2012 Day 95- Haunted Doors 2.0

Welcome back Ghouls! Last year we introduced the rolling door concept courtesy of my friend James Beach (Garage of Terror). This was a definite breakthrough as in the past we had major issues with doors derailing from floor-based tracks. Very bad! The suspended rolling door eliminates all of this hassle. I presented a way to open and close the doors last year remotely using a pulley mechanism. See this post to review the concept. Now James has a haunt that attracts mostly young visitors from what I understand. The guests for our haunt are much older, high school to adult. I had to make these doors a little more robust. Each door weighs about 25 pounds or so. The cost is around $15-20 per door: a couple dollars each for 2 caster wheels, a 2x2 for framing, 2x4 I beam. 4 brackets each about 99c and hardboard piece about 10 bucks. I present here details on the crypt exit door. This door will be controlled by an operator using a 2x2 handle. He or she can see through the one way window and will know when to open it!

Video demonstration of crypt exit door from outside and then inside the crypt! Notice how the mechanism is quite smooth. I put a 2x2 cube on either end of the track to act as stops. (see image below)

Components of a suspended sliding door 

You can add weight to the bottom if necessary as sometimes the doors will sway if not weighted down. The plastic on the right is there to prevent light leaks from inside the crypt

2x2 handle for opening and closing

Door is unmounted here showing the caster wheels bolted to 2 brackets which sit on either side of the 2x4 I beam (when mounted of course). You might have to drill an extra hole in the bracket on the bottom to secure the bottom portion. These brackets are very thin and easy to drill through

This is the inside of the same door as seen from within the crypt. I used a vacuform panel surrounded by pieces of foam from an old hot tub cover which when painted black look like old stone slabs!