Replacing the Sauna Mini Door Frame

These instructions guide you through replacing the Sauna Mini Door Frame. Follow each step carefully. Written instructions are designed to stand on their own, but embedded videos are included for visual reference if needed.

Embedded Video Instructions

📹 Video 1: Assembling the Bottom Door Beam & Corner Posts

📹 Video 2: Completing Door Frame Assembly & Installing L-Brackets

Step-by-Step Instructions

1. Inspect & Test for Warping Before Assembly

📌 Before installing the new door frame, check for any warping in the door posts.

✔️ Lay each door post flat on the ground and check all four sides.
✔️ Look for any gaps between the ground and the beam—this will indicate warping.
✔️ If a post is warped, set it aside and contact support before proceeding.
✔️ Perform this test for both vertical posts and header beams.

2. Prepare the Door Glass

✔️ Lay the glass door on four 4x4 blocks, one under each corner.
✔️ The handle side with door plugs should be facing up.
✔️ The larger hinge assembly is the bottom of the door, and the smaller hinge assembly is the top.

3. Prepare the Bottom Door Beam & Hinges

✔️ Locate the bottom door beam:

• 50” long
• Full-sized (no dado, no angle cuts, no notches)
• 4 drilled holes with inserts
  ✔️ Remove the bottom hinge hardware from the original door and install it on the new bottom door beam.
  ✔️ Lay the bottom door beam at the base of the door, with the trim and hardware facing toward the glass.

4. Prepare the Corner Posts

✔️ Locate the new right (heater) corner post:

• 86” long with a dado
• Trim on the glass side of the post
  ✔️ Lay this post on the handle side of the door, with the dado facing up and the trim facing toward the glass.

✔️ Locate the new left corner post:

• 86” long with a dado
• Trim on the glass side of the post
  ✔️ Lay this post on the hinge side of the door, with the dado facing up and the trim facing toward the glass.

5. Assemble the Bottom Door Beam & Corner Posts

✔️ Use 5” lag bolts and flat washers to assemble:

• Lag bolts go through the holes at the bottom of the bottom door beam and into each corner post.
  ✔️ Reference Video 1 (0:00 - 0:30) for visual guidance.

6. Insert the Assembled Structure Around the Door

✔️ The right/heater corner post trim will sit on top of the glass.
✔️ The left corner post trim will sit beneath the glass.
✔️ The hinge plate on the bottom door beam will insert onto the post at the bottom of the door.
✔️ Reference Video 2 (0:00 - 0:20) for proper placement.

7. Prepare the Header Beams

✔️ Locate the new top header beam:

• 50” long
• Angle cut running the length of the beam, with notch cuts on either end

✔️ Locate the new bottom header beam:

• 44” long
• Full-sized (no dado, no angle cuts, no notches)
• Trim on the glass side of the post

✔️ Assemble the top & bottom header beams:

• Use 3” lag bolts and flat washers.
• Lag bolts go through the holes at the top of the top header and into the bottom header.

✔️ Lay the assembled headers at the top of the door, with the trim facing the glass.

8. Assemble the Header & Corner Posts

✔️ Attach the header assembly to the corner posts.
✔️ The large section of trim will sit on top of the glass, while the small section of trim will sit below the glass.
✔️ Use 5” lag bolts and flat washers through the corner posts into the bottom header.
✔️ Reference Video 2 (0:20 - 1:30) for visual assembly guidance.

9. Install the L-Brackets for Stability

✔️ Identify the correct brackets:

• Brackets with larger holes → Used at the bottom of the door jamb assembly.
• Brackets with smaller holes → Used at the top of the door jamb assembly.
  ✔️ Secure each bracket using 8 wood screws per bracket.
  ✔️ Reference Video 2 (1:30 - End) for installation guidance.

10. Ensure the Sauna is Level Before Final Assembly

📌 Before proceeding with final assembly, check that the sauna is level.

✔️ Check Leveling in Three Key Areas:

• Front-to-back (measure from the door frame towards the back wall).
• Side-to-side (check across the width of the door frame).
• Diagonal measurements (measure from one top corner to the opposite bottom corner to confirm squareness).

✔️ If the sauna is not level:

• Use shims or adjust positioning before securing all fasteners.
• Ensuring a level sauna will prevent door misalignment and extend the longevity of the structure.

📌 Once level, finalize installation by tightening all hardware securely.

11. Final Inspection & Testing

✔️ Confirm all hardware is securely tightened.
✔️ Open and close the door several times to check for smooth operation.
✔️ Ensure the door sits flush within the frame and against the door trim.

12. Required Photos for Job Completion

To verify the job is complete and the issue is resolved, take the following photos and submit them to the support team:

📸 1. Warping Test Results – Show each door post laying flat on the ground before installation.
📸 2. Frame Installation – Capture a wide shot of the fully assembled door frame in place.
📸 3. Level Check – Provide a photo of the level placed on the door frame showing correct alignment.
📸 4. Hardware & Clamps – Close-up shots of hinges, clamps, and all fasteners to confirm secure installation.
📸 5. Door Functionality – Show the door fully closed and fully open, ensuring smooth operation.

🔹 Submit these photos via the support portal or email upon completion.

Completion

✅ Sauna Mini Door Frame Replacement is Complete!

• If any issues persist, consult support for further troubleshooting.
• For warranty-related concerns, document any issues with photos/videos and submit them to the support team.

Additional Notes for Technicians:

• Always check for warping before installation.
• Ensure all trim pieces are correctly placed before securing bolts.
• A properly leveled sauna prevents door misalignment and extends the structure’s life.