CUTOUT AND FRAME DIMENSIONS
Door Width - Actual measurement may vary 1/2 to 1 inch.
Cut-Out Size - Width and height of hole needed in door.
Frame Size - Outside finished dimension of window.
Door Thickness - All standard items made for 1 3/8 inch.
For other thickness, sizes and dimensions, email support@lumidoor.net.
01 - Disassemble window insert
- Lumidoor window inserts are shipped assembled to avoid damage.
- Use a Philip head screwdriver to remove the 4 screws on the rear frame of the window insert.
02 - Remove acrylic panel
- Use a Philip head screwdriver to remove the 2 screws holding the acrylic panel to the front of the window insert frame.
- You will need a smaller screwdriver than used in step 01.
- Set the acrylic panel aside in a place it where it will not get scratched.
03 - Paint the frame
- Paint the outside surface of each frame and allow to dry.
- Be sure to paint the thin areas highlighted on each frame with the green arrows as it is visible after installation.
- Allow the paint to dry completely.
04 - Reattach acrylic panel
- Align the marks on the inside of frame and edge of acrylic to place the panel in original position.
- Make sure the decorative film texture side is facing the table surface.
- Reattach the acrylic panel to the front frame using removed screws.
- DO NOT REATTACH BACKSIDE FRAME.
- Set the front and rear frames aside until the door is ready.
05 - Mark door for cutting
- Remove the door to be updated with window and place it on a pair of sawhorses.
- Place towels or blanket on sawhorses to protect door surface from scratches.
- Insure the area underneath top panels to be removed is clear.
- Mark the area to cut using a marker and a straight edge.
- The edge of the panel is difficult to see while cutting.
06 - Drill pilot holes
- Drill 2 pilot holes where shown using a 5/8 inch or larger drill bit. Holes should be drilled completely through the door.
- Holes need to be large enough for jigsaw blade to be inserted in next step.
07 - Set up jig saw
- Install a long blade into a jig saw. Shown are blades purchased at home improvement store. They are 5 1/4 inches long.
- Apply chair pads or other protection to the base of the saw to protect the door finish while cutting out the panel(s).
08 - Begin cutting panel
- Starting from the drilled holes, cut to the adjacent corners of the marked cutout.
- When reaching the end of the cut, allow the jigsaw blade to stop completely before removing to avoid damage to the door.
09 - Cutout panel
- Repeat cutting from both directions in both holes until the panel is removed.
10 - Trim corners
- Remove the remaining sections in the corner for a finished rectangular opening for the window to be installed.
- Now is a good time to vacuum the sawdust. Be sure to use a brush attachment to avoid scratching the door paint.
11 - Install front insert
- Lay the front window insert frame into the door.
- The surface of the door seen here should be the front of the door. The window film should be on this side of the door.
- Make sure the window is sitting level in the cut out. Measure the distance from the top of the window to the top of the door on both sides and adjust as needed.
12 - Secure front frame
- Prepare 2 clamps by installing a chair pad or other protective material to one side of the clamp. (or use a cloth when clamping to protect door finish)
- Use a board and clamps to secure the front window frame and acrylic panel in place.
- Protect the finish of the frame and door by putting a towel or other material under the board. I use a board with painters tape on the underside – shown in inset.
13 - Install rear frame
- Flip the door over so the backside of door and window insert are facing up.
- Make sure the front window frame does not move during flipping to maintain levelness when complete.
- Place the rear frame in the cutout and secure to the front of the frame using the screws removed earlier.
- Make sure front and rear section alignment marks are on same side. Push up on the frame front while screwing in to insure a snug fit.
- The front and rear are aligned when assembled before shipping and screws should find previously drilled holes when tightening.
14 - Caulk edges
- Remove the clamps and board securing the frontside frame.
- Caulk around the backside edges of the frame where it meets the door (green arrows)
- Flip the door over and caulk edges of the front side frame.
- OPTIONAL - Use wood filler or putty to fill in screw holes, sand and paint for a finished appearance.
