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How to Install Barn Doors (Full Guide)

Contents

Safety

Warning!

  • Failure to wear proper safety gear (i.e., eye protection) may result in serious injury or death. Always wear proper safety gear before using power tools.
  • Improper operation of power tools may result in loss of control, serious injury or death. Always ensure you have complete control of the power tool and the work area is free of hazards before operating any tool.
  • Lack of secure clamping of the door may result in unexpected movement of the door, loss of power tool control and serious injury or death. Always securely clamp the door in place before cutting or drilling the door.
  • Lack of nor improperly installed Anti-jump Disc may result in the door coming off the track and cause serious injury or death. Installation of Anti-jump Disks is required for the safe operation of this hardware. Installed correctly, these discs will keep the door securely attached to the track.

 

Caution!

  • Mishandling of heavy objects (i.e., doors) may cause a loss of balance and severe injury. Always be sure you have a secure hold on the item and that the objects are balanced before moving. Always wear safety shoes when lifting heavy objects
  • Getting body parts (i.e., hair, fingers) caught in moving parts may cause pinching and severe injury. Do not put fingers in parts that may move and always remove or contain anything on your body that may become entangled with a moving part.
  • Closing sliding doors with your hand on the end of the door may result in your hand or fingers, getting caught between the door and other solid objects (i.e., another door, molding), causing severe injury. Always use the door handle to operate doors.

 

Notice: Use of excessive force when opening and closing the door(s) may damage the hardware.

Always hold the handle and gently open and close the door(s).

 

Stop! If not familiar with installation, please consult a professional. Hanging a door is a two (2) person job.

Parts

Flat Track Hardware

Before you begin, check that you have the parts you need in your kit. The table below indicates the model and quantity of parts.

Header Board

What is a Header Board?

Install your sliding hardware with ease by using our Header Board! Our Header Board is the fastest and easiest way to hang up our hardware. The board mounts securely to the wall with lock fasteners that screw directly into the studs, removing the need for support inside the wall.

 

Header Boards are compatible with the following hardware styles: Classic, Aero, Prop, Mini, Hammered Flat Track hardware, and Hex Bar and Swiss Rod Architectural hardware. The Header Board supports doors up to 400 lbs. with ease. You can even match your Header Board to your door’s wood species!

 

Each Header Board is shipped ready to install, complete with all the hardware and instructions needed for installation.

Header Board Installation

Tools Needed:

 

• Pencil          

• Level            

• Power Drill

• 1/4" Drill Bit

• Tape Measure

• 5/6" Hex Driver

• Stud Finder

1. Locate and mark studs in your installation location.

 

2. Mark where you would like the door edge to be when the door is closed. Add 1.5” to that to ind the board edge location.

 

3. Find your horizontal “drill line”. This can be igured by measuring your door height + 2”. This will leave a 1/2” gap under the door, the drill line calculation can be adjusted accordingly.

 

4. From your board edge mark, measure to the center of each stud marked in step 1 and mark your board’s corresponding location along the center drill line. This step keeps your mounting screws hidden behind your track.

 

5. Predrill your board at the stud locations with a ¼” drill bit.

 

6. Hold your board up on the wall, align the end marks, and drill line. Be sure to use a level to install the board. Sliding doors that are not level will only want to stay open or closed. Using your 5/16” driver, install your board with the provided screws. We recommend an impact driver or power drill for this process.

Structural Support

Installation Steps in this Section

1. Check the top of door clearance
2. Check structural support
3. Check door to wall clearance
4. Assemble the door(s)
5. Mounting the track for a single door
6. Mounting the tracks for bi-parting doors

Tools Required

1. Check Top of Door Clearance

Before mounting the track, measure and check there will be sufficient clearance for the hanger. The table above shows the minimum clearance needed between the top of the door and the ceiling line.

2. Check Structural Support

If there is not adequate support (i.e., blocking or head casing) for the weight and movement of the door(s), then you must add structural support before attaching the track(s) and door(s) to the wall. Follow these steps to add structural support to an unfinished or finished wall.

Unfinished Wall

1. Determine which direction you wish to open the door and add or install structural support in that direction.


2. Check the length of the track(s) and determine the number of blocks you will need. Keep in mind the suggested door-to-frame overlap of 1” per side for doors up to 54” and 2” overlap per side for larger door sizes.

 

3. Cut the 2x6 block(s) to the correct length(s) between the wall studs.

 

4. Place the blocking at the appropriate height. Note: Add 2” to the height of the door; this is the ideal center of the block in.

 

5. Position the wide face of the blocking so it is flush with the front surface of the wall studs.

 

6. Securely fasten the blocking to the wall studs.

Finished Wall

Important! The maximum door weight rating for attaching a door to head casings alone with no wall blocking is 75 lb. The head casing must be a least 1” thick, and hardwood such as oak or poplar is recommended. We also recommend that you paint or stain the head casing before attaching it to the wall. See our Header Board on page 4 for the easiest application to a finished wall. *see unfinished wall section for installing structural support for heavier doors.

 

 

1. Determine which direction you wish to open the door and follow thedirections below.

 

2. Check the length of the rail(s) and cut the head casing to the desired length.

Note: The size of the head casing can be oversize if desired.

 

3. Using a stud-finder, find and lightly mark the location of the wall studs.

 

4. Place and level the head casing.

 

5. Securely fasten the head casing to the wall studs at the marked locations.

3. Check Door to Wall Clearance

Important! All hanger styles except Aero require a minimum clearance of 3/8” between the door and wall / existing molding. See the table below for typical standoff arrangements. Recess the bolt heads, or use standoff extensions to achieve the necessary clearance.

Door to Wall Clearance

Door Thickness Tools
- Up to 1 3/4" - 1 1/8" standoff base
- From 2" to 2 1/4" - Standoff base plus 1/2" extension

 

*Note: Maximum total standoff depth of 1-7/8” to maintain door weight rating.

Assembling the Door

Important! Each hardware style is rated to handle a maximum door weight. Do not attach a door that exceeds the weight capacity of the hardware.

Track Type Maximum Door
Weight (lb)
Classic 400
Aero 150

 

Cut the T-Guide Slot (Skip If Using Recommended C-Guide)

Bottom guides keep the door from swinging in and out. We offer three bottom guide styles, the T-Guide, C-Guide, and the

Wall Mounted Stay Roller. Of the three guides, only the T-Guide requires door preparation. Follow these steps to cut the slot for the T-Guide:

 

1. Securely clamp the door.

 

2. Using a router with 1/4” slot cutter, cut a slot that is 5/16” wide by 1/2”deep. Several passes of the router will be necessary. 

Attaching the Hangers

There are multiple types of hangers for the flat track system. All of them, except Aero, require mounting holes drilled through the door. For Classic, drill a 3/8th clearance hole into the side.

 

Important! Do not drill side mounting holes if you have Aero hardware. Classic, Prop, Hammered, and Horseshoe hangers are mounted on the front (outside face) of the door.

 

NOTE: If you ordered the hanger kit at the same time as your door, the door will be pre-drilled for the hardware unless specified otherwise during the sign-off process.

Attaching Hangers to the Door

1. Place the hanger, with a 2 1/2” spacer set into the groove of the wheel, ontop of the door. Note: You can use stiff cardboard if needed.

 

2. Position the hanger at the desired distance in from the outside edge of the door. Note: Two inches (2”) is the recommended distance from the outside edge of the hanger and outside edge of the door for all hangers.

 

3. Place a square against the hanger and square the hanger to the door.

 

4. Mark the hole positions.

 

5. Setup your power tool with the correct drill bit.

 

6. Drill a pilot hole through the face of the door.

 

7. Drill the clearance hole.

 

8. Place the hanger over the mounting holes and square it to the door.

 

9. Insert the correct hex bolts and washers from the back of the door.

Examples of Attaching The Hanger

Classic Hanger

Attaching Aero Hangers

Aero hangers can be mounted on the top of the door (non-mortised) or recessed in a pocket (mortised). For this reason, if you order the Aero hardware kit at the same time as your door, the door will be mortised for recessed installation unless specified otherwise during the sign-off process. Note: If you choose to mount the hanger on the top of the door without a pocket, add 3/16” to the track mounting height.

 

Follow the steps below to create and attach the hangers in a recessed pocket. Skip to step 3 if your door is already mortised.

 

1. Determine the desired distance in from the outside edge of the door.

Note: Two (2”) inches is the recommended distance from the outer edge of the hanger strap and the outside edge of the door.

 

2. For regular Aero, layout and cut a pocket that is 1 1/8” wide and a minimum 4 1/2” long.

Note: You will need to cut, or chisel, clearance for the hanger strap.

 

3. After ensuring the hangers are aligned and level, drill diameter pilot holes for the screws.

 

Soft Stop

Upgrade to Soft Stop (Sold Seperately)

No more slamming doors! Meet the revolutionary new Soft Stop 2.0 system. Here to civilize your sliding barn door hardware and provide a clean, soft close. Inspired by the effortless movement seen in our range of Hardware products, the Soft Stop mechanism will gently, quietly, and smoothly assist your sliding door to its final open or closed position. Soft Stops are sold separately. Soft Stop should be attached to the track before attaching the track to the wall or ledger board. Soft Stops are intended for regular, moderate use. Do not use excessive force when operating your sliding barn door.

Parts and Installation

Note: 1/8" Spacers are only needed for tracks with more than 4 holes.

Step 1.

Attach the soft stop to the bracket.

Step 2.

Attach the soft stop and bracket to the track system.

Step 3.

Attach the track to the wall or ledger board.

 

Hang the door and move it to the end of the track or desired position.

 

Attach the trigger between the tabs of the actuator. Adjust the trigger height if needed.

 

Mounting a Single Door

Follow these steps to mount the track for a single door:

1. To locate the position of the first mounting hole on the track:

    a. Mark where the closed position of the door will be and measure 1 1/8” in from this point.

    b. Mark the location of the first mounting hole.

    c. Calculate the distance from the floor to the track mounting holes. Mark the position for the first mounting hole.

    d. Snap a level guideline as a guide for your remaining holes.

Track Mounting Hole Calculation (From Floor)

2. You can mount the track with, or without, Drywall Anti-crush Rings:

 

If you are mounting the track without Drywall Anti-crush Rings:
    a. Pre-drill 1/8” diameter pilot hole for the first mounting hole.
    b. Drill a 3/8” diameter hole for the first mounting bolt.

 

If you are mounting the track with Drywall Anti-crush Rings:
With proper blocking behind the drywall, you can mount the track(s) on top of the drywall or use Drywall Anti-crush Rings. Note: The optional Anti-crush Rings come in 1/2” and 5/8” thickness.

 

    a. Use a 1 1/4” spade/paddle bit and drill a clean hole through thedrywall until you reach the blocking.
    b. Insert the Drywall Anti-crush Ring (sold separately).
    c. Pre-drill 1/8” diameter pilot hole for the first mounting hole.
    d. Drill a 3/8” diameter hole for the first mounting bolt.

3. Hold the track to the wall. Loosely screw the track in place.

 

4. Level the track and mark the remaining mounting hole locations along with your level line guide. Note: If multiple tracks (i.e., 10 ft., 12 ft., 14 ft. kits) are being installed for a single door, then you may use a Splice Plate to connect the tracks.

 

5. Repeat step 2 on the remaining mounting holes.

 

6. On the first mounting hole, remove the track. Place a Standoff (and extensions, lip pointing down into the standoff base, if using) behind the track and place an End Stop on the track. Note: Depending on your installation, you may have a Fixed End Stop or an Adjustable End Stop.


If you are attaching a Fixed End Stop:
   

    a. Place an End Stop over the mounting hole (with the cushion padfacing the center of the track).
    b. Loosely screw the Lag Screw into the wall.
    c. On the opposite end mounting hole, place a Standoff (and extensions, if using) behind the track and an End Stop on the            front of the track.
    d. Place a Standoff behind each of the remaining mounting holes and securely screw the track to the wall.

 

If you are attaching an Adjustable End Stop:
Important! If your installation requires Adjustable End Stops, they must first be placed at their proper location on the track before attaching the track to the wall.


    a. Loosen the set screws with the Allen wrench provided.
    b. Slide the Adjustable End Stop on track (with the cushion pad facingthe center of the track).
    c. Place a Standoff behind each of the remaining mounting holes andscrew the track to the wall.
    d. Hang the door(s).
    e. Adjust the End Stops to the desired final position, and securely tightenwith the Allen wrench.

Attaching the Door

To attach the door to the track:

1.  Lift the door and place the track into the hanger wheel’s grooves.
2. Move the door from end to end to check how the door slides.

Door Guide Installation

This section provides installation instruction for the following door guides: T-Guide, C-Guide (optional), Wall Mounted Stay Roller (optional), IndustrialFloor Mounted Stay Roller (Optional)

How to install a T-Guide, C-Guide, or Wall Mounted Stay Roller:


1. Plumb and block the door, so it is square to the floor.

 

2. Determine how wide the door overlap is (minimum 1”). Note: The door overlap is the distance between the leading edge of the door when fully open and the trailing edge of the door when fully closed.

 

3. Mark the centerline of the overlap.

 

4. Place the guide and slide it to the centerline of the overlap and mark the base’s edges.

 

5. Remove the door from the track.

 

6. Re-align the guide to the base markings. Pre-drill and install the guide.

 

7. Put the door back on the track and slide it to test. If necessary, adjust the guide so it is square to the door.

 

Install Anti-Jump Disc

WARNING! Lack of or improperly installed Anti-jump Disc may result in the door coming off the track and cause severe injury or death. Installation of Anti-jump Disks are required for the safe operation of this hardware. Anti-jump Discs keep the door securely attached to the track.

 

To install the Anti-jump Disc on all hardware models:

 

1. Locate the screw for the Anti-jump Disc 3/8” of an inch in from the door’sfront edge - between the hanger and outside edge of the door.

 

2. Drill a pilot hole for the screw.

 

3. Place the Anti-jump Disc on the top of the door and screw in place.

 

4. Repeat steps 1 through 3 for the remaining disc.

 

Product Care

Powder Coated Finishes

If damage to a powder coated finish occurs during installation, apply touch-up paint(not included, available for purchase).

 

Raw Steel

An attractive surface rust may develop on raw steel in humid environments. Surface rust does not affect the structural integrity of the hardware. If this appearance is not desired, remove rust deposits using a ScotchBrite™ pad and then apply wax, such
as Johnson® Paste Finish Wax. After letting the wax sit, buff with a lint-free cloth.

 

Brushed Stainless Steel

 

   • Use a Scotch-Brite™ pad to buff out minor scratches and imperfections.
   •
Periodically check the hardware for loose fasteners. Verify fasteners are secure.
   •
Keep the track and wheels free of dust and debris. Periodically wipe the track with a lint-free cloth dampened with                        water, a household stainless steel cleaner, or a silicone spray.

Warranty

REALCRAFT HARDWARE WARRANTY
Hardware manufactured by Real Carriage Door & Sliding Hardware (hereafter referred to as “Real”) is warranted to be free from defects in material and craft under intended use for a period of 2 years from the date of purchase by the original owner. This warranty does not cover finishes. Hardware sold by RealCraft but manufactured by others will be covered under the manufacturer’s warranty. If RealCraft determines that any hardware is defective, RealCraft will, at its option, repair or replace the defective part(s). Under no circumstances, RealCraft is liable for indirect or consequential damages of any kind. RealCraft will not be liable nor assume responsibility for damage or operational failures caused by supporting structures, surrounding structures, and/or equipment. RealCraft is not responsible if the hardware is overloaded beyond the manufacturer’s
rated capacity or improperly used in an application beyond the manufacturer’s intended or recommended use, nor is RealCraft liable for external causes such as abuse or acts of Nature. Periodic maintenance and adjustments are the responsibility of the owner. RealCraft will not cover maintenance and/or adjustments or any services. Any hardware that has been modified voids all
warranties. RealCraft will assume no liability for any labor charges relative to the removal or reinstallation of any product.

 

WARP WARRANTY
Definition: “Warp” refers to a variation within the plane of the door itself. Warp does not refer to the door in relation to the frame or jamb in which it is hung.

 

Allowable Tolerance: Pursuant to WDMA I.S.6A, the allowable tolerance for 1-3/4” (and thicker) doors is 1/4” maximum in any 3’6” x 6’8” section.
Action on any claim for warp may be deferred for up to one year after project completion to permit doors to acclimate to temperature and humidity conditions. The deferral period does not count against the warranty period.

 

REAL BARN DOOR KIT WARRANTY
Real Barn Door Kits (hereafter referred to as RBDK) manufactured by RealCraft is warranted to be free from defects in material and craft under intended use for 1 (one) year from the date of purchase by the original owner. Nicks, scratches, splinters, and rough spots are not considered defects and are inherent in a natural product. This warranty shall not extend or cover exterior
uses of the RBDK. This warranty shall not extend or cover non-sliding applications of the RBDK. Finishes, whether applied by RealCraft or the original owner, are not covered in this warranty. The RBDK must be adequately sealed on all sides with a high-quality sealant or primer and finish paint within 7 (seven) days of receiving the kit. This warranty shall not extend to or cover
any damages or claims for defects if the RBDK is not sealed and/or painted within the specified period. Should the RBDK be found defective as determined by RealCraft or its representatives (e.g., warp-age, structural cracks, etc.), RealCraft will replace or repair said part(s). RealCraft will not be liable for applying a finish to replacement parts. Maintenance and adjustments are the
owner’s responsibility. RealCraft will not reimburse for any maintenance services, nor will Real assume liability for any labor charges relative to the removal or re-installation of replacement part(s). Any door that has been modified beyond its intended use voids all warranties.

 

NATURAL PRODUCT WARRANTY
As wood is a material with natural properties and inherent characteristics, the following
are not considered defects:


1.  Knots (filled or unfilled) in Rustic, Reclaimed or so-called “Knotty” wood doors, or doors over 2-1/4” in thickness.

 

2. Natural color, texture, and density variances in any species

 

3. Nicks, scratches, splinters, tight knots (smaller than a quarter), or “wooly” areas in some hardwoods.

 

4. Superficial surface checks up to 3/64” in width

 

WARRANTY

Door(s) manufactured by RealCraft are warranted to be free from defects in material and workmanship under intended use for a period of 1 year from the date of purchase by the original owner. Hardware manufactured by RealCraft are warranted to be free from defects in material and workmanship under intended use for a period of 2 years from the date of purchase by the original owner. Please see full barn door warranty for details.