ROCKWELL 4-IN-1 DOOR. Two Panel Door. Half X Door. Z Combination Door. Double X Door

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1 ROCKWE 4-IN-1 DOOR Two Panel Door Half X Door Double X Door Z Combination Door Choose between four door styles with this Door Kit. Our versatile Rockwell Door Kit is very easy to assemble. All materials and hardware needed to assemble any of the four styles are included

2 PEASE READ these important notifications before proceeding. If any of the slats have been damaged during shipping, call us at and we will expedite replacement slat(s) or parts as needed. ay out your Door slats and parts according to the illustration shown below to accurately identify which part needs to be replaced, if any. PEASE NOTE: These instructions are specific to a particular door size and type. Adjustments may be needed on your part for changes in specifications and measurements, as well as door types that are different from these. We recommend a dry assembly. It is recommended you not use glue or adhesive of any kind while assembling your Door. If you are having problems installing your Door, please call Rustica at and our friendly representatives will be happy to assist you. Page 2

3 Two Panel Door Tools Needed Ratchet with 7/16 socket and a socket extension Drill with #2 Phillips bit ay out your Door Parts as shown below. Parts Included E1 A4 C1 C2 C2 C2 C2 C2 C2 C3 R E side view front view A3 B1 B2 B2 B2 B2 B2 B2 B3 F A2 Description Qty Description Qty Side Rail eft 1 C1 C3 Top End Slats 1 each R Side Rail Right 1 C2 Top Center Slats 6 each* A2 Bottom Rail 1 B1 B3 Bottom End Slats 1 each A3 Middle Rail 1 B2 Bottom Center Slats 6 each* A4 Top Rail 1 6 ag Bolts 8* E Industrial Hangers 2 F Falcon Door Pull 1 E1 Grabber Screws 36* * Quantities will vary depending on Door size. All quantities in this table are for an average-size single Door order. Page 3

4 Two Panel Door Assembling Your Door 1. Slide all B slats to the right into R. Next, slide A2, Bottom Rail, up to R and the B Slats. Attach with the bottom, right-hand ag Bolt () by hand, then by using a ratchet. Have someone help keep the door, slats and rails in place as you attach the ag Bolts. Keep your ag Bolts straight as they go in to keep your door square. A4 E1 C1 C2 C2 C2 C2 C2 C2 C3 R A3 B1 B2 B2 B2 B2 B2 B2 B3 A2 Page 4

5 Two Panel Door 2. Slide Center Rail A3 down on top of the B Slats and into Slat R. If necessary, have someone help keep the door square as you attach with the ag Bolts. Have all ag Bolts go in straight, using your hands first, then a ratchet. 3. Slide all C Slats down and to the right into Center Rail A3 and Side Slat R. Then slide top rail A4 down over the tops of the C Slats. A4 A4 C1 C2 C2 C2 C2 C2 C2 C3 R C1 C2 C2 C2 C2 C2C2C3 R A3 A3 B1 B2 B2 B2B2B2 B2B3 B1B2B2B2B2B2 B2B3 A2 A2 4. Slide Side Slat over to cover the left edge of your Door. Insert the ag Bolts by hand, then use a ratchet to fully tighten. If necessary, have someone help you hold all slats and rails in place while you are positioning and fastening. 5. Attach Slat to the door using the 6 ag Bolts. Insert by hand, then use a ratchet to tighten. Page 5

6 Half X Door 4. Slide all C Slats into R and A3 grooves. Once all of the slats have been positioned, place the A4 Top Rail onto the C slats and in the R grooves. Fasten A4 into place with a ag Bolt, first with your hand, then tighten with a ratchet. Be sure the ag Bolt is going straight in and not at an angle. A4 C1C2 C2 C2 C2 C2 C2 C3 A3 5. Slide Side Slat into place, attaching with 6 ag Bolts, tightening by hand. Once you have determined all are in place straight, tighten ag Bolts with a ratchet. A2 6. When the Door is assembled, place A5, A6 and A7 (Diagonal Rails) onto the door so the predrilled holes are facing up and so they form an X that runs from corner to corner. Attach using the 3/4 Grabber Screws and a drill with a Phillips bit. Attach the Door Pull and your Door is ready to hang. Page 6

7 Z Combination Door 4. Slide Top Rail A4 into place, to cover the tops of the C Slats. Install top ag Bolt. 5. Slide Side Slat into place, attaching with all three ag Bolts, tightening by hand. Once again, have someone help you keep all of the Slats straight. Once you have determined all are in place, tighten ag Bolts with a ratchet. A4 6. When the Door is assembled, place A5 Rails 7. Attach the Door (Diagonal Rails) onto the door so the predrilled Pull and your holes are facing up and so they run the same way, Door is ready to from corner to corner. Attach using the 3/4 hang. Grabber Screws and a drill with a Phillips bit. A5 E1 A6 Page 7

8 Double X Door 4. Slide all C Slats into R and A3 grooves. Once all of the slats have been positioned, place the A4 Top Rail onto the C slats and in the R grooves. Fasten A4 into place with a ag Bolt, first with your hand, then tighten with a ratchet. Be sure the ag Bolt is going straight in and not at an angle. Fasten by hand, then with a ratchet. C1 C2 C2 A4 A5 A7 A6 B5 B6 5. Slide Side Slat into place, attaching with 6 ag Bolts, tightening by hand. Once you have determined all are in place straight, tighten ag Bolts with a ratchet. B7 6. When the Door is assembled, place A5, A6 and A7 (Top Diagonal Rails) onto the door so the predrilled holes are facing up and so they form an X that runs from corner to corner. Attach using the 3/4 Grabber Screws and a drill with a Phillips bit. A5 A6 A7 Repeat for B5, B6, and B7 (ower Diagonal Rails). B5 B6 Attach the Door Pull and your Door is ready to hang. B7 Page 8

9 Installing the Falcon Door Pull The location where you attach your Door Pull is up to you. We suggest you don t attach your Door Pull too close to the edge of your Door or a seam, as this would weaken the integrity of your Door. Typically we recommend that the center of your Door Pull be lined up 3 from the bottom of the door. 3 ft. Installing the Industrial Hangers Parts Included Hanger Assembly Track Adjustable Spacers Hard Stops ag Screws Hex Bolts Acorn Nuts Anti-jump Brackets 1 Washers Grabber Screws Door Guide Instructions Page 9

10 Installing the Industrial Hangers 1. Measuring and Marking Your Hanger Holes 2. Drilling Pilot Holes Door Top ay your Door facing UP on saw horses. Pencil a line 2 parallel from the Door edge (this marks the proper location for the Hanger edge). Using your Hanger as a guide, line up your Hanger with the line you just made. Holding your Hanger in place, measure a 2-3/8 gap between the top of the Door and the bottom of the Wheel (see below). Mark the center of both Hanger holes (these indicate where you should drill to attach your Hanger to your Door). Repeat Step 1 on the opposite Door edge. 2 " Door Front Door Edge Using a drill with a 1/8 bit, drill a pilot hole all the way through the Door where you have marked. (one pilot hole for each hole in the Hanger). Repeat Step 2 on the opposite edge of the Door. Door Top Door Edge Door Front Door Top 2-3/8 1/8 3. Drilling Countersink Holes 4. Drilling ag Screw Holes Door Top Door Top Door Back Door Front ay the Door facing DOWN on the saw horses. Using a drill with a 1-1/8 spade bit or Forstner bit (a Forstner bit is preferred), drill a 7/16 deep hole, centering your 1-1/8 spade or Forstner bit directly over the 1/8 pilot hole. Repeat Step 3 on the opposite edge of the Door. Door Edge ay the Door facing UPWARDS on the saw horses. Using a drill with a 3/8 drill bit, drill all the way through the Door, through your pilot holes (Step 2). Repeat Step 4 on the opposite edge of the Door. Door Edge 1-1/8 1/8 3/8 Page 10

11 Installing the Industrial Hangers 1. Installing Your Hanger Assembly To Your Door 2. Tightening Your Hanger Assembly Thread the Hex Bolts with the Washers through the back of the Door. Thread the Hanger assembly through the Hex Bolts on the front of the Door. Holding Hex Bolts in place using a ratchet with a 5/8 socket, lightly tighten your Acorn Nuts by hand. Hex Bolt Using a 9/16 wrench for the Acorn Nut and a ratchet with a 5/8 socket and for the Hex Bolt, gently tighten, being careful not to damage your Hanger or Acorn Nuts. Repeat Steps 1 and 2 on the opposite edge of the Door. 5/8 9/16 5/8 1 Washer Acorn Nut CRITICA! If the holes in your Track do not line up with your wall studs, you must mount a Header onto your wall attaching the Header through the wall studs. Then you can mount your Track onto the Header. Ideally, the Header should extend 2 further than the end of your Track on either end. For instructions on How to Install a Header visit or see page 14 for How to Install a Header. 1. Measuring for Track Position IMPORTANT! If you are installing our Flat Track System, proceed. If you are installing either a Tube, Box, Bypass, J Track, or Ceiling Mount Track System, go to and download Installation Instructions specific to your Track System. The number of holes in your Track depends on the length of track ordered. Door Height } } 1/2 1-5/8 This 1-5/8 measurement ensures coverage of your doorway and makes it so your Track assembly will not be visible from the other side of your Door. 1-5/8 + Door Height + 1/2 = # of inches up from finished floor where you will pencil a horizontal line for your Track. This line will mark the center of the Track and your penciled line will be visible trough the Track holes. Check to see if your floor is level. If your floor rises more than 1/2 along the length of the Track, you risk your Door rubbing or sticking at this high point. If your floor is not level, measure up from the highest point of your floor to find your Track hole center position to attach the Track to your wall. To determine where to install your Track, add together 1-5/8 (space above door) plus 1/2 (floor gap) to the height of your Door. This measurement is how high up on your wall (from your floor up) you should install the Track. This is where you will mark a horizontal line on your wall parallel to the finished floor, the same length of your Track. Page 11

12 Installing the Track The number of holes in your Track depends on the length ordered. There will typically be four holes unless your Track is 3 6 or longer. 1. Marking and Drilling Track Holes Fifth hole on tracks 3 6 or longer Hold up your Track so that the marked line from the previous step is visible through the Track holes. Mark an intersecting line in the center point of each of the Track holes. Set the Track down. Using a drill with 1/4 drill bit, drill out your marked Track holes.* *Be sure you are drilling into wall studs. If your track holes are not lining up with your studs, you will need to install your Track onto a header. The header needs be attached to your wall through the studs. This will provide the stability your wall needs to hold the weight of your Door. 1/4 2. Hanging Your Track oosely attach one end of the Track using a Spacer and a Hard Stop or a ag Soft Stop (see below). Swing the Track up and loosely attach the other end, using a Spacer and a Hard Stop or a ag Soft Stop (see below). The center holes can now be loosely attached (see below). 9/16 3. Hole Installation The end holes will be installed with a Hard Stop. In this order: Adjustable Spacer, Flat Track, Hard Stop, 1 Washer, and ag Screw. Using a ratchet with a 9/16 socket, tighten the ag Screw most of the way, enough to hold the Track in place, but allowing the Track to move. Swing the Track up to be horizontal, and repeat the same step on the opposite end of the Track. The hardware for the middle holes will be installed in this order: Adjustable Spacer, Flat Track, 1 Washer, and ag Screw. Using a ratchet with a 9/16 socket, tighten the ag Screw most of the way. Repeat on all remaining middle Track holes. After all ag Screws are in, fully tighten all using your ratchet with socket, being careful not to over-tighten to avoid stripping the wall studs. 9/16 Page 12

13 Installing the Door Guide and Anti-Jump Bracket 1. Installing Your Door ift your Door up to your Track at a slight angle. Carefully rest both Wheel grooves onto the top of the track. Guide the Door to the resting position. 2. Door Guide Part 1 3. Door Guide Part 2 Use your level to plumb* your Door. With the Door in the closed position, place the Door Guide half way into the Door mortise (the groove that runs along the bottom of a wood Door). Double check that your Door is plumb.* Hold the Door Guide firmly in position. Using a drill with a Phillips bit, install a 1 Grabber Screw to secure your Door Guide to the floor. *Plumb - perfectly vertical. Slide the Door into the open position exposing the other edge of the Door Guide. Using a drill with a Phillips bit, install a second 1 Grabber Screw. 4. Aligning Anti-jump Bracket Place your Anti-jump Bracket against the outside edge of your Door. Slide the Bracket up until there is a 1/16 to 1/8 space between the top of the Anti-jump Bracket and the bottom of the Track. 5. Installing Anti-jump Bracket Holding the Anti-jump Bracket firmly in place, drill Grabber Screws into each of the two holes in the Bracket until screw heads are flush with your Bracket. Installing this Bracket will ensure your Door will not come off its Track. Page 13

14 Installing a Header PEASE NOTE: We strongly advise you to have someone help you install your Header. We recommend your Header be 4 longer than your Track (Header would extend 2 past Track on both ends). Determining Header ocation Once you have penciled a line onto your wall for where your track will be installed (as per Track Installation Instructions), locate and mark where the wall studs are. Studs are marked When installing your Track, be sure you are drilling into wall studs or into a Header that is installed through the wall studs. This will provide the stability your wall needs to hold the weight of your Door. Measuring for your Track holes On your Header, measure in 3 from the end and 3 from the top and 3 from the bottom of the header Page 14 R H

15 INSTA Installing A TION INS a Header T R U C TION S Attaching Header Place your Header onto your wall with the bottom 2 of the Header below your marked track line. Have someone hold the Header in place while you continue your pencil line for the holes in your Track from your wall onto the Header. Ensure your line is plumb using a level. Mark for holes to be drilled making sure you will be drilling into studs. Drill 1/8 diameter pilot holes through the Header. Attach Header to the wall with 1-1/2 Grabber Screws and a drill. Track holes center over marked line for Track location Wall stud markings Header 2 { } 2 Doorway Your Header is ready for your Track System to be installed. R H Page 15

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