Replies

1. 
   jackplane | Jan 31, 2005 05:53pm | #1

   Your idea has merit. I'd probably rout the groove top and bottom and epoxy in (and screw) metal flat bars, for more strength. Either way, more important is to rout top to bottom and add a spline, glue and clamp.

2. 
   mike4244 | Jan 31, 2005 05:55pm | #2

   I think your idea will work. You could use flat iron instead of wood on the bottom, this way the mortise can be shallow. Make sure the edges being joined are square and straight.It may pay to saw joined edges , then biscuit join. Use two layers of biscuits, Keep biscuits at least 1/4" from surfaces.

   mike

3. 
   Dave45 | Jan 31, 2005 06:04pm | #3

   Be really careful getting your track installed just right.  You're doubling (maybe even more than doubling) the width of most pocket doors and that will magnify the effects of any errors in the track installation.

1. 
   papasmack | Jan 31, 2005 06:33pm | #4

   Thank everyone for the response. I think I will look into using the flat metal bar as well.

1. 
   Steinmetz | Feb 01, 2005 09:14am | #5

   Pap, the previous posters gave you good advice
   IE: steel bands top and bottom.
   By using two doors spliced together,
   the center stile will be enormous and out of proportion
   with a similiar shop built door.

   Since both ends of the full sized door
   protrudes behind the stops and into the pocket,
   you might want to add 3/4' vertical banding
   to the left and right stiles?
   (Thereby allowing enough material to remove
   from the center) (Equally from each door )On such a wide pocket door, two bottom guides
   will prove troublesome. Rather a Single centered
   bottom guide is more 'Forgiving'. Use top mounted hangers,as opposed to 'Side mount',
   as they are hidden from veiw. Stein.

   Edited 2/1/2005 1:17 am ET by steinmetz

1. 
   dondownunder | Feb 01, 2005 10:13am | #6

   Stein

   I had the same thought in the begining but if the new door is made to look like two doors, eg by an obvious arise,  then proportions would be retained.

   I agree about the single guide.

   Don

1. 
   papasmack | Feb 01, 2005 06:39pm | #7

   Good thoughts. My idea is that when the door is closed, it will look like two doors so I have no problem with the center stiles coming together. I was thinking I would route a very small reveal on one door so they look as if they are still two separate doors that are tightly closed. The original door had one bottom guide, so I will stick with that. Also, I am going to use the origianal 90 year old hardware and rail. The roller mechanism is top hung, so it will be out of view.

4. 
   WillGeorge | Feb 02, 2005 06:50am | #8

   I have.. But only about 4.5 feet wide.. I used some heavy glass in frames doors.

   I just used dowels, good glue.. There about 10 years now and still works fine.

   I did, however, add more top roller assemblies and the track I stiffened up a bit...