New sliding doors to the deck.

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Project by riverguy posted 12-21-2012 10:05 PM 1928 views 3 times favorited 7 comments Add to Favorites Watch

Here’s a sliding door I did for our house in Hawaii. The photos show the ugly original aluminum doors that always left a lot of nasty hardware in the visual opening even when the doors were “fully open.” So I removed all that hardware and cased in a new frame to accommodate new doors. They are made of made of kd clear fir to compliment the woods used throughout this classic 1948-vintage plantation-style home. The doors were trimmed with mahogany for contrast. The mahogany trim also created the stops for the big piece of laminated safety glass. The glass door hangs from a heav-duty set of rollers that ride in a track that extends five feet beyond the opening. The bottom of the door is secured with an oak spline set into a groove in the bottom of the door. The spline is secured with 6 set screws so it can be slid out the end for easy hanging and removal of the heavy door. The spline then rides in a groove milled into a full-length oak threshold.

The screen door hangs from a closet-door track tucked under a valance that matches the exterior trim. As a finishing fun touch, I incorporated the outside door pull into the mahogany trim. It’s all finished with four coats of spar varnish.

The reason for the 6” wide stained-glass panel at one edge of the door was that the deck was not quite wide enough to let me slide a full-width door completely out of the opening, so I felt a decorative panel would make the project look more finished (not to mention better planned) than to have part of the door sticking into the opening.

The finished project made a huge difference in the feel of the kitchen and its openness to the outdoors.

-- Skip, Forestville, CA,

7 comments so far

View woodshaver's profile


3555 posts in 2444 days

#1 posted 12-21-2012 11:09 PM

Now that is one handsome door! I like the handel very cool !!!

-- Tony C UAW, St Augustine FL, My high school shop teacher said "You can do it"... Now I can't stop!

View a1Jim's profile


113833 posts in 2668 days

#2 posted 12-22-2012 12:14 AM

Super looking door ,very nice.

-- Custom furniture

View MedicineMan's profile


106 posts in 1558 days

#3 posted 12-22-2012 01:19 AM

Great looking doors. I hope to learn how to make a door on tracks to make a sliding screen for my den. Did you get the rollers at a box store and use an aluminum track? Yours looks sturdy and I bet it slides smoothly. Great post.

View riverguy's profile


98 posts in 1155 days

#4 posted 12-22-2012 05:51 AM

MedicineMan, the hardware I use for these kinds of doors is this Stanley BP150N-41 BP150N-41 HANGER SET # 40-5304, and the appropriate track that is sold wherever you find the above hardware. I’ve been getting it at our local well-supplied lumber yard, but on occasion I’ve seen them at HD, too. Just google the part number and you’ll find a supplier near you. The hardware is easy to install and adjust for fine-tuning the height once installed. It is also designed for easy removal of the doors, should it be required. The track is aluminum, but it is pretty heavy duty and the whole setup is rated at 200 lbs. My 5’ wide door with a huge piece of laminated safety glass weighed about 70 pounds, a guess, since I couldn’t have lifted it into place had it much heavier! The much lighter screen door is hung from regular single-roller closet door hardware, and it works just fine. Hope that helps!

-- Skip, Forestville, CA,

View Rob186's profile


23 posts in 1425 days

#5 posted 12-24-2012 01:38 AM

The door looks great i think I am going to have to give door making a try

View stormin349's profile


4 posts in 89 days

#6 posted 09-03-2015 07:51 PM

Riverguy,You did a beautiful job on those doors !!! My 6’ slider is all rotted out and I cant afford a new one,as I am disabled,live on SSI and have a 15 year old to spend every cent on for clothes,shoes, seems like he grows an inch a night…I know I can make the doors as they are 6’x3’,but my problem is I am looking for a breakdown of how Anderson or another good company puts them together so I can see what weather stripping to use and where to put it,as I don’t want to guess,and have snow in the living room,also I want to keep the heat in,I am a few miles outside of Boston,and I am sure u saw the mess of a winter we had,Blizzard,after Blizzard…I could’nt even find my car in the driveway,The snow was pilled up 40 or 50 feet high everywhere,after the front end loader were done making even more of a mess,But they really had nowhere to put the white stuff.
Would u know of a blueprint showing what weatherstripping goes where ? There are so many different types,that the more I look,the more confused I get,and I am already confused enough on my own !!
Great Job on those doors and and thank you for your time. Have a great day

-- stormin349

View riverguy's profile


98 posts in 1155 days

#7 posted 09-04-2015 02:55 AM

Stormin Norman, Thank you for your kind words about that sliding door!

You present a tough question because there are so many variables. The door you referred to, for example, was in Hawaii. In Hawaii there is absolutely no use for any kind of weatherstripping, so that door represents one extreme in the variables. Your situation appears to be close to the other end!

And then we have the design of your door itself, the frame or jamb in which it operates, and so on. My first question would be, what kind of weatherstripping does the existing door use? My second question is, how about repairing the existing door instead of building a new one? If only the bottom is rotted, that would be easier to replace than to build a whole new door.

The door you referred to, by the way, cost me about $400 to build, not including the hanging hardware.. The clear, kiln-dried, vertical-grain fir is very costly now, and just the 1/4” thick 5’ x 5’ piece of safety glass was around $250.

If you do want to build a new door and weatherstrip it in a manner different from what’s there now, I recommend taking a trip to Home Depot or better yet, a really good, old-fashioned hardware store if you’re lucky enough to have one close by, and ask to see all of their weatherstripping options that might apply to this job. At Home Depot, you could also take a look at some actual doors to see what’s used on theirs. And at the hardware store, there’s a good chance you might even find someone there who knows something about the subject. And what I always do when faced with a challenge like this is to google something like “how to weatherstrip a wood-framed sliding door,” and if that doesn’t bring you what you need, rephrase the question. I almost always score the information I need on almost any subject with this method.

I’m sorry I am not of more help here, but Hawaii spoiled me when it comes to things like weather-sealing. Every home we lived in there for our 19 years in the Islands had those drafty old louver windows (jalousies) that allow the breeze to come though unabated even when tightly closed! We had no heat of any kind and needed no A/C, either. The temperature was always nearly perfect.

So why did we ever leave? It’s all about those grandkids . . .

Best to you, and if you care to, let me know how you finally solved the problem!

Skip (riverguy)

-- Skip, Forestville, CA,

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