Sprung Handle Installation Instructions

Contents

This document outlines the installation process for Corston sprung door handles. It includes a list of components, required tools, and detailed step-by-step instructions.

Components Included:

• Handles (x2)
• Threaded Spindle (x1)
• Thread Lock (x1)
• Grub Screws (x2)
• Grub Screws with pre-applied threadlock (x2)
• Flat Plate Long Lever (x2)
• M4 Through Bolts (x2)

Tools You'll Need

• Drill
• Palm Router
• Installation Jig (18247)
• Flat Head Screw Driver
• Router Bit (17101)
• PZ2 Driver Bit
• 10mm Drill Bit
• Pliers
• Wood Working Chisel

Installation Steps

When installing the handles into a new door, it is suggested to drill the pocket for the latch to sit in first, and then drill the holes for the door handle.

1. Step 1: Mark Centre Lines

   Mark the centre lines on both sides of the door based on the existing spindle hole. [Diagram: Door edge with centre lines and spindle hole marked.]

2. Step 2: Position and Secure Jig

   Line the Installation Jig (18247) up using the notches in the jig and the lines on the door. Screw the jig to the door using the wood screws provided. [Diagram: Jig attached to door edge with screws, drill shown.]

3. Step 3: Route Latch Pocket

   Using a palm router and the router bit (17101), route out a pocket 10mm deep into the door. [Diagram: Palm router cutting into door edge.]

4. Step 4: Remove Jig

   Unscrew the jig from the door. [Diagram: Jig removed from door edge.]

5. Step 5: Shape Latch Pocket

   Using a chisel, remove the radiused corners from the pocket. [Diagram: Chisel shaping the door pocket. Shapes indicating pocket and removed corners.]

   Repeat steps 2, 3, and 4 on the other side of the door.

6. Step 6: Drill Through Holes

   Using the screw holes as a pilot hole, carefully drill out the through holes with a 10mm drill bit. [Diagram: Drill with 10mm bit drilling through door.]

7. Step 7: Prepare Screws

   Clip snap-off screws to size so that they are smaller than the depth of the door. [Diagram: Pliers cutting a screw.]

8. Step 8: Attach Plates

   Screw the threaded bar through the plate and door into the lugs on the back of the second plate. [Diagram: Cross-section of door showing threaded bar connecting plates.]

9. Step 9: Install Spindle and Tighten

   Place the spindle through plates, using a flat head screwdriver, carefully tighten up the screws. [Diagram: Spindle inserted, screwdriver tightening screws.]

10. Step 11: Attach Roses and Handles

    Screw roses and handles onto the spindle, leaving a small gap between the rose and handle. [Diagram: Handles and roses being attached to spindle, small gap shown.]

11. Step 12: Adjust Gap

    If after screwing the handle on there is a gap bigger than 1mm between the handle and rose, use the washer to fill the gap. [Diagram: Close-up showing gap > 1mm and washer insertion.]

12. Step 13: Secure Handles

    Screw grub screws in, making sure the handle is level. Ensure the spindle is orientated so the grub screw is screwed into the groove in the spindle. [Diagram: Grub screw being tightened on handle.]

13. Step 14: Test Operation

    Check handle turns smoothly. [Diagram: Handle being turned.]

14. Step 15: Remove Handles (for Thread Lock)

    Remove handles. [Diagram: Handles being removed.]

15. Step 16: Apply Thread Lock

    Apply thread lock to the spindle and re-install the handle. [Diagram: Bottle of thread lock, application to spindle.]

16. Step 17: Use Pre-applied Thread Lock Screws

    Replace the grub screw in the handle with the grub screw with pre-applied thread lock. [Diagram: Grub screw with thread lock shown.]

17. Step 18: Final Installation and Curing

    Re-install and wait for thread lock to set (approximately 45 minutes). [Diagram: Handle re-installed, clock icon showing 45 mins.]

Swapping the Mechanism

Depending on the orientation of the door, latch, and plates, you may need to switch the mechanism on the back of the plates. This is an easy process that only requires a couple of steps.

1. Step 1: Check Mechanism Orientation

   Looking at the back of the plate, check that the limiter tab of the mechanism is facing towards the hinges. If not, then move to step 2. [Diagram: Back of plate showing mechanism and limiter tab direction.]

2. Step 2: Unscrew Mechanisms

   Unscrew the mechanisms from the back of the plates. [Diagram: Screws being removed from mechanism.]

3. Step 3: Switch Mechanism

   Switch the mechanism over. [Diagram: Two mechanisms shown, one flipped.]

4. Step 4: Secure Mechanism

   Screw the mechanism on to the plates. [Diagram: Mechanism being screwed onto plate.]

5. Step 5: Install Handles

   Install handles into the door. [Diagram: Handles being fitted to the door.]