Install Falcon Exit Device

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Today, we’re going to be installing a Falcon exit device crash bar on a door that is constantly beat up by skis, boots, luggage racks, and anything else you can imagine that would be traveling through the hallways of a ski resort. In the original equipment that we are pulling off the door, I found all kinds of broken pieces. The first and most important thing that I will be focusing on with this project is to solve the problem long term. The way we can do this most effectively is to eliminate as many protruding and moving parts as possible. Getting rid of the original lever, in this case, will remove the biggest moving part and by doing so, will do away with many of the parts that are continuously breaking. After the lever is disassembled, we will go ahead and install the cover plate to cover up the previous holes and damage from a very rough installation. You can tell by looking at these holes that they were not precision drilled and no jig was used. This particular cover plate is a matte black one that is readily available at nearly any hardware store. Once the cover plate is in place, I can go ahead and re-install my jig to get a hole that works. Refer to the instructions to ensure that you have proper drill points and installation holes so that you can align the holes for the two through bolts that are going to go through this plate and the rim cylinder that will be mounted outside. Once finished, take a moment to admire and appreciate the fact that there are no protruding parts that are going to get caught on ski boots, ski jackets, etc. Next, we will need to trim down the tailpiece with the Dremel so that it fits nicely. The bolts that are locking the exit device to the pull trim are actually going completely through the door, so this is the strongest bond possible. You want to make sure that the through bolts and screws are set all the way and that nothing is sticking out. This will ensure that nothing is sticking out later down the road. After installation on this side, the device is hanging down just a little bit and there is a tiny spot that didn’t get painted. Because of the three dimensional sides of that gap, the maintenance team decided that it would simply be painted with touch up paint.

On the back side of the panic exit device, I am, again, going to be utilizing through bolts. I do this whenever I can on wooden doors, as wood screws are a particularly bad idea for nearly any application that is going to sustain a beating day to day. When installing the strike, make sure you have the proper gap. I had to move the exit device down a little so it was not being installed on the three dimensional trim. For this project, I drilled and tapped with Milwaukee combos that worked on this application. Unfortunately, I was unable to install the heavy-duty handle that came with the device because they only sent one screw and one HD washer. For the time being, we have mounted a temporary handle and will be back upon arrival of the correct hardware.

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