ROCKWELL
4-IN-1 DOOR
Tw o Panel
Door
H alf X
D oor
Double X
Door
Z C omb inati on
D oo r
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.
P LE AS E RE A D
th e se i m po rt a n t n o ti f i c at i o ns be fo re pro c e edi ng .
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 below 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.
Tw o Panel Door
Tools
Needed
Ratchet with socket Drill with Phillips bit
Parts Included
A4
D1
A1
L C1 C2 C2 C2 C2 C2 C2 C3
A1
R
D1
D1 D1
A3
B1 B2 B2 B2 B2 B2 B2 B3
D1
D1
A2
E side view front view
F
A1 L
A1 R
A2
A3
A4
E
Description
Side Rail Left
Side Rail Right
Bottom Rail
Middle Rail
Top Rail
Industrial Hangers
Qty
1
1
1
1
1
2
B2
D1
F
Description
C1 C3 Top End Slats
C2 Top Center Slats
B1 B3 Bottom End Slats
Bottom Center Slats
6” Timberlocks
Falcon Door Pull
* Quantities will vary depending on Door size. All quantities in this table are for an average-size single Door order.
Qty
1 each
6 each*
1 each
6 each*
6*
1
Tw o Panel Door
Assembling Your Door
1.
Slide all B slats to the right into A1 R. Next, slide A2, Bottom Rail, up to A1 R and the B Slats. Attach with the bottom, right-hand Timberlock (D1) by hand, then by using a ratchet. Have someone help keep the door, slats and rails in place as you attach the Timberlocks. Keep your Timberlocks straight as they go in to keep your door square.
A4
D1
D1
A1
L
C1 C2 C2 C2 C2 C2 C2 C3
A1
R
A3
D1
D1
B2 B2 B2 B2 B3
B1 B2 B2
D1
D1
A2
Two Panel Door
2.
Slide Center Rail A3 down on top of the B Slats and into Slat A1 R. If necessary, have someone help keep the door square as you attach with the Timberlocks. Have all
Timberlocks go in straight, using your hands first, then a ratchet.
D1
D1
A4
A1
L
C1 C2 C2 C2 C2 C2 C2 C3 A1
R
A3
D1
D1
3.
Slide all C Slats down and to the right into
Center Rail A3 and Side Slat A1 R.
Then slide top rail A4 down over the tops of the C Slats.
D1
A4
D1
A1
L
C1 C2 C2
A3
B1 B2 B2B2 B2B3
B1 B2 B2B2 B2B3
A1
R
D1
D1
D1
D1
A2 D1
A2
4.
Slide Side Slat A1 L over to cover the left edge of your Door. Insert the Timberlocks 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 A1 L.
A1
L
5.
Attach Slat A1 L to the door using the 6” Timberlocks. Insert by hand, then use a ratchet to tighten.
Half X Door
4.
Slide all C Slats into A1 R and A3 grooves. Once all of the slats have been positioned, place the A4
Top Rail onto the C slats and in the A1 R grooves.
Fasten A4 into place with a Timberlock, first with your hand, then tighten with a ratchet. Be sure the Timberlock is going straight in and not at an angle.
A4
A1
L
C1 C2 C2 C2 C2 C2 C2 C3
A3
A1
L
5.
Slide Side Slat A1 L into place, attaching with 6”
Timberlocks, tightening by hand. Once you have determined all are in place straight, tighten Timberlocks with a ratchet.
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 1-1/4” Grabber
Screws and a drill with a Phillips bit.
Attach the Door Pull and your Door is ready to hang.
Z C omb ination Do or
Half X Doo r
Z Co mbination Door
4.
Slide Top Rail A4 into place, to cover the tops of the C
Slats. Install top Timberlock.
A4
5.
Slide Side Slat A1 L into place, attaching with all three Timberlocks, tightening by hand. Once again, have someone help you keep all of the Slats straight. Once you have determined all are in place, tighten Timberlocks with a ratchet.
A1
L
6.
When the Door is assembled, place A5 Rails (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 1-1/4” Grabber Screws and a drill with a Phillips bit.
7.
Attach the Door
Pull and your
Door is ready to hang.
A5
E1
A6
5.
Slide Side Slat A1 L into place, attaching with 6”
Timberlocks, tightening by hand. Once you have determined all are in place straight, tighten
Timberlocks with a ratchet.
A1
L
Double X Door
4.
Slide all C Slats into A1 R and A3 grooves. Once all of the slats have been positioned, place the A4
Top Rail onto the C slats and in the A1 R grooves.
Fasten A4 into place with a Timberlock, first with your hand, then tighten with a ratchet. Be sure the Timberlock is going straight in and not at an angle. Fasten by hand, then with a ratchet.
A1
L
C1 C2 C2
A4
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 1-1/4” 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
B5
A7
B6
A6
B7
A5 A6
B5
A7
B6
B7
Ins tallin g 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.”
Ins talling the Industrial Hangers
Parts Included
Hanger Assembly Track Adjustable Spacers Hard Stops or Lag Soft Stops
Lag Screws Hex Bolts Acorn Nuts Anti-jump Brackets
1” Washers Grabber Screws Door Guide Instructions
Ins talling the Industrial Hangers
1. Measuring and Marking Your Hanger Holes
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.
2
"
• 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.
Door Front
Door Edge
Door Top
2-3/8”
2. Drilling Pilot Holes
Door Top
• 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
1/8”
Door Front
3. Drilling Countersink Holes
Door Top
Door Back
4. Drilling Lag Screw Holes
Door Top
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.
1-1/8” 1/8”
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.
3/8”
Door Edge
Ins talling the Industrial Hangers
1. Installing Your Hanger Assembly To Your Door
• 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
5/8”
2. Tightening Your Hanger Assembly
• 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”
Acorn Nut 1” Washer
Me as uring for Track Position
1. Measuring for Track Position
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.
}
Ins talling the Track
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.
1/4”
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
Hard Stop or Lag Soft Stop
• 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.
• The end holes will be
installed with a either a Hard
Stop a Lag Soft Stop.
• In this order: Adjustable Spacer,
Flat Track, [Hard or Lag Soft]
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.
9/16”
I nst al ling th e Door Guide and Anti-Jump Bracke t
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
• 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.
3. Door Guide Part 2
• 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.
