johnson 1500HD Series Pocket Door Frame Instructions

johnson 1500HD Series Pocket Door Frame

Specifications:

• Product Name: 1500HD Series Pocket Door Frame
• Door Compatibility: 1″ (25mm) to 1-3/4″ (45mm) thick doors up to 200 lbs. (90 kgs)
• Construction: Made for 2×4 stud walls

Product Usage Instructions

• Construct Rough Opening
  Header must be square, plumb with studs, and level. The minimum height is 84 1/2″ (2.14m) and width is 2 times the door width plus 1″ (25mm).

• Measure and Mark
  Measure up from the finished floor to 80-3/4″ (2.05m) or from the sub-floor to 81-1/2″ (2.07m) for door clearance. Mark each rough stud and drive a flat headnail on the center, protruding 1/8″ (3mm).

• Install Frame Header End Plates
  Slip slots in Frame Header End Plates over nails in rough studs, level the header, set nails, and drive nails through the remaining holes in end plates.

FAQ:

• Q: What door sizes are compatible with the 1500HD Series Pocket Door Frame?
  A: The frame is compatible with doors ranging from 1-28″ to 1-36″ wide and 80″ high. For converging doors, two frames and the 1555 Converging Door Kit are required.

• Q: How should I adjust the installation for doors of different heights?
  A: If the door is shorter than 80″ (2m), lower the header and cut the bottom ends of Split Studs. If the door is taller, order longer Split Studs and raise the header.

1500HD SERIES POCKET DOOR FRAME
1500HD MADE FOR 2″ X 4″ STUD WALLS

For 1″ (25mm) to 1-3/4″ (45mm) doors to 200 lbs. (90 kgs).

1500HD SERIES SET NUMBERS AND SIZES

• 152468HD FOR 1-28″ (710mm) X 80″ (2,03m) Door, Puerta, Porte
• 152668HD FOR 1-30″ (761mm) X 80″ (2,03m) Door, Puerta, Porte
• 152868HD FOR 1-32″ (812mm) X 80″ (2,03m) Door, Puerta, Porte
• 153068HD FOR 1- 36″ (913mm) X 80″ (2,03m) Door, Puerta, Porte

INSTALL VIDEO

CONVERGING DOORS REQUIRE TWO FRAMES AND THE 1555 CONVERGING DOOR KIT.
Frames for Doors up to 48″ (1.2m) wide and 96″ (2.44m) high are available.

USE QR CODE TO ORDER 1555

NOTE:
Instructions are for an 80″ (2,03m) door, if the door is shorter, lower the header and cut the bottom ends of Split Studs, if the door is taller than 80″ (2m), order longer Split Studs and raise the header.

Installation

1. CONSTRUCT ROUGH OPENING Header must be SQUARE and PLUMB with studs and LEVEL. Minimum Height is 84 1/2″ (2,14m) width is 2X Door width plus 1″ (25mm).

2. Measure up from the finished floor 80-3/4″ (2.05m) or from the sub-floor to 81-1/2″ (2.07m). This will give 3/4″ (19mm) to 1-1/2″ (38mm) clearance under the door. Mark each rough stud and drive a flat headnail on the center, leaving 1/8″ (3mm) protruding. (Frame header end brackets will rest on these nails).

3. Snap a chalk line on the floor even with side jambs.

4. Slip slots in Frame Header End Plates over nails in rough studs. LEVEL HEADER. Set nails and drive nails through the remaining holes in end plates. (If you have the 2/6″ (761mm) or Universal Frame and using another size door, see cutting instructions)

5. Slip fingers of the Floor Plate into Split Steel Studs as shown. Butt Split Steel Studs against header nailer and screw into place with two (2) 3/4″ (19mm) X #8 Pan Head Screws. Attach other Split Steel Studs midway in the “Pocket” opening. Plumb Split Steel Studs between chalk lines and nail to the floor. (On masonry, use industrial adhesive or Tapcon fasteners.)

6. Apply desired wall material with 1″ (25.4mm) X #6 Self-drilling drywall screws. Use seven (7) screws per Split Steel Stud.

7. Seal all edges and faces of the door panel with paint or sealing stain.

8. Fasten the 1513 Bumper on the back edge of the door 40″ (1m) from the bottom edge.

9. A. Attach door plate 1121 on top of door 2-3/4″ (70mm) from each edge with lock tab on the same side.
   B. Insert hangers 1125 into the track alternating wheel positions for even weight distribution.
   C. Mount the door by locating door plate 1121 under the adjusting bolt of the 1125 hanger. Lift the door and push the bolt into the door plate. Repeat with other hanger/door plate.

10. Install finished jambs, split header, and casing as shown. Fasten the split header on the 1121 lock lever side with screws for future door removal or adjustment. DO NOT USE JAMBS WITH DADO’S.
    Note: minimum 3/16″ (5mm) clearance between jamb and door.

11. Fasten 1550 Guides on finished split jambs at the door bottom so the door is held in the center of the opening.

Cutting Instructions for unmarked or non-standard door widths, use QR code.

• Frame Height Cutdown: Cut from the bottom of metal split studs only (the end without holes).
• Cut difference in door height: Ex. 80″ frame, 79″ door height, cut 1″ from the bottom of each split stud.

OPTIONAL ACCESSORIES

CUTTING INSTRUCTIONS

POCKET DOOR FRAME HEADER
2/6″ [762mm] and 3/0″ [914mm] Pocket Door Frames are marked for cutting to shorter standard door widths.

1. Remove the Adjustable End Bracket.
2. At the desired door size marking, cut the wood header only.
3. Turn the header over and cut the track 1-3/8″ [35mm] shorter than the header.
4. Replace the Adjustable End Bracket on the new cut end of the header.
5. Turn the Header on the side and cut the Header Trim Board ONLY at the proper mark. Remove the cut-off end and discard.
6. Turn the Header and cut the other side.

Cutting header for other than standard door width:

• Measure the door width and multiply by 2. Add 1″ (25mm).
• Mark the header and cut (Step #2). Cut track (Step #3).
• Measure door width. Add 1″ (25mm). Mark header Trim board and cut.

Cutting Instructions for unmarked frames or nonstandard door widths

1. Mark Header and Side Nailers for door size.
2. Remove the Adjustable End Bracket.
3. Cut through the WOOD part of the header only at the mark.
4. Turn the Header over and cut the Track 1-3/8″ shorter than the wood Header.
5. Replace the Adjustable End Bracket on the new cut end of the header.
6. Turn the Header on the side and cut the Side Nailer Trim Board ONLY at the mark. Remove the cut-off end and discard.
7. Repeat step #6 on the other Side Nailer Trim Board.

SPECIAL APPLICATIONS

INTERSECTING WALLS

DOOR SWEEP

TRANSOM

BI – PARTING POCKET DOOR

1555 CONVERGING DOOR KIT

FOR USE WITH TWO JOHNSON 1500, 1560, 2511, 2710 OR 2711 SERIES POCKET DOOR FRAMES

1555PPK3 CONVERGING DOOR KIT
For joining two Johnson 1500, 1560, 2511, 2710, or 2711 Pocket Door Frames.

• Remove and discard end plates from the “door opening” end of each header.
• Cut 7/8″ (22mm) from the length of each header (wood part only) where discarded end plates had been located. Cut ends square to keep the header straight when joined.
• Butt cut ends together and insert the “U” channel, aligning the cut ends of headers with the center mark stamped in the channel. Using the channel as a guide, drill two 3/16″ (4.7mm) holes through headers at the outer channel holes. Insert screws through these holes and into the top plate on top of the header. Tighten, forming a one-piece header.
• Drill a 1/4″ (6.3mm) hole at the channel center where the header ends meet to enable the lag screw to be fastened into the rough header for increased center support.
• Insert stops into the track and leave loose until doors are hung, then tighten. Proceed with regular frame assembly instructions.

BOTTOM GUIDE SET

2041 PDF BOTTOM GUIDE SET

1. ROUT 5/16″ (8mm) X 1″ (25mm) groove in the bottom of the Door.
2. MORTISE end of Door’s front edge for 2040 Groove Cover. 1-1/8″ (28.6mm) wide X 1-1/2″ (38mm) high X 3/32″ (2.3mm) deep.
3. ATTACH 2041 Guide to floor bracket located at edge of the front pocket opening. Use a tall guide if the Frame Floor Bracket is attached to the sub-floor or a short guide when it is attached to the finished floor.
4. ATTACH 2040 Rout Groove Cover in the mortise area.

CONVERGING CORNER POCKET

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