how we did it

When I was creating the new office space for Love Nest Design I knew I needed a very large door to divide the dining room space from the office.  Keeping curious kiddies at bay when deadlines loom was a must, and when it comes to little ones sometimes it really is out of sight, out of mind…at least for an hour or two while daddy entertains them.

It is also important for a home office to be separate from the rest of the house, a physical separation between work responsibilities and home responsibilities.   It keeps the guilt of not cleaning up the breakfast dishes from tarnishing the motivation to focus on your business.  SO.  I needed a door.

The span of the opening was a little less than 6 feet, not your average sized door.   It would have to be custom, and it needed to function: divide the space when needed, and ‘disappear’ when not required, to keep the floor plan more open. But what other function could I get out of such a wide span of vertical space?  Organization in any office is key. Calendars, paperwork, inspiration, reminders, they all need to have a functional space.  Cork boards have always been a go-to solution for these obvious office requirements.  So, oversized cork board door it is!

I already had a collection of very large sheets of cork that were salvaged from a public school reconstruction.  The door itself had to be light enough to work on a sliding door system, but rigid enough to support a usable cork board.

PM building the door 1

In order to achieve this we used two flat, hollow core doors and biscuit joined them together down the middle.  We knew the eventual hardware would also support keeping this wide door rigid.

Screen shot 2013-08-26 at 5.09.12 PM

{biscuit joint via}

The cork, which is less than 1/4″ thick was backed with a thin MDF.  Both were then adhered to the hollow core doors using construction adhesive.  Aesthetically,  the warmth in the color of the cork was nice in a space that was to be mostly white. But I wanted something more.  A little wow.  I went with the bold black stripes, painted directly on the cork.  With a crisp white frame added,  the look was complete.  Then came the hardware.

PM building the door 2

We designed and built our own hardware for this project.  I wanted a specific look; black in color and with an industrial feel.  We sourced all parts separately and spent a few hours debating the logistics of a functioning sliding door.  This is what we came up with:  1/4″ x 2 1/2″ steel flat bar was lagged to the wall with 5/16″ x 3″ lag bolts, using small squares of 3/4″ thick cherry to hold it off the wall far enough for the rollers to clear.  The rollers are 5″ pulleys, held in place by 1/2″ carriage bolts, and all supported back down to the door with two pieces of 1″ x 1/2″ x 1/2″ C-channel steel bar.  We also added small rollers on the wall just above the baseboard to keep the door from bumping the wall and to help it slide more easily.

building door 4

The door installed quite easily and slides along the entire length of the wall its mounted on.  I love the look!  but I also love the function.  Stay tuned next week and I’ll reveal how the door looks while its functioning as a cork board.

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