70. TOOLS

How to Install the Mortise Roller System

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First of all: make sure these screws are tight - shown at right. They should have locktite on the threads. It's possible this did not happen at the factory.

SIZE OF THE WOOD DOOR: Dimensions on the drawing are based on a 1" overlap on the height. In other words, the door extends one inch higher than the opening. This is changeable. The width is also generally 1" wider than the opening on both sides. There is 5/16" Gap at the bottom for the bottom guide. So the height of the door shoul be 2" wider than the opening and 11/16" taller than the opening.

Typically people want to mount his system on a stud wall with drywall. See the If the drywall crushes and it will, then the hanger will tilt and the roller will hit the hanger.
   If you install two wood screws into the drywall so that the heads are flush with the drywall, then the weight of the doors and stainless steel will not crush the drywall.

1. Mark the Hanger Location.	2. Add hidden support screws
3. Drill Pilot Holes	4. Mount the Hanger

ALTERNATIVE IDEA FOR SHEET ROCK:   Possibly a better alternative would be to cut a section of closet pole or plywood and using a hole saw slightly smaller than the hanger base, cut out the drywall with the same hole saw with pilot bit removed and replace that piece of drywall with the section of closet pole or plywood which you just cut to the thickness of the drywall.
   The Rollers with safety pin require drilled track which we have done by the factory and there is no chance that the holes will line up with the studs. So you need to have blocking behind the drywall, between the studs, and you need to replace the drywall or support the hanger with screws. A hardwood ledger is nice in case you need to control the gap between door and wall to miss the baseboard for instance.
Rollers with safety pin require drilled track. We have pre-drilled track. The holes will not line up with your studs. So you need to have blocking behind the drywall.

CEMENT OR STEEL HEADER:Of course, if you are installing onto cement wall or brick, your job is actually easier.

One note: It is possible that the placement of the roller and the placement of the hanger and stop will work out to be such that the stop wants to be right where the hanger is. But it can't be there. So you need to move the roller in or out on the door or use one of our alternate stops.

Rollers with safety pin require drilled track. It's very hard to drill the holes, let alone accurately so we have pre-drilled track. The holes will not line up with your studs. So you need to have blocking behind the drywall.

The drawing shows the drywall has been replaced with wood and mudded to look like drywall. you can also use cement board over blocking.You can also screw in several screws underneath the hangers so that the heads of the screws are flush with the drywall. These screws will keep the drywall from crushing.

Of course, if you are installing onto cement wall or brick, your job is actually easier.

Installing the Hangers:
Basically what I would do is draw a line 2 11/16" above the bottom of the header assuming you want a 1" overlap on the height. The line should follow the floor and the floor should be level. If the track is not level then the door will probably roll to the low side. If the floor is not level then you will have a big gap on one side.
Install the track on the wall. Difficulty and technique depend on how long the track is. You could use a laser level or install one hanger on one end and then set the track with hangers attached and install the other screws with a level on the track. Most installers are capable of figuring this out.

Where to mortise the roller into the top of the door is more comlicated and depends on how thick your door is. If your door is 1 3/8", you might not be able to get a small gap between the door and the wall, (A).
The formula is
Door Width + Gap A = 2 1/4" with GD-02A
Door Width + Gap A = 1 7/8" with GD-03A

Once the track is installed, remove the safety pin from the roller and hang the door on the track. Replace the safety pin. Then install the floor guide to keep the door from swinging	Notch in would be 5/8" wide and 1/2" Tall
MAKE SURE THE ROLLER SCREW ON THE TOP IS TIGHT.
Finally , install the stops. The Cylindrical Stops come apart for installation and fastening.
Allen wrenches are required for this. The hieght of the door can adjusted a little with the allan set screw on the top of the roller.