Does anyone out there have experience in designing/ building oversized sliding doors?
I'm searching for advice on the design of a 7'-4" high x 6'-8" wide x 1-3/4" maple veneered solid core interior door- expecting an MDF core w/ solid rails, stiles, and blocking for hardware, plywood facing and veneer, assuming about 200 plus lbs.
The door mfr's I normally deal with (some of whom are bidding on the remaining doors of the job) have told me that their equipment/press sizes preclude the creation of doors of such a size, and that they would be unable to warranty any such door against warping- not that a warranty was asked for in this particular case... they (understandably) just don't want an unhappy customer.
The proposed door is to be hung on a face mounted industrial track permitting it to slide along and cover a 7'-0" x 6'-4" opening in that wall (to butt a perpendicular wall on the opposite side of the opening)- more of a sliding partition than a door. No securing hardware required, and not much concern with acoustic sealing when closed.
I've had no trouble finding appropriate hardware, just can't find anyone to build such a door for fear of severe warping problems. While I can appreciate the dangers of a normally hung door warping, I fail to see that the dangers would be as great in the case of a non-latching top hung slider. How much warping am I looking at? Is it possible to warp an (mostly) MDF door enough to significantly affect the operation of its sliding track hardware?
Any advice would be appreciated.