z bar inset for an integral window - milgard windows & doors · 2 la7975 ‐ a read all instruc...

Z‐Bar Inset for an Integral Window

Installa on Instruc ons

LA7975 ‐ A

2 LA7975 ‐ A

Read all instruc ons before installa on.

Milgard Z‐Bar Inset is part of the Window Assembly.

Do not a empt to remove the Z‐Bar from the replacement Window. It is factory sealed to prevent

water intrusion.

Use exterior grade high quality sealants. For compa ble TiteBond® Sealant colors refer to page 13.

Integral Z‐Bar Inset Instruc ons

For Milgard Essence Series® Windows and Doors

Required Tools

Screwdriver with #2 Phillips bit

Caulking Gun

3 LA7975 ‐ A

Integral Z‐Bar Inset Parts

Z‐Bar Inset All Sides Z‐Bar Inset with Groove Filler

PART DESCRIPTION PART NUMBER

1 Z‐BAR INSET ‐ HEADER/SILL EX7856XX

2 Z‐BAR INSET ‐ LEG EX7856XX

3 CORNER KEY IM8035MI

4 1/8” x .123‐.188 ALUMINUM RIVET FA7451

5 (WINDOW FRAME) VARIES


1 Z‐BAR INSET ‐ HEADER EX7856XX

2 Z‐BAR INSET ‐ LEG ‐ LEFT EX7856XX

3 Z‐BAR INSET ‐ LEG ‐ RIGHT EX7856XX

4 GROOVE FILLER EX7852XX




4 LA7975 ‐ A

Integral Z‐Bar Inset Parts (Con nued)

Z‐Bar Inset with Stucco Key


1 Z‐BAR INSET ‐ HEADER EX7856XX

2 Z‐BAR INSET ‐ LEG ‐ LEFT EX7856XX

3 Z‐BAR INSET ‐ LEG ‐ RIGHT EX7856XX

4 STUCCO KEY EX7812XX




5 LA7975 ‐ A

Integral Z‐Bar Inset Corners

Exterior View Interior View

Top Miter

Z‐Bar Inset All Sides shown

Z‐Bar Inset shown in yellow

Window Frame shown in blue


Bo om Miter


Bo om Groove Filler


Bo om Stucco Key

6 LA7975 ‐ A

Prepare Original Window

1 Fully prepare the opening.

These instruc ons only cover steps specific to installing Milgard Z‐Bar.

For informa on on preparing the opening, please refer to other installa on instruc ons.

Other installa on instruc ons cover:

Removing the original sash and glass.

Removing original frame legs.

Proper blocking and flashing of original sill

Using shims to level sill.

7 LA7975 ‐ A

Fit Z‐Bar Inset to Opening

2 Either measure or dry fit replacement Window within opening. Trimming may be necessary.

Verify Z‐Bar Flange will fully seat

against original Window Frame.

Do not a empt to remove the Z‐Bar

from the replacement Window. It is

factory sealed to prevent water

intrusion.

For best performance, make sure the

Z‐Bar overlaps the original frame at

least 3/4".

3/4" MINIMUM

If placing replacement window inside

exis ng trim, trimming the Z‐Bar Inset

may be necessary. See page 8.

8 LA7975 ‐ A

Fit Z‐Bar Inset to Opening (Con nued)

Measure the trim opening at mul ple

loca ons to ensure an accurate fit. Original

trim may not be square or uniform.

Lay unit on a flat surface with trim side up.

Scribe or mark trim to a create a cu ng

line. Mark Z‐Bar Trim 1/8” to 1/4” smaller

than trim opening.

Mask exposed surface to protect during the

cu ng process.

Cu ng blade must be rated for non‐

ferrous materials and designed to cut

aluminum. It is recommended to use a

Tracksaw/Railsaw to maintain a straight cut.

Corner Rivets are aluminum with aluminum

mandrels. Use same cu ng blade to cut

through rivets.

Dry fit window in opening.

9 LA7975 ‐ A

Sealing Surfaces

3 Apply Sealant on back side of Z‐Bar Inset.

Leave 4" sealant gaps 4" from each Sill

Corner.

If the original Window Frame has weeps,

leave sealant gaps at each weep.

10 LA7975 ‐ A

Shimming

4 Set Window into opening. Center Window between the original Jambs.

Install 1/4” diameter Backer Rod between

Z‐Bar and original trim. Seal between edge

of Z‐Bar and original trim.

5 Shim next to each “Through the Jamb” hole.

Check and correct Window for plum,

square, and cross leg.

EXTER

IOR

IN

TERIO

R

Fully seat Window against original Window Frame.

11 LA7975 ‐ A

Installa on Screws

6 Remove indicated Jamb material to access predrilled installa on holes.

Note: Some windows may have

predrilled holes through the Jamb

material.

7 Install provided screws through predrilled holes. Fully seat screws.

8 Replace Wood.

12 LA7975 ‐ A

Exterior Sealing

9 Run a bead of sealant where the Z‐Bar edge meets the stucco.

Put a bead around the full perimeter

of the Window.

Note: Leave a gap of at least 2" at

each original weep hole loca on.

EXTER

IOR

13 LA7975 ‐ A

Interior Sealing

10 Seal between original and new Window Frames.

Do not seal between original frame

and Jamb Extensions if present.

Apply sealant over any shims to

ensure a con nuous seal.

INTER

IOR

14 LA7975 ‐ A

Clean Up

Wipe up any excess sealant.

Clean up scuff marks with soap and water.

TiteBond® WeatherMaster Sealant Compa ble Colors

Milgard Pale e Color Titebond® WeatherMaster™ Color

Reference Milgard Part Number

Bark 44061 SE7673AR

Black Bean 44031 SE7673BL

Bronze 45841 SE7673ZB

Cinnamon 45521 SE7673CI

Classic Brown 44211 SE7673LW

Espresso 45661 SE7673EX

Evening Sky 45531 SE7673ES

Fern 45651 SE7673FN

Fog 46681 SE7673FO

Frost 44001 SE7673FS

Harmony 44641 SE7673HR

Ivory 45511 SE7673IV

Pea Pod 49211 SE7673PP

Sand 46041 SE7673SD

Tweed 44691 SE7673TE

Twilight 44031 SE7673BL

15 LA7975 ‐ A

REV ECN DESCRIPTION DATE DRAWN APPD.

A 4019ECNEG RELEASE 08/25/2015 NDS VM

REVISIONS

z bar inset for an integral window - milgard windows & doors · 2 la7975 ‐ a read all instruc...

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