Build the large 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. Use a level, rigid, continuous support at least 96.092 in (2440.74 mm) × 48.092 in (1221.54 mm). Support the entire veneered floor and all edges. The furniture and building floor need qualified review for the actual complete loaded weight.
2. The conservative bed-volume envelope is 19.63 cubic feet (556 L), before wood support displacement. At an assumed wet bulk density of 100 lb/ft³ (1602 kg/m³), the bed alone is 1963 lb (890 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. Allow roof removal above, supported pane removal in front and vent cleaning at both sides. The reference width including veneered vent captures is 96.811 in (2459 mm). Flush retainer heads add no exposed bolt tail. Rehearse the empty transport route; provide extra working space for people and tools.
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–H11 before dependent purchases or cuts. Obtain KV acceptance for this steel system, wider panes, carrier geometry, adhesive mounting, right-jamb relief and removable anti-lift design. Save the supplier response; rejected details need redesign.
2. Choose ONE exterior species: maple, white oak or walnut. The schedule needs seven 48 in (1219.2 mm) × 120 in (3048 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 steel ball-bearing 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 matching steel Roll-Ezy 993 upper channel, 995 shoes, 997 carriers and 999 lower track, the 963L lock and PL Premium 1390595. Inspect straightness, zinc finish and freely rolling balls. The complete system is specified for openings up to 144 in (3657.6 mm), without track joints. Resolve the current 36 in (914.4 mm) pane wording against the older 12-foot opening instructions with KV before purchasing this wider-pane system. Internal product geometry and the right-jamb relief need received-sample approval.

Check before continuing: Received wood gauges and matched KV993/995/997/999 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. Measure the compressed actual underlay plus 45 mil (0.045 in / 1.14 mm) EPDM on a smooth offcut, away from folds. The reference 0.08 in (2.03 mm) underlay plus 0.045 in (1.14 mm) liner totals 1/8 in (3.18 mm); these are unmeasured allowances. Record the received result on the height strip and coordinate changes before cutting.
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 8 in (203.2 mm) for the maximum total bed, 10 in (254 mm) for the retaining-panel top and 11 in (279.4 mm) for the vent bottom. Transfer these marks to the build.

Check before continuing: 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 six labeled PLY layouts. Each needs at least 96 3/8 in (2447.93 mm) × 48 3/8 in (1228.73 mm) usable oversized stock to include the rough blank, 1/8 in (3.18 mm) kerf and edge trim. Check every sheet; an exact nominal 96 in (2438.4 mm) × 48 in (1219.2 mm) sheet is too small for this method. Finish floor and roof at 96 in (2438.4 mm) × 48 in (1219.2 mm), with grain along the width. Do not shrink the shell to fit short stock.
2. At the reference 45/64 in (17.86 mm) plywood gauge, sides finish at 48 in (1219.2 mm) × 46 19/32 in (1183.48 mm), the back at 94 19/32 in (2402.68 mm) × 46 19/32 in (1183.48 mm), and each retainer layer at 94 19/32 in (2402.68 mm) × 10 1/8 in (257.18 mm). Fit the mating pieces using the received gauge and square reference edges; revise all dependent dimensions when the gauge changes.

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. Tables distinguish rough blanks from final sizes; leave the final line during rough cutting, then fit paired pieces 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 four roof openings

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

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

1. On the roof, mark four 18 in (457.2 mm) × 40 in (1016 mm) openings. Their front edges are 4 in (101.6 mm) from the front; left edges are 6 in (152.4 mm), 28 in (711.2 mm), 50 in (1270 mm) and 72 in (1828.8 mm) from the left. Keep all three 4 in (101.6 mm) webs intact for the roof ribs.

Check before continuing: All four 18 × 40 in (457.2 × 1016 mm) outlines and three 4 in (101.6 mm) webs match the schedule before cutting.

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9. Mark both raised wall vents

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

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

1. On each side, mark a 36 in (914.4 mm) × 5 in (127 mm) opening starting 6 in (152.4 mm) behind the front edge. Its lower edge is 11 in (279.4 mm) above the finished-floor mark, not the floor underside.

Check before continuing: Both 36 × 5 in (914.4 × 127 mm) outlines start 11 in (279.4 mm) above the actual finished liner floor; verify every margin before cutting.

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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. Dry-place the capture strips over the waste-side margins. Each mesh edge must sit 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 all three rib webs remain intact.

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11. Prepare safe wide frame and strip stock

Parts: F0L, F1L, F0R, F1R, F0T, F1T, CLB, CLU, CLT, CRB, CRU, CRT, CF, CB, CT, CR1, CR2, CR3, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, RTLF, RTLA, RTMF, RTMA, RTNF, RTNA, RTRF, RTRA, RTLL, RTLR, RTML, RTMR, RTNL, RTNR, RTRL, RTRR, LCL, LCR, LCF1, LCF2, LCF3, LCF4, LCB1, LCB2, LCB3, LCB4, LCQL, LCQ1, LCQ2, LCQ3, LCQR, LCPL, LCP1, LCP2, LCP3, LCPR, CFL, CF1, CF2, CF3, CFR, CM1, CM2, CM3; use labeled picture and schedules

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

1. Use PINE-FRAME layouts for named jamb and header layers. Rip 3 1/2 in (88.9 mm) strips from guarded, safely held stock with featherboards and push sticks; crosscut to the named lengths. Preserve the separate trial board for hardware and finish samples.
2. Plane safe full-width PINE-THIN blanks to 3/8 in (9.53 mm) before routing the wire pockets and ripping 1 in (25.4 mm) capture strips and 1/2 in (12.7 mm) liner clamps. Follow machine minimum feed lengths. Never machine a loose small strip near an exposed cutter.

Check before continuing: Frame and thin-strip stock is identified, sound and prepared for safe final cuts.

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12. Cut and dress the solid supports

Parts: F0L, F1L, F0R, F1R, F0T, F1T, CLB, CLU, CLT, CRB, CRU, CRT, CF, CB, CT, CR1, CR2, CR3, VLB, VLT, VLF, VLA, VRB, VRT, VRF, VRA, RTLF, RTLA, RTMF, RTMA, RTNF, RTNA, RTRF, RTRA, RTLL, RTLR, RTML, RTMR, RTNL, RTNR, RTRL, RTRR, LCL, LCR, LCF1, LCF2, LCF3, LCF4, LCB1, LCB2, LCB3, LCB4, LCQL, LCQ1, LCQ2, LCQ3, LCQR, LCPL, LCP1, LCP2, LCP3, LCPR, CFL, CF1, CF2, CF3, CFR, CM1, CM2, CM3; use labeled picture and schedules

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

1. Use the ten SOLID layouts for four bottom cleats, five rear uprights, five front posts, three upper supports and three roof ribs. Nominal 2-by-2 lumber has a reference 1 1/2 in (38.1 mm) square section; measure it before cutting. These are solid members, 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 sixteen 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 twenty-four 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, F1L, F0R, F1R, F0T, 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.
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 opening gauge for the reference about 87 5/8 in (2225.68 mm) × 33 in (838.2 mm) opening, then substitute the actual dry-frame dimensions. Cut a smooth 1/4 in (6.35 mm) nominal (6 mm) disposable panel sample; it is a fit gauge, never a substitute door.
2. Assemble offcuts of the actual 999 lower track, 997 carrier, 995 shoe and 993 upper channel around a 1/4 in (6.35 mm) nominal (6 mm) disposable panel gauge. Use the matching family throughout; the model shows nominal envelopes rather than a fabrication drawing of the proprietary sections.
3. The manufacturer deducts 1 1/4 in (31.75 mm) from the distance between the OUTSIDE top of the upper channel and OUTSIDE bottom of the lower track. Include the actual bond beds when locating those faces. Confirm rolling, upper engagement, lift-out and the 1 in (25.4 mm) closed overlap with the sample. Also make a steel-offcut-to-bare-wood bond sample under the reassemble and release the final glass sizes operation’s preparation and cure; reject peeling or failed adhesion before committing the tracks. Resolve current pane-size limits before the trial. Do not use aluminium-system vinyl, wheels or top clips in this steel family.

Check before continuing: The matched sample rolls and lifts out with retention removed. The cured bond sample holds without peeling. No glass has been ordered.

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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 a liner offcut over an eased wood support and into a corner. Keep the central floor reference mark distinct from the raised wood support shelf. Reserve 1/8 in (3.18 mm) at each wall for the lining and folds; a larger fold must be accommodated and deducted from the clear 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 attach the bottom wood supports operation 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: The four held cleats match the named datums; clearance holes, stopped pilots and front retainer recess are correct before applying glue.

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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 all three intermediate rear uprights

Parts: CM1 — Intermediate back upright; CM2 — Intermediate back upright; CM3 — Intermediate back upright

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

1. Place CM1, CM2 and CM3 against the inside of the back at centres 24 in (609.6 mm), 48 in (1219.2 mm) and 72 in (1828.8 mm) from the left outside face. Each fits between CB and CT and is about 43 5/8 in (1108.08 mm) long in the reference shell.
2. Clamp each upright square with its bottom bearing fully on CB. Transfer the add the intermediate rear supports operation stations through P04. Drill #8 clearance through the plywood and stopped 7/64 in (2.78 mm) starting pilots into the solid pine.
3. Fit the listed #8 × 1 1/4 in (31.75 mm) screws from the back. Tighten evenly by hand, keeping the back flat and the upper wood support level. Confirm all points remain buried.
4. Check all three intermediate uprights and both rear corner uprights bear on their lower wood supports. Ease the edges that the liner will wrap around. Leave the five front posts loose until the retainer is seated in the next step.

Check before continuing: Five rear uprights are square and secure; no screw point or sharp corner meets the future liner.

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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 10 in (254 mm) above the finished floor, before adding the track. An 8 in (203.2 mm) total bed leaves 2 in (50.8 mm) to the wood top.

Check before continuing: The held retainer is seated flat against the front cleat, with its top level at the marked height before fastening.

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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 unpunctured liner. Over this about 87 5/8 in (2225.68 mm) opening, sight the retainer top with a long straightedge before the posts are bolted; plane nothing, but shim or re-clamp any bow now.

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 all five front posts

Parts: CFL, CF1, CF2, CF3, CFR, BTL1, BTL2, BT11, BT12, BT21, BT22, BT31, BT32, BTR1, BTR2; use labeled picture and schedules

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 on CLB and CRB and CF1/CF2/CF3 on CF behind the retainer. The middle-post centers are X = 24 in (609.6 mm), 48 in (1219.2 mm) and 72 in (1828.8 mm) from outside left. Their reference length is 8 5/8 in (219.08 mm). Clamp each square with its front face against RB3 and top flush with the retainer.
2. Fit three side screws per end post at 2 1/2 in (63.5 mm), 5 1/2 in (139.7 mm) and 8 1/2 in (215.9 mm) above the finished floor, using clearance through each side and stopped pilots into its clamped post. Keep all five posts clamped, square and bearing on their lower cleats; the middle posts are secured by their two through-connections.

Check before continuing: All five posts bear on their named cleats and are square; each end post has three side screws and ten total through-connections remain to fit.

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25. Trial the flush retainer connection and nut recess

Parts: CFL, CF1, CF2, CF3, CFR, BTL1, BTL2, BT11, BT12, BT21, BT22, BT31, BT32, BTR1, BTR2; use labeled picture and schedules

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 ten flush retainer screws

Parts: CFL, CF1, CF2, CF3, CFR, BTL1, BTL2, BT11, BT12, BT21, BT22, BT31, BT32, BTR1, BTR2; use labeled picture and schedules

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 two centres per post at 3 1/4 in (82.55 mm) and 7 1/4 in (184.15 mm) above the finished floor. Their X coordinates are 1 29/64 in (36.91 mm), 24 in (609.6 mm), 48 in (1219.2 mm), 72 in (1828.8 mm) and 94 35/64 in (2401.49 mm) from outside left. These revised centres avoid N10’s own three end-post 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: Ten joints close flat, threads fully engage and all tails remain safely recessed.

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27. Inspect and protect the recessed hardware

Parts: CFL, CF1, CF2, CF3, CFR, BTL1, BTL2, BT11, BT12, BT21, BT22, BT31, BT32, BTR1, BTR2; use labeled picture and schedules

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 retainer fastener pierces the wet-zone membrane; only the scheduled clamp screws pierce the upper dry band. 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; F1L — L jamb layer; F0R — R jamb layer; F1R — R jamb layer; F0T — Header 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 the clear height at three positions. Reference width is about 87 5/8 in (2225.68 mm) and height is about 33 in (838.2 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 six mesh pieces

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

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

1. Cut four roof pieces 19 in (482.6 mm) × 41 in (1041.4 mm), and two side pieces 37 in (939.8 mm) × 6 in (152.4 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 four 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 six 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 openings and dry-seat the widened one-inch captures with routed pockets facing the wire. Full outer lands touch the wall; all cut ends and crossings fit inside the pocket.
2. Clamp without bowing the mesh. Transfer the revised stations on the solid outer lands, outside the wire perimeter. Drill #6 clearance through the strip only, then stopped pilots 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, CR1, CR2, CR3, MTL, MTM, MTN, MTR, RTLF, RTLA, RTMF, RTMA, RTNF, RTNA, RTRF, RTRA, RTLL, RTLR, RTML, RTMR, RTNL, RTNR, 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 CR1, CR2 and CR3 between the front frame position and rear upper wood support, with centres 26 in (660.4 mm), 48 in (1219.2 mm) and 70 in (1778 mm) from the left outside edge. All three ribs lie beneath the solid webs between openings. Transfer their top-down #8 screw stations through the roof into each rib.
2. Centre MTL/MTM/MTN/MTR beneath their roof openings. Fit sixteen one-inch captures with the routed pockets facing the wire. Drill the revised outer-land stations and stopped roof pilots; fit #6 × 1 in (25.4 mm) screws flush without crushing the strips.
3. Turn the roof with a helper and check every point remains beneath the outer face. All three ribs sit between the openings and end 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 — KV999 Roll-Ezy lower track; TRACK-T — KV993 Roll-Ezy upper channel; JAMBL — KV993 vertical jamb receiver; JAMBR — KV993 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. Cut the received KV993 upper channel and two jambs, KV999 lower track, two KV995 shoes and two KV997 carriers only after H01 acceptance. Upper/lower reference length is 87 11/32 in (2218.53 mm), jamb length 31 9/32 in (794.54 mm). Two 144 in (3657.6 mm) KV993 bars are needed; the other profiles need one each. Protect jaws, square-cut, deburr and preserve every required carrier ball.
2. The reference glass and shoe width is 44.1689 in (1121.89 mm) and carrier length 65.7533 in (1670.13 mm). These are fitting references. Final shoe/carrier cuts follow the cured measured opening and fabricator-approved panes; no joined track lengths.

Check before continuing: Matching received profiles and cut lengths are accepted; every carrier ball remains retained, and all cut edges are smooth. No glass order released.

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34. Fit the jambs and approved divider relief

Parts: TRACK-B — KV999 Roll-Ezy lower track; TRACK-T — KV993 Roll-Ezy upper channel; JAMBL — KV993 vertical jamb receiver; JAMBR — KV993 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 supplier acceptance, relieve only the right-jamb central divider between 1 7/8 in (47.63 mm) and 3 1/8 in (79.38 mm) above the retaining top. Preserve backing web and outside walls; smooth the cut and trial the exact ratchet clip against its cushion.
2. Dry-fit the four reference bond beds at 1/32 in (0.79 mm), using actual matched samples. Mark and mask clean bare-wood contact footprints beneath both tracks and behind both jambs. Stop veneer outside these footprints. Do not drill the rolling anvils or add track-mounting screws.

Check before continuing: Only the scheduled local divider interval is removed. Backing web and both outer legs are intact; the received lock clip clears and bare bond seats remain masked.

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35. Align and temporarily clamp the rolling tracks

Parts: TRACK-B — KV999 Roll-Ezy lower track; TRACK-T — KV993 Roll-Ezy upper channel; JAMBL — KV993 vertical jamb receiver; JAMBR — KV993 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 the running lanes vertically using the actual section centers, a straightedge and plumb gauge. Both horizontal tracks must be straight and parallel. Use padded temporary clamps while the disposable panel gauge rolls end to end.
2. Trial four plain neoprene cushions ending between the horizontal tracks. Their accepted contact bond replaces end tabs and screws; no head may enter a glass, shoe or carrier path. The final track-bond operation and full cure occur after finishing, before glass measurement.

Check before continuing: Upper/lower lanes are straight, parallel and vertically aligned in the held trial. Four cushions have no screw tabs and stay clear of the running paths.

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36. Predrill the removable anti-lift inserts

Parts: ALF1, ALF2, ALF3, ALF4, ALB1, ALB2, ALB3, ALB4, STOPLF, STOPLB, STOPRF, STOPRB; use labeled picture and schedules

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

1. With the accepted disposable closure gauge fully seated, trial eight smooth HDPE inserts in the actual upper lanes. Reference installed thickness is 11/32 in (8.73 mm). Machine from wide supported stock; do not treat purchased 1/2 in (12.7 mm) sheet thickness as the finished insert thickness. Leave at most 1/16 in (1.59 mm) upward glass play and prove positive lower-shoe capture.
2. Use four strips per lane with three closed internal joints. Shorten only the two outside ends by 1/8 in (3.18 mm) to clear cured jamb cushions during lowering. Keep complete top restraint through every operating position; use distinct outer and middle cut lengths.
3. Remove glass while drilling all eight insert patterns before finishing. Transfer the exact two stations per strip, countersink actual #4 heads flush, drill clearance through HDPE and upper web and stopped pilots into the header. Trial the driver with its pane parked clear of each hole. Support loose strips while moving a pane; never let a strip fall on the glass.

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 the labeled complete dry fit and predrilled anti-lift patterns, then remove tracks, mesh captures, walls, frame, retainer, roof, posts and all ten retainer screw sets for finishing. Keep the glued floor/cleat and laminated retainer/frame assemblies intact. No concealed nut or recess may be left uninspected.
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, carriers, mesh and liner outside the sanding/coating area. Mask clean bare-wood track-bond footprints and required glue/bearing seats. The veneer supplier must accept the complete prepared substrate; do not put an unapproved film beneath an adhesive.
4. One-coat planning area including conservative wood rectangles, veneer topcoat, trial and contingency is 599.91 square feet (55.73 square metres). Plan 12 US quart cans (0.946 L each), supplied as 6 two-can packs. Additional coats or balancing layers require 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 one uniform coat to the exposed wood faces, all edges and opening reveals. The manufacturer’s application range is 60–90°F (16–32°C) below 85% relative humidity (RH). Ventilate the work area and use the label’s protective equipment.

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. At each vent, stop edge strips at bare fitted butt joints and leave a 1/64 in (0.4 mm) service seam between the wall skin and finished capture outline. Fit the actual cured layers; do not veneer hidden bearing faces.

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. Roof, underside and both side faces use two matched pieces meeting at the depth midpoint Y = 24 in (609.6 mm). Dry-match shade and grain, knife-fit a flush butt seam with no overlap ridge, and retain the rough trim allowance. 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 cured shell, five front posts and ten flush retainer screw/washer/locknut sets before lining covers their interior access. Recheck threads, recessed tails and bearing without crushing the wood. Confirm full support, square frame and flat capture lands. Dry-fit the tracks in the masked bare seats; then complete the following bond operation.

Check before continuing: The shell is square, ten recessed connections are accessible and fully engaged, and dry-fitted tracks match clean bare bond seats. Complete bonding next.

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45. Bond the steel tracks to their bare seats

Parts: KV993 / KV999 tracks and jambs; accepted PL Premium bond

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

1. Use Loctite PL Premium 1390595 only after the approved steel-to-bare-wood sample. Remove footprint masks; clean the wood and degrease received zinc-steel contact faces using the accepted preparation. Keep both surfaces dry and the rolling channels protected.
2. Bond each track or jamb only to its own wood member, never across a removable joint. Reference cured bed is 1/32 in (0.79 mm). Assemble within 15 minutes and brace straight for at least 24 hours, keeping adhesive out of glass and ball channels.
3. Reserve 48 hours at 78°F (26°C) and 50% relative humidity before loading; cold or dry conditions require longer according to the label and technical sheet. Check cured adhesion, straightness and the fitting gauge before cushions or final glass measurement. A failed sample or loose track requires an accepted repair and repeat cure.

Check before continuing: All four bonds have completed their required cure and the matched gauge moves freely.

Required wait: At least 24-hour bracing; 48-hour reference load wait under specified conditions, longer when required.

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46. 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 KV/DAP approval of the received zinc-plated steel and plain neoprene. Trial cleaning and two-face coating on matching offcuts. Never use this bond on EPDM, glass or HDPE.
2. Cut four 31 9/32 in (794.54 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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47. 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. After the steel-to-wood track bond and four cushions are fully cured, measure the smallest width between closing cushion faces. Add the accepted one-inch overlap, then divide by two for equal panes. Measure between the OUTSIDE top of the upper channel and OUTSIDE bottom of the lower track, then subtract the manufacturer 1 1/4 in (31.75 mm) reference deduction. Include actual bond beds; the received system and fabricator govern.
2. Planning pane is 44.1689 in (1121.89 mm) × 31 21/32 in (804.07 mm) × 6 mm thick, about 29.83 lb (13.53 kg). These are NOT glass order sizes. Specify monolithic tempered glass, polished edges and no holes after the fabricator checks the actual hardware and opening. All cutting and edge work precedes tempering.
3. Make each shoe the accepted pane width. For each carrier, add the measured cushion-to-cushion span to one shoe length, then divide by two. Reference carrier length is 65.7533 in (1670.13 mm). Preserve required bearing balls and trial complete travel before the order is released.
4. KV currently describes doors up to 36 in (914.4 mm) while its older sheet covers openings up to 12 feet and a maximum height-to-width ratio of 2:1. This reference pane exceeds 36 in (914.4 mm) width. Obtain written acceptance of this actual pane size/mass, matched open-stock system, adhesive installation and modified jamb before purchase or fabrication. Keep steel tracks dry; no mist, condensation or substrate in the channels. No load capacity is inferred.

Check before continuing: Bonding is fully cured, tracks remain straight, and the final glass, shoe and carrier dimensions have been recorded from the received system.

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48. Lay protective underlay and the one-piece liner

Parts: LINER, LCL, LCR, LCF1, LCF2, LCF3, LCF4, LCB1, LCB2, LCB3, LCB4, LCQL, LCQ1, LCQ2, LCQ3, LCQR, LCPL, LCP1, LCP2, LCP3, 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 128 in (3251.2 mm) × 80 in (2032 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 ten 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 protects the central floor, cleats and all ten posts. The uncut membrane rests without tension; no sharp contact remains.

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49. Fold corners and mark the actual liner heights

Parts: LINER, LCL, LCR, LCF1, LCF2, LCF3, LCF4, LCB1, LCB2, LCB3, LCB4, LCQL, LCQ1, LCQ2, LCQ3, LCQR, LCPL, LCP1, LCP2, LCP3, 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 all five front posts and all five 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 8 in (203.2 mm) above it, clamp screw centers 9 3/8 in (238.13 mm) above it and final liner top 9 3/4 in (247.65 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 corners and post pleats lie without tension; actual floor, bed, clamp and top marks are recorded.

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50. Fasten the twenty removable liner clamps

Parts: LINER, LCL, LCR, LCF1, LCF2, LCF3, LCF4, LCB1, LCB2, LCB3, LCB4, LCQL, LCQ1, LCQ2, LCQ3, LCQR, LCPL, LCP1, LCP2, LCP3, LCPR; use labeled picture and schedules

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

1. Install all ten short rounded post clamps LCQL/LCQ1/LCQ2/LCQ3/LCQR and LCPL/LCP1/LCP2/LCP3/LCPR first while the long side clamps are absent; this preserves straight driver access. Then fit LCB1/LCB2/LCB3/LCB4 and LCF1/LCF2/LCF3/LCF4, 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 eighty-four scheduled clamp screws may pierce the dry band, from 9 1/8 in (231.78 mm) to 9 5/8 in (244.48 mm) above the central liner floor, centered at 9 3/8 in (238.13 mm). Keep the basin below 9 1/8 in (231.78 mm) uncut and unpunctured.
2. Pre-drill clearance through each held wood clamp and stopped #6 pilots in its named wood receiver with the loose membrane and underlay removed. Refit the relaxed layers, then hand-puncture only the marked screw stations inside the upper dry band. Never drill loose rubber 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 twenty clamps bear in the stated order; only the eighty-four scheduled dry-band screws pierce the lining and the basin below stays intact.

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51. Complete the 24-hour shallow liner check

Parts: LINER, LCL, LCR, LCF1, LCF2, LCF3, LCF4, LCB1, LCB2, LCB3, LCB4, LCQL, LCQ1, LCQ2, LCQ3, LCQR, LCPL, LCP1, LCP2, LCP3, LCPR; use labeled picture and schedules

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

1. With all twenty clamps and all ten retainer connections installed 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 18.41 US gallons (69.68 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 full 24 hours have passed with no unexplained level drop or dampness. Water has been removed without tipping, and the enclosure is dry.

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

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52. Glaze the shoes and place both ball carriers

Parts: GL — Tempered glass leaf; GR — Tempered glass leaf; HL — KV995 glass shoe; HR — KV995 glass shoe; CARRIERL — KV997 free rolling ball carrier; CARRIERR — KV997 free rolling ball carrier

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

1. Inspect the tempered panes and deburred shoes on a padded clean bench. Fit each 995 shoe to its matching pane using the actual Roll-Ezy fit verified in the make the track and liner fitting gauges operation; do not hammer a tight shoe onto glass. This family uses continuous free-rolling carriers, not individual wheels, aluminum-system vinyl, end caps or top clips.
2. Place one correctly cut 997 carrier on each 999 lower-track anvil. With the left leaf closed, its rear-lane carrier starts at the left stop; with the right leaf closed, its front-lane carrier ends at the right stop. Their about 65 3/4 in (1670.05 mm) reference lengths extend beyond the shoes so each shoe remains supported as its carrier travels at half door speed.

Check before continuing: Each pane is seated in its accepted shoe; both trimmed carriers retain their balls and occupy the correct lane before either pane is inserted.

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53. Seat the rear leaf, then the front leaf

Parts: GL — Tempered glass leaf; GR — Tempered glass leaf; HL — KV995 glass shoe; HR — KV995 glass shoe; CARRIERL — KV997 free rolling ball carrier; CARRIERR — KV997 free rolling ball carrier

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

1. With a helper, lift the left closing pane into the rear upper channel, bring its shoe over the carrier and lower gently. Fit the right closing pane in the front lane. Keep glass supported near both ends and prevent it twisting. Confirm that the curved shoes sit on the balls and the carriers remain inside their channels.
2. Slide each leaf through its full path and close onto the cushions with 1 in (25.4 mm) overlap. Check at both ends and the middle: smooth motion, no metal scraping, no carrier running out from under a shoe, and continuous upper-channel engagement. Reset any carrier that has crept before continuing; never force a jammed door.

Check before continuing: Both doors roll on the matched carriers, remain supported through full travel and have intact glass edges.

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54. Install anti-lift inserts around the parked panes

Parts: ALF1/ALF2/ALF3/ALF4 and ALB1/ALB2/ALB3/ALB4; sixteen #4 × 3/4-inch screws

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

1. Remove the lock and have a helper control the seated pane. Each lane contains four strips. To expose a screw left of the enclosure center, park that pane fully right; to expose a screw right of center, park it fully left. Keep each loose strip supported while exposing its own two screws.
2. With both end strips absent and the pane parked right, insert middle strip 3 into the exposed left end and slide it to its mark. Then repeat the same insertion for middle strip 2. The strips pass above the glass without pressure. Hold it up without forcing the glass. Fit both screws of each middle strip from a clear pane position, moving the supported pane only with the driver removed and the strip controlled. Then fit the two end strips with the pane parked clear of each.
3. For service, remove both end strips first. Release middle strip 2 while supporting it, park the pane right, slide it left into the empty end and lower it. Then release strip 3 and slide it through the vacated middle space to the left end before lowering. Repeat for the other lane. Never lift a pane until all four strips in its lane are removed. Actual tool, grip and received-profile trials remain required.

Check before continuing: Both lanes have continuous capture; all sixteen screws and all eight strips can be safely installed and removed.

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55. Prove cushion and anti-lift retention

Parts: ALF1, ALF2, ALF3, ALF4, ALB1, ALB2, ALB3, ALB4, STOPLF, STOPLB, STOPRF, STOPRB; use labeled picture and schedules

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

1. Inspect all four cured bond-retained cushions. They end between the horizontal tracks and have no tabs or screws. Glass closes on soft rubber; peeling or shifted cushions require repair, full cure and renewed checks.
2. At both ends and the middle, gently lift each pane. Its shoe must remain positively captured within the lower track. Unscrew the inserts and demonstrate lift-out with a helper, then reinstall and repeat the retention check. Correct any fit that allows derailment with the inserts installed.

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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56. 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 received ratchet clip and removable lock secure both closed panes, clear the approved jamb notch, and release without force.

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57. 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. Locate each pull with its nearest edge at least 3/4 in (19.05 mm) inward from that pane’s closing edge, clear of the jamb noses. Follow the pull maker’s cleaning, adhesive and dwell instructions. Prove the complete bypass path before bonding.
2. Remove the unlocked lock body before sliding. Reference single-leaf access is 42.5126 in (1079.82 mm) × 31 9/32 in (794.54 mm). Reserve at least 41 in (1041.4 mm) service width; larger equipment requires both panes or roof removal. Trial the ratchet clip against the opposite cushion before its metal reaches the jamb; never force beyond the actual stop.

Check before continuing: Accepted pull bonds have completed their dwell; handles clear all hardware and the supported service route is documented.

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

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58. 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: six screws along each side wood support, eight across the front header and eight 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 roof screw locations accessible in the final equipment arrangement. Remove equipment and disconnect power before roof service. A screen-top fixture is permitted only where its instructions allow it and its complete weight is carried by qualified framing; this mesh has no fixture load rating.

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

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59. Inspect construction and rehearse maintenance

Parts: Named parts shown in the picture

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

1. Inspect every scheduled screw, all ten recessed retainer nut stacks and complete threads, mesh, glass, roof, lock and anti-lift inserts. Repair every loose fitting, split, burr or stripped receiver. Keep exterior drives accessible; interior retainer service requires complete removal of bed, 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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60. 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 3/8 in (9.53 mm), tilts the bottom 3 degrees toward the room (about 1.66 in (42.16 mm) at the bottom), lowers 1 in (25.4 mm), then withdraws 6 in (152.4 mm) toward padded supports. Keep the pane fully supported throughout. 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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61. Remove and inspect the liner for maintenance

Parts: Twenty 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 twenty 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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62. Place and measure the total bed

Parts: SUBSTRATE — 8-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 8 in (203.2 mm); for example, 2 in (50.8 mm) drainage leaves at most 6 in (152.4 mm) for the remaining layers.
3. The reference usable rectangle between lined supports is 91 11/32 in (2320.13 mm) × 41 15/16 in (1065.21 mm), about 26.6 square feet (2.47 square metres). Above the eight-inch total bed, height below upper supports is 36 31/32 in (939.01 mm), before equipment deductions. Confirm received geometry.
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. Refit the roof with all 28 scheduled attachments after loading; 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 freeboard and documented remaining usable space.

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63. 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 96 in (2438.4 mm) × 48 in (1219.2 mm) × 48 in (1219.2 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 exact mounting, separation and combustible-clearance instructions. Fit fixtures inside or above the screen only where that product permits the position, with guards and a qualified support carrying the weight. Keep hot parts clear of wood, liner, glass and animal contact; the mesh itself has no fixture load rating.

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

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64. 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. Finish the new reveal and complete its full cure before commissioning.
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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