Crowning when drilling a composite door

I installed a masonite solid core composite barn door. I had to drill 4 5/16 holes in the top of the door to put in sleeves to accept the screws that attach the door to the hardware.

The issue is some of the holes aren't flush with the top of the door and resulted in a crooked door. I took all the hardware off and used a chisel to remove excess material around the holes the best I could, but when I re-inserted the sleeves, it was the same issue.

Is there a certain drill bit I should be using? Any other suggestions? Maybe a slightly bigger drill bit and only going 1/4 deep?

I don't know if crowning is the proper term, but basically the material around the outside of the hole sticks up.

 

An how would anyone know without a picture?

 

Forstner bits or Brad point drill bits will make a cleaner hole.

I can't see how this would result in a "crooked door". Crooked how?

 

I agree with Joe, we need a visual on this. http://www.doityourself.com/forum/el...your-post.html

 

The door hangs crooked because the hardware is not flush with the top of the door. There are two hangers. One is more flush (but not totally). The picture below is the one that is worse.

The sleeve will not screw in any further even though I drilled the hole plenty deep for the sleeve.



The sleeve looks something like this:

 

Seems to me like the mount is installed backward. The pin sticking up should be centered directly over the door, (just like a pocket door would be) and the mount should lay right on top of the door, shouldn't it? Otherwise the door will tip when it hangs rather than hanging plumb. No idea whose hardware that is or we could look up the directions.

 

The rod the door hangs on sits between that pin and a roller that you cannot see in the picture.

I have the directions. The issue is the hardware isn't sitting flush with the door. This is due to the way the composite drilled.

 

This is like trying to solve a puzzle where you only have half the pieces.

 

When using those metal thread inserts you need to drive them slightly below the surface and then use a SHARP chisel to carefully remove the raised burr. Or, you can counter-bore the hole by first drilling a hole the same as the outside diameter of the insert about 1/16 to 3/32 inch deep BEFORE drilling the hole the insert will screw into. Use a Forstner bit for the counter-bore to get a flat bottom.