⚠ Concept-grade, first-order. Dimensions are parametric + a worked 8″-barrel example — enough to model and quote CNC. Final to-scale CAD + FEA + a PE on the stored-energy load path before any metal hangs. Serrated-clamp grip must be bench-tested.
Everything else in the kit is stock (springs, tube, drums, cables, cones, hoist, motor). These brackets are what doesn't exist — the parts you CNC / weld, and your patent. All anchor to the door's fixed steel or the building structure — never wood.
Part 01 · Barrel Drive Ring — the crux
Dimension
Parametric
Worked (8″ barrel)
Note
Bore Ø
= barrel OD (D)
8.00″
Slip-fit to the barrel, serrated inner face
Ring OD
D + 2.5″
10.5″
~1.25″ wall around the bore
Thickness (t)
0.625″
0.625″
0.5–0.75″ steel plate/billet
Split
1 cut, 2 halves
—
Wraps existing barrel, no curtain removal
Clamp bolts
4× 3/8-16 Gr8
across split flanges
Holds 2,592 in-lb by friction w/ big SF
Locating pins
3× 1/4″
shallow into barrel
Positive anti-slip backstop
Drum bolt circle
6× 5/16-18
~7.5″ BC
Mounts the grooved drum / sprocket
Part 02–05 · The bracket family (anchor to STEEL, never wood)
Because the new torsion tube sits offset from the wall (parallel to the barrel), and the motor stands off further than a resi setup, the brackets bridge from solid anchor points out to the tube. Anchor points, in order of preference: the door's existing barrel end plates (heavy steel, already bolted to the jamb), the wall angle, or building structural steel. Long standoff tube arms each side where the reach is big.
#
Bracket
Anchors to
Holds
Make
02
Tube end-bearing brackets (×2)
door's barrel end plates (steel) or wall angle
the new torsion-tube bearings
weld/CNC
03
Center anchor bracket
structural steel / wall angle
stationary spring cone (reacts ~1,728 in-lb)
CNC
04
Motor standoff mount
wall / structure, stood off to reach tube
jackshaft operator (far from wall)
CNC
05
Standoff / spreader arms
span anchor point → offset tube (long tubes ea. side if needed)
bridges the gap, sets the offset
weld/CNC
Steel-to-steel bolted/welded only — no wood blocking. Faster install, stronger, sellable, and it's what makes the bracket system your proprietary, patentable kit (the S1 slice).
What I need from you to lock the exact dimensions
Barrel OD (measure the pipe) — sets the ring bore + the whole size.
Bare barrel length past the curtain edge — where the ring sits (needs ~1–1.5″ clear).
Existing end-plate geometry — bolt pattern / thickness (so the tube brackets tie into steel).
Wall-to-barrel offset + headroom — sizes the standoff arms + motor mount reach.
Chosen drum/sprocket + shaft dia — fixes the drive-ring face bolt circle + tube bearings.
Give me those 5 numbers/photos on a real door and I turn this parametric set into fixed, CNC-ready dimensions + a clean drawing per part.
Operator, hoist, and release routing
Builder rules from the real-part board
Drive point: clamp/bolt the rotating barrel or rotating spider/end wheel, not the fixed dead shaft.
Service side: place motor, hand-chain hoist, and emergency release on the same jamb side where possible.
Pulley assist: use heavy commercial sheaves/blocks on punch-angle standoffs; resi pulleys are visual references only.
8500-style operator: prototype/off-label on rolling steel; commercial jackshaft remains the lower-risk product path.
Guarding: optional removable cover over spring, sprocket/chain, cable, and sheave zones with inspection slots and warning labels.
Research & test — what you've gotta prove (my notes)
Clamp grip test — bench-prove the serrated ring holds 2,592 in-lb by friction before trusting it (the #1 unknown).
Real curtain weight — from the slat datasheet, not a guess; it drives every number.
Spring-house spec — hand them torque + turns + cycle target (25k) → exact commercial spring + cycle rating.
Fleet-angle check — confirm ≥18″ pulley standoff in the real layout so the cable doesn't jam.
Drop-safety — select + arrest-test a barrel governor (mandatory, PE item).
PE review — drive ring + anchor + drop-safety on the stored-energy load path, ≥5 SF.
Provisional filed FIRST — before any public demo, pitch, or offer. Then CNC under NDA → bench → film.