By Paul Bianchina
Pocket doors - doors that slide back into a hidden cavity in the wall - are a handy solution to door installations in a variety of areas. They can free up space in a tight bathroom, block off noise from the utility room without interfering with the washer, or even be used in pairs to create an impressive entry to a den or dining room.
But when they quit working right, pocket doors can be a perplexing item to repair - it's difficult to see how to obtain any access to them. So it's helpful to understand how a pocket door is installed in the first place, because repairing one involves reversing some of those installation steps.
During the time when the wall is being framed, the pocket doorframe is installed. The frame consists of a slender box that resembles a tall, narrow crate. There is a front consisting of two vertical boards and back that's a single vertical board, with horizontal slats on both sides that connect to the front and back. On top, a long horizontal board is installed that holds a metal track, and a finished jamb leg is installed at the end of that track.
When the installation of the frame and track is complete, it takes up a space in the wall that is twice the width of the door itself. Drywall is then installed over the pocket door frame, leaving an opening in the wall that's slightly wider that the width of the door.
Next, rollers are installed on the top of the door, and the door is installed by placing it in the opening, holding it at a slight angle, and then lifting it up and hooking the rollers into the overhead track. The roller mechanisms are then adjusted to raise the door and get it plumb to the opening, ensuring smooth operation and a proper height clearance over the floor.
At this point, the door is hanging on its track but it will actually swing back and forth, like a flap over an opening. So the final step is to install a pair of trim boards vertically on each side of the opening in the frame where the door disappears into the wall. This finishes off the installation, and prevents the door from moving back and forth in the opening. With some installations, a pair of horizontal trim pieces are also installed on the top board, on either side of the track, to help conceal the track and further stabilize the door.
To remove and repair a pocket door, the first few steps need to be reversed, starting with the removal of the trim boards that lock the door in place. First, identify the two vertical trim boards, one on either side of the opening into the wall. If the boards are painted, use a utility knife to carefully score through the paint along the edges of the board. Then, use a small, stiff putty knife and work the blade between the back of the trim board and the door frame behind it. Work slowly and carefully, and create a small gap along the back of the board.
Finally, work a small, flat-bladed pry bar into the gap and gently pry the trim boards off. Keep your putty knife flat behind the pry bar as you pry with it to prevent damaging the doorframe. If necessary, remove the horizontal top trim boards alongside the track, using the same method
With the trim boards off, you can now remove the door. This is done by swinging the door through the opening until it's at about a 15 or 20 degree angle, then lifting up so that the wheels dislodge from the track - for large or heavy doors, this may be a two-person operation.
Close the door and examine the shape of the overhead track. Some types resemble an inverted U-shape, with the opening for the wheels pointing down, while other types resemble the letter C, with the opening for the wheels facing to one side. With the U-shaped track, the door can be swung to either side for removal; with the C-shaped track, you will need to swing the door so that the door bottom goes in the direction of the closed part of the "C".
From here, the repairs depend on the specific problem you are having with the door. If it is rubbing on the floor, you can adjust the rollers up to provide additional clearance - if the rollers are already adjusted all the way up, then you will need to carefully mark and cut a small portion off the bottom of the door. If you are having trouble rolling the door, the wheels may need to be simply cleaned and oiled, or you may have a wheel that is "dead" - stuck and unable to roll - in which case you will need to replace the roller mechanisms. Check with a door company or larger home center or hardware store for replacement roller assemblies - remember that the replacement parts need to be compatible with the existing track, so take your old ones along for reference.
Finally, reinstall the door in the same manner that you removed it, and then reinstall the trim pieces.
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