ZEKOO Barn Door Hardware Kit Installation Guide
- June 4, 2024
- ZEKOO
Table of Contents
Barn Door Hardware Kit
Installation Guide
Main Components
TOOLS REQUIRED
IMPOR TANT : BEFORE YOU BEGIN
IF INSTALLING DIRECTLY INTO A NON-CONCRETE WALL, DO NOT ATTEMPT TO INSTALL THE
RAIL SOLELY TO THE DRYWALL OR ANY WALL SURFACE AS THIS MAY NOT SUPPORT THE
WEIGHT OF THE RAIL AND MOUNTED DOOR. THE RAIL MUST BE INSTALLED ONTO A PIECE
OF SOLID WOOD BLOCKING (SOLD SEPARATELY). USING MOUNTING SCREWS (ALSO SOLD
SEPARATELY) ENSURES THE SOLID WOOD BLOCK IS SECURED TO THE STRUCTURAL SURFACE.
USE A STUD FINDER WHERE NECESSARY TO LOCATE STUDS AND SECURE THEM SAFELY.
TYPICAL SOLID WOOD BLOCKING SHOULD BE 1″ X 4″ TO THE LENGTH OF THE RAIL. NOTE,
THE MAXIMUM THICKNESS OF THE DOOR MUST BE 1 3/8″. IF INSTALLED WITH THE FLOOR-
MOUNTED DOOR GUIDE, THE DOOR MUST BE MORTICED 1/4″ WIDE X 3/4″ DEEP CENTRALLY.
A SECONDARY WALL-MOUNTED DOOR GUIDE HAS ALSO BEEN PROVIDED FOR NON-MORTICED
DOOR INSTALLATION.
Step 1. Door Preparation
doors are pre-routed along the bottom and do not require door preparation.
Mortice 1/4″ wide x 3/4″ deep groove centrally to the bottom of the door for
use with the floor-mounted door guide. This will ensure smoothness of door
travel side-to-side and will prevent the door from swinging in and out.
Step 2a. Door Preparation –
Strap Installation for Bent Strap
Position each strap to the front of the door center to the stile or a minimum
of 2″ from the edge of the door. Cut a piece of cardboard 2″ high and place it
between the wheel (inner groove) and the top of the door to correctly position
the height of the straps.
Mark holes with a pencil and pre-drill 3/8″ holes, then secure them into
place. Repeat from the second strap.
Step 2b. Door Preparation –
Strap Installation for Top Mount Position each roller a minimum of 4″ from the
edge of the door.
Mark the first hole with a pencil and pre-drill 1/8″ holes, then secure it
into place. Mark the second hole with the roller in place to ensure the roller
is secure. Repeat for the second roller.
Step 3. Door Preparation –
Anti-jump block installation
Position each anti-jump block at least 1″ from the edge of the straps. Tighten
slightly to secure into place.
Step 4. CONCRETE Wall Preparation
IF INSTALLING INTO DRYWALL, PLEASE PROCEED TO STEP 7. Position the rail by
measuring up from the door height (H) + 1 3/4″ to the center of the track.
Also ensure a gap of 3/8″ at the bottom. Ensure the rail is level and leave a
minimum of 2″ from the end of the rail to the side of the opening (as shown).
If installing with an opening for 80″ standard door size, remove the top trim
and cut the side trim horizontally along the height of the opening.
Image for bent strop shown
Step 5. CONCRETE Wall Preparation
Position the rail in place ensuring that it is level, mark the holes on the
rail using a pencil, and pre-drill 5/16″ holes into the concrete.
Step 6. CONCRETE Rail Installation
When installing directly into concrete, insert using the provided anchors and
carriage bolts (with washers). Ensure to unscrew to separate the carriage bolt
and anchor to install correctly, securing a wrench. Ensure to insert both
stoppers on either side of the rail inside the first hole.
Step 7. 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. Position the solid wood blocking by measuring up from the door
height (H) – 1 3/4″ to the center of the track. Also ensure a gap of 3/8″ 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). If installing with an opening for 80″ standard door size, remove the
top trim and cut the side trim horizontally along the height of the opening.
Image for bent strap shown
Step 8. DRYWALL Wall Preparation
Position the rail on top of the wood blocking ensuring levelness, mark the
holes using a pencil, and pre-drill 5/16″ holes into the wood blocking.
Step 9. DRYWALL 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 a wrench.
Ensure to insert both stoppers on either side of the rail inside the first
hole.
Step 10. Hanging the Door
Place the assembled door onto the secured rail and tighten each anti-jump
block. Ensure all parts are operating correctly by sliding the door side-to-
side.
Step 11. Floor-Mounted Door Guide Installation
Once the door is plumb, position the floor-mounted door guide inside the
morticed door, and line up close to the opening. Slide the door side-to-side
to ensure functionality for final placement then mark holes with a pencil and
pre-drill 1/4″ holes. If drilling directly into a concrete floor, use the
provided anchors.
Step 12. OPTIONAL Track Joiner
Note: Track joiner sold separately. Designed to join (2) tracks for wider
opening applications. Align the two tracks together. Position the track joiner
on the front face of the tracks, with the lip under the bottom edge. Use the
Allen key to fasten the four screws in place.
Step 13. Stopper Installation
Slide the door closed and correct the position of both stoppers. Using the
provided Allen key, tighten into position.
Image for bent strap shown
Step 14. Fill-in Plug
If your track has 2 holes on each end, it has been prepared for kit expansion.
Ask your supplier about a track joiner (sold separately) to expand your kit.
If you do not wish to add another kit, use the plugs supplied to fill the
holes. This will complete the installation of the Barn Door Kit.
