1. Introduction
This manual provides comprehensive instructions for the installation, operation, and maintenance of your ZEKOO 4 FT Bypass Sliding Barn Door Hardware Kit. Please read this manual thoroughly before beginning installation to ensure proper setup and safe operation. Retain this manual for future reference.
This kit is designed for double wooden doors, featuring a single track bypass system suitable for low ceiling applications. It includes all necessary hardware for mounting two doors to slide past each other on a single rail.
Image 1.1: Installed ZEKOO 4 FT Bypass Sliding Barn Door Hardware Kit. This image shows the complete hardware system with two wooden barn doors installed, demonstrating the bypass functionality.
2. Package Contents
Verify that all components listed below are present and undamaged before proceeding with installation. If any parts are missing or damaged, contact ZEKOO customer service for assistance.
- 1 x 4FT Rail (Track)
- 3 x Spacers
- 4 x Rollers (Hangers)
- 4 x Door Stoppers
- 4 x Anti-jump Pads
- 2 x Floor Guides
- 1 x Step-By-Step Installation Manual (PDF available online: Installation Manual PDF)
- Small accessories (screws, bolts, etc.)
Note: Doors are not included with this hardware kit.
3. Specifications and Requirements
| Feature | Detail |
|---|---|
| Brand | ZEKOO |
| Model Number | GCM5161 |
| Track Length | 4 Feet (48 inches) |
| Material | Carbon Steel (Black electrostatic sprayed finish) |
| Door Thickness Compatibility | 1-3/8" to 1-3/4" |
| Maximum Door Weight | 230 lbs per door |
| Minimum Ceiling Clearance | 6 inches (from top of door to ceiling) |
| Roller Material | Nylon wheels with Gcr15 steel bearings |
| Assembly Required | Yes |
Door Sizing Guidelines:
- For proper coverage, each door panel width should be 6 inches wider than half of the opening width.
- The total track length is typically the opening width plus 1 foot.
Image 3.1: Sizing and Clearance Diagram. This image illustrates the recommended track length, maximum door panel width, and minimum ceiling clearance (6 inches) for the bypass system. It also shows the door weight limit of 230 lbs.
Image 3.2: Hardware Dimensions. This image provides detailed measurements for various components of the hardware kit, including hanger dimensions and spacing from the wall.
4. Setup and Installation
Installation requires careful measurement and adherence to safety guidelines. It is recommended to have two people for installation. Refer to the included step-by-step installation manual for detailed diagrams and instructions. A digital version is available here.
4.1 Tools Required (Not Included):
- Measuring Tape
- Pencil
- Level
- Drill
- Drill Bits (appropriate for wood and masonry, if applicable)
- Wrench/Socket Set
- Stud Finder (essential for secure mounting)
- Screwdriver
4.2 Pre-Installation Checks:
- Wall Structure: Ensure the wall where the track will be mounted is structurally sound and can support the weight of the doors and hardware. Locate wall studs using a stud finder. If studs do not align with pre-drilled holes, a header board (1x4 or similar) securely fastened to studs is recommended.
- Door Thickness: Confirm your doors are between 1-3/8" and 1-3/4" thick. Doors outside this range may not function correctly.
- Ceiling Clearance: Verify at least 6 inches of clearance above the top of your door opening to accommodate the hardware.
- Door Overlap: Account for door overlap. Each door should be wider than half the opening width to ensure full coverage when closed.
4.3 Key Installation Steps (Summary - Refer to PDF for full details):
- Mark Track Position: Measure and mark the desired height for the track, ensuring sufficient clearance above the door opening. Use a level to ensure the line is perfectly horizontal.
- Drill Pilot Holes: Drill pilot holes for the track mounting bolts. If mounting into studs, use appropriate wood drill bits. If mounting into drywall without studs, use heavy-duty anchors (not always included, and often less reliable than stud mounting or a header board).
- Mount Track: Secure the track to the wall using the provided spacers and bolts. Ensure the track is firmly attached and level.
- Install Rollers on Doors: Attach the rollers (hangers) to the top edge of each door. Pay attention to the orientation and spacing as per the manual. Ensure bolts are tightened securely.
- Hang Doors: Carefully lift and hang the doors onto the track rollers.
- Install Door Stoppers: Position and secure the door stoppers at the ends of the track to prevent doors from rolling off. Adjust their position to control the door's travel range.
- Install Anti-Jump Pads: Attach anti-jump pads to the top edge of the doors, above the rollers, to prevent the doors from lifting off the track.
- Install Floor Guides: Mount the floor guides to the floor directly below the door opening. These guides prevent the bottom of the doors from swinging out. The floor guides support two installation methods: for slotted doors and unslotted doors.
Image 4.1: Product Upgrades and Clearance. This image highlights the reduced gap between doors (by 3/4" compared to double track bypass) and the minimal 6" ceiling clearance required, making it suitable for smaller spaces.
Image 4.2: Design Updates. This image details the anti-jumper mechanism designed to prevent doors from lifting off the track, and an aesthetic improvement eliminating visible "dissonance" holes.
Image 4.3: Floor Guide Installation Options. This image demonstrates how the floor guide can be installed for both doors with a bottom slot and doors without a bottom slot.
5. Operation
Once installed, the bypass barn doors operate by sliding smoothly along the single track. Gently push or pull the doors to open or close them. The nylon wheels and Gcr15 steel bearings are designed for quiet and fluid movement.
Image 5.1: Doors in Open Position. This image shows the bypass barn doors fully open, demonstrating how they slide to reveal the space behind them.
6. Maintenance
Regular maintenance ensures the longevity and smooth operation of your barn door hardware kit.
- Cleaning: Wipe the track and rollers periodically with a soft, damp cloth to remove dust and debris. Avoid abrasive cleaners.
- Lubrication: The roller bearings are pre-lubricated. If movement becomes stiff over time, a small amount of silicone-based lubricant can be applied to the roller axles. Avoid oil-based lubricants that can attract dust.
- Hardware Check: Periodically inspect all bolts and screws for tightness. Re-tighten any loose fasteners to prevent sagging or instability.
- Floor Guides: Keep floor guides free of debris to ensure smooth door movement.
Image 6.1: Core Parts - Roller Bearings. This image provides an exploded view of the roller assembly, emphasizing the dowel design for secure fit and the high-purity Gcr15 steel lubricated bearings, tested for over 160,000 cycles for smooth and quiet sliding.
7. Troubleshooting
If you encounter issues with your barn door hardware, refer to the following common problems and solutions:
| Problem | Possible Cause | Solution |
|---|---|---|
| Doors do not slide smoothly or are stiff. |
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| Doors lift off the track. |
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| Doors hit the wall or each other. |
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| Gap between doors when closed. |
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8. Warranty and Support
ZEKOO is committed to product quality and customer satisfaction. If you have any questions, require replacement parts, or experience issues with your hardware kit, please contact ZEKOO customer service. We aim to respond to inquiries within 24 hours.
For missing or broken parts, replacements will be sent promptly.
Contact Information: Refer to your purchase documentation or the ZEKOO official website for the most current customer service contact details.
