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.
Door Astragal Installation Instructions
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.
Aluminum Astragal set over the Door Edge (Top View)
A wide carpenter’s level is used to verify the astragal is even with the top of the door.
Checking the Astragal Alignment with the Door
The screw locations are marked on the door to drill pilot holes in the door edge.
Mark the Screw Locations to attach the Astragal
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.
Drill Pilot Holes for the Astragal Attachment Screws
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.
Attach the Astragal with Screws to the Door
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.
Aluminum Astragal and Vinyl Snap-In Covers
Full length view of the patio French door with the aluminum astragal. This really cleaned up the door’s appearance!
Aluminum Astragal Installed on the Patio French Door
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.
Bottom View of the New Astragal on the Patio French Door
The new astragal seals evenly between the two doors to keep out drafts, rain, dust, bugs and such.
Astragal Weatherseal between the Patio French Doors
Full view of the doors and new astragal.
Patio French Doors and New Aluminum Astragal
The last thing to do is clean and paint the doors.
Hope this helps,
Bob Jackson
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Thanks for the tutorial. I’ve been searching for a solution to our weatherizing problem for months — 40 year old house with slightly warped, double entry doors that have significant gaps at the top and bottom of center. (That’s just the way it was constructed.) A major part of the problem was finding the correct terminology for the Astragal. Now it’s time to eschew the folded pieces of paper towel that have been stopping up the gaps — time to do it right and get it fixed. Thanks again.
Hi, Bob,
Really appreciated your tutorial. Here’s my issue: I want to replace a wooden astragal that was damaged during a break-in. The old astragal that was part of the door is 1/2″ thick where it fits between the doors.
I wonder whether the Astraseal astragal would work in this particular application. I like the Astraseal and think it would be a much more secure addition to the double doors to prevent future break-ins.
The AstraSEAL™ aluminum astragal is 1-1/8 inches thick on the door gap measurement, so it wouldn’t fit the 1/2″ gap between your doors.
Are you sure your doors have a 1/2 inch and not a 7/8 inch gap? Check that the door is plumb with a bubble level and measure the door gap. 7/8 inch is a standard french door gap dimension. See the Ultimate Compatible Astragal by Endura Products.
If you have difficulty fitting an aluminum astragal and your door is solid wood, you could remove the door and have the outside edge trimmed (sawed) to widen the door gap. I’d take it to a millworks and cabinet shop for a precision job. Measure twice, cut once.
See the illustration #5 on page 2 of the Ultimate Astragal Lite installation instructions. The required gap between the doors is 13/16 inches. Only 5/16 inch greater than than the 1/2 inch gap per your measurements.
Bob,
Thanks for taking the time to e-mail me and to answer my query–it was helpful in making a determination to mill the customers door vertically to fit the astragal.
Steve