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Z‐Bar Inset for an Integral Window
Installa on Instruc ons
LA7975 ‐ A
2 LA7975 ‐ A
Read all instruc ons before installa on.
Milgard Z‐Bar Inset is part of the Window Assembly.
Do not a empt to remove the Z‐Bar from the replacement Window. It is factory sealed to prevent
water intrusion.
Use exterior grade high quality sealants. For compa ble TiteBond® Sealant colors refer to page 13.
Integral Z‐Bar Inset Instruc ons
For Milgard Essence Series® Windows and Doors
Required Tools
Screwdriver with #2 Phillips bit
Caulking Gun
3 LA7975 ‐ A
Integral Z‐Bar Inset Parts
Z‐Bar Inset All Sides Z‐Bar Inset with Groove Filler
PART DESCRIPTION PART NUMBER
1 Z‐BAR INSET ‐ HEADER/SILL EX7856XX
2 Z‐BAR INSET ‐ LEG EX7856XX
3 CORNER KEY IM8035MI
4 1/8” x .123‐.188 ALUMINUM RIVET FA7451
5 (WINDOW FRAME) VARIES
PART DESCRIPTION PART NUMBER
1 Z‐BAR INSET ‐ HEADER EX7856XX
2 Z‐BAR INSET ‐ LEG ‐ LEFT EX7856XX
3 Z‐BAR INSET ‐ LEG ‐ RIGHT EX7856XX
4 GROOVE FILLER EX7852XX
5 CORNER KEY IM8035MI
6 1/8” x .123‐.188 ALUMINUM RIVET FA7451
7 (WINDOW FRAME) VARIES
4 LA7975 ‐ A
Integral Z‐Bar Inset Parts (Con nued)
Z‐Bar Inset with Stucco Key
PART DESCRIPTION PART NUMBER
1 Z‐BAR INSET ‐ HEADER EX7856XX
2 Z‐BAR INSET ‐ LEG ‐ LEFT EX7856XX
3 Z‐BAR INSET ‐ LEG ‐ RIGHT EX7856XX
4 STUCCO KEY EX7812XX
5 CORNER KEY IM8035MI
6 1/8” x .123‐.188 ALUMINUM RIVET FA7451
7 (WINDOW FRAME) VARIES
5 LA7975 ‐ A
Integral Z‐Bar Inset Corners
Exterior View Interior View
Top Miter
Z‐Bar Inset All Sides shown
Z‐Bar Inset shown in yellow
Window Frame shown in blue
Exterior View Interior View
Bo om Miter
Exterior View Interior View
Bo om Groove Filler
Exterior View Interior View
Bo om Stucco Key
6 LA7975 ‐ A
Prepare Original Window
1 Fully prepare the opening.
These instruc ons only cover steps specific to installing Milgard Z‐Bar.
For informa on on preparing the opening, please refer to other installa on instruc ons.
Other installa on instruc ons cover:
Removing the original sash and glass.
Removing original frame legs.
Proper blocking and flashing of original sill
Using shims to level sill.
7 LA7975 ‐ A
Fit Z‐Bar Inset to Opening
2 Either measure or dry fit replacement Window within opening. Trimming may be necessary.
Verify Z‐Bar Flange will fully seat
against original Window Frame.
Do not a empt to remove the Z‐Bar
from the replacement Window. It is
factory sealed to prevent water
intrusion.
For best performance, make sure the
Z‐Bar overlaps the original frame at
least 3/4".
3/4" MINIMUM
If placing replacement window inside
exis ng trim, trimming the Z‐Bar Inset
may be necessary. See page 8.
8 LA7975 ‐ A
Fit Z‐Bar Inset to Opening (Con nued)
Measure the trim opening at mul ple
loca ons to ensure an accurate fit. Original
trim may not be square or uniform.
Lay unit on a flat surface with trim side up.
Scribe or mark trim to a create a cu ng
line. Mark Z‐Bar Trim 1/8” to 1/4” smaller
than trim opening.
Mask exposed surface to protect during the
cu ng process.
Cu ng blade must be rated for non‐
ferrous materials and designed to cut
aluminum. It is recommended to use a
Tracksaw/Railsaw to maintain a straight cut.
Corner Rivets are aluminum with aluminum
mandrels. Use same cu ng blade to cut
through rivets.
Dry fit window in opening.
9 LA7975 ‐ A
Sealing Surfaces
3 Apply Sealant on back side of Z‐Bar Inset.
Leave 4" sealant gaps 4" from each Sill
Corner.
If the original Window Frame has weeps,
leave sealant gaps at each weep.
10 LA7975 ‐ A
Shimming
4 Set Window into opening. Center Window between the original Jambs.
Install 1/4” diameter Backer Rod between
Z‐Bar and original trim. Seal between edge
of Z‐Bar and original trim.
5 Shim next to each “Through the Jamb” hole.
Check and correct Window for plum,
square, and cross leg.
EXTER
IOR
IN
TERIO
R
Fully seat Window against original Window Frame.
11 LA7975 ‐ A
Installa on Screws
6 Remove indicated Jamb material to access predrilled installa on holes.
Note: Some windows may have
predrilled holes through the Jamb
material.
7 Install provided screws through predrilled holes. Fully seat screws.
8 Replace Wood.
12 LA7975 ‐ A
Exterior Sealing
9 Run a bead of sealant where the Z‐Bar edge meets the stucco.
Put a bead around the full perimeter
of the Window.
Note: Leave a gap of at least 2" at
each original weep hole loca on.
EXTER
IOR
13 LA7975 ‐ A
Interior Sealing
10 Seal between original and new Window Frames.
Do not seal between original frame
and Jamb Extensions if present.
Apply sealant over any shims to
ensure a con nuous seal.
INTER
IOR
14 LA7975 ‐ A
Clean Up
Wipe up any excess sealant.
Clean up scuff marks with soap and water.
TiteBond® WeatherMaster Sealant Compa ble Colors
Milgard Pale e Color Titebond® WeatherMaster™ Color
Reference Milgard Part Number
Bark 44061 SE7673AR
Black Bean 44031 SE7673BL
Bronze 45841 SE7673ZB
Cinnamon 45521 SE7673CI
Classic Brown 44211 SE7673LW
Espresso 45661 SE7673EX
Evening Sky 45531 SE7673ES
Fern 45651 SE7673FN
Fog 46681 SE7673FO
Frost 44001 SE7673FS
Harmony 44641 SE7673HR
Ivory 45511 SE7673IV
Pea Pod 49211 SE7673PP
Sand 46041 SE7673SD
Tweed 44691 SE7673TE
Twilight 44031 SE7673BL
15 LA7975 ‐ A
REV ECN DESCRIPTION DATE DRAWN APPD.
A 4019ECNEG RELEASE 08/25/2015 NDS VM
REVISIONS