Industrial Style Slide Door

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Introduction: Industrial Style Slide Door

Hi

I found some plywood sheets from my workplace wood dumpster.

Those we're in good condition, so i decided to re-use them as a part of the "industrial style" slide door.

Other materials we're bought or found from a shop.

Video shows the process.

Material:

2" x 4" 8 meters.

Plywood 2 pcs. 8 x 800 x 1000mm

5 x 30mm flatbar 2000m to slide rail.

5 x 60mm flatbar 2 pcs. 250mm long for roller arms.

4 x 20mm flatbar 8 psc 100mm long for slide rail holder hooks.

Screws, nuts and bolts, washers.

"rollers" I used ones with 50mm diameter, with 8mm center hole. Those we're bought from the hw-store sailing section. Costed 5€ (dollars) each.

2mm mild steel sheet for the corners. 8 pieces 150mm x 150mm

Tools: (What i used)

Drill and drill bits. 8mm, 4mm

Circular saw

Miter saw

Angle grinder ( 1mm cut off wheel, 40 grit flap disk)

Chop saw


Step 1: Frame..

I started the making process with cutting the 2" x 4".

I wanted to make door with size 200cm x 90 cm, i cut the pieces 10cm longer, as a working allowance.

I used circular saw to make grooves to the 2" x 4", i made groove 25mm deep and 8mm wide. ( can be made with table saw too)

Plywood will be sunked to that groove.

Then i made miters, and cut the pieces to the right size.

Step 2: Continued...

Continued by cutting plywood to the right size.

Installed them inside the frame, and connected parts together with screws.

Applied layer of acrylic filler to the joints and knots.

Didn't use glue at all, because i want to get door looking "old". When there's no glue joints move and the filler cracks.

I think it looks neat after while. My intention is to apply some dark wax to the cracks after couple weeks, to get cracks more visible. (i'll update this instructable then)

Painted with matte white paint.

Step 3: Corner Brackets..

To the corner brackets i cut 8 pieces 150x 150x 2mm mild steel.

Drilled holes for screws with 4mm drill, and for the center one for the decoration with 32mm drill.

Then i cut the pieces to desired shape with angle grinder using 1mm thick cut off wheel.

Bend the parts with my diy bending brake.

You can see it here:

https://www.instructables.com/id/Sheet-Metal-Plast...

Attached the corner brackets with screws, and finished the door by sanding paint smooth and "worn".

Step 4: Hardware..

I made slide rail from 5 x 30mm flat bar. Lenght 2 meters.

I drilled 8 pieces of 6mm holes to it for the hooks that connects rail to the wall.

Roller arms are made from 5 x 60mm flat bar 2 pieces 250mm long. Two 8mm holes for connecting arms to the door. One for the roller.

8 hooks, Two 4mm holes for attaching hooks to the wall, one to connect it to slide rail.

I drilled holes for the longer pieces, i like its easier to handle workpieces that way, small pieces are difficult to clamp.

After drilling i cut pieces with chop saw.

Step 5: Bending..

Then i bend the hooks.

Simple "fishook" shape.

Roller arms are bend so that the roller comes to the center of the door, then door stays balanced and moves easily.

Made the arms by fit and shape method, without counting angles etc..

Step 6: Finished..

Rollers are attached to the arms with 8mm bolts, nylock nuts and washers.

After installing the rail to the wall, door is just lift to its place.

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    40 Comments

    On my wayyyy too long list. Great job IMHO. About the rollers, here is someone who adapted skateboard wheels:

    https://www.instructables.com/id/Make-sliding-barn-doors-using-skateboard-wheels/

    Congrats !!!

    but I have to say you went the hard way :-)

    but I know you've done it with and for pleasure

    you can buy this sliding door kits,the rail and a prefabricated door and just fit it :-) I've recently done two sliding doors with these kits and it was pretty straightforward.

    Regards from the Azores islands (Portugal)

    Thanks sousap. Can you share a link of where you get the above mentioned kits? Thanks in advance!

    this is a portuguêse brand APC

    I used the 4000 or 4500 or 5000 series, can't remembre now

    details here page 188

    our local menards.com and probably homedepot.com have hanging door kits.

    You can get the hardware by piece that's intended for barns and out-buildings, or as a kit for interior use. From what I've seen the interior kits are much more expensive, have more design constraints, and are less robust.

    He started by finding a couple pieces of scrap ply and wanted to find a use for them. That's how a lot of my best projects start! With the steel, rollers, and 2x4's, he probably spent less than 20 dollars on this, maybe 1/3 of what just a roller/hanger kit costs.

    You are absolutely right. I bought things with 20$, everything else i allready had.

    There was no kind of rails i wanted, and making them was quick and easy task. I decided it was better option for me.