DOOR INSTALLATION AND REPLACEMENT
THE FOLLOWING PROCEDURES GOVERN THE CUTTING OF A HOLE IN A BULKHEAD AND THE SUBSEQUENT INSTALLATION OF A WATERTIGHT DOOR AND ITS FRAME. DIFFERENT PROCEDURES ARE FOLLOWED WHEN INSTALLING A FLANGE TYPE DOOR.
WHEN CUTTING A NEW OPENING IN A BULKHEAD TO INSTALL A DOOR OR VERIFYING THAT AN EXITING OPENING IS THE RIGHT SIZE, PLEASE REFER TO THIS TABLE AND TO NOTE 9 BELOW, WHICH DETAILS THE 1-1/4" OVERLAP OF THE DOOR FRAME AND BULKHEAD:
CLEAR OPENING AND BULKHEAD CUT DIMENSIONS
FOR STANDARD SIZE DOORS
CLEAR
OPENING
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FRAME
WIDTH
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BULKHEAD
CUT WIDTH
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BULKHEAD
CUT HEIGHT
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BULKHEAD CUT
CORNER RADIUS
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18" X 36"
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4-3/4"
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25"
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43"
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11-1/2"
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26" X 45"
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4-3/4"
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33"
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52"
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11-1/2"
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26" X 54"
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4-3/4"
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33"
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61"
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11-1/2"
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26" X 57"
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4-3/4"
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33"
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64"
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11-1/2"
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26" X 66"
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4-3/4"
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33"
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73"
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11-1/2"
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30" X 66"
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4-3/4"
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37"
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73"
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11-1/2"
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36" X 66"
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4-3/4"
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43"
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73"
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11-1/2"
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PREPARING THE BULKHEAD
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INSPECT THE BULKHEAD FOR STRAIGHTNESS.
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IF THE BULKHEAD IS WARPED OR TWISTED, STRAIGHTEN IT WITH A STRONG-BACK. USE AN ANGLE OR FLAT BAR.
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IF THE BULKHEAD IS BOWED, MAKE A CUT IN THE PLATE AND USE A STRONG-BACK TO STRAIGHTEN THE BOWED AREA. THEN REWELD THE CUT.
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IF THE BULKHEAD HAS NO HEADER OR LONGITUDINAL T-BAR AT ABOUT 6' ABOVE THE DECK, INSTALL A NEW ONE. LOCATE THE HEADER 6" ABOVE THE UPPER EDGE OF THE LOCATION FOR THE CLEAR OPENING OF THE WATERTIGHT CLOSURE. WELD THE ENTIRE LENGTH OF THE HEADER.
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IF THE VERTICAL STIFFENERS IN THE BULKHEAD ARE MORE THAN 12" FROM THE LOCATION FOR THE DOOR FRAME, INSTALL CHOCKS AROUND THE FRAME, ONE CHOCK ABOVE AND BELOW THE INTENDED LOCATION OF EACH DOG. CHOCKS MUST BE OF THE SAME MATERIAL AS THE DOOR FRAME.
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THE AREA OF THE BULKHEAD THAT CONTACTS THE CLOSURE FRAME MUST BE SMOOTH. NO WELDS OR TACKS ARE PERMITTED IN THE LAP AREA. FOR A STEEL BULKHEAD, GRIND THE SURFACE TO REMOVE ALL ROUGHNESS.
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REMOVE THE DOOR FROM THE DOOR FRAME.
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TO MARK THE CUTTING LINE, HAVE ANOTHER PERSON HOLD THE DOOR FRAME AGAINST THE BULKHEAD IN THE EXACT LOCATION WHERE THE CLEAR OPENING IS TO BE CUT. MARK THE CUTTING LINE FOR THE CLEAR OPENING BASED ON 1-1/4" OVERLAP OF THE FRAME AND THE BULKHEAD. FOR A STEEL DOOR, CENTER PUNCH THE LINE EVERY 1/2". WHEN THIS STEP IS DONE, REMOVE THE DOOR FRAME FROM THE BULKHEAD.
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USING AN EXOTHERMIC TORCH OR PLASMA CUTTER, CUT THE OPENING FOR THE DOOR IN THE BULKHEAD AND REMOVE THE CUT PANEL.
INSTALLATION OF THE DOOR FRAME STEEL-TO-STEEL
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ALIGN THE DOOR FRAME OVER THE CLEAR OPENING AND USE C-CLAMPS TO HOLD THE FRAME IN PLACE. IF THIS IS A ONE MAN OPERATION, TACK TWO 2" X 2" X 1/4" THICK PLATES ABOUT 12" APART TO USE AS A LEDGE TO SET THE FRAME ON WHILE YOU CLAMP IT IN PLACE.
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TACK WELD (SKIP WELD) THE DOOR FRAME TO THE BULKHEAD EVERY 6" ON BOTH SIDES. KEEP THE HEAT EVEN SO AS NOT TO DRAW AND WARP THE ASSEMBLY. TACKS ON OPPOSING SIDES OF THE FIT-UP SHOULD BE STAGGERED. TACKS SHOULD BE APPROXIMATELY 1" LONG.
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FILL IN BETWEEN THE TACK WELDS, WORKING FROM ONE END TO THE OTHER AND STAGGERING WELDS TO PREVENT WARPING. MOVE FROM ONE SIDE OF THE INSTALLATION TO ANOTHER OFTEN TO KEEP THE HEAT EVEN.
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AFTER THE STRUCTURE HAS BEEN COMPLETELY WELDED, CHIP AWAY ALL SLAG.
INSTALLATION OF THE DOOR FRAME STEEL-TO-ALUMINUM
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ALIGN THE DOOR FRAME OVER THE CLEAR OPENING AND USE C-CLAMPS TO HOLD THE FRAME IN PLACE. IF THIS IS A ONE MAN OPERATION, TACK TWO 2" X 2" X 1/4" THICK PLATES ABOUT 12" APART TO USE AS A LEDGE TO SET THE FRAME ON WHILE YOU CLAMP IT IN PLACE.
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DRILL HOLES FOR HUCK RIVETS THROUGH THE FRAME AND BULKHEAD. FOR A STANDARD 8 OR 10 DOG DOOR, DRILL APPROXIMATELY 60 HOLES. DRILL THE HOLES CLOSE ENOUGH TO THE OUTER EDGE OF THE DOOR FRAME TO AVOID HAVING HUCK RIVETS INTERFERE WITH THE OPERATION OF THE QUICK ACTING LINKAGE ASSEMBLY.
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MAKE SURE THE BULKHEAD IS SMOOTH. APPLY TWO LAYERS (8-1/5 MILS EACH, 17 MILS TOTAL) DIELECTRIC BARRIER TAPE TO THE AREA OF THE BULKHEAD THAT WILL BE IN CONTACT WITH THE DOOR FRAME. THE TAPE MUST BE INSTALLED ALONG THE ENTIRE EDGE OF THE CLEAR OPENING. CUT CURVED PIECES OF TAPE FOR THE CORNERS.
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USE C-CLAMPS TO SECURE THE DOOR FRAME TO THE RIM OF THE CLEAR OPENING TEMPORARILY.
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INSTALL HEX HEAD BOLTS AND NUTS IN ENOUGH OF THE RIVET HOLES TO SECURE THE FRAME.
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REMOVE THE C-CLAMPS.
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HUCK RIVET THE FRAME TO THE BULKHEAD.
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WHEN THE FRAME IS COMPLETELY HUCK RIVETED, USE A UTILITY KNIFE TO REMOVE EXCESS DIELECTRIC TAPE.
INSTALLING THE DOOR
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MOUNT THE DOOR IN THE FRAME AND MAKE ADJUSTMENTS TO HINGES, LINKAGES AND DOGS.
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INSTALL A DOOR STOP AND KEEPER.
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INSTALL A HASP AND KEEPER, IF APPLICABLE.
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FOR INDIVIDUALLY DOGGED DOORS, INSTALL WRENCH STOWAGE BRACKETS ON THE BULKEAD INSIDE AND OUTSIDE THE DOOR.
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