Rustica Hardware 12K1FS3070SI6BF Installation guide

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ROCKWELL

Two Panel

Door

Half X Door

Z Combination

Door

Double X Door

DOOR

4

1

in

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.

2.24.2017

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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: ese instructions are specic to a

particular door size and type. Adjustments may be

needed on your part for changes in specications and

measurements, as well as door types that are dierent

from these.

We recommend a dry assembly. It is recommended you

not use glue or adhesive of any kind while assembling

your Door.

PLEASE READ these important notifications before proceeding.

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.

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Parts Included

Two Panel Door

B2

C1

B2

B2 B2 B3

A2

A1

L

A3

B1 B2

D1

x 8

A4

A1

R

C2

C2 C2

C2

C2 C2

C3

Description Qty Description Qty

A1 L Side Stile Left 1 C1 C3 Top End Slats 1 each

A1 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

Tools

Needed

Ratchet with 7/16” deep

socket or a standard 7/16”

socket with extension

Drill with Phillips bit

F

side

view

front

view

E

x 36

* Quantities will vary depending on Door size. All quantities in this table are for an average-size single Door order.

Rubber Mallet

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B2

C1

B2 B2 B2

B3

A2

A1

L

A3

B1

B2

A4

A1

R

C2

C2 C2

C2

C3

1.

Assembling Your Door - Lay out your door as shown below.

Two Panel Door

Door bottom

with mortise

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 A1 and A2) are

oriented with the mortise facing down toward the

bottom of the door (the side that will be closest to the

oor when the door is hung).

Mortise

7

/16”

Slide all B slats to the right into A1 R. Next, slide A2, bottom Rail, up to A1 R and the B Slats.

Tap slats gently into place with a rubber mallet.

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Two Panel Door

2.

Slide Center Rail A3 down on top of the B Slats and into

Side Stile A1 R. Gently tap with a rubber mallet.

Slide all C Slats down and to the right into Center

Rail A3 and Side Stile A1 R. en slide top rail A4

down over the tops of the C Slats. Gently tap with

a rubber mallet.

3.

Slide Side Stile A1 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.

4.

B2

C1

B2 B2 B2 B3

A1

L

A3

B1 B2

A4

A1

R

C2

C3

A2

B2 B2

C1

B2B2B2 B3

A1

L

A3

B1

B2

A4

A1

R

C2

C2 C2

C2

C2 C2 C3

A2

5.

Attach Stile A1 L and A1 R to the door using the

6” Lag Bolts. Insert and tighten by hand, then use a

ratchet to tighten all Lag Bolts.

A1

L

7

/16”

7

/16”

7

/16”

7

/16”

A1

L

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Demi porte X

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.

6.

Half X Door

Complete Steps 1 through 5

from Pages 4 and 5.

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Porte combinaison Z

6.

Attach the Door Pull and your Door is ready to hang.

E1

x 36

A5

A6

When the Door is assembled gently tap all parts

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.

7.

Z Combination Door

Complete Steps 1 through 5

from Pages 4 and 5.

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Porte double X

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.

6.

A5

A6

B6

B5

B7

A7

Double X Door

Complete Steps 1 through 5

from Pages 4 and 5.

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Installation de la poignée de porte Falcon

Installation du système de quincaillerie industrielle

e 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.

Installing the Falcon Door Pull

Installing the Industrial Hardware System

Hanger Assembly Track Adjustable Spacers

Lag Screws Hex Bolts Acorn Nuts Anti-jump Brackets

1” Washers Grabber Screws

Door Guide

Instructions

Parts Included

Lag Soft Stops

3 ft.

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Installing the Industrial Hardware System

"

 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.

1. Measuring and Marking Your Hanger Holes

 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

 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.

2. Drilling Pilot Holes

3. Drilling Countersink Holes 4. Drilling Lag Screw Holes

 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.

1/8”

1-1/8”

3/8”

Door Edge

Door Front

Door Top

Door Edge

Door Back

Door Top

Door Front

Door Top

Door Edge

Door Top

2-3/8”

1/8”

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Installing the Industrial Hardware System

1. Installing Your Hanger Assembly To Your Door 2. Tightening Your Hanger Assembly

5/8”

 read 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

1” Washer Acorn Nut

 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”

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.

Determining Header Location

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).

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.

Installing a Header

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Installation d'un en-tête

Measuring for your Track holes

On your Header, measure in 3” from the

end and 4“ from the top and 2” from the

bottom of the header.

4”

3”

2”

4”

3”

2”

Your Header is ready for your

Track System to be installed.

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

Doorway

Header

Wall stud

markings

Installing a Header

} 2”

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}

 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” (oor 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.

}

Door Height

1/2”

1-5/8”

Door Height

1/2”

+

=

This 1-5/8” measurement

ensures coverage of your door-

way and makes it so your Track

assembly will not be visible from

the other side of your Door.

# of inches up from your =nished oor 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.

Measuring for Track Position

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.

1. Marking and Drilling Track Holes

 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).

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.

Fifth hole

on Doors

3’ 6” or wider

The number of holes in your Track

depends on the length of track ordered.

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Installation de la piste

Installing a Header

2. Hanging Your Track

 e 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.

 e 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”

 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).

 e center holes can now be loosely

attached (see below).

9/16”

3. Hole Installation

Installing the Track

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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.

1. Installing Your Door

4. Aligning Anti-jump Bracket

 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.

 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 rmly in place, drill

Grabber Screws into each

of the two holes in the

Bracket until screw heads are

ush with your Bracket.

Installing this Bracket will

ensure your Door will not

come o its Track.

Installing the Door Guide and Anti-Jump Bracket

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WE LOVE WHAT YOU’RE

houzz

DOING WITH THE PLACE

Congratulations on your decision to bring home an

American-made product of the highest quality. We

hope your piece brings art and function into your life.

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a chance to win a $500 Rustica instore credit

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