Tools needed:

  • Philips head hand screw driver or battery powered screw driver
  • Small flat head screw driver
  • Utility knife
  • Putty knife
  • Gloves & safety glasses
  • Two saw horses and a piece of plywood roughly the same size as the door
  • One assistant

Cut-out Instructions

Actual hole cut in door shall measure exactly 1” larger than glass or louver size purchased. Doorlights and louvers for 1-3/4″ and 1-3/8″ doors measure net 1/16″ scant for a snug fit.


Installation option #1 Replacing doorglass while still in door.

  1. Prepare to remove existing doorglass. The inside frame will either have plastic plugs or plastic putty covering the screws. Using a small flat head screw driver, remove the plugs or dig the putty out of the hole so that you can see the brass screws below.
  2. If the door and plastic frame have been painted, use a utility knife to carefully cut a path along the edge of the frame and door, on both sides of the door. This will allow the frame to separate from the door without excess peeling.
  3. Remove the screws from around the frame using a Philips head screw driver or battery powered screw driver. Your assistant should stand on the outside of the door and support the frame and glass because they will come loose once all of the screws are removed. Do not press against the glass.
  4. The inside frame will pry apart from the outside frame with gentle effort. The glass will remain stuck to the outside half of the frame. Do not attempt to remove the glass from the outside frame. Apply pressure to the bottom corner of the glass from the inside until the frame releases from the door. Your assistant can grab the outside frame and glass and pull back gently to help release the existing doorglass. Safely remove both frame halves and glass from your work area and place in a box or area out of reach of children for later disposal.
  5. Wearing gloves, carefully remove any residue on the door from the frame’s caulking or paint. Use a stiff putty knife along the edge. Beware, the edge of the door can be uneven or sharp.
  6. With an assistant, holding the new glass and outside frame together, lift and gently set the new glass, into the opening starting at the bottom. One of you should be on the inside and one on the outside.
  7. Push the frame all of the way into the opening until it seals. RSL has supplied the frame with a FTD(frame to door) sealant that prevents seal failure. Have your assistant apply pressure to the outside frame, ensuring that it will stay in the opening without falling out.
  8. While standing on the inside, continue to press against the glass so that it can not fall apart from the outside frame. Set the inside frame(with holes in it) into the opening , being careful to match the alignment pins or screw holes to the outside frame. Make sure that your assistant is still on the outside and applying light pressure against the frame to keep it secure in the opening.
  9. You can gently tap the frame to make sure that it fits securely against the door surface. Once in place, install in all four corners until snug. Check that new doorglass fits evenly on the door. Then install the remainder of the screws using a hand screw driver or an battery powered screw driver and tighten each screw in a clockwise direction. Do not over tighten(set screw gun clutch to #5 which is 8-10 inch/lbs of torque). Your assistant should apply pressure against the frame on opposite side of each screw hole as it is installed.
  10. Install the plugs (provided in bag) into the screw holes. This makes for a nice finished appearance. If you prefer, you can use a plastic filler instead of the plugs.
  11. Clean you glass with any household glass cleaner and enjoy your new RSL doorglass.

 Installation option #2 Replacing glass by removing door.

  1. Set up two saw horses with plywood or similar covering.
  2. Remove hinge pins and pick up door and place it flat on two saw horses and table top, with inside of door facing up. If door knob and deadbolt are installed, remove hardware and set aside to be reinstalled or place door on table top with knob and deadbolt hanging off the edge of the work surface. This will allow the door to lie flat.
  3. Prepare to remove existing doorglass. The inside frame will either have plastic plugs or plastic putty covering the screws. Using a small flat head screw driver, remove the plugs or dig the putty out of the hole so that you can see the brass screws below.
  4. If the door and plastic frame have been painted, use a utility knife to carefully cut a path along the edge of the frame and door on both sides. This will allow the frame to separate from the door without excess peeling.
  5. Remove the screws from around the frame using a Philips head screw driver or battery powered screw driver.
  6. The inside frame will pry apart from the outside frame with gentle effort. The glass will remain stuck to the outside half of the frame. Do not attempt to remove the glass from the outside frame. Lift door so that the glass and frame can be removed. Apply pressure to the bottom corner of the glass from the inside until the frame and glass release from the door. Safely remove both frame halves and glass from your work area and place in a box or area out of reach of children for later disposal.
  7. Wearing gloves, carefully remove any residue on the door from the frame’s caulking or paint. Use a stiff putty knife along the edge. Beware, the edge of the door can be uneven or sharp.
  8. Place the new outside frame and glass onto the table top. Pick up the door and place the outside down over the new glass and frame. Carefully adjust the door so that the glass and frame are evenly viewed through the door opening.
  9. Push the door all of the way down onto the new frame until it seals. RSL has supplied the frame with a FTD(frame to door) sealant that prevents seal failure.
  10. Place the inside frame(with holes in it) into the opening , being careful to match the alignment pins or screw holes to the outside frame.
  11. You can gently tap the frame to make sure that it fits securely against the door surface. Once in place, install screws in all four corners until snug. Check that the new doorglass fits evenly on the door. The install all of the screws that were provided using a hand screw driver or an battery powered screw driver and tighten each screw in a clockwise direction. Do not over tighten(set screw gun clutch to #5 which is 8-10 inch/lbs of torque).
  12. Install the plugs (provided in bag) into the screw holes. This makes for a nice finished appearance. If you prefer, you can use a plastic filler instead of the plugs.
  13. Clean you glass with any household glass cleaner and enjoy your new RSL doorglass.

RSL Hurricane Impact Installation Instructions

  1. Remove the insert from its box and inspect for any shipping damage.
  2. Remove rubber spacers from glass.
  3. Place outside frame (with glass sealed to it) on a flat, solid surface that is clean and free of any abrasives that could scratch the frame.
  4. Neatly apply 3/16” bead of Dow Corning 995 Structural Sealant (supplied by RSL) in the groove around the perimeter of the outside frame.
  5. Carefully align the door cut-out over the frame & lower door into silicone.
  6. Place inside frame into door cut-out, align male/female pieces, and carefully apply pressure by hand to snap frame halves together.
  7. Install zinc coated screws (supplied by RSL) into predrilled holes loosely. Then tighten with no more pressure than 18-20 inch/lbs. Over tightening can damage window.
  8. Snap screw covers on inside frame, starting with the short pieces. Then install longer pieces by bowing in the middle in order to snap together.