ROCKWELL 4 in 1 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. Two Panel Door Half X Door Double X Door Z Combination Door R 8.22.2016
PLEASE READ these important notifications before proceeding. If any of the slats have been damaged during shipping, call us at 800-891-8312 and we will expedite replacement slat(s) or parts as needed. Lay out your Door slats and parts according to the illustration shown at right to accurately identify which part needs to be replaced, if any. PLEASE 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 1.800.891.8312 and our friendly representatives will be happy to assist you. Page 2
Two Panel Door Tools Needed Ratchet with 7/16 deep socket or a standard 7/16 socket with extension Drill with Phillips bit Rubber Mallet Parts Included A4 D1 x 8 L C1 C2 C2 C2 C2 C2 C2 C3 R side view front view A3 E x 36 B1 B2 B2 B2 B2 B2 B2 B3 F A2 Description Qty Description Qty L Side Stile Left 1 C1 C3 Top End Slats 1 each R Side Stile 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 D1 6 Lag Bolts 8* E Grabber Screws 36* F 12 Falcon Door Pull 1 * Quantities will vary depending on Door size. All quantities in this table are for an average-size single Door order. Page 3
NOTE: Your door has a mortise (a 1/2 groove that runs along the bottom of your door) that will house the door guide. When assembling the door make sure that all pieces with a mortise (pieces and A2) are oriented with the mortise facing down toward the bottom of the door (the side that will be closest to the floor when the door is hung). Door bottom with mortise Two Panel Door Assembling Your Door - Lay out your door as shown below. 1. Slide all B slats to the right into R. Next, slide A2, Bottom Rail, up to R and the B Slats. Tap slats gently into place with a rubber mallet. 7 /16 A4 L C1 C2 C2 C2 C2 C2 C2 C3 R A3 B1 B2 B2 B2 B2 B2 B2 B3 A2 Mortise Page 4
Two Panel Door 2. Slide Center Rail A3 down on top of the B Slats and into Side Stile R. Gently tap with a rubber mallet. 7 /16 3. Slide all C Slats down and to the right into Center Rail A3 and Side Stile R. Then slide top rail A4 down over the tops of the C Slats. Gently tap with a rubber mallet. A4 A4 7 /16 L C1 C2 C2 C2 C2 C2 C2 C3 R L C1 C2 C2 C2 C2 C2 C2 C3 R A3 A3 B1 B2 B2 B2 B2 B2 B2 B3 B1 B2 B2 B2 B2B2B2 B3 A2 A2 4. Slide Side Stile L over to cover the left edge of your Door. If necessary, have someone help you hold all slats and rails in place while you are positioning all parts. Lightly tap all into place with a rubber mallet. 5. Attach Stile L and R to the door using the 6 Lag Bolts. Insert and tighten by hand, then use a ratchet to tighten all Lag Bolts. 7 /16 7 /16 L L Page 5
Complete Steps 1 through 5 from Pages 4 and 5. Half X Door 6. When the Door is assembled, place A5, A6 and A7 (Diagonal Rails) onto the door s bottom panel 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
Z Combination Door Complete Steps 1 through 5 from Pages 4 and 5. 6. When the Door is assembled gently tap all parts 7. Attach the Door Pull and your Door is ready to hang. into place with a rubber mallet. Place both A5 Diagonal Rails onto the door so the predrilled holes are facing up and so they run the same way, from corner to corner. Attach using the 3/4 Grabber Screws and a drill with a Phillips bit. A5 E1 x 36 A6 Page 7
Double X Door Complete Steps 1 through 5 from Pages 4 and 5. 6. When the Door is assembled, gently tap all parts into place. 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. Repeat for B5, B6, and B7 (Lower Diagonal Rails). Attach the Door Pull and your Door is ready to hang. A5 A6 A7 B5 B6 B7 Page 8
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 could 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 Hardware System Parts Included Hanger Assembly Track Adjustable Spacers Lag Soft Stops Lag Screws Hex Bolts Acorn Nuts Anti-jump Brackets 1 Washers Grabber Screws Door Guide Instructions Page 9
Installing the Industrial Hardware System 1. Measuring and Marking Your Hanger Holes 2. Drilling Pilot Holes Door Top Door Top Lay 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 Edge Door Front Door Top 1/8 2-3/8 3. Drilling Countersink Holes 4. Drilling Lag Screw Holes Door Top Door Top Door Back Door Front Lay 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 Lay 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
Installing the Industrial Hardware System 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 Installing a Header PLEASE 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 Location 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. Page 11
Installing a Header Measuring for your Track holes 3 3 On your Header, measure in 3 from the end and 3 from the top and 3 from the bottom of the header. 3 3 3 3 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 3 Grabber Screws and a drill. Track holes center over marked line for Track location Wall stud markings Header } 2 Doorway Your Header is ready for your Track System to be installed. Page 12
If you are installing a Flat Track System, proceed. If you are installing a Tube, Box, Bypass, J or Heavy-Duty Bypass Track System, call our helpful Customer Service Representatives for instructions on how to install these track systems. Measuring for Track Position 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 your =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. The number of holes in your Track depends on the width of Door and length of Track ordered. There will typically be four holes unless your Door is 3 6 or wider. 1. Marking and Drilling Track Holes Fifth hole on Doors 3 6 or wider 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 (see page 12). Page 13
Installing the Track Installing a Header 2. Hanging Your Track Loosely attach one end of the Track using a Spacer and a Hard Stop or a Lag Soft Stop (see below). Swing the Track up and loosely attach the other end, using a Spacer and a Hard Stop or a Lag 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 Lag Screw. Using a ratchet with a 9/16 socket, tighten the Lag 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 Lag Screw. Using a ratchet with a 9/16 socket, tighten the Lag Screw most of the way. Repeat on all remaining middle Track holes. After all Lag 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 14
Installing the Door Guide and Anti-Jump Bracket 1. Installing Your Door Lift 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 15
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