1. Product Overview
This manual provides instructions for the assembly, installation, operation, and maintenance of your Calhome K Series DIY Wood Bi-Fold Barn Door with Sliding Hardware Kit. This product is designed to offer a space-saving and functional door solution for various interior applications. The door is constructed from 100% solid natural knotty pine wood and includes a complete sliding hardware kit.
Image 1.1: Assembled Calhome K Series Cherry Red Bi-Fold Barn Door.
2. Safety Instructions
- Always wear appropriate personal protective equipment (PPE) such as gloves and safety glasses during assembly and installation.
- Ensure the installation surface (wall) is structurally sound and capable of supporting the weight of the door and hardware.
- It is recommended that two people perform the assembly and installation due to the size and weight of the door components.
- Keep all small parts and hardware out of reach of children.
- Follow all local building codes and regulations for door installation.
3. Package Contents
Verify that all components are present and undamaged before beginning assembly. If any parts are missing or damaged, contact customer support.
Image 3.1: Door planks, screws, and packaging as received.
Image 3.2: Complete sliding hardware kit components.
3.1. Door Components
- Pre-cut wood planks (quantity varies by door width)
- Horizontal and diagonal support planks
- Assembly screws
3.2. Hardware Kit Components
- Sliding track rail
- Rollers/Hangers (2 sets)
- Floor guides
- Door stoppers
- Anti-jump pads
- Wall spacers and lag bolts
- Bi-fold hinges (multiple sets)
- Fasteners and tools for assembly
4. Setup and Assembly
The door comes as a DIY kit requiring assembly of the wood panels and installation of the sliding hardware. Refer to the detailed diagram below for plank arrangement and screw placement.
Image 4.1: Door panel assembly diagram.
4.1. Door Panel Assembly
- Identify Planks: Lay out all wood planks and identify them according to the numbering in Image 4.1 (e.g., planks 1, 2, 3, 4, 5, 6, 7). Note that the quantity of plank 2 may vary based on door width.
- Connect Vertical Planks: Utilize the tongue and groove profile of the planks to connect the vertical panels securely. Ensure they sit flush against each other.
- Attach Horizontal and Diagonal Supports: Position the horizontal (e.g., plank 5) and diagonal (e.g., plank 6) support planks as shown in the diagram. The pre-drilled holes are designed for precise alignment.
- Secure with Screws: Use the provided ST4.2x20mm screws to fasten the support planks to the main vertical panels. Ensure screws are driven straight and do not overtighten to avoid splitting the wood.
- Repeat for Second Door Leaf: Assemble the second door leaf following the same steps.
- Install Bi-Fold Hinges: Attach the bi-fold hinges to connect the two door leaves. Ensure hinges are aligned correctly for smooth folding action.
4.2. Sliding Hardware Installation
- Measure and Mark: Determine the desired height for the sliding track. Mark the drilling points on the wall, ensuring the track is level.
- Drill Pilot Holes: Drill pilot holes at the marked locations. Use appropriate drill bits for your wall material.
- Install Wall Spacers and Lag Bolts: Secure the wall spacers and lag bolts to the wall, ensuring a firm attachment for the track.
- Mount Sliding Track: Attach the sliding track rail to the installed lag bolts.
- Attach Rollers to Door: Secure the roller hangers to the top edge of the assembled bi-fold door.
- Hang Door: Carefully lift and hang the door onto the sliding track. This step requires two people.
- Install Anti-Jump Pads and Door Stoppers: Attach the anti-jump pads to the top of the door and install the door stoppers at the ends of the track to prevent the door from rolling off.
- Install Floor Guides: Position and secure the floor guides to the floor directly beneath the door to ensure stable sliding.
5. Operation
To open the bi-fold barn door, gently push or pull the door leaves along the track. The bi-fold mechanism allows the door to fold inward, maximizing space. To close, reverse the motion, ensuring the door leaves align properly.
6. Maintenance
- Cleaning: Wipe the wood door panels with a soft, damp cloth. Avoid harsh chemicals that may damage the finish. Clean the hardware with a dry cloth.
- Hardware Check: Periodically inspect all screws and bolts for tightness. Tighten any loose fasteners to ensure safe and smooth operation.
- Lubrication: Apply a silicone-based lubricant to the sliding track and roller wheels annually to maintain smooth movement.
- Wood Care: The wood is pre-finished. If the finish shows wear over time, consider applying a suitable wood stain or sealant to protect the wood.
7. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Door does not slide smoothly | Track obstruction, dirty rollers, misaligned track, lack of lubrication. | Clear track, clean rollers, check track alignment, lubricate track and rollers. |
| Door panels do not sit flush | Improper assembly of wood planks, loose screws, warped wood. | Disassemble and re-assemble planks carefully, ensuring tongue and groove connections are secure. Tighten all screws. If wood is warped, contact customer support. |
| Door is difficult to fold/unfold | Misaligned bi-fold hinges, stiff hinges. | Check hinge alignment and adjust if necessary. Lubricate hinges. |
| Door track appears too long for space | Incorrect measurement or product selection. | If the track is too long, it may need to be cut to size by a professional, or an alternative hardware track may be required. |
8. Specifications
- Brand: Calhome
- Model Number: BF-1100-2-S+K38H
- Door Dimensions (Assembled): 38 inches (width) x 84 inches (height) x 1.5 inches (thickness)
- Material: 100% Solid Natural Knotty Pine Wood (door), Steel (hardware)
- Color: Cherry Red
- Item Weight: Approximately 70 Pounds
- Assembly Required: Yes
- UPC: 197819074718
9. Warranty and Support
For any questions, missing parts, or issues not covered in this manual, please contact Calhome customer support. Refer to your purchase documentation for specific warranty details. General customer support is available to assist with product inquiries and troubleshooting.
