Installation Guide for Johnson 1500HD Series Pocket Door Frame

Quick Guide from the Manual

The Johnson 1500HD Series Pocket Door Frame is designed for 2x4 stud walls and supports doors weighing up to 200 lbs (90 kg). Before starting, ensure your rough opening height is at least 84 1/2 inches (2.14m) and the width is 2x the door width plus 1 inch (25mm). If your door is not the standard 80-inch height, you must adjust the header and split studs accordingly.

Rough Opening Construction

The rough opening must be square, plumb, and level. Construct the header and side jambs to the required dimensions. Snap a chalk line on the floor to align the side jambs. Measure up from the finished floor (80-3/4 inches) or sub-floor (81-12 inches) to mark the stud locations for the header end brackets. Drive a flat head nail into each stud, leaving 1/8 inch protruding to support the header.

Header Installation

Slide the slots in the frame header end plates over the nails installed in the rough studs. Level the header, then secure it by driving nails through the remaining holes in the end plates. Ensure the header is properly aligned before finalizing the attachment.

Split Steel Stud Installation

Insert the fingers of the floor plate into the split steel studs. Butt the studs against the header nailer and secure them with two #8 x 3/4 inch pan head screws. Position the remaining split steel studs midway in the pocket opening. Ensure they are plumb between the chalk lines and nail them to the floor. For masonry floors, use industrial adhesive or Tapcon fasteners.

Door Hanging

Attach the 1121 door plate to the top of the door, 2-3/4 inches from each edge, with the lock tab facing the same side. Insert the 1125 hangers into the track, alternating wheel positions for weight distribution. Mount the door by locating the door plate under the adjusting bolt of the hanger, lifting the door, and pushing the bolt into the door plate. Repeat for the second hanger. Fasten the 1550 guides to the finished split jambs at the bottom to keep the door centered.

Finishing and Adjustments

Apply wall material using 1 inch #6 self-drilling drywall screws, using seven screws per split steel stud. Seal all edges and the face of the door panel with paint or sealing stain. Fasten the 1513 bumper on the back edge of the door, 40 inches from the bottom edge.

Cutting Instructions for Non-Standard Sizes

If your door width is not standard, you can cut the frame to fit. Remove the adjustable end bracket, cut the wood header to the desired size, and turn the header over to cut the track 1-3/8 inches shorter than the wood header. Replace the end bracket on the new cut end. Turn the header on its side and cut the header trim board to the appropriate mark. Repeat for the other side.