Henderson PDK3, PDK4, PDK5, PDK6, PDK7 Instruction Manual

The Pocket Door Kit

FITTING INSTRUCTIONS - NOTICE DE POSE - MONTAGE HANDLEIDING - MONTAGEANLEITUNG

ISTRUZIONI DI MONTAGGIO - INSTUCCIONES DE MONTAJE

Warranty. This product is covered by a 10 year manufacturer’s warranty. Please see the P C Henderson website for terms and conditions.

WATCH THE INSTALLATION VIDEO

Visit: www.pchenderson.com/pocket-door-installation
Or scan the QR code using your phone

Door sizes and kits numbers - for doors up to 60kg

For doors up to and including standard door sizes Kit number

1981mm (78”) high x 762mm (30”) wide doors PDK3
1981mm (78”) high x 838mm (33”) wide doors PDK4
2040mm high x 762mm wide doors PDK5
2040mm high x 826mm wide doors PDK6
2040mm high x 726mm wide doors PDK7
2315mm high x 930mm wide doors PDK10

Door thickness between 28mm and 44mm - Maximum door weight 60kg - Wall cavity 95mm

Tools required

1 x Phillips screws driver

1 x Spirit level

1 x Junior metal hack saw
(only needed if reducing kit in size)

1 x Tenon wood saw
(only needed if reducing kit in size)

1 x Tape measure

1 x Drill + 2mm drill bit1 x Allen Key - 5mm 1 x Adjustment spanner

Kit components

1 x Plastic guide

2 x Clipstops

2 x Hanger apron plates

1 x Rubber stop

Screw A x 4

3

/4” CSK. HD. Pozi

(19mm)

Screw B x 8

1” BUT. HD. Pozi
(25mm)

Screw C x 8

13/4” CSK. HD. Pozi
(44mm)

Screw D x 14

5

/8” BUT. HD. Pozi

(16mm)

Screw E x 8

11/2” BUT. HD. Pozi
(38mm)

Screws shown actual size

2 x Hangers

2 x Stud insert brackets

1 x Track, head and
end brackets

4 x Uprights including
timber infill

Step 1 – Preparing the Rough Opening

Kit assumes installer is using standard (C16/C24) studwall timber 47mm x 100mm (actual size 45mm x 95mm)

How

to calculate the opening width required
Opening width in mm = (Door width in mm x 2) + 30mm
Opening height in mm = (Door height in mm) + 90mm

Refer to Figure 1.
Note: 90mm = door floor clearance range (8 - 15mm) + door to track clearance range (26 - 33mm) + header/

track clearance 49mm
Finished studwall is 95mm thick plus plaster board used i.e. 95+12.5+12.5 = 120mm

Rough opening width - W

(Including any liners)

Rough opening

height - H

Figure 1.

Quick look up table for opening sizes when using UK standard door sizes

Kit No.

PDK3 1981mm (78”) high x 762mm (30”) wide doors 2071mm 1554mm
PDK4 1981mm (78”) high x 838mm (33”) wide doors 2071mm 1706mm
PDK5 2040mm high x 762mm wide doors 2130mm 1554mm
PDK6 2040mm high x 826mm wide doors 2130mm 1682mm
PDK7 2040mm high x 726mm wide doors 2130mm 1482mm
PDK10 2315mm high x 930mm wide doors 2405mm 1890mm

Standard door size

Rough opening width - WRough opening height - H

FFL

Ensure that the rough opening is as square as possible to aid the fitting of the pocket door system, and so allowing the door
to operate correctly when the installation is completed.
For double doors the rough opening width is as for one door multiplied by 2 and the 2 kits MUST be fixed directly to a
suitable lintel.The tw

o middle support brackets are not to be used.

Step 2 - Install Guide screws

Fit a guide screw - A to both frame uprights of the opening at the door height plus 28mm (measured from the
Finished Floor Level - FFL).The screws should be fitted on the centre line of the cavity, refer to diagram for details (Fig

2.1). Fix both screws into the frame until the head of the screws are protruding about 3mm from the frame uprights.

Screw - A Screw - A

C

L

Height of Guide screws

= Door Blank Height + 28mm

Figure 2.1.

Frame

Upright

(not by PCH)

Frame

Upright

(not by PCH)

Figure 2.

Step 3 - Fit stud insert brackets

Cavity side

Opening side

FFL

Using the Track and Head assembly as a template,
mark on the floor between the vertical uprights
with a soft pencil the lines as shown on diagram.
These lines are the position of the stud insert
bracket near the pocket opening. Fit remaining stud
insert bracket half way between the rough opening
upright and the first fitted stud insert bracket using
screws - D (see Fig 5).

Intermediate
stud bracket

Pencil lines

=

=

Pencil lines

Figure 3.

Figure 3.1.

Step 4 - Fitting the track & head assembly

Insert both hangers and clipstops into the track with the hanger ‘ears ‘ facing the clipstops at each end of the track,
as shown in Fig. 4.1. Carefully lift the Head and Track assembly into the opening, then hook the metal brackets at
both ends of the assembly on to the protruding guide screws fitted earlier. Then rotate the assembly into the final
upright position (Fig.4).Whilst holding the assembly with one hand, screw the guide screws home at both ends.This
should hold the Head and Track assembly in position with friction. Do not let go of the assembly if it is not held
securely in place by the screws. Using a spirit level,check and correct the assembly ensuring it is level in all directions.
Using screws B secure end brackets as indicated in Fig 4.2 & Fig 4.3.

‘Ear’ ‘Ear’

Figure 4.1.

Screw - A

Figure 4.2.

Screws - D

Screws - B

Figure 4.

Screw - A

Screw - D

NOTE: For biparting door applications,

discard the brackets for the opening
side. Instead soffit fix this side of the
track to the overhead lintel.

Screws - B

Figure 4.3.

Step 5 - Fit uprights

Slot first upright into stud insert bracket (as indicated in
Figure 5.) and line the top of the upright against the side of
the wooden head fascia. Check upright for vertical alignment
with a spirit level, then screw the top of the upright to the
wooden header board through the slots on the back of the
upright. Repeat this for the second upright on the opposite
side. Slot the third upright on the intermediate stud insert
bracket,use a spirit level to check vertical alignment and then
screw the top of the upright in to the wooden header board,
through the slots on the back of the upright, (as indicated in
figure 5.1).
Repeat step for the forth upright on the opposite side.

Wooden header board

Wooden head fascia

Screws - C

Upright

Screws - D

Stud insert
bracket

Figure 5.

Upright

Figure 5.1.

Step 6 - Installing the guide

Using screws A position the guide assembly on the centre line of the cavity and in front the
of stud insert bracket (figure 6.), checking the distance between the guide uprights is correct
for the thickness of the door before screwing down to the floor, do not overtighten.

Pencil line

Screws - A

Centre

line

Pocket

cavity

Guide fixed on

centre line

Opening

Figure 6.

Step 7 - Fitting the apron plates to the door

The centre of the apron plates must be no closer to the corners of the door than 160mm (figure 7). Position the
centres of the apron plates along the centre of the door blank. Using screws E fix both the hanger apron plates on
to the top face of the door.

IMPORTANT: If installing our optional SOFT50 add on kit, please refer to Husky 50 Soft Stop fitting instructions for
installation of apron plates and hanging of door.

Centre of the

door blank

Centre of

hanger

Hanger apron plate

> 160mm

Screws - E

Figure 7.

Step 8 – Hanging of the door

Move the hangers within the track to align with the hanger apron plates on the door. Carefully hook the door, via
the apron plates, on to the bolt heads hanging beneath the hangers. The bolts heads must be firmly seated on the
underside of the apron plates behind the apron plate ‘ears’.When in place adjust the door for height and alignment
to the frame upright. When adjusted correctly screw down the lock nuts and tighten with a spanner.

Figure 8.

Step 9 – The finishing touches

Now with the door hung, position the clip stops to the desired positions within the track to limit the travel of the door,
then tighten the clip stop bolts to fix in position. Remember that when the door is in the open position there will have
to be enough of the door protruding from the pocket to pull the door shut.Alternatively the door may be flush with the
pocket if used in conjunction with the Henderson 395 flush door lockset. Screw the rubber stop supplied into the frame
upright on the pocket side,in alignment with door,at a height of approximately 50mm above the FFL (as indicated in figure

9).When the installation of the Henderson Pocket Door Kit is complete and the door is running smoothly, the plaster
board panels can be fitted to the uprights to create the wall pocket, and then the desired mouldings and skirting board
to finish off.

Rubber Stop

Screw - B

Figure 9.

Ironmongery available

To complement the installation of your Henderson
Pocket Door System, we can supply a range of flush
pulls and lock catches. Please contact P C Henderson
sales department for further information.

Reducing the kit size

Kits can be reduced both in height and width to meet particular
door sizes.To reduce the height of a kit cut down the uprights
by the same amount, starting from the bottom of each upright
(avoid cutting through the side slots). To reduce the width of the
kit cut down the track and timber head assembly separately. Cut
from the opening side by the difference between the kit door
width and the door to be used in equal proportion.
For further information contact the P.C. Henderson Technical
Department.

12.5

32.0

32.0

12.5

Upright

Upright

Upright

Baton

Baton

12.5

12.5 offset

Plasterboard

Architrave

Plasterboard

Architrave

Plasterboard

Architrave

Plasterboard

Optional door frame lining

Suggested finishing touches (not supplied by PCH)

1. Attach baton on the face of the
cavity upright with fixing, ensure
flush with edge.

Fixing maximum length = 25mm

2. Attach baton on to the edge of
the cavity upright with fixing, ensure
flush with front.

3. Attach plasterboard with fixing,
butt up to edge of baton edge.

4. Attach architrave with fixing,
ensure flush with edge.

Panel pin

Fixing maximum length = 25mm

NOTE

PCH suggests the use of plain

square edge timber.

Fixings could be screws, panel pins

and/or grab adhesive.

5. As an additional feature the
baton could be routed to accept a
brush strip.

P C Henderson Ltd, Durham Road, Bowburn, Co. Durham, DH6 5NG, UK
UK Sales
t: [phone]
e: [e-mail]
w: www.pchenderson.com

UK Registered Address: P C Henderson Ltd, Durham Road, Bowburn, Co. Durham, DH6 5NG
Republic of Ireland Registered Address: P C Henderson Ltd, Westlink Industrial Estate, Kylemore Road, Dublin 10, Ireland
Holland Registered Address: Henderson Nederland BV, Rootven 14, 5531 MB, Bladel

Export Sales
t: [phone]
e: [e-mail]
w: export.pchenderson.com

Part No: 666770

November 2019

Issue 15