STAINLESS STEEL TOP MOUNT ROLLING DOOR HARDWARE KIT INSTRUCTIONSRevised October 2018

Review instructions fully prior to use for important safety information. Always check Rockler.com to confi rm that you are using the most recent version for your product.

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GENERAL SAFETY WARNINGS

This product is designed only for specific applications as defined in the instructions and should not be modified or used for any manner not described in these instructions. Use only recommended accessories. Before using the Stainless Steel Top Mount Rolling Door Hardware Kit: READ, UNDERSTAND and FOLLOW ALL INSTRUCTIONS AND SAFETY WARNINGS. KEEP THESE INSTRUCTIONS READILY AVAILABLE FOR FUTURE REFERENCE.

> Always confirm that you are using the most recent version of the Instructions and safety warnings for your product (see the Instructions link on the product page at Rockler.com).

> Before using another tool with this product, always read, understand and follow the instructions and safety warnings in the owner’s manual for that tool. If you do not have the owner’s manual, obtain one from the tool’s manufacturer before using it with this product.

> Before using any chemical with this product, always read, understand and follow all safety warnings and guidelines in the manufacturer’s Safety Data Sheet (SDS; formerly called “MSDS”), especially regarding: • How to safely use the chemical, including potential hazards and recommended first aid measures; • Personal safety equipment required to safely use the chemical (e.g. gloves, eye protection, mask/respirator, etc.); • Proper and safe handling, storage and disposal of the chemical.

> Before using this product, review and verify that all tools to be used with it have safety equipment installed and are in proper working order as defined by the tool’s owner’s manual.

> Do not use this product until you have read and are confident you understand: • Product Specific Safety Warnings (p. 3); • Parts List (p. 4); • Install the Brackets (pp. 5-6); • Install the Round Rails (p. 6); • Cut Slot in Bottom of Door (p. 7); • Install the Door Hardware (pp. 7-8); • Hang the Door and Install the Floor Center Guide (p. 8).

> The user assumes all risk and responsibility for the proper and safe use of this product and for ensuring product suitability for the intended application.

> It is the sole responsibility of the purchaser of this product to ensure that any anyone you allow to use this product reads and complies with all instructions and safety precautions outlined in this manual prior to use.

> Follow all standard shop safety practices, including: • Keep children and bystanders away from the tool operating area; • Do NOT use power tools in explosive environments, or in the presence of flammable liquids, fumes or dust; • TURN OFF AND UNPLUG all power tools BEFORE making any adjustments or changing accessories; • Remain alert and use good judgment. Do not use this product if you are in any way impaired by medications, alcohol, drugs or fatigue; • Keep your work area well lit and clean; • Dress appropriately. Secure loose clothing, remove all jewelry and tie up long hair before using this product; • ALWAYS wear safety glasses, hearing protection and respiratory protection that complies with NIOSH/OSHA/ANSI safety standards; • Use dust collection tools and dust face masks to reduce exposure to dust; • Use safety equipment such as featherboards, push sticks and push blocks, etc., when appropriate; • Maintain proper footing at all times and do not overreach; • Do NOT force woodworking tools.

> These warnings and instructions do NOT represent the total of all information available regarding tool safety, use and technique. Always seek out opportunities to learn more and improve your skills and knowledge.

Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known ot the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. For more information go to www.P65Warnings.ca.gov/wood.

Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.

Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injuryor property damage.Notice indicates important or helpful information and/or user tips.

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PRODUCT SPECIFIC SAFETY WARNINGS

> To avoid serious injury, keep hands and fingers away from spinning router bit. Maintain awareness of the bit at all times.

> Maximum weight capacity (including door and hardware): 200 lbs.

> This Rolling Door Hardware MUST be mounted to structurally sound solid wood wall studs for safe operation. Do NOT mount to studs that have wood rot, termite/other pest damage or significant sections of material cut out.

> Do NOT use wall anchors or drywall anchors to mount Rolling Door Hardware.

> Do NOT install against walls with metal studs or to brick or masonry.

> For use only with structurally sound solid wood doors. Use of doors made from composite, poor quality or deteriorated material could allow the hardware to unexpectedly pull out of the door during installation or use, possibly resulting in personal injury or property damage.

> You MUST install the included Rail Stops (6 and 7) to help ensure the door cannot come off the track. Failure to properly install these safety items could result in serious injury.

> Never use a power tool on an unsecured workpiece. The workpiece could shift, potentially causing dangerous kickback, damage and serious injury.

> Use proper lifting technique and get the help of another adult to lift the door, if necessary. Failure to do so could result in serious injury.

> After use, periodically recheck all mounting hardware and tighten as necessary to ensure that it is properly secured.

> If you are building a door, make it a minimum of 1" taller and 2" wider than the door opening. Depending on your installation area, you might want to increase the door dimensions.

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PARTS LIST

Quantity1 Round rail 22 Rail Coupler 13 Brackets 54 Bracket Shims 55 Top Mount Roller 26 Left Rail Stop 17 Right Rail Stop 18 Floor Center Guide 19 #12 x 11⁄4" Flathead Screw 310 #10 x 3" Flathead Screw 511 M6 x 30mm Hex Drive Flathead Bolt 412 Threaded Insert (for M6 bolt) 413 4mm Hex Wrench 114 6mm Hex Wrench 1

Discard any parts not shown above

5

1

8

4

3

2

12

9

10

11

14

13

7

6

5

Install the Brackets

> This Rolling Door Hardware MUST be mounted to structurally sound solid wood wall studs for safe operation. Do NOT mount to studs that have wood rot, termite/other pest damage or significant sections of material cut out.

> Do NOT use wall anchors or drywall anchors to mount Rolling Door Hardware.

> Do NOT install against walls with metal studs or to brick or masonry.

1. At the mounting area above the door opening, use a stud finder to locate and mark all wall stud locations along the full 787⁄8" length of the planned installation. Be sure to mark at least one stud location on each side that’s outside the edges of the door opening. Fig. 1.

2. Use a level to mark a level line along the full 787⁄8" length of the installation area at a height equal to the height of your door plus 23⁄8". Fig. 2.

3. Choose five stud locations distributed as evenly as possible along the horizontal line and drill a 3/32" diameter pilot hole at those points.

4. Gather the Brackets (3). Use the 4mm Hex Wrench (13) to loosen the socket-head screw on each Bracket enough that the front section can rotate down to provide full access to the mounting hole. The black plastic spacer in each Bracket might fall out as you do this, so be sure to catch them and keep track of them. You will need to reinsert them when mounting the Round Rail (1). Fig. 3.

5. Sight down the length of the installation location on the wall (or use a long level or other straightedge) to determine if there are any big surface inconsistencies. If there are,

Fig. 1

787⁄8"

Stud locations

Fig. 2

Fig. 3

Door height plus 23⁄8"

Bracket Back Plate

Bracket Front Plate

Black Spacer

Socket-head Screw

Rail (unmounted)

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make note of where they are so you can use one or more of the included Bracket Shims (4) behind the Bracket to even it out.

6. At each pilot hole location, secure a Bracket (3) to the wall by driving a #10 x 3" Flathead Screw (10) into a wooden wall stud and using Bracket Shims (4) if needed. Make sure that each Bracket is secured tightly and positioned so that the channel will run parallel. Fig. 3.

Install the Round Rails1. Press the Rail Coupler (2) into the open end of one of the Round Rails (1); then press the open end of the other Round Rail onto the Rail Coupler to form one long rail for the door to slide on.

2. Before mounting the Rail (1 and 2), determine roughly where you want the door to stop when open and when closed. (It’s easier to do this now because you might need to position the Rail Stops [6 and 7] between Brackets, and you won’t be able to do that after the Rails have been attached.) Fig. 4.

3. Once you decide on the locations, slide the Left and Right Rail Stops (5 and 6) into rough position on the Rail, making sure the heads of the set screws are facing out. (You will fine-tune the position and tighten the screws after you have hung the door.)

4. Lift the Rail assembly onto the Brackets. Make sure to reinsert the black plastic spacer in each Bracket, rotate the front section back into position and tighten the socket-head screw to capture the Rail. Continue until all Brackets are tightened.

Fig. 3

Fig. 4 - Approximate open and closed door positions

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10

Black Spacer

Socket-head Screw

Bracket Front Plate

Bracket Back Plate

6 7Rail (before mounting)

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The Floor Center Guide (8) is designed to keep the door from swinging out or in as it is opened and closed. You must cut a 3/8" wide x 5/8" deep slot along the bottom of the door to accommodate it. Fig. 5.

1. Clamp or otherwise secure the door on a work surface with the bottom edge of the door overhanging slightly. Clamp sacrificial scrap pieces to the leading and trailing edges of the door to prevent tearout as the bit enters and exits the door.

2. Lay out the location of the slot on the bottom edge of the door, keeping in mind that it must be centered. Measure down from the top face of the door to gauge the setup for the initial cut with your router. (You will need to cut the slot in at least two passes.)

3. Chuck a 1/4" bearing-guided slot-cutting bit (92200 or 91785, sold separately) in a handheld router and set the bit depth for the first cut.

4. Make sure that the door is securely clamped. Then, with the router base resting on the face of the door and the bit clear of the door bottom, start the router and slowly rout the slot. Keep the bit’s guide bearing in contact with the door bottom as you make the first cut.

5. Turn off and unplug the router; then adjust the bit cutting depth for the second cut needed to achieve the 3/8" wide slot.

6. Plug in the router and make the second cut to complete the slot.

Install the Door Hardware1. Lay out and drill 8mm or 5/16" pilot holes for the Threaded Inserts (12) on the top of your door, as shown in Fig. 6. The outer holes should be 3" in from their respective corners. All holes should be centered on the width of the door’s top edge.

Cut Slot in Bottom of Door

THESE WARNINGS PERTAIN TO ALL REMAINING STEPS:

> To avoid serious injury, keep hands and fingers out of the path of spinning router bit. Maintain awareness of the bit at all times.

> Turn off and unplug your router before changing the bit or adjusting the cutter height.

> Never use a power tool on an unsecured workpiece. The workpiece could shift, potentially causing dangerous kickback, damage and serious injury.

Fig. 6 - Top edge of door

Fig. 5

Bottom edge of door

5/8"

3/8"

51⁄8"

3"

8mm or 5/16" pilot holes centered on the width of door’s top edge

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The Floor Center Guide must be positioned so it will remain in the slot in the bottom of the door through the door’s full range of travel.

Distributed by Rockler Companies, Inc.Medina, MN 55340

53051Rev 10/18

Cover Size

Check Rockler.com for updates to these instrutions. If you have further questions, please contact our Technical Support Department at 1-800-260-9663 or support@rockler.com

2. Use the 6mm Hex Wrench (14) to drive the Threaded Inserts (12) into the top of the door until they are flush with the surface. Try to keep the inserts perpendicular to the door top as you drive them. Fig. 7.

3. Install the Top Mount Rollers (4) on the door, using the 4mm Hex Wrench (13) to drive and fully tighten the M6 x 30mm Hex Drive Flathead Bolts (11). Fig. 7.

Hang the Door and Install the Floor Center Guide

1. Lift the door onto the Rail, making sure the wheel of each Top Mount Roller (4) is engaged on the Rail and the door can move freely.

2. With the door properly positioned on the Rail and hanging freely, position the Floor Center Guide (8) as shown in

Fig. 8. The vertical posts should be centered in the slot in the bottom of the door, and the Floor Center Guide should be positioned just past the rear edge of the door opening.

3. Mark the screw locations for the Floor Center Guide and drill pilot holes, if necessary. Secure the Floor Center Guide with three #12 x 11⁄4" Flathead Screws (9). Fig. 8.

4. Finalize the positioning of the Left and Right Rail Stops (7 and 7) to provide the desired overlay at the front and back of the door. Tighten the Rail Stops with the included 4mm Hex Wrench (13).

Fig. 7

Fig. 8

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12

12

11

4

8

9

> Maximum weight capacity (including door and hardware): 200 lbs.

> Use proper lifting technique and get the help of another adult to lift the door, if necessary. Failure to do so could result in serious injury.