpers, W200 screws, hand driver, square

Before you start: Seat left roof first, then right. Do not glue them down.

Fit the removable roofs. Picture explains the action; use the linked drawing for exact settings.

1. Set the LEFT lower tongue on the center rib. Lower the RIGHT upper tongue onto it; both outside faces finish level.
2. Drive the eighteen listed roof screws into solid support lands, nine per half. Keep the center fixings outside the thin overlap.
3. Check every seated edge gap and all screen/frame clearances. For service, remove screws and lift the right roof clear first; the fixed support frame remains in place.

Check before continuing: Both roofs seat flat and can be removed without disturbing the center post or ribs.

Watch out: The viewer’s hide-roof control is not permission to remove structural framing.

Keep beside this step: Roof Joint (p. 73) · Drilling Key (p. 89)

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Screens and final checks · 30 OF 32

30. Seal the dry-basin seams

Parts: Floor P01 · Dry-bed retaining face P05 · L side P03L · R side P03R · Full back P04

Have ready: Selected DAP00688 silicone, accepted coating coupon, masking

Before you start: HOLD: DAP 00688 excludes use on or near zinc and galvanized metal. This build has zinc hardware. Resolve that conflict with the manufacturers, or revise the system and recheck it, before this operation.

Seal the dry-basin seams. Picture explains the action; use the linked drawing for exact settings.

1. Proceed only after the documented corrosion-compatibility hold is closed. A coated screw head is not manufacturer approval.
2. Only after full coating cure, clean and mask the dry-basin seams and lower fixed cleat edges. Use the exact accepted silicone formulation without substituting a mildew-additive product.
3. Tool continuous nominal 1/4 in (6.35 mm) beads where the seam diagram identifies them. Seal penetrations without covering removable screen/roof parts or sliding channels.
4. Keep a same-depth cutoff sample. Wait for full through-cure and verify adhesion to the actual coating; record dates and conditions.

Check before continuing: Seams are continuous and accepted samples are cured through, without peeling.

Watch out: A surface skin or an odor check does not establish through-cure.

Allow time: Reserve at least 7 days for the project seam/coupon hold; actual product, bead depth and conditions may require longer. This is a project hold, not an immersion approval.

Keep beside this step: Finishing (p. 102) · Receiving (p. 103)

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Screens and final checks · 31 OF 32

31. Check the installation before use

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Receiving/commissioning records, scales, straightedge, actual equipment instructions

Before you start: Do not add animals or contents until unresolved installation and use holds are resolved.

Check the installation before use. Picture explains the action; use the linked drawing for exact settings.

1. Verify continuous flat support under the full 96 ×24 in floor. Measure the actual shell, dry bed and equipment mass; check the support and building floor separately. Obtain qualified review where inputs or capacities are uncertain.
2. Check locks, lift prevention, gaps, exposed wire, fixings, coating and full opening/removal paths. Keep bed depth at or below 4 in (101.6 mm) and side vents unobstructed.
3. Commission species/feeder containment, ventilation, humidity, protected heat and cable/electrical interfaces against their actual requirements. No species suitability, load capacity or heat clearance comes from this shell guide.

Check before continuing: Every required hold has evidence; prototype/physical/qualified status remains separate from digital checks.

Watch out: Average pounds per square foot does not approve a building floor.

Keep beside this step: Commission Record (p. 104) · Front Frame (p. 70)

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Screens and final checks · 32 OF 32

32. Clean, inspect and service the shell

Parts: Parts identified in the picture and linked workshop reference; complete IDs in the source schedule.

Have ready: Soft cleaning tools, accepted cleaner, replacement parts list

Before you start: Empty the shell and safely isolate equipment before service. Never move it filled.

Clean, inspect and service the shell. Picture explains the action; use the linked drawing for exact settings.

1. Inspect glass edges, tracks, lock clips, lift blocks, screen capture, floor support and coatings regularly and after any equipment or loading change. Stop use if a joint loosens, support settles, glass catches or a finish fails.
2. For glass service, remove the lock body and lift blocks before lifting an empty pane from its carrier. For roof service, remove the right half before the left; keep frame and ribs fixed.
3. Clean only with the trial-approved method. Replace damaged screens/rings or worn closures with the same verified system; repair coating fully and allow cure before reuse. Record the work and the new acceptance checks.

Check before continuing: Parts remain replaceable and maintenance does not bypass the original fit, cure or containment checks.

Watch out: Do not slide, lift or relocate the filled assembly.

Keep beside this step: Retention Service (p. 76) · Commission Record (p. 104)