This project is continued from Part 2.
After removing the old wooden astragal and glue the split door frame, I’m now ready to install the new AstraSEAL™ aluminum astragal on the patio French door. The installation instructions are a single page and the job was straightforward. The astragal is 1-3/4 inches wide (to fit a 1-3/4 inch thick door) and 79-1/4 inches tall.
Install the New Aluminum Astragal
The aluminum astragal has very tight tolerances and fits very snugly over the edge of the 1-3/4″ wide door. Begin by aligning the astragal evenly with the top of door and use a flat hand to press the astragal onto the door edge, working evening from top to bottom along the length of the door. It’s a very tight fit – but take it slow and it’ll go on.
This view from the top of the door clearly shows how the astragal “clamps” itself over the door edge. The red line traces the door profile to more clearly show the fit between the astragal and the door. Click on the image for a full size view.
A wide carpenter’s level is used to verify the astragal is even with the top of the door.
The screw locations are marked on the door to drill pilot holes in the door edge.
The instructions say to remove the astragal before drilling pilot holes for the attachment screws. Since the astragal had already clamped itself tightly to the door, I chose to leave it on and drill the 1/8 inch pilot holes with it in place, being careful not to let the drill chuck make contact with and mar the aluminum.
The astragal is attaches to the door with the supplied screws. Don’t over torque the screws or you’ll strip the threads out of the wood.
Two vinyl snap-in covers are provided with the astragal to cover the channel between the slide bolts and strike plates for the door lock. The dead bolt plate and strike plate are adjustable. I used the old astragal to align the two plates, then marked and cut the vinyl covers with a hack saw to fit.
Full length view of the patio French door with the aluminum astragal. This really cleaned up the door’s appearance!
Reinstall the French Door
To rehang the door, retract the slide bolts on the astragal, align hinge leaves on the door and jamb, then slide in the door hinge pins. This French door weighs 65 lbs and a helper is needed to hold the door.
The New Astragal
The new astragal fits perfectly! I really liked the sturdy aluminum construction and the steel rods for the slide bolts. The rods extend up to ~3 inches beyond the door top and bottom edges to securely fasten the door in the sill and top jamb.
The new astragal seals evenly between the two doors to keep out drafts, rain, dust, bugs and such.
Full view of the doors and new astragal.
The last thing to do is clean and paint the doors.
Hope this helps,
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