Garage Storage and Organization System Installation Instructions

Transcription

1 Garage Storage and Organization System Installation Instructions EasyClosets.com

2 HOW TO USE THESE INSTRUCTIONS Thank you for your purchase! Please read each step of this manual thoroughly to ensure proper installation of your new EasyClosets garage system. These instructions assume that you are installing our standard units (unmodified heights and depths) in a garage with drywall over standard wood frame construction (i.e. 2" x 4" or 2" x 6" framing). If any aspect of your installation does not apply to these standard construction methods, contact Customer Service ( ). Installation into metal studs or masonry walls will require additional hardware available from your local hardware store. Our limited lifetime warranty* is based on following proper installation techniques. Installing your garage system in any manner other than the steps outlined in this manual may lead to structural failure of the system. Watch install video. Scan the QR code and see how easy it is to install your new system. Or, visit Garage Cabinet Installation * For complete warranty information, visit EasyClosets.com P2

3 SECTION GUIDE SECTION 1 GETTING STARTED: Take an inventory of your shipment before beginning installation to ensure your order is complete and correct. SECTION 2 BASIC INSTALLATION INSTRUCTIONS: This section provides detailed instructions for assembling and installing your garage storage and organization system. SECTION 3 INSTALLING GARAGE CABINET COMPONENTS: This section provides detailed instructions for installing custom components such as drawers, doors and slatwall. GETTING STARTED RECOMMENDED TOOLS 4 HARDWARE ILLUSTRATIONS 4 INITIAL PREPARATION a. Check your contents 5 b. Remove old shelving 5 c. Prepare walls 5 BASIC INSTALLATION INSTRUCTIONS ASSEMBLING AND INSTALLING CABINETS a. Assemble cabinets 6 b. Add support cleats and corner brackets for cabinets 6 c. Attach legs to base and full cabinets 8 d. Locate studs and position cabinets 9 e. Secure cabinets 10 f. Install work surface 12 INSTALLING GARAGE COMPONENTS INSTALLING COMPONENTS a. Drawers 13 b. Doors 18 c. Slatwall 19 P3

4 GARAGE STORAGE AND Organization SYSTEM Please take the time to inventory and inspect your parts before beginning the assembly. If any pieces are damaged or missing, contact Customer Service ( ) immediately. REQUIRED TOOLS Step Ladder Measuring Tape Level Hacksaw Stud Finder #2 Phillips Screwdriver Drill, Driver Hammer, Mallet HARDWARE (MAY VARY BASED ON ORDER) 50mm Screw 33mm Screw 3-1/2" Black Screw Euro Screw (#6) 5/8" Screw Confirmat Screw Shelf Pin 2-1/2" Slatwall Screw (White or Gray screw head) Full Extension Drawer Glide Support Cleat Screw L-Bracket Handle (style may vary) Black Finishing Washer Dowel Leg Assembly (Leg, Insert, Foot, Screws) Door Hinge Drawer Front Adjuster Screw Toggle/ Toggle Bolts (#8) 9/16" K-Lath Screw P4

5 GETTING STARTED INVENTORY MATERIAL PRIOR TO INSTALLATION! A. CHECK YOUR INVENTORY BEFORE BEGINNING INSTALLATION! 1. Check Boxes: Ensure that you have received all boxes in your shipment. Each box is labeled with a company packing label. Note each box as well as the total number of boxes in the shipment. IMPORTANT: Checking all of your inventory will ensure that you have all the materials you need before you start. It will help the installation process run smoothly and will help to prevent delays. Example of packing label: Example of complete parts list: 2. Compare Box Contents to Packing Label: Open each box and compare the contents against the itemized list on the packing label. 3. Organize Material: Organize the material by size and part type. 4. Take an Inventory of the Contents: Take a full inventory. Use the complete parts list or Order Summary, as a checklist. Once all material has been inventoried, if any pieces are damaged, missing or incorrect, please keep all packing material and contact Customer Service ( ). B. REMOVE OLD SHELVING 1. Remove any existing shelving or cabinets. C. PREPARE WALLS 1. Spackle and Repaint: If desired, fill holes with spackling and repaint wall(s). As you fill in the holes, note these locations, as they often mark the locations of the studs. P5

6 GARAGE CABINET ASSEMBLY 1. Install Dowels: Place glue into pre-drilled dowel holes (largest holes) and insert the dowels into the corresponding holes in the decks and cleats. Use a mallet to tap in the dowels if necessary. 2. Install Decks: Lay one vertical panel on the floor with the holes facing up. Add glue to pre-drilled dowel holes in the vertical and install top and bottom decks onto the vertical panel. Use a mallet to tap the decks flush with the vertical panels if necessary. Deck Deck 3. Install Cleats: Add glue to pre-drilled dowel holes in the vertical panel and install the cleats onto the vertical panel. Use a mallet to tap the cleats flush with the vertical panels if necessary. 4. Insert Back Panel: Slide the back panel into the grooves in the top and bottom decks with the white side facing inside the cabinet. The back panel slides in front of cleats and into the groove of the vertical on the floor. P6

7 GARAGE CABINET ASSEMBLY 5. Install Second Cabinet Vertical: Add glue to the pre-drilled dowel holes in the second vertical panel and place it on top of the assembly. Line up the dowels and dowel holes and push the vertical down and flush with the decks and cleats. Use mallet to tap the vertical panel flush with the decks and cleats if necessary. 6. Drive Screws Into Top Vertical: Drive Confirmat screws through the top vertical panel into the top and bottom decks. Screws should be flush with vertical panel. Hold the unit together and turn the cabinet over so the bottom vertical panel is now facing up. Two people are recommended for lifting and moving cabinets. Confirmat Screw 7. Install Final Screws: Install Confirmat screws through the second vertical panel into the top and bottom decks. Drive 50mm screws through both decks into the top and bottom cleats. Confirmat Screw 50mm Screw P7

8 GARAGE CABINET ASSEMBLY ATTACH LEGS TO BASE AND FULL CABINETS (OPTIONAL) 1. Assemble Legs: Using a mallet, or hammer and block, tap the knock-in inserts into legs. 2. Attach Legs to Cabinet: With the long edge of the leg plate perpendicular to the cabinet side, attach legs to the bottom of the cabinet 2" from the front edge of the cabinet and 2" from the back edge of the cabinet and just in front of the rear cam fittings using #10-3/4" screws. The legs should extend under the cabinet panels and be flush to the outside edges of the cabinet. (See Illustration 8.2) NOTE: Follow the leg attachment instruction below if your order included legs. If your order did not include legs proceed to the next page of instructions. NOTE: Garage legs may be shortened as much as 3" before the knock-in inserts are installed. Cut the legs with a hack saw. 3. Proceed to Step 6 on Page 9 After Installing Legs Illustration 8.2 P8

9 GARAGE CABINET INSTALLATION 1. Stage Cabinets: Stage cabinets about 5 ft. from wall where they will be installed, allowing room to work and walk behind. 2. Locate and Mark Studs: The cabinets will be installed to the wall by attaching them to the wood studs in the wall. Locate the wood studs by using a stud finder. Verify the stud locations by tapping a nail into the wall, if the nail goes easily into the drywall, you are not hitting the wood stud. After finding the wood studs, mark their locations on the drywall. Wood studs are typically 16" apart from center to center. 5. Rest Cabinet on Cleat: Rest the back of the constructed cabinet up onto the cleat on the wall. Two people are recommended for lifting the cabinet onto the support cleat. (See Illustration 9.5) Illustration Layout Cabinets: Layout your cabinet configuration to accommodate for stud support. Ideally, each cabinet will have two studs for support. 4. Install Wall Cleat: Level a cabinet support cleat with the top of the cleat 6" up from the floor. Install the cabinet support cleat to the wall by driving support cleat screws through the pre-drilled cleat holes and into the wood studs. If there is only one stud behind the cabinet support cleat, screw into that stud, and use an included toggle/ toggle bolt to attach the cleat at a second point in the farthest hole away from the wall stud. (See Illustration 9.4) Illustration Secure Cabinet: One person will hold the cabinet in place while a second person will screw the cabinet to the wall. Cabinet Support Cleat 6" Support Cleat Screw NOTE: If there is only one stud behind the cabinet support cleat, attach one side of the cabinet support cleat to the stud and the other side with the toggle/toggle bolt. Cabinet Support Cleat Hold metal channel flat alongside plastic straps & slide channel through hole. Pull strap ends toward you until channel rests behind wall. Slide cap along straps with other hand until flush with wall. Place thumb between straps at wall. Push thumb side to side, snapping off straps level with flange of cap. Place cabinet support cleat over flange. Insert bolt and tighten until snug. P9

10 GARAGE CABINET INSTALLATION 7. Attach Cabinet to Wood Studs: Transfer the stud locations on the wall to the inside of the cabinet and drill pilot holes through the center of the top and bottom cleats. Attach cabinet to the wood studs with the 3 1/2" black screws and finishing washers. (See Illustration 10.7) 8. Install Tall Cabinet: The tall cabinets are built by installing a bottom cabinet and then placing a second cabinet on top of the first. Attach the top cabinet to the wall studs with the 3 1/2" blackscrews and finishing washers. (See Illustration 10.8) Illustration 10.7 Illustration 10.8 Second Cabinet Studs First Cabinet 3-1/2" Black Screw Black Finishing Washer P10

11 GARAGE CABINET INSTALLATION 9. Install Cabinet Support Cleat: Cabinet support cleats are also used for mounting upper cabinets. First determine how high you want to install your cabinets, and install your cabinet support cleat accordingly. Please refer to Garage Cabinet Installation step 4 for cabinet support cleat installation instructions. A 24" upper cabinet is 23.7" (602mm) and a 31" upper cabinet is 31.25" (794mm). To line up the top of an upper cabinet with the top of a storage cabinet, determine if you ordered a 24" or 31" cabinet, and measure that size down from the top of the storage cabinet. Install the top of your wall cleat at this height. (See Illustration 11.9) 10. Secure Upper Cabinet: Rest the back of your constructed upper cabinet on the cabinet support cleat. One person should hold the cabinet in place while a second person screws the cabinet into the wood studs in the same manner as the base cabinets. After the upper cabinet is secured to the wood studs, you can remove the cabinet support cleat. (See Illustration 11.10) Illustration Illustration 11.9 Cabinet Height Cabinet Support Cleat P11

12 WORK SURFACE INSTALLATION 1. Position Work Surface: Position work surface and add shims to level it, if necessary. 2. Install L-Brackets: If work surface is not supported at both ends by base cabinets, you will need to install L-brackets. Attach L-brackets to studs using 50mm screws, and to the cabinet vertical with the (#8) 9/16" K-Lath Screws. Also use the (#8) 9/16" screws for attaching the L-brackets to the work surface. (See Illustration 12.2) 3. Position and Secure Work Surface: The work surface can be anchored by driving 4 33mm screws from below through the top deck of any base cabinets or it may be secured by setting the work surface in a bed of caulk. Only a few dots or lines of caulk are necessary. Clamp or use masking tape to hold work surface in place while caulk is setting. Follow instructions provided with the caulk for drying time. Illustration mm Screw 33mm Screw L-brackets for unsupported end or back edge (#8) 9/16" K-Lath Screw Top Deck P12

13 INSTALLING COMPONENTS Now that your cabinets have been assembled, you can begin installing your garage components (any drawers, doors or other items that are unique to your garage storage and organization system). Refer to the page numbers below to find the instructions for the component(s) you have in your garage system. INSTALLING GARAGE SYSTEM COMPONENTS Drawers 13 Doors 18 Slatwall 19 DRAWERS A. INSTALL DRAWER FRONT 1. Attach Handles: Attach handle to the drawer front using the drawer handle screws provided. (See Illustration 13.1) 2. Attach Drawer Front to Drawer Box: Attach drawer Illustration 13.1 Handle Screws Drawer Front Adjuster Hole front to drawer box using the drawer front adjuster screws. Do not use power drill or power screwdriver! Use manual screwdriver. Do not fully tighten the front to the box. You will need to adjust the drawer faces Drawer Front Handle for proper leveling and spacing once all of the drawers are installed. (See Illustration 13.2) NOTE: The drawer front adjuster holes may be off-center on the drawer front; and some drawer sizes will have 2 sets of drawer front adjuster holes. Illustration 13.2 Drawer Front Adjuster Hole Drawer Front Drawer Box The front adjuster holes you will use to attach the drawer front to the drawer box is determined by the location within the Drawer Tower (please see Drawer Tower image). A drawer can be positioned at the top, center, or bottom of a drawer tower unit. Please refer to the Drawer Front Guide on pg. 14 to determine the orientation of your drawer front as well as what drawer front adjuster holes you will use when attaching the drawer front to the drawer box. Drawer Tower Drawer Front Adjuster Screws Top Center Bottom P13

14 INSTALLING COMPONENTS DRAWERS Drawer Front Guide 5" Drawers Top 5.4" top/bottom drawer front 10" Drawers Top 10.4" top/bottom drawer front 15" Drawers Top 15.45" top/bottom drawer front Center 5" center drawer front Bottom 5.4" top/bottom drawer front Holes 2.5" from bottom of drawer front Holes at center of drawer front Holes 3" from bottom of drawer front Center 10" center drawer front Bottom 10.4" top/bottom drawer front Use holes 3.8" from bottom of drawer front Holes 3.8" from bottom of drawer front Use holes 4.3" from bottom of drawer front Installation Example: When installing a 10" drawer in the bottom position of a drawer tower, position the drawer front adjuster holes at 4.3" up from the bottom of the drawer front. Use that orientation and those drawer front adjuster holes when attaching your drawer front to your drawer box. Center 15" center drawer front Bottom 15.45" top/bottom drawer front Use holes 6.6" from bottom of drawer front Holes 6.6" from bottom of drawer front Holes 7" from bottom of drawer front B. ATTACH DRAWER GLIDES 1. Disassemble Your Full-Extension Steel Glides: To disassemble the glide, first fully extend the glide. Then press the black release tab. Finally, pull each end in an opposite direction to separate. (See Illustration 14.1) 2. Attach Smaller Glide Section to Drawer Box: Position glide flush to the drawer box bottom and front. Using two ( #6) 5/8" screws, secure the glide to the box through the round and horizontal oblong holes in glide. (See Illustration 14.2) Illustration 14.1 Drawer box section Illustration 14.2 Pull Vertical panel section Flush with drawer box bottom and front (#6) 5/8" Screw P14

15 INSTALLING COMPONENTS ATTACH DRAWER GLIDES (CONTINUED) 3. Identify and Mark Glide Positions: Refer to Drawer Glide Positions illustration (below) to identify and mark the locations for attaching your glides to the vertical panels. Drawer Glide Positions Glides above a 5" drawer are installed in the 4th hole above the previous glides. 5" 5" Glides above a 10" drawer are installed in the 8th hole above the previous glides. 5" Glides above a 15" drawer are installed in the 12th hole above the previous glides. 10" Glides for the lowest drawer are installed in the 1st open hole above the bottom cam shelf. 15" P15

16 INSTALLING COMPONENTS ATTACH DRAWER GLIDES (CONTINUED) 4. Attach Larger Glide Section to Vertical: When fully retracted, position glide flush with the front of the vertical. Using Euro Screws, secure the glide into the pre-drilled holes in the vertical. It may be necessary to extend the glide to access the mounting holes. (See Illustration 16.4) 5. Line Up Member and Vertical Panel Holes: Use the Drawer Glide Positions illustration and the drawer configuration in your cabinets to determine where drawer glide cabinet members are required. Line up the holes in the CR member with the holes in the right vertical panel. Use the Euro Screws to attach the drawer glides into the pre-drilled holes in the vertical panels. Illustration 16.4 Start one hole up from bottom cam shelf Euro Screws Drawer Section (use #6 screws) Vertical Section Black Release Tab (Opposite Side) Euro Screw P16

17 INSTALLING COMPONENTS DRAWERS C. INSERT DRAWERS INTO UNIT 1. Insert Drawers: Insert drawer straight into glides on verticals. Push firmly to engage the ball bearings. Once fully inserted, pull glides out to make sure that they move smoothly. (See Illustration 17.1) Illustration 17.1 Assembled Cabinet Assembled Drawer D. ADJUST DRAWER FACES 1. Level the Top Drawer Face: Make sure that the drawer face adjuster screws are not full tightened. If you have more than one drawer, start by leveling the top drawer face. Once level, fully tighten the drawer face adjuster screws. Illustration 17.2 NOTE: Never use a power drill to tighten drawer face screws! Always use a manual screwdriver. 2. Examine Shadowline: For the drawer below, examine the shadow line between the top of this drawer face and the bottom of the drawer face above. Adjust the face so that the shadow line is uniform across the width of the face. (See Illustration 17.2) 3. Repeat Step for Each Additional Drawer Below P17

18 INSTALLING COMPONENTS DOORS ASSEMBLING HINGES AND INSTALLING DOORS 1. Assemble Hinges: Assemble hinges using Illustration Install Door Plate onto Back of Door: Make sure that the straight side of the hinge is parallel to the edge of the door. Use two (#6) 5/8" screws to attach. (See Illustration 18.2) 3. Position the Door: Hold door against unit and position it so that the top and/or bottom cam shelves are partly covered by the door. Illustration 18.1 Illustration 18.2 (#6) 5/8" Screw Step 1: Insert notch over hinge pin Step 2: Pivot top section down and push onto lever to snap together. 4. Attach Cabinet Plate: Screw the pre-installed hinge screws on the Cabinet Plate into the closest pre-drilled holes at the front of the vertical. (See Illustration 18.4) 5. Adjusting Hinges: The hinges can be adjusted slightly using A & B as noted in Illustration Illustration 18.4 Illustration 18.5 Door Plate Screw A: Moves hinge forward and backwards along vertical. Cabinet Plate Screw B: Moves hinge left to right along cam shelves. P18

19 INSTALLING COMPONENTS SLATWALL Overview: Slatwall is shipped in standard 48" x 15" pieces unless you changed the sizes during the design process. If your order includes slatwall, they may be cut to size with any saw. Slatwall panels are installed by driving 2 1/2" slatwall screws through the slots into studs in the wall. Slatwall screws have a white or gray head to match your slatwall color. 2-1/2" Slatwall Screw (White or Gray screw head) P19

20 HAVE ANY QUESTIONS? Give us a call Monday to Friday: 8:00 AM to 9:00 PM E.S.T. Saturday: 10:00 AM to 4:00 PM E.S.T. Se habla Español IDEAS? COMMENTS? to: production@easyclosets.com EasyClosets 19 Chapin Road, Building D P.O. Box 2020 Pine Brook, NJ EasyClosets.com EasyClosets ITEM #ECCABINETS-INS REV. 05/13