Just another garage guide rail hanger project

[ryanjg117]

I've been looking for better storage options for my guide rails, and I know the Track Rack is quite popular, but I was looking for something that would (mostly) support the guide rail along its length, rather than just at the ends. I also wanted to design something that would use my existing garage door bracket installation points, not requiring drilling into the door itself.

I had some spare baltic birch plywood sitting around, so decided to use that for the backing material, along with a lip that runs along the bottom to support the guide rail on its thick side, with the splinterguard facing up. There is also a shallow lip along the top for the turn latches to mount. These hangers were longer than 8 feet, so I had to add a joint. I picked it dead square in the middle, probably not the best given there's also hardware mounted there, but I offset the joint locations of the lips and it's strong enough, especially with the center-mounted support bracket.

My favorite part about this project is the black plastic turn latches, McMaster part number 1579N12. For some reason it's really satisfying to turn these knobs up and easily access the guide rail I need. Behind these turn latches, I used steel tee nut inserts (McMaster 90975A301) and button head hex drive screws to connect them (McMaster 91255A245). I used threadlocker to keep the screw from moving when I turn the latches, and dialed in the tightness so they don't swing freely.

I used SendCutSend to laser cut some custom mounting brackets to attach the guide rail hangers to the doors.

This design is custom to my doors. I made it as wide as I could. I was elated to just BARELY be able to fit the Festool 106" guide rail. Back bracing was cut on the CNC, obviously! Happy to share 3D files or DXFs if anyone has an interest in building something similar.

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[squall_line]

How much overall weight did that add to the door?  I wonder about spring tension and an opener.

 

[ChuckM]

Good question about loading.

My neighbor runs a garage door installation and repair business, and has been advising us against putting any extra weight on the garage door, unless it's light-weight insulation material. The other thing he told us to avoid doing: leaving the garage door partially or half open.

Maybe we have very very cold winters, and cold plays a factor about the doors. Other than insulation, I add no stresses to the door.

 

[Crazyraceguy]

My OCD could not have the logos upside down, but I like the look of the carrier itself. The angled lightening pockets look very professional.
As of now, I store mine vertically, but that won't always be the case. The 2424 and 3000 rail will never fit in my garage shop that way. A horizontal solution will be in my future.

 

[ryanjg117]

How much overall weight did that add to the door?  I wonder about spring tension and an opener.

Weight was a concern, which is why I routed out about half of the backing. Each hanger is around 10 lbs without the guide rail.

Not observing any issues with the added weight, but it's probably a good idea to re-tension the torsion rod to rebalance the door. Not something I'm going to do myself.