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I am in the process of installing mine today . Shown in the pic is the 5' X 7' left side of the two panels . fitting in opening on a Rollup 7 X10 clopay door , Fabricated in African Mahogany and Cedar .I took a few pics along the way , if it comes out respectable , I will post them.The pics show a mock up of the hinge winges in masonite, I Just bent up the Fake hinge wings in metal plate , came out nice, also epoxied some nuts washer and bolt threads . I know you don't have exposed nuts on a real hinge for security , but they just looked so nice, as opposed to a carriage bolt head . Will get a pic of hinge plates , and post pics of process from beginning , later today . I keep having to adjust springs when adding the sections , will order new Springs when i get through today and weigh total door with hardware , after dealing tension . Got a feeling I will be opening the door manually for the wifey till the new springs come.
Wood Gas Engineering Urban design Rolling
 

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Discussion Starter · #3 ·
Got side tracked today, but got the faux doors installed . Tightening the springs 3 times before finally
to heavy on the next to last panel . The wood came in weighing at 116 lbs . putting the hinge plates , and latch bolt on then doing the final weighing for torsion spring upgrade.
Plant Property Building Lighting Wood
 

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Discussion Starter · #5 ·
Had a time getting the 8 panels to line up . The wife backed through the door with the BMW , forgot to roll it up.
I pulled it back in with a come along, but never got it exactly right.
 

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Discussion Starter · #9 ·
the panels weighed in at 114 LBS, the hardware another 35lbs. Still got the locking bolt/Bar to put on in the middle of doors. Disconnected springs , weighed door, right at 305. In the process of ordering 330 lb springs so I can add weight to tune out balance. Got a block and tackle pulling the door open till I get the new torsion springs.
The hinge plate were 12g a metal cut on bandsaw , heated and bent . Nuts and washers were epoxied together , with a small washer in them. Screwed on, and added the 1" pieces of threaded rod I cut , to cover screws inside nuts.
 

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Discussion Starter · #15 ·
I ended up with 330 lbs extra longevity HD springs, think I remember th being about. 35" as opposed to the original
21" springs . Weigh your door springs unloaded before installing anything on them
Because a regular scale will work . My balance freight scale only went to 300, so it through me for a loop. Had to dismantle hurricane bars on back to see when weight went down to make sure it was right at 300 for sure. Always get your springs with extra weight added on , you can always add weight to balance out cantilever action. To small and they are useless. I did know the weight of the added wood and hardware was 134lb, but never weighed the door only before hand . Once you realize that you have to be about dead nuts on weight, you won't run into any problems . Too much spring shuts down the operator as fast as to much weight , seems like there is about maybe a 10 lb allowance . DDM will ask for the numbers on the cable pulley and the number on the spring cone, radius on curve track , good to go from there .
 

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Discussion Starter · #17 ·
You can see in pics of the back , I put in plywood backing
So I could shoot the panels up with finish gun . The other plywood is covering hole for lights I took out. Tossing up ,making some curved frames and putting in some colorful art glass.
 

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I'm sorry if it's been said already, but where do you buy the hardware, metal frame and rails for it? Was it online? I'm still new to Woodworking and metal but this is definitely something I am going to want to do in the future when we build a house. Hopefully by then I'll be comfortable enough to tackle a project like this
 
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