Advice Request for Large Pocket Doors

[sheperd80]

Hey folks, im gonna be building some doors for a customer soon and could use some advice. The existing pair are solid 4' wide pocket doors (8' opening) standard height and thickness. She wants them replaced with glass panel doors. As much glass as possible.

Ive never seen a door that large with a basic frame and one giant glass panel. Should i be dividing the glass into multiple panels with cross rails and mullions between? She would definitely prefer one glass panel but im a little hesitant Whatever route i go ill probably use a 6" rails and stiles with some nice deep mortise and tenons ( i dont have a DF700 yet :-/ )

The other snag is, id like to use the existing track so i dont have to do surgery on her house. Its a nice sturdy T-track in good shape, and does well with the existing doors which are quite heavy.

Any input here would be greatly appreciated.

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[tjbnwi]

How thick are the existing doors?

The glass will have to be tempered, the door will be pretty heavy.

Tom

 

[Discap]

I have several exterior doors that are one piece glass, double pane actually. The stiles are 5" lower rail is probably 10" upper body s 5".

Bill

 

[Naildrivingman]

How thick are the existing doors?

The glass will have to be tempered, the door will be pretty heavy.

Tom

I second this.

You may not have any choice as to do surgery if the existing hardware cannot bear the new doors.  Easy solution would be to weigh the existing door(s) and then research the weight of the glass (glass vendor should have that info).  Suffice to say, it’s gonna be heavy.

Additionally, tempered glass scratches very easily.  May not be ideal for this application.  Depending on your local codes, you may be able to use laminated glass (windshield).

This sound like a challenging project. Keep us informed.

 

[sheperd80]

How thick are the existing doors?

The glass will have to be tempered, the door will be pretty heavy.

Tom

I havent been to her house since the request, but from memory i wanna say theyre 1-3/4" thick.

I believe tempered is required for anything less than 2' off the ground here. These are interior doors but i think that still applies.

One online glass weight calculator said the panels will be about 55 lbs each, another said 48 lbs. Theres no option for tempered when calculating the weight. Is tempered heavier?

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[Naildrivingman]

How thick are the existing doors?

The glass will have to be tempered, the door will be pretty heavy.

Tom

I havent been to her house since the request, but from memory i wanna say theyre 1-3/4" thick.

I believe tempered is required for anything less than 2' off the ground here. These are interior doors but i think that still applies.

One online glass weight calculator said the panels will be about 55 lbs each, another said 48 lbs. Theres no option for tempered when calculating the weight. Is tempered heavier?

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I can’t comment on the weight.

You are correct that “safety” glass will be required. It is required in all doors and certain windows.  I suggested laminated glass as a potential option to minimize scratching.

It sounds like a fun project. I hope it works for you.

 

[Oldwood]

Tempering does not change the weight calculation but laminated will increase the weight a lot. Where I work it is a square foot measure that requires tempered but we always use tempered in doors regardless of the size of the glass. I think if you are careful with your mortise and tenon work and insure a good glue joint you won't have any problems.

The fact that your doors are hung from the top rather than the side eliminates most of the racking forces on the joints.

 

[tjbnwi]

As long as you do not go overboard with "as much glass as possible" this will be an easy build.

Verify the hardware will take the weight.

Tempered glass is not heavier than regular glass.

If the doors are 1-3/4" thick you have plenty pf material for the M&T.

The door pictured is 3/0 6/8 1-3/4" thick. Fabricated using the DF 700.

Tom

 

[sheperd80]

Ok ive never used laminated glass before but i'll look into that vs tempered.

That door looks great Tom. Looks like qswo and a Stickley finish to my amateur eye. Beautiful work.

Thanks for all the input folks! Looking foward to this. I havent built many doors so this will be a good one for me.

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