How To Remove & Replace An Existing Pocket Door
If your looking to replace a pocket door without cutting open your wall. You've come to the right place. This is a step by step process to remove and add a new door without cutting any walls.
Step 1 Trim
The first thing I will do is remove the casing around the outside of the door. This part is not necessary to remove the door, however I am changing the color of the door so I will be adding new trim to match after I change the door.
Step 2 Door Frame
Getting into the actual door removal. To remove the door you will have to remove the two pieces of trim on the top and side on both sides of the door. The trim pieces are large flat bars on the inside of the door frame. Pry against a putty knife to gently remove the trim. You will probably want to reinstall these later so try to be careful removing them. Once you remove the first two remove the same trim on the other side of the door.
Step 3 One More Piece
Once all four of those trim pieces are removed if you look up inside the door frame there is a track. Your door will roll on one side of the track. On the side opposite the track from the open side, remove the trim piece against the wall. It's probably screwed down so unscrew it and then carefully pry it off.
Step 4 Remove The Door
Once you have removed all of that trim, close the door and lift the door up from the bottom. Lift outward away from the open side of the track. An easy way to think of it is look at the track and stand on the closed side and lift the door toward yourself. This may take a little bit of wiggling and adjusting to get it to let loose.
Step 5 Saving The Hardware
Next remove the original rollers. They will have a few screws holding them in place so unscrew them. Measure the location of the old rollers and mark your new door so the rollers sit in the exact same spot.
Step 6 Setting Up The New Door
Your new pocket door will need a latch the same style as the old door. Measure the old door and mark out the same location on the new door. Using a jigsaw cut the opening for the latch. I like to clean up the edges with a little bit of sandpaper. Once that's done push the latch in until it slides flush make sure it can sit flush with the front of the door. Screw down the latch into the door. Measure the old door dimensions. The new door may be slightly larger in length or width. Use a straight edge and a circular saw and trim the new door to match. If you are cutting the width make sure you cut the side of the door that will be furthest in the wall. Tip: wrap the cut in painters tape to keep it from splintering.
Step 7 Install
Now the new slab door is ready to go back in as your new pocket door. Tip: Before you put the door back in this is a great time to wipe clean the old track. Install it the same way the original door came out, except in the opposite order. Sometimes it may take a few adjustments and attempts to get all the rollers to sit properly in the track. After a few attempts once the door is finally back in and rolling smoothly. Reattach any and all the trim you removed. Use an 18 gauge brad nail gun or if you don't have one glue will also work in a pinch to reattach the trim.
That's it it's all done for my door I'll paint the frame and add new casings to complete the look. Tip: If your new door doesn't sit quite right like the old one did, the rollers will have small nuts you can reach up and turn to adjust how it sits. Enjoy!