Our shower door has 4 sets of rollers that hold the sliding door. The top two have screws that you adjust to make the door level. When the door shuts, a magnetic catch seals the side of the door but only if the door aligns correctly to the wall
We bought the door back in 2014 and have had a couple of failures of these bearings before. I’ve previously asked the manufacturer to send out spares. We received a set of 4 bearings and I’ve only got 2 lower bearings left.
This week, one of the top bearings failed again. That means we’ve had three failures now as I’ve no spares left in the drawer. It failed mid-week and I did not have time to make a replacement one evening. So I just smothered it with hot glue to keep it in one piece till the weekend.
A few years back, I cast a big block of aluminium, which was ideal for this job. The first step was to cut a pocket for the adjuster. I added a cross vice to the drill and chucked up a milling cutter. This is not really recommended practice as a drill is not really designed for this operation. I should save up for a mill/drill.
My first attempt messed up as I cut the hole too big.
So I started on a second attempt. This time I cut the block to size first. I used the angle grinder and flap disk to square it up given that my lathe was buried under a couple of other projects. The pocket was milled correctly this time. Then a 5mm hole drilled for the adjustment screw. This was counterbored for the nylock nut that fits on the other end.
The last thing was to cut a hole for the mounting screw. Luckily there was a threaded insert that could be removed from the broken part but this had a large 10mm head. Didn’t have any milling cutters that large but I found a tee cutter which was the right diameter so used that for spot facing the hole.
The flapdisk was used for rounding off the corners. A file and some green scotch pads were used for smoothing off the surfaces.
The repaired component should be a lot stronger than the original and hopefully, I won’t need to replace any more. I fitted the part and adjusted the door level again. You can see it here with our other replaced part, the 3D printed clip for the stationary pane.