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.
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
Angle grinder ( 1mm cut off wheel, 40 grit flap disk)
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:
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.
Participated in the
Woodworking Contest 2017