is page intentionally left blank.
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
Page is loading ...
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 specic to a
particular door size and type. Adjustments may be
needed on your part for changes in specications and
measurements, as well as door types that are dierent
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.
Page is loading ...
Parts Included
Two Panel Door
B2
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
Page is loading ...
B2
B2
C1
B2 B2 B2
B3
A2
A1
L
A3
B1
B2
A4
A1
R
C2
C2 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.
Page is loading ...
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
B2
C1
B2 B2 B2 B3
A1
L
A3
B1 B2
A4
A1
R
C2
C2
C2
C2
C2
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
Page is loading ...
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.
Page is loading ...
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.
Page is loading ...
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.
Page is loading ...
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.
Page is loading ...
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”
Page is loading ...
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
Page is loading ...
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”
Page is loading ...
}
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”
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.
Page is loading ...
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
Page is loading ...
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
Page is loading ...
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.
Don’t be a stranger, follow us on social media @RusticaHardware
Post images of your finished project on
Facebook or Instagram with #TitleContest for
a chance to win a $500 Rustica instore credit
Page is loading ...
/
