Cut to Size
Cut from 96" to 78" - done
Tag end rough, other end worse ~ 4" both sides
Edges and Ends
Board S1S, will be covered
Clean edges and square ends - done
Pilot Holes
1/8" toggle bolts and 2" screws spaced according to safety factor = 2 using ChatGPT spec of 30 lb shear strength for zinc bolt
Surface Coat
Can be done in place
Only need protection, stain or single coat
Mount
Span 78", Door 32"
Header 32", Open 46"
What would be the complete span safety factor if using the screws spaced 9" and the bolts 6"
To calculate the complete span safety factor, considering both the 2" deck screws spaced 9" apart in the solid wood header for 32" of the span and the 1/8" zinc toggle bolts spaced 6" apart for the remaining span, we need to integrate the capacities and distributions of these two fastening methods. However, without specific load capacities for the screws in wood, we'll use general assumptions and focus on conceptual understanding.
The complete span safety factor, combining the use of 2" deck screws spaced 9" apart in the solid wood header for 32" of the span and 1/8" zinc toggle bolts spaced 6" apart for the remaining span, is approximately 5.1. This means the combined mounting system is capable of supporting over five times the weight of the 100 lb door, indicating a robust and safe installation based on these assumptions
Here's what DALL-E came up with for the layout, not really very useful:
