Thetford Service Doors Installation Manual

Step 1: Prepare Templates

Diagram Description: Shows parts labeled #1 through #6, which are components of the service door assembly. The text indicates these numbers are used for reference in the installation instructions.

To install the service door, Thetford recommends separating parts #1 to #6 before starting. These numbers are used as a reference in the installation instructions.

Step 2: Mark and Drill Interior Holes

Diagram Description: Shows template B+C being placed on the inside of a wall. A drill is shown creating two holes. A measurement of 3mm is indicated for the drill bit size.

Cut out template B + C and place it on the inside of the vehicle, on the right location and drill two holes through the wall.

Step 3: Mark Exterior Outline

Diagram Description: Shows template A being placed on the outside of a vehicle, aligned with the holes drilled in the previous step. The text indicates these holes serve as reference points.

Cut out template A and place it on the outside of the vehicle. Use the holes made in step 1 as a reference.

Step 4: Check Space and Outline

Diagram Description: Shows a diagram indicating a minimum space requirement for the service door. Another diagram shows template A being replaced by templates B+C, and the outline of template C being drawn on the wall.

Check the minimum available space for the service door.

Replace template A with template B + C and draw an outline of template C on the wall.

Step 5: Apply Protective Tape

Diagram Description: Shows template B+C being removed, and protective tape being applied around the drawn outline, both inside and outside the line.

Remove template B + C and stick protective tape around the outline both inside and outside the drawn line.

Step 6: Drill Cut-out Hole

Diagram Description: Shows a drill bit (8mm indicated) drilling a hole in the wall. A note states that the cut-out wall panel will be used as the door panel.

Drill a hole in the wall. ⚠️ NOTE: The cut-out wall panel will be used as the door panel. Only drill in the indicated place!

Step 7: Saw Cut-out Panel

Diagram Description: Shows a saw cutting along the drawn outline. Notes emphasize perpendicularity and that the cut-out panel is the door panel.

Saw along the cut-out. ⚠️ NOTE 1: Make sure this cut-out is perpendicular! ⚠️ NOTE 2: The cut-out wall panel will be used as the door panel. Only saw in the indicated places!

Step 8: Fit Door Frame

Diagram Description: Shows the door frame (#3) being fitted into the cut-out opening in the wall. Protective tape is being removed from the wall.

Check if the door frame (#3) fits. Remove the protective tape from the wall.

Step 9: Reinforce Wall and Secure Frame

Diagram Description: Shows aluminum strips (25x3mm) being used to create a frame. This frame is then placed into the cut-out wall opening to reinforce it and secure the door. A note mentions cutting into foam if hammering is difficult.

Make an aluminium frame (strips to be 25 x 3 mm) to strengthen the wall and secure the door. Place the frame into the cut out wall. If only hammering is difficult, first cut into the foam.

Step 10: Position Template B

Diagram Description: Shows template B being placed on the sawn-out panel (which will become the door). A note emphasizes aligning decorative stripes.

Place template B on the sawn-out panel. ⚠️ NOTE: Make sure that the decorative stripes on the panel are in line with those on the vehicle!

Step 11: Draw Outline on Panel

Diagram Description: Shows an outline being drawn on the sawn-out panel, and protective tape being applied around this outline.

Draw an outline on the sawn-out panel. Place protective tape around the outline both inside and outside the line.

Step 12: Saw Door Panel

Diagram Description: Shows the sawn-out panel being sawed to size, and protective tape being removed.

Saw the door panel. Remove the protective tape.

Step 13: Attach Brackets

Diagram Description: Shows brackets (#6) being attached to the inner side of the door (#2).

Place the brackets (#6) on the inner side of the door (#2).

Step 14: Seal Outer Door Edge

Diagram Description: Shows sealant (or tape) being applied to the groove on the outer side of the door (#1) to ensure a watertight connection.

Apply sealant (or tape) in the groove of the outer side of the door (#1) to create a water-tight connection.

Step 15: Fit Door Panel

Diagram Description: Shows the cut-out door panel being fitted into the outer side of the door (#1).

Fit the door panel in the outer side of the door (#1).

Step 16: Assemble Door Halves

Diagram Description: Shows the inner side of the door (#2) being tapped into the outer side of the door (#1).

Tap the inner side of the door (#2) into the outer side of the door (#1).

Step 17: Seal Outer Frame

Diagram Description: Shows sealant (or tape) being applied to the groove of the outer frame (#3) for a watertight connection.

Fill the groove of the outer frame (#3) with sealant (or tape) to create a water-tight connection.

Step 18: Attach Outer Frame to Wall

Diagram Description: Shows the outer frame (#3) being screwed to the wall.

Screw the outer frame (#3) to the wall.

Step 19: Attach Inner Frame to Wall

Diagram Description: Shows the inner frame (#4) being connected to the wall from the inside of the vehicle, using screws or double-sided tape.

On the inside of the vehicle, connect the inner side of the frame (#4) to the wall, either with screws or double sided tape.