Step 3: Removing the Packaging

ATTENTION! Do not sit or store products in direct sunlight. Most Sun products are shipped in protective packaging. This packaging is designed to protect the product from dirt, dust and minor debris while being shipped, handled and stored. Because of the characteristics of this packaging, do not sit or store products (with the protective clear wrap packing) in direct sunlight. Keep uninstalled products in a safe place, out of direct sunlight. Remove the clear wrap packing before installing the products.

a) Remove the packaging. Remove the protective plastic wrap and any other packing materials from the window. Be careful not to cut the screen cloth or damage the window. Leave the sash in the closed and locked position until later. Some products also have additional support members attached for shipping and handling. These members may be wood strips used to protect the nail fins, or shipping handles (on some door products) that are added to assist in transporting the product. Remove these additional support materials prior to installation.

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Step 4: Applying Jamb Extensions

If you do not need jamb extensions, or your jamb extensions were factory applied skip to Step 5.

All Sun products are available with factory applied jamb extensions to meet various wall thickness requirements. If your products requires jamb extensions, and you ordered them “not applied”, apply them now as follows:

a) Window face down. Place the window on a suitable (flat, clean) work surface, exterior face down.

b) Measurements. Measure the width and height of the window.

c) Cut the extensions to length. Cut the jamb extensions so that when they are applied the outer face of the extensions will be flush with the outer face of the window jamb. Extensions should form butt joints at the corners.

Note: Depending on the thickness of your jamb extension the jamb material will either be:
1” thick or less = square stock approximately 3/4” x thickness.
2” thick or less = 11/16” stock that has a manufactured groove in its outer face for fastening.

d) Fasten the extensions. Set the extension, on the corresponding face of the window jamb. (The recessed groove on 2” material faces outward). Using appropriately sized Brad Nails (see note below), fasten 1” thick or less extensions straight through the extension into the window jamb. Fasten 2” thick or less extensions through the fastening groove into the window jamb. Fasten approximately every 8”.




Note: Brad Nails should penetrate the window jamb 3/8” to 1/2”. Brad Nails should not penetrate the window jamb more than 1/2”. Doing so may interfere with the function of some products. (See illustration)






e) Fasten the corners. Fasten all four sides as described above and then fasten the butt joint corners through the lapping extension into the end of the joining extension.

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Step 5: Setting the Window

ATTENTION! These steps may require 2 or more people.

a) Apply Sealant to nail fin. Place the window on a suitable work surface exterior face down. Apply a continuous bead of High Grade Exterior Sealant to the back side of the top and side nailing fins near the outer edge of the fin. Do not apply sealant to the bottom nailing fin. Note: High Grade Exterior Sealant should conform to AAMA 808 specification.





b) Place window into opening. From the exterior, place the window into the opening. With the bottom of the window resting on the sill, center the window from side to side, then press in place to contact the High Grade Exterior Sealant with the weather resistive barrier or sheathing surface.

c) Temporarily fasten. To temporarily hold the window in the opening, fasten the top corners of the window through the nail fin with 2” galvanized nails. Note: a nail can be driven through the aluminum nail fin but you may find it helpful to pre-drill holes for fastening. Note: While temporarily fastening, leave nail heads raised in case they need to be pulled for window adjustment purposes.

d) Level the sill. The window must be level, plumb and square to operate correctly. Working from the interior side of window, place a level on the window sill and check for level. If necessary shim under the low corner until level is achieved. You may need to loosen the top corner to make this adjustment.
ATTENTION! Only place shims under the bottom corners. Shimming anywhere else under the bottom rail may cause it to bow.

e) Square the sides. Working from the interior side of window, measure diagonally from one top corner of the window frame to the opposite bottom corner. Next, measure the other corners. These measurements should be equal. If they are not, the window is not square. Shift the bottom of the window until these measurements are the same.

f) Fasten all four corners. Once the window is level and square, fasten all four corners.








g) Shim the window sides. Use a level or good straight edge to check the sides for plumb. Apply shims (on both sides of the window) at the top and bottom corners, the midpoint, and halfway between the corners and the midpoint. Shim to achieve plumb.
ATTENTION! Do not over-shim or under shim. Do not shim above the window. Proper shimming is required for correct operation and optimum performance of the window.

h) Check operation. Check the operation of the window. Unlock the sash and check its full operation. Sashes should open and close completely without binding. Tilt-in sash windows should tilt-in and close without excessive force. Hung sash windows midpoint meeting rails should be parallel with each other. Sashes that are difficult to open or tilt (tilt-sash windows only) are probably over-shimmed and have too much tension against the jambs. If a window is under-shimmed it will not have a proper weather seal and hung sash windows will slip or slide down when opened. If the window does not seem to operate properly, go back to step 2e and adjust the window for level, square and plumb. Readjust the shims.

i) Finish fastening. Once you have verified that the window is level, square and plumb, and that it operates correctly, finish fastening through the nail fin, applying a nail at least every 12”.

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