Okay, let's break down roughing in for card readers and wire feeds in aluminum and glass doors. This is trickier than working with solid wood or metal doors because of the thin profiles and potential for glass breakage. Here's a structured approach to help you, along with considerations based on your images and typical rough-in details

1. Understanding the Challenges & Planning
Limited Space

Aluminum door frames are thin. You're working with very little room to run wires and mount hardware.

Glass Proximity

Drilling near glass is always risky. Vibration can crack the glass. Precise measurements and careful execution are essential.

Frame Integrity

Weakening the frame structurally can compromise the entire door.

Aesthetics

Exposed wiring and poorly placed hardware will look unprofessional. Concealment is key.

Door Usage

Consider the door's frequency of use. Heavy traffic requires more robust solutions.

Door and Frame Type

Confirm door and frame type prior to any work.

Door handing

Confirm door swing, and hardware handing prior to work.

2. Preliminary Steps (BEFORE Cutting Anything!) Review the Card Reader & Locking Hardware Specs

Absolutely crucial! Get the dimensions and mounting requirements (hole sizes, backset, mounting depth) of the exact card readers and electric locks you'll be installing. This information dictates everything.

Door and frame information

confirm thickness and composition of door, and frame prior to doing work.

Confirm wiring requirements Confirm wire counts, and gauge requirements prior to installation, and pulling wire. Create a detailed plan

Draw a schematic showing the location of each component (card reader, electric lock, power transfer hinge, wiring pathways). Include measurements relative to fixed points on the door frame.

Mark it up! Using your schematic, use a dry erase marker to layout locations and measurements on door and frame. Consult with the security system installer

Talk to the people who will be installing the final hardware. They might have specific requirements or preferred locations.

3. Rough-In Locations & Considerations (Based on Common Scenarios) Card Reader



Placement

Typically mounted on the secure side of the door, usually near the handle. Consider ergonomic height and accessibility requirements.

Mounting

You'll likely need to drill through the aluminum frame. Use a hole saw of the correct diameter (based on the card reader specs).

Wiring

Route the wiring within the frame if possible. If not, you'll need to use surface-mounted raceway, which should be as minimal and discreet as possible.

Electric Strike or Magnetic Lock



Placement



Electric Strike

Replaces the existing strike plate in the door frame.

Magnetic Lock

The magnet mounts to the frame header, and the armature plate mounts to the door.

Wiring

Run wiring from the power supply (usually above the door in the ceiling) down to the strike or maglock. This is where the "mortise wire feed" comes in.

Power Transfer Hinge



Purpose

Transfers power from the frame side to the door side through the hinge. Essential for electrified locks.

Location

Usually the top hinge (least stress).

Installation

Requires replacing one of the existing hinges with a power transfer hinge. You'll need to run low voltage wires to that hinge location in both the door and the frame.

Door Cord/Loop



Purpose

An alternative to power transfer hinges. A flexible conduit ("door loop") runs from the frame to the door, protecting the wires.

Location

Typically mounted near the hinge side of the door, allowing the loop to flex as the door opens and closes.

Considerations

More visible than power transfer hinges.

4. Rough-In Procedures - General Steps Safety First

Wear safety glasses and gloves.

Protect the Glass

Apply masking tape to the glass around the areas you'll be working on to prevent scratches and chips. Consider using a thin piece of plywood or hardboard as a shield.

Pilot Holes

Always start with a small pilot hole before using larger drill bits or hole saws. This prevents the bit from wandering and damaging the surrounding area.

Lubrication

Use cutting oil or lubricant when drilling through aluminum to reduce friction and heat.

Slow and Steady

Drill slowly and apply consistent pressure. Avoid forcing the drill bit.

Deburr

After drilling, deburr all holes with a deburring tool or a countersink bit to remove sharp edges that could damage wires.

Wire Routing



Concealment

Run wires inside the aluminum frame whenever possible.

Protection

Use grommets or bushings to protect wires where they pass through holes.

Strain Relief

Provide strain relief for all wires to prevent them from being pulled or stressed.

Mortise Wire Feed



Careful measurement

Ensure correct wire length, and positioning prior to installation.

Drilling

Requires drilling a hole through the door frame to run wires to the electric strike or other locking hardware.

Routing

Fish wires through the frame. Use fishing tools.

Door Loop



Mounting

Securely mount the door loop to both the door and the frame.

Wiring

Run wires through the flexible conduit.

5. Specific Considerations for Glass & Aluminum Doors (and your photos) Frame Type

Your photos show relatively thin aluminum frames. This is extremely important.

Glass Type

Is the glass tempered? This is crucial. If it's not tempered, drilling near it is incredibly risky. If it is tempered, it cannot be cut or drilled.

Panel Removal

Can the glass panels be removed from the frames before you start drilling? This is the best approach if possible. It minimizes the risk of damaging the glass.

6. Answering Your Specific Questions "Glass and aluminum frame sections that need roughed in for card reader access, and hinge and mortise wire feeds." Card Reader

Mount on the aluminum frame, away from the glass edge, following the card reader manufacturer's instructions. Carefully route wires inside the frame or use surface-mounted raceway.

Hinge Wire Feeds (Power Transfer Hinge)

The most challenging. The frame is thin! Measure very carefully to make sure the hinge fits and that you can route the wires.

Mortise Wire Feed

Drill through the frame for the electric strike. Route the wires carefully to avoid sharp bends.

Important Reminders



LOCAL CODES

Always comply with local building and electrical codes.

LICENSING

In many jurisdictions, you need a license to perform electrical work.

INSURANCE

Make sure your insurance covers this type of work.

PROFESSIONAL HELP

If you are not comfortable with any of these procedures, hire a qualified professional. Damage to the glass or the door frame can be very expensive to repair.*

Document everything: Keep detailed records of your work, including measurements, wire runs, and hardware locations. This will be helpful for future maintenance and troubleshooting.Provide more specifics about the hardware, glass type, and frame details. The more information you provide, the more specific my advice can be. Good luck! Flag for review