DOOR INSTALLATION AND REPLACEMENT (FLANGE TYPE)

THE FOLLOWING PROCEDURES GOVERN THE REPLACEMENT OR INSTALLATION OF A FLANGE TYPE WATERTIGHT DOOR.  DIFFERENT PROCEDURES ARE FOLLOWED WHEN INSTALLING A WATERTIGHT DOOR THAT IS WELDED TO A BULKHEAD.

1. CUT OUT THE DOOR FRAME THAT IS TO BE REPLACED.  THE USE OF A PLASMA CUTTER IS RECOMMENDED, BUT AN EXOTHERMIC TORCH CAN ALSO BE USED.
   
   
2. MEASURE AND MARK A ZONE ABOUT 10" WIDE AROUND THE EDGE OF THE CUT.  MAKE SURE THERE ARE NO ELECTRICAL CABLES OR MOUNTED PARTS IN THIS AREA.
   
   
3. FOR A STEEL BULKHEAD, GRIND THE AREA INSIDE THE ENTIRE ZONE (INCLUDING 10" BORDER) DOWN TO BARE METAL AND REMOVE ANY SLAG LEFT WHEN YOU REMOVED THE OLD DOOR FRAME.  GRIND THE DECK AREA BELOW THE CUTOUT APPROXIMATELY 3" FROM THE BULKHEAD.
   
   
4. MEASURE THE DISTANCE FORM THE DECK TO THE BOTTOM CUT TO ALLOW EXTRA CLEARANCE ON THE BOTTOM EDGE OF THE FLANGE.
   
   
5. REMOVE THE DOOR FROM THE DOOR FRAME.  REMOVE THE DOG SHAFTS AND LINKAGE ASSEMBLIES.  REMOVE ALL THE BUSHINGS.  SAVE ALL THE PARTS THAT HAVE BEEN REMOVED BUT REPLACE ANY PARTS THAT ARE SEVERELY WORN OR DAMAGED.
   
   
6. LAY THE DOOR FRAME ON A SHEET OF 3/16" OR 1/4" PLATE.
   
   
7. MEASURE THE DISTANCE FROM THE EDGE OF THE PLATE TO THE BOTTOM EDGE OF THE DOOR FRAME.  SEE THAT THE MEASUREMENT TAKES INTO ACCOUNT THE DISTANCE FROM THE DECK TO THE EDGE OF THE BOTTOM CUT.  ADD 1-1/2" TO 2" TO ALLOW THE DOOR FRAME AND FLANGE TO OVERLAP.  NOW MARK THE BOTTOM OF THE FLANGE.
   
   
8. MEASURE APPROXIMATELY 6" FROM THE OUTSIDE EDGE OF THE DOOR FRAME ON THE THREE REMAINING SIDES AND MARK THIS DISTANCE.
   
   
9. MARK THE DOOR DRAPE ON ALL FOUR SIDES.  TRACE AROUND THE OUTER EDGE OF THE DOOR FRAME.
   
   
10. REMOVE THE DOOR FRAME AND MEASURE THE DISTANCE ON THE BACK SIDE OF THE FRAME FROM THE EDGE TO THE CLOSEST SLEEVE.  ALLOW CLEARANCE FOR THE WELD BEAD.  ADD THIS MEASUREMENT TO THE INSIDE OF THE TRACED DOOR FRAME MARK.  YOU HAVE NOW DEFINED THE OVERLAP AREA.  MARK THIS MEASUREMENT ALL THE WAY AROUND THE INSIDE OF THE TRACED DOOR FRAME MARK.
    
    
11. CUT THE OUTERMOST MARK AND THE INNERMOST MARK.
    
    
12. LAY THE DOOR FRAME ON A TABLE OR THE DECK.
    
    
13. PLACE THE FRAME ON TOP OF THE DOOR.  ADJUST THE POSITION OF THE FLANGE.  SECURE THE FLANGE TO THE DOOR USING WELDING VISE GRIP TYPE C-CLAMPS.
    
    
14. TACK WELD THE FRAME TO THE FLANGE AT APPROXIMATELY 8 PLACES EVENLY SPACED ON EACH SIDE OF THE FRAME/FLANGE ASSEMBLY.  KEEP THE HEAT EVEN SO AS NOT TO DRAW AND WARP THE ASSEMBLY.
    
    
15. FILL IN BETWEEN THE TACK WELDS, WORKING FROM ONE END TO THE OTHER AND STAGGERING WELDS TO PREVENT WARPING.  TURN THE ASSEMBLY OVER OFTEN AND WELD BOTH SIDES TO KEEP THE HEAT EVEN.
    
    
16. AFTER THE WELDS HAVE COOLED, TAKE THE ASSEMBLY AND THE DOOR TO THE INSTALLATION AREA.
    
    

1. INSPECT THE DOOR TO MAKE SURE ALL PARTS ARE OPERABLE AND FREE OF DEFECTS.
   
   
2. WELD L-BRACKETS IN PLACE AT THE MOST WARPED PLACES.  INSTALL STEEL WEDGES ON THE FLANGE (NOT THE DOOR FRAME).  HAMMER THE WEDGES TO FORCE THE BULKHEAD TO MEET THE FLANGE OR AT LEAST GET CLOSE ENOUGH FOR ANY GAP TO BE FILLED BY A WELD BEAD.
   
   
3. WELD THE DOOR IN PLACE.  REMOVE ALL SLAG.
   
   
4. INSTALL BUSHINGS, DOGGING ASSEMBLIES AND LINKAGE ON THE DOOR.  IF THE CLOSURE MECHANISM DOES NOT WORK FREELY, GRIND AS NECESSARY TO CREATE PROPER CLEARANCES.  WHEN THE DOOR IS CORRECTLY POSITIONED, REMOVE THE CLOSURE ASSEMBLIES.
   
   
5. CLEAN AND PRIME THE AFFECTED AREA.
   
   

1. WHEN THE PAINT IS DRY, INSTALL THE DOGGING AND LINKAGE MECHANISMS.
   
   
2. INSTALL THE DOOR IN THE FRAME, INSPECT ITS OPERATION AND MAKE ADJUSTMENTS AS REQUIRED.
   
   
3. CONDUCT A CHALK TEST.
   
   
4. INSTALL A DOOR STOP AND KEEPER.
   
   
5. INSTALL A DOOR HASP AND KEEPER AS REQUIRED.
   
   
6. FOR INDIVIDUALLY DOGGED DOORS, INSTALL WRENCH STOWAGE BRACKETS ON THE BULKHEAD INSIDE AND OUTSIDE THE DOOR.