Accordion door roller

Replacing a broken plastic accordion door roller

I purchased a Spectrum vinyl accordion door from Home Depot, and installed it in my basement. Unfortunately, my dogs have a habit of jumping against it, which pulls the top rollers out of the track. Somewhere between the rollers getting pulled out of the track, and getting pushed back into the track, two of the plastic rollers got broken. After searching around, both online and at the store, I could not find replacement rollers anywhere. Since I didn't want to replace the door, and also because I didn’t want to replace breakable plastic rollers with new breakable plastic rollers, I decided to make replacement rollers out of brass.

In addition, because the rollers are difficult to push back into the suspension track, I decided to improve on the original design by making the tops of the rollers conical. The conical design automatically spreads the sides of the roller track apart, making it much easier to pop the roller back into the track.

Here are the measurements I used for the roller; these measurements will need to be adjusted for each make of accordion door.