Flush mount door – The industries latest innovation

Garage doors have been largely the same for some time. That is to say that innovation in the industry, in terms of the door itself, has been largely non-existent. In 1921, the first sectional door was created and ever since then it has been a combination of springs, cables, sections, tracks, rollers and hinges. Some changes have come in the form of insulation and seals, but largely, they are the same as they have been for 100 years.

However, our friends at Super Sneaky have innovated in a big way. They have created a system that has allowed us to adapt current industry standard doors and hardware to be mounted flush to the outside of the building. Hence the name, “Flush Mount” doors. It takes a little bit of work adapting a regular sectional door to mount flush to the outside of a building, but most of our installers get the hang of it after one or two installs. We simply use a hardware kit which we get from Super Sneaky to make the door a flush mount door.

This style of door increases curb appeal in a new way. The doors can be clad to match the outside of the building, essentially concealing the door. Or they can be clad in a different material to create a unique accent wall. Either way, architects are starting to explore the possibilities and seem to be enjoying the new options this type of door brings to their arsenal of creativity.

Here is what you need to know about how the flush mount system works. Firstly, the rough opening needs to be framed differently. Traditionally, you frame the opening to the same dimensions as the door. In the case of a flush mount door, you need it to be wider and high, so keep that in mind. Secondly, you’ll need the hardware kit. It comes with the appropriate top fixtures, rollers, brackets and just about everything you’ll need to convert your standard lift sectional door to a flush mount door. You’ll need to provide a solid shaft, preferably with a center coupler to allow for adjustment. You’ll also need to order your door with horizontal tracks that are 2’ longer than you would typically need for that size of door. So, if your door is 8’ high, get horizontal tracks for a 10’ high door. Since the rollers are adjustable to get a good seal along the jamb, you’ll want to put your rollers in #1 hinges and double the hinges up on either side (you’ll need double end caps for this). Then it’s a matter of protruding the exterior sheathing into the opening to the appropriate dimensions for the door, cutting down the tracks and mounting them to the sheathing and studs, installing the door and operator.

Once that is all done, the door is ready to be clad like the exterior of the home. One thing you should note is that it is better to prep the sections prior to installing them in the tracks. We prefer to do that step in the shop in a prepared work area. We glue and screw strips of plywood to accommodate what ever type of cladding is going on the door. Once the door is clad, you’ll have to weigh it and get the appropriate springs for the new weight.

These doors need to be run by a trolley operator. The hardware does not allow the door to be operated by a jackshaft operator due to the need for the top section to be pulled back before lifting. The new Maxum Operators seem to be a good fit for this type of work, but we have also used the regular 8165’s and our counter-parts in Toronto have used Sommer operators. Any Trolley should work. Just keep in mind that you’ll want a rail that is 2’ longer than you would normally get for that high of a door. So again, an 8’ door needs a 10’ rail. That way the customer gets the entire height of the opening.

We’re really loving the options this type of door is giving us. So are designers, architects and most of all, homeowners. For more information on this system or if you would like to get your hands on a kit, feel free to contact me via email at j.carrier@eagleoveheaddoor.ca.
I’m sure you’ll be happy you did and so will your customers.

Call for more information about flush mount doors (306) 861-7736

Flush Mount Doors