86-1/2" TRACK INSTALLATION GUIDE

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Stewart Crawford
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1 BARN TRACK 86-1/2" TRACK INSTALLATION GUIDE

2 READ ALL INSTRUCTIONS AND REVIEW DIAGRAMS BEFORE BEGINNING THE INSTALLATION TO GET A THOROUGH UNDERSTANDING OF THE PROCESS. BEFORE YOU BEGIN This kit comes with the 3 styles of door guides (A, B and C). If using either door guide A or C the door must be mortised (grooved) centrally, 1/4" (7 mm) wide X 3/4" (20 mm) deep. Do not mortise the door if using floor guide B. If installing directly into a non-concrete wall, do not attempt to install the track directly to the drywall or other non-structural wall surfaces, as this may not support the weight of the track and mounted door. The track must be attached to a piece of solid wood blocking (sold separately). Use a stud finder where necessary to locate studs, using mounting screws (sold separately), attach the solid wood blocking to the wall studs. PARTS LIST B(x4) C(x1) A(x2) PM6x10(x4) K (x1) L (x1) J2.5mm(x1) R4mm(x1) E M8x90(x6) D(x6) S(x6) Q(x1) F1(x1) F2(x1) F3(x1) O ST5.5x32 (x2) G1 ST4.2x35 (x 2) G2 ST3.5x19 G3 ST4.2x35 (x 2) N (x1) I (x2) H1 (x2) H2 ST3.5x32 (x 2) H3 (x 2) M M10x55 (x 4) bolts for 1-3/8 thick doors 2

3 TOOLS REQUIRED Ø10 Ø10 Ø10 Ø5.5 Ø5.5 Ø5.5 ASSEMBLY INSTRUCTIONS 1 (406mm) A or C: 86 1/2"( 2198mm ) (4 06mm ) (406m m) (406m m) (4 06mm) DRYWALL WALL PREPARATION: When installing into drywall, a piece of 1" x 4" solid wood blocking is required to be mounted to the wall before proceeding with the rail installation. H+1.7"(43mm) If installing with an 80 standard door size opening, remove the top trim and cut the side trim horizontally along the height of the opening. Floor Guide A or C (Figure 1A): "(10mm) 86 1/2"( 2198mm ) Position the solid wood blocking by measuring up from the door height (H) /16" (43mm) to the center of the track. Also ensure a gap of 6/16" (10mm) at the bottom. Lastly, ensure the solid wood blocking is level and leave a minimum of 2" from the end of the blocking to the side of the opening (as shown). (4 06mm ) (406mm) (406mm) (4 06mm) (406mm) Floor Guide B (Figure 1B): H+1.77"(45mm) Position the solid wood blocking by measuring up from the door height (H) /16" (45mm) to the center of the track. Also ensure a gap of 6/16 (10mm) at the bottom. Lastly, ensure the solid wood blocking is level and leave a minimum of 2 from the end of the blocking to the side of the opening (as shown). 0.47"(12mm) 3

4 1.57" 2 D C K/L RAIL INSTALLATION: When installing into the solid wood block and wall, insert using the provided wall screws. Align each spacer to the rail holes, inserting spacers and screws (with washers), and securing with a wrench. Ensure to insert both stoppers on either side of the rail inside the first hole. Track must be installed into wood studs, solid wood, blocking or extended head casing. S E 3 (4 0m m) (X 2) 3.5 4" (90mm ) drill out " (6 5m m) I INSTALLING HANGERS: Position hanger on the front of the door so it is parallel to the edge of the door, leaving at least 2" between the edge of the door and the hanger. Adjust vertical placement of hangers leaving 1-1/2" from the top of the door to the center of the first hanger hole. Mark hanger screw locations and repeat for the second hanger. Using a 3/8" drill bit, drill through holes on the door. For 1-3/8" doors, use 2-5/32" bolts and for 1-3/4" doors, use 2-1/2" bolts to mount the hangers as shown. 4 (X 2) A INSTALLING ANTI-JUMP DISCS: Fasten anti-jump discs to top of door by placing them at least 1" from the edge of the door. 4

5 5 2 1 HANGING THE DOOR: Place assembled door with hangers onto track. Use a level to plumb the door. Make sure all parts work properly by sliding door back and forth. After the door is plumb, position one doorstop so door overlaps opening by 1" when in the open position. Tighten doorstop once positioned correctly (do not tighten the second doorstop yet). Mark centerline of overlap and place center of Floor Guide in line. Slide the door closed and secure the Floor Guide. If securing to a concrete floor, use provided anchors. Tighten the second doorstops. Slide door all the way to ensure proper Doorstop and Floor Guide installation. 6A 6B 6C L L+ 2mm A B C G 1 G 3 30mm 25.1m m F 1 H1 7mm 20m m G 2 F 2 H2 30mm F 3 H3 7mm 20m m SECURING FLOOR GUIDES: Use an appropriate floor guide style (A, B or C) and secure as indicated in the diagram above. A mortise channel must be cut into the door for an installation using floor guides A and C. 5

6 7 STOPPER INSTALLATION: Slide the door closed and to correct position of both stoppers. Use the provided 2.5mm Allen Wrench to tighten into position. J (X 2) 8 9 (X 4) N O B INSTALLING HANDLE: Install the provided door handle to the outside of the barn door to complete the installation of the Builders Choice Barn Door Kit. HOLE COVERS: If doorstops are positioned so that Multiple Track Connecting Adapter holes are exposed, insert hole caps. 10 Q DOUBLE DOOR CONNECTOR Connector is provided for double door application only. Install as depicted. P 4MM R 2018 OrePac Building Products. All rights reserved. OP

x2 1/4 (6mm) Floor Anchor

x2 1/4 (6mm) Floor Anchor INSTALLATION GUIDE Main Components x1 Rail x5 Wall Spacer x2 Anti-jump Block x2 Straight Strap x1 Right Stopper x1 Left Stopper x5 5/16 (8mm x 60mm) Carriage Bolt x5 5/16 (8mm x25mm) Anchor x5 5/16 (8mm