In this example we will be turning a 1-lite door insert into a 6-lite door insert using Decralite Coping Machines and Decralite Lineal Bars.
The Lineal Bar specs we will be using in this example is: 1/4” thick x 1” wide, OG profile.
To obtain equal lites on this door insert, you must subtract the width of both vertical bars and the single horizontal bar. Each vertical bar subtracts 1” from the width, and each horizontal bar subtracts 1” from the height.
Daylight Opening: 35” by 21”
Adjusted Daylight: (35 subtract 2) by (21 subtract 1) 33 by 20.
The graphic below shows your adjusted daylight in green, and the SDLs (subtracted daylight) in red. Now that you have subtracted your SDL widths from your daylight opening, you can find your individual lite sizes by dividing your adjusted daylight opening by number of lights.
Adjusted daylight: 33 by 20
Equal Horizontal spacing = 33 / 3 = 11” per lite
Equal Vertical spacing = 20 / 2 =10” per lite
Each Individual Lite: 11” by 10”
Now that we have obtained all the daylight sizes, we can decide how we are going to cut the material, and determine what length needs to be added for coping.
The best practice is to have your shortest dimension run the full length of the insert, and cut the longer dimension bar into segments. In this case, we would be cut two vertical bars at the full length, and the horizontal bar will be cut into three pieces:
So far, we have:
3 pieces @ 11”:
2 Pieces @ 21”
Each piece will have to be cut to the length of the daylight opening, plus the end condition. For this Insert, we have 2 separate end conditions. One condition is for the OG Intersection, and one condition is for the frame intersection.
The first two pieces to be cut and placed will be the vertical pieces. The framing end condition that we are using is 3/16” wide. This means we will cut the bar at 21 3/8”, and then cope the ends.
Next, there will be two pieces being cut with one OG intersection end condition and one framing end condition. Total Bar Length = 11 7/16”
Then, there will be a single piece being cut with two OG intersection end conditions. Total bar width = 11 1/2”
Now that you have all your bars cut down to the right size, you are able to piece them together on your Door Insert or Window.