VAR1 VAR2 Standard Install

vario™ I/II Standard 4C configurable mail shelter

Installation Instructions

2

www.florencemailboxes.com 48284 I-II/Std Rev F

ongratulations on the purchase of your new vario™ 4C configurable mail shelter from Florence Manufacturing! The residents in your neighborhood will thank you for selecting a manufacturer with over 75 years experience in keeping mail safe. In

addition, this unique and innovative product will enhance the property on which you are installing it, and provide shelter to your Florence versatile™ 4C mailbox suites for years to come. Florence products are well known for their great design, high levels of performance, and are trusted by builders and property owners across the nation and in Canada alike. Your new vario™ mail shelter is no exception. Originating from the desire for more architecturally pleasing design options for centralized delivery - the U.S. Postal Service’s preferred method of mail delivery for new developments - the vario™ mail shelters provide you with the flexibility and opportunity to personalize your final product for seamless integration within your neighborhood and surrounding architecture. While good design may stand out - the excellent vario™ design fits in! If for any reason you need assistance with installation, or have questions on included parts for your vario™ mail shelter, please do not hesitate to contact your local Authorized Florence Dealer. Additionally, you may download pad specifications and/or other technical documents at www.florencemailboxes.com if needed. The vario™ mail shelter’s unique design ensures your mailbox system will be in compliance with the U.S. Postal Service’s STD-4C, the latest regulation and installation requirements for mounted mailboxes. Please see diagram below for illustration: U.S. Postal Service STD-4C installation guidelines require the following:

1. At least one customer compartment shall be positioned less than 48 inches from the finished floor.

2. No parcel locker compartment (interior bottom shelf) shall be positioned less than 15 inches from the finished floor.

3. No patron (tenant) lock shall be located more than 67 inches above the finished floor.

4. No customer compartment (interior bottom shelf) shall be positioned less than 28 inches from the finished floor.

5. The USPS Arrow lock shall be located between 36 and 48 inches above the finished floor.

C

3


Table of Contents

Get to Know Your vario™ ........................................................................................... 4

Make Your vario™ Uniquely Yours ............................................................................ 5

Hardware List ............................................................................................................... 6

Suggested Tools for Installation ................................................................................. 10

Step 1 - Install Plastic Hole Plugs ............................................................................... 11

Step 2 – Install Vertical Uprights and Hilti Anchors................................................. 12

Step 3 – Install Roof End Trusses............................................................................... 17

Step 4 – Install Horizontal Beams .............................................................................. 18

Step 5 – Install Lower Roof Stringers ........................................................................ 20

Step 6 – Install Roof End Truss Support ................................................................... 22

Step 7 – Install Upper Roof Stringers ........................................................................ 24

Step 8 – Adjust vario™ and tighten hardware .......................................................... 28

Step 9 – Install Peak Roof Trusses and Stringers ...................................................... 29

Step 10 – Install Roof Sheathing Support Brackets and Plywood Seam Support .... 32

Step 11 – Install Mailbox Casing Mounting Nuts ...................................................... 33

Step 12 – Install Plastic Plugs ..................................................................................... 35

Step 13 – Assemble 4C Mailbox Casings.................................................................... 37

Step 14 – Install versatile™ 4C Mailbox Casings ...................................................... 42

Step 15 – Install Side Panels ....................................................................................... 45

Step 16 – Install versatile™ 4C Mailboxes................................................................. 48

Appendix A – Roof Finishing Tips ............................................................................. 50

Appendix B – Hardware Finishing Option ................................................................ 54

Appendix C – Shelter Leveling Guide........................................................................ 55

Technical References: Pad specifications, dimensions, and other product specifications are available to download at www.florencemailboxes.com/downloads

4


Get to Know Your vario™

Before the assembly process begins, please review the illustration below. The major components that you will be working with and that are referred to in this instruction manual are identified so as you are installing your vario™ mail shelter, you will be familiar with the terms that are used.

Vertical Upright Horizontal Beam

Roof End Truss Lower Roof Stringer

Roof End Truss Support

Upper Roof Stringer

Gable Peak Roof Stringer

Gable Peak Roof Truss

Roof Sheathing Brackets

Side Panel

5


Make Your vario™ Uniquely Yours

When the shelter assembly is completed, you may finish the roof and side panel exterior surfaces with materials that fit your neighborhood surroundings. All it takes is a little plywood for the roof and exterior finishing materials of your choice.

Note: Plywood, roof and exterior end panel finishing materials not include in mail shelter kit; provided by others. Detailed pad specifications are available for download from auth-florence.com

6


Hardware List All hardware illustrated here is to full scale. The amount of hardware included will vary depending upon model type being installed. This list is for identification purposes only.

4817

6 B

olt,

3/8-

16 x

1-1

/2

4817

9 B

olt,

3/8-

16 x

6-1

/2

4818

0 B

olt,

3/8-

16 x

3-1

/4

4817

8 B

olt,

3/8-

16 x

5

4818

1 B

olt,

3/8-

16 x

2-3

/4

7


Hardware List (Full Scale) continued

4819

2 B

olt,

3/8-

16 x

5 (

Thi

n H

ead)

4819

5 S

crew

, Soc

ket H

ead,

3/8

-16

x 1-

1/4

4824

8 S

crew

, #12

x 1

-5/8

Dril

l Poi

nt T

eks

4

4819

7 B

olt,

3/8-

16 x

5/8

4818

7 N

ut, S

quar

e, 3

/8-1

6 x

1/4

Thi

ck

4817

7 N

ut, 3

/8-1

6

4817

5 W

ashe

r, 1

3/32

ID x

13/

16 O

D

4818

5 S

crew

, #8

x 3/

4 P

an H

ead

T20

Tor

x D

rive

9222

9 S

crew

#10

-32

Pan

Hea

d S

S

Tap

tite

4829

1 S

crew

#10

-32

x 1/

2 T

-25

Tor

x

8


Hardware List (Full Scale) continued Hilti anchoring system, epoxy and application gun are also included with each model type. Please see pages 15 – 16 for details.

4836

2 N

ut, H

ex, 5

/8-1

1

4836

3 N

ut, H

ex, 3

/4-1

0

4836

4 W

ashe

r, .6

87 ID

x 1

.75

OD

4836

5 W

ashe

r, .8

13 ID

x 2

.00

OD

4836

7 A

corn

Nut

, 5/8

-11

4836

6 A

corn

Nut

, 3/8

-16

4836

8 A

corn

Nut

, 3/4

-10

9


Hardware List (not to scale) continued Additional parts are included with your shelter kit and are shown here for ease in identification of each part. Top Roof Sheathing Bracket Bottom Roof Sheathing Bracket

48140 – Vertical Support Plastic Plug 48249 – ½” Plastic Plug (150 mph models) 48246 – 1” Plastic Plug 48245 – ½” Plastic Plug (90 mph models)

48369 – Vinyl Cap 1/8” 48345 – Plywood Support Bracket

10


Suggested Tools for Installation

• 9/16” socket • 9/16” wrench • Ratchet • 7/32” allen wrench • Cordless drill with proper socket adapter(s) • Hammer drill with 11/16” masonry bit • Air tank or vacuum to remove dust from holes that are drilled in concrete • 15/16” wrench or large crescent wrench • Hammer • Rubber mallet • 6’ Step ladder • Screw driver or taper punch for aligning mating holes • Torx-Plus driver bit - #25 • Torx-Plus driver bit - #20 • Level • 25’ Tape measure • Phillips driver bit - #3 • Grout trowel • Grouting bag

Additional tools may be required for the roof and side panel exterior finishing. Tools and hardware will depend on types of finish materials you select. For helpful Finishing Tips, see the appendices beginning on page 50 of this manual.

11


Step 1 - Install Plastic Hole Plugs a) Lay the vertical uprights on the ground and install one 48140 2 x 4 rectangular plastic

hole plug into each end of the top tube on the vertical uprights. Two (2) plastic hole plugs are required for each vertical upright. A rubber mallet should be used to tap the plugs into place. See Figure 1.

Figure 1 – Rectangular 2 x 4 Plastic Plug Installation

48140 Plastic Plug, 2 x 4

Vertical Upright

48140 Plastic Plug, 2 x 4

12


Step 2 – Install Vertical Uprights and Hilti Anchors a) Locate where the vertical upright mounting anchor holes are to be drilled using the

foundation dimensions shown in Figures 2 through 5. Hint: The horizontal mounting beams can also be used to help determine the

distance between the vertical uprights.

Figure 2 – Vario I 90MPH Anchor Hole Location

Figure 3 – Vario I 150MPH Anchor Hole Location

Front of vario™

Front of vario™

13


Figure 4 – Vario II 90MPH Anchor Hole Location

Figure 5 – Vario II 150MPH Anchor Hole Location

Power line location for AC light option

Front of vario™

Power line location for AC light option

Front of vario™

14


b) Place the vertical upright into position. Drill holes in the concrete while the vertical upright is in position. See pages 15 and 16 for drill bit size to use.

c) Install the Hilti anchors (included) as shown in the Hilti instructions on the following pages.

d) Note the direction of the tube on top of the vertical support. The long portion of the tube should point toward the side where the mailboxes will be installed. See Figure 6 below.

e) Loosely install the nuts on the anchors. Do not completely tighten hardware yet. All hardware will be tightened in a later step!

CAUTION: MAKE SURE ALL HOLES ARE DRILLED PRIOR TO COMMENCING TO APPLY ADHESIVE! THE HY-150 ADHESIVE

CURES VERY QUICKLY!

Front of mailboxes on this side

Figure 6 – Profile of vertical upright with front of mailboxes indicated by arrow

Longer end of tube should point toward the “outside”, which is the side that the mailboxes are installed

15


4.2.4 HIT HY 150 MAX Adhesive Anchor (5/8” Anchors)

HIT-TZ and HIT-RTZ Installation Instructions (All 90 MPH Standard vario™ Models)

1 2 3 4 5 5 6

4.2.4 HIT HY 150 MAX Adhesive Anchor Adhesive Anchoring Systems

HIT

HY 150

HIT

HY 150

HIT

HY 150

HIT

HY 150

PUSH

Do Not Twist

Drill hole using a roto-hammer or Hilti diamond coring machine and an 11/16” carbide masonry bit.

Do not adjust the HIT-TZ rod between the gel and cure times. Apply a load only after the appropriate cure time has elapsed.

Fill the hole 1/2 to 2/3 full. If the hole is full of water, it is suggested to start injecting from the bottom of the hole and fill entirely with adhesive.

Inject adhesive starting from the bottom of the hole.

Push the HT-TZ in the hole to verify sufficient hole depth (only threads visible). For floor applications pushing the rod compacts the drill dust.

16


3X 3X

3X

1. Drill anchor hole with a 13/16” carbide bit.

2. Insert air nozzle to bottom of

hole and blow out all dust and

debris from the hole using

compressed air.*

3. Clean hole with wire brush.

Proper hole cleaning is essential.

4. Insert air nozzle to bottom of

hole and blow out all dust and

debris from the hole using

compressed air.

5. Put foil pack into foil pack

holder. Remove cap covering

threaded projection.

6. Screw on static mixer. 7. Put holder/ foil pack into

appropriate dispenser.

8. Discard first two trigger pulls of

adhesive from each foil pack.

9. Inject adhesive into hole without

forming air pockets starting at the

bottom until 1/2 to 2/3 full. Use

mixer filler tube extensions when

needed to reach the hole bottom.

10. After injecting adhesive

depressurize the dispenser

by pressing the release button.

11. Insert rod, insert or rebar. Twist

during installation. Fastener may

be adjusted during specified

gel time.

12. Do not disturb anchor

between specified gel

time and cure time.

13. Apply specified torque as

required to secure items to be

fastened. Do not exceed

maximum torque specified.

Hilti, Inc. (US) 1-800-879-8000 | www.us.hilti.com | en español 1-800-879-5000 | Hilti (Canada) Corp. 1-800-363-4458 | www.ca.hilti.com | Product Technical Guide 2006

* For holes with standing water, holes must be flushed clean with water, brushed with a wire brush and again

flushed clean with water or other means removing any debris or slurry in the hole. Standing water must be

removed prior to performing the remainder of anchor installation.

Adhesive Anchoring Systems

4.2.4 HIT HY 150 MAX Adhesive Anchor

HAS Rod Installation Instructions (All 150 MPH Standard vario™ Models)

Note that the beveled end of the anchor is installed into the hole.

17


Step 3 – Install Roof End Trusses a) Place roof end truss in position on top of vertical support(s) using holes closest to the

outside. b) Insert 48176 bolts with 48175 washers through the top tube on the vertical support and

thread into the end truss. See Figures 7 through 9. DO NOT use a power tool to start threading the bolt into the nut, as it could cause the threads to strip. Repeat for the other end truss.

c) NOTE: If the AC lighting option was purchased, the end truss with the wiring harness installed in it must be on the right side of the vario™ as viewed from the front.

d) Do not completely tighten hardware yet.

Attention! Use hole closest to the outside end of vario™

Figure 9 – End truss installation

Figure 8 – Installation of roof end truss bolts

48175 washer

48176 bolt

Figure 7 – End truss installation

18


Step 4 – Install Horizontal Beams a) Determine which holes in the vertical supports (uprights) will be used to mount the

horizontal beams. The position of the horizontal beam placement is dependent on which Florence versatile™ 4C mailbox suites will be installed in the mail shelter. This is to ensure compliance with USPS STD-4C installation requirements referenced on page 2. See Figure 10 below.

Figure 10 – Horizontal Beam Locations by Florence versatile™ 4C mailbox suites

Install top horizontal mounting beam using these holes for 4C mailbox suites A, C, F, G, and H

Install top horizontal mounting beam using these holes for 4C mailbox suite E

Install bottom horizontal mounting beam using these holes for 4C mailbox suites A and E

Install bottom horizontal mounting beam using these holes for 4C mailbox suite C

Install bottom horizontal mounting

beam using these holes for 4C mailbox suite G

Install bottom horizontal mounting beam using these holes for 4C mailbox suite F

Vertical upright

Install bottom horizontal mounting

beam using these holes for 4C mailbox suite H

19


b) Install the upper and lower horizontal beam(s) between the vertical uprights using (4) 48192 bolts, (4) 48175 washers, and (4) 48177 nuts per beam. Do not completely tighten hardware yet. See Figures 11 and 12.

Figure 12 – Installation of horizontal mounting beams

Note orientation of end brackets!

Upper horizontal beam

Lower horizontal beam

Figure 11 – Installation of horizontal mounting beams

48175 washers

48192 bolts DO NOT

use washers on these

bolts!

Vertical upright

48177 nuts

Lower horizontal beam

Attention! Suite F mounting location shown. See Figure 10 for specific location for your vario™

A, C, F, G, H

E

A & E

C G F

H

20


Step 5 – Install Lower Roof Stringers a) Subassembly: Insert link tubes into lower roof stringers. See Figure 13.

b) Secure with 48176 bolts and 48175 washers. Figure 14 illustrates the location of bolts in this step. Do not completely tighten hardware yet.

Slide link tube into stringer tube

Slide link tube into stringer tube

Link tube

Stringer tube

Link tube

Figure 14 – Lower stringer subassembly

Figure 13 – Lower stringer subassembly

48175 washer

48176 bolt

Note that these small holes must face towards the inside of the vario™ when the stringer is installed!

21


c) Before placing stringer in position, note that the small holes shown in Figure 14 must face towards the inside of the vario™ when the stringer is installed!

d) Carefully place lower stringer into position. e) The link tubes at the end of the stringers should be inserted into the “U” shaped channels

on the end trusses. See Figure 15. f) Repeat for the other side of the vario™. g) Do not attach stringer to end trusses with hardware until the next step.

Lower stringer assembly

“U” shaped channels

Link tube

Link tube

Figure 15 – Lower roof stringer being placed into position

22


Step 6 – Install Roof End Truss Support a) Install end truss supports to the roof end truss using (2) 48176 bolts and (2) 48175

washers for each end truss support. Note that the 48176 bolts go through the end truss support angle bracket, the end truss “U” shaped channel, and into the lower stringer link tube. Do not completely tighten hardware yet. See Figures 16 and 17.

Figure 16 – End truss support bracket installation

Figure 17 – Detail of end truss support bracket installation

End truss support

Lower stringer

48175 washers 48176 bolts

“U” Shaped channel on end truss

Angle bracket on end of end truss support

23


b) Attach the other end of the end truss support to the vertical upright using (2) 48178 bolts, (4) 48175 washers, and (2) 48177 nuts. See Figures 18 and 19.

c) Do not completely tighten hardware yet. Figure 19 – Detail of end truss support bracket installation

Figure 18 – End truss support bracket installation

Flat bracket

End truss support

48177 nut

48175 washer

48178 bolts

48175 washer Vertical upright

48175 washer

24


Step 7 – Install Upper Roof Stringers a) Sub-assemble the upper roof stringers, noting the orientation of the stringer tube. See

Figure 20.

b) Install upper stringers to small link tubes using (4) 48181 bolts, (4) 48177 nuts, and (8) 48175 washers. Do not completely tighten hardware yet. See Figure 21.

Figure 20 – Assemble upper roof stringer

Figure 21 – Assemble upper roof stringer

Link Tubes

Upper stringer

48181 bolts

48175 washers

48177 nuts

Note that these small holes must face towards the outside of the vario™ when the stringer is installed!

25


c) Place the ends of the upper stringer assembly into the “U” shaped channels on the end trusses. See Figure 22.

Figure 22 – Install upper roof stringer

Upper roof stringer “U” shaped

channels

These small holes must face towards the outside of the vario™.

26


d) Attach to end trusses with (4) 48181 bolts, (4) 48177 nuts, and (8) 48175 washers. Repeat for other side. See Figures 23 through 26.

48181 bolts

48177 nuts

48175 washers



27



48175 washers 48181 bolts

48177 nuts


28


Step 8 – Adjust vario™ and tighten hardware Ensure that all vario™ components are plumb and square, then tighten all hardware. Use a level and/or a plumb bob to ensure squareness. Be careful not to strip the threads of the bolts and nuts! Tighten hardware in the order listed below:

a) Bottom horizontal mounting beam(s). * Note: DO NOT tighten TOP horizontal mounting beam until after mailbox

casings are installed. b) End truss to stringer joints. (Upper and lower stringers.) c) End truss to vertical upright joints. d) End truss support to vertical upright joint. e) Concrete anchors that secure vertical uprights.

See Figure 27 for hardware location and sequence.

Figure 27 – Hardware tightening sequence

(b)

(a)

(b) (c)

(e)

(d)

Do not tighten upper horizontal mounting beam(s) until after mailbox casings are installed

29


Step 9 – Install Peak Roof Trusses and Stringers a) Place peak roof end trusses on top of roof end trusses. Use (1) 48179 bolt, (1) 48177 nut,

(4) 48175 washers, and (2) 48195 screws to secure each truss. See Figures 28 and 29.

Figure 29 – Installation of gable peak roof end truss

Peak roof end truss 48179 bolt and 48175 washer

48195 screw 48175 washer

48177 nut 48175 washer

48195 screw 48175 washer

Figure 28 – Installation of gable peak roof end truss

30


b) IMPORTANT! Bolt 48179 goes through the bottom angle of the Gable Peak roof end truss, through the end truss bottom stringer, and through the top tube of the vertical support. See Figures 30 and 31.

Figure 31 – Installation of peak roof end truss – bottom view showing how bolt 48179, nut 48177, and washer 48175 are installed

Figure 30 – Bolts into peak roof end truss

End truss bottom stringer

Top tube of vertical support

Bottom angle of peak roof truss

Bolt 48179 goes through all three components

31


c) Place the peak roof stringer on the peak end trusses. Attach using (4) 92229 screws. See Figures 32 and 33.

92229 screw

Peak roof stringer

Figure 33 – Installation of peak roof stringer

Figure 32 – Installation of peak roof stringer

32


Step 10 – Install Roof Sheathing Support Brackets and Plywood Seam Support a) Install roof sheathing* support brackets and plywood seam support to the upper and

lower stringers using the pre-drilled holes and 92229 screws. See Figures 34 and 35.

*Roof sheathing (plywood) NOT included in vario™ mail shelter kit; supplied by others.

Figure 35 – Installation of roof sheathing support brackets and plywood seam support

Figure 34 – Installation of roof sheathing support brackets

92229 screw

Upper stringer

Lower roof sheathing support bracket

Lower stringer

Upper roof sheathing support bracket

92229 screw

Plywood seam support NOTE: THIS IS USED ON VARIO II ONLY

92229 screw

33


Step 11 – Install Mailbox Casing Mounting Nuts a) On ends of the upper and lower horizontal mounting beams there is an enlarged area of

the slot in the beam. See Figures 36 and 37.

Figure 37 – Close-up view of enlarged area of slot

Enlarged area in slot

Lower horizontal mounting beam

Figure 36 – Mounting beam slot

34


b) Insert (2) 48187 square nuts for each cabinet in both the upper and lower beams through the enlarged area and slide down as needed to make room for each subsequent nut. See Figure 38 and 39.

Figure 39 – Installation of casing nuts

Figure 38 – Installation of casing nuts

48187 square nut

Lower horizontal mounting beam

48187 square nut, installed

35


Step 12 – Install Plastic Plugs a) Install 48245 1/2" diameter plastic hole plugs and 48246 1” diameter plastic hole plugs

into any holes on the vertical upright top tube that are open. See Figure 40.

48246 Plastic plug, 1”

Vertical upright top tube

48245 Plastic plug, 1/2”

Figure 40 – Installation of round plastic plugs

36


b) Install 48245 1/2" diameter plastic hole plugs into any holes on the vertical uprights that are open. See Figure 41.

Figure 41 – Installation of round plastic plugs

48245 plastic plug, 1/2” Vertical

upright

37


Step 13 – Assemble 4C Mailbox Casings The mailbox casings are shipped unassembled. Five panels are used to make each mailbox casing: top, bottom, back, LH side, and RH side. Note: If installation of shelter does not include mailboxes, skip to Step 15.

a) Place casing back panel on a flat surface, being careful not to scratch paint. See Figure 42.

Casing back panel

Figure 42 – Casing assembly – back panel

38


b) Place one side panel into position. Use 48291 screw to attach side to back. See Figures 43 and 44.

Casing back panel

Casing side panel 48291 screw

Figure 43 – Casing assembly


39


c) Repeat for the other side. See Figure 45.

d) Place top panel (top and bottom are interchangeable) on back and sides as shown in Figure 46.



Casing back panel Casing side panel

Casing top panel

40


e) Attach top to sides and back using 48291 screw. See Figure 47. Figure 48 shows a different view of this assembly step.


Figure 48 – Casing assembly – alternate view


48291 screw Casing top panel


48291 screw

Casing top panel

41


f) Repeat for the bottom panel. The mailbox casing is now complete. See Figure 49. g) Assemble any additional casings in the same manner.


42


Step 14 – Install versatile™ 4C Mailbox Casings a) Place the 4C mailbox casings into the vario™

between the upper and lower horizontal beams. See Figure 50.

b) Slide one 48187 square nut so it lines up with the hole in the top panel of the 4C casing on each side of the top panel.

c) Repeat for the bottom panel. Note: Use of a long skinny tool - such as a screwdriver or piece of wire may be necessary to help place the square nut directly in sight of the casing holes.

Figure 50 – Installing mailbox casing in vario™

Figure 51 – Sliding nuts in horizontal beam

43


d) Secure bottom of casing to lower horizontal beam using (2) 48197 bolts and (2) 48175 washers. Thread 48197 bolt into 48187 square nut. See Figures 52 and 53.

e) Secure top of casing in the same manner to upper horizontal beam using (2) 48197 bolts

and (2) 48175 washers.

Figure 52 – Install mailbox casing

48197 bolt

48175 washer

48187 square nut

Figure 53 – Install mailbox casing

44


Note: Casings may be placed directly next to each other or with equal spacing distance between them. Final installation placement is up to the individual installer. See Figures 54 and 55.

f) Adjust casing position to user preference. g) Tighten casing bolts. h) Tighten upper horizontal mounting beam hardware.

Figure 54 – Casing adjustment – gap between casings

Figure 55 – Casing adjustment – no gap between casings

45


Step 15 – Install Side Panels a) Install each side panel using (4) 48178 bolts and (4) 48175 washers per panel. Note –

make sure the unfinished plywood surface faces outwards. See Figures 56 through 58.

Figure 56 – Side panel installation (mailbox casings not show for clarity)

Figure 57 – Side panel installation Figure 58 – Side panel installation

48175 washers

48178 bolts

Unfinished plywood

48175 washers

48178 bolts

Unfinished plywood

46


b) Attach side panel so that there is more surface protruding towards the back of the vario™. The side panel is designed to cover the mailbox casings for a more complete, finished look. See Figure 59.

Figure 59 – Side panel installation

Side panel

Raw plywood surface

Mailbox casings hidden behind side panel

47


Note: Refer to page 18 for individual versatile™ 4C mailbox suite mounting placement. Your vario™ mail shelter kit is now assembled; ready for your finish material, and Florence versatile™ 4C mailbox suites. The addition of plywood to the roof as well as finishing material to both the exterior end panels and roof may be completed either before or after mailbox installation in the next step. Finishing materials are your choice so that your new vario™ mail shelter fits seamlessly into the surrounding neighborhood and are provided by others.

Figure 60 – Mailbox casings for Florence versatile™ 4C Suite F installed in vario™ mail shelter

48


Step 16 – Install versatile™ 4C Mailboxes Listed below are the steps to install your Florence versatile™ 4C mailboxes into the vario™ mail shelter. For more detail, please refer to the installation instructions included with your Florence versatile™ 4C mailboxes.

a) First, place the bottom of the 4C mailbox into the casing as shown in Figure 61.

b) Tilt the top of the 4C mailbox completely into the casing. Make sure the mailbox trim is flush against the front of the casing. See Figure 62.

Figure 61 – 4C installation


4C Mailbox

Push 4C mailboxes completely into the casing.

49


c) Open the master doors of the 4C mailbox so the hold-open arms secure the doors in the open position. See Figure 63.

d) Using the screws provided with the 4C mailbox, secure the 4C into the mailbox casing. See Figure 64.

e) Close the master load doors.

Congratulations! Your vario™ mail shelter is now complete.


Figure 63 – 4C Master Load Doors Open

4C Master load doors

50


Appendix A – Roof Finishing Tips

The materials you choose to use to finish the exterior of your vario™ roof and side panels is certainly up to you…after all, that’s what makes your mail shelter “uniquely yours”. However, we wanted to provide you with the following tips and suggestions to assist you in preparing for your finishing touches.

• Roof sheathing material – 3/4” plywood suggested.

• Painting exposed underside of roof sheathing – paint plywood prior to mounting it to the vario™ shelter roof structure if you intend to paint exposed surfaces. This will minimize risk of paint drippings marring the powder coat on your mailbox and shelter surfaces.

• Vario™ roof surface dimensions – the roof patterns shown below are provided to serve as a guide for determining the amount of roof sheathing you will need for the vario™ shelter types discussed in this manual.

SIDE BOTTOM TRUSS PLYWOOD

2'

4'-7 116"

1'-918"

55°

VARIO 1 STANDARD

1'-918"

45°

55°

10 916"

10 916"

SIDE TOP TRUSS PLYWOOD

FRONT AND BACK BOTTOM TRUSS PLYWOOD

7'-11316"

2'55°55°

4'-378" 1'-5"

1'-5"

FRONT AND BACK TOP TRUSS PLYWOOD

1'-21516"

4'-378"

SIDE BOTTOM TRUSS PLYWOOD

2'

4'-7 116"

1'-918"

55°

VARIO 2 STANDARD

1'-918"

45°

55°

10 916"

10 916"

SIDE TOP TRUSS PLYWOOD

FRONT AND BACK BOTTOM TRUSS PLYWOOD

8'-5 116"

2'55°55°

5'-718" 1'-5"

1'-5"

FRONT AND BACK TOP TRUSS PLYWOOD

1'-21516"

5'-718"

Figure A1 Figure A2

51


• Included in your kit are screws (48185) to install plywood sheathing to upper and lower

roof sheathing brackets. See Figures A3 and A4.

Figure A4

Figure A3

48248 Screw

Plywood sheathing (provided by others)

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• Screws (48248) to install plywood to the vario™ frame are also included. See Figures

A5 and A6.

Figure A6

Figure A5

48248 Screw

Plywood sheathing (provided by others)

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• Vinyl caps (48369) are provided in your kit. These can be installed on the tips of the 48248 screws that protrude through the underside of the frame. See Figure A7.

• When using asphalt shingles, 5/8” roofing nails are suggested so that nails do not protrude through the bottom side of the 3/4” plywood sheathing.

• Flashing material is recommended when roofing the vario™. Figure A8 shows an example of flashing installed with typical asphalt shingles. Flashing and hardware used will vary based on roof material selected.

Figure A8

Flashing material (provided by others)

Figure A7

48248 Screw

48369 Vinyl cap

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Appendix B – Hardware Finishing Option

• Acorn nuts are included in your vario™ kit as an optional finishing accessory. These can be installed over any exposed bolt threads as desired. See Figures B1 through B3 for examples.

Figure B3 Figure B2

Figure B1

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Appendix C – Shelter Leveling Guide In a perfect world, there would be no need to provide this guide. However, we know that construction professionals have to deal with all types of site issues, so we offer the following suggestions on how to correct for foundations that may not be perfectly level. In the event the concrete pad the vario™ is to be installed on is not level, the vertical uprights may be adjusted. Figures C1 through C5 provide a suggested leveling technique. The hardware depicted in this illustration is provided with your vario™ shelter kit for your convenience. 1) Install the hex nuts on the Hilti™ anchors as shown in Figure C2. 2) Place the flat washers on the nuts.

Figure C1

Figure C2

Hex nut

Flat washer

Hilti™ anchor

Concrete pad

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Hex nut

Flat washer

Lock washer Fill this space with grout

Concrete pad

Figure A3 shows the hex nuts and flat washers installed on the Hilti™ anchors. 3) Install the vertical upright onto the Hilti™ anchors and the flat washers. 4) Adjust hex nuts up or down to achieve the desired height. See Figure C4. 5) Secure the vertical upright in place by installing the flat washers, lock washers, and hex nuts. 6) To finish, grout should be installed to fill the void underneath the vertical upright. See Figure C5.

Concrete pad

Figure C3

Figure C5

Figure C4

Concrete pad

Adjust hex nuts up or down as needed

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VAR1 VAR2 Standard Install

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