Suggestions for a 48" wide pocket door

Does the pocket door hardware you have have a weight rating because both of your methods will result in an extremely heavy door at 48” wide, most of those kits are made for a max of 36” or for 48” a 2 door split. A solid door is going to be much lighter easier to build and less troublesome than the plywood door that has been trimmed out. Since you mentioned that you have never made a door before a good material to pratice with is 2x’s as they are inexpensive and already the right thickness and if your anything like me will destroy at first couple attempts. For these the freud door set for the router is pretty easy to learn with.

-- Potential is limited only by imagination

The hardware has a 200lb weight limit.

-- Greg D. -- the price of freedom is tolerance

I agree with Brandon, make the door with real wood. Its a great skill builder. Remember the 2 x material is only to practice on. It will not stay straight. It has the wrong moisture content. When you are ready to make the final door use kiln dried wood.

-- Jack T, John 3:16 "For God so loved the world that he gave his only Son, so that everyone who believes in him might not perish but might have eternal life."

As a remodeling contractor I deal with decisions similar to this all the time.

The design style is dictated by the overall style of the house. If it is a traditional house with frame and panel doors or a modern aesthetic with slab doors, then in each case I match it appropriately.

Or we choose door, trim, and hardware to completely change a look. To me the design is the driving force behind the decisions and then the appropriate engineering and construction can be figured out.

-- Todd A. Clippinger, Montana, http://americancraftsmanworkshop.com

You might want to think about if you want any glass in the door. I did one in my basement and used glass doors to let the light come through. Just a thought.

-- Bob K. East Northport, NY