ROCKLER Heavy-Duty Cross Dowel and Bolt Instructions

: June 9, 2024
: ROCKLER

Table of Contents

ROCKLER Heavy-Duty Cross Dowel and Bolt
GENERAL SAFETY WARNINGS
Installation
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

ROCKLER Heavy-Duty Cross Dowel and Bolt

ROCKLER Heavy-Duty Cross Dowel and Bolt product

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 Heavy-Duty Cross Dowel and Bolt: 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:
- Installation
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 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 weatherboards’, 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.

WARNING:
Drilling, sawing, sanding or machining wood products can expose you to wood dust, a substance known to 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:
Danger indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING:
Warning indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION:
Caution indicates a hazardous situation that, if not avoided, may result in minor or moderate injury or property damage.
NOTICE:
Notice indicates important or helpful information and/or user tips.
PRODUCT SPECIFIC SAFETY WARNINGS
CAUTION:
After installation, periodically check all hardware to make sure it hasn’t come loose during use, and retighten as necessary. Non-permanent blue thread locker also could be used to help prevent loosening.

Installation

NOTICE:
Minimum stock thickness: 11⁄2″
Successful installation of this hardware depends on accurate measuring and marking, followed by drilling straight holes that align properly in both workpieces. There are a lot of variables in determining where to drill for the holes, including the dimensions of your stock and whether the outside edge of the assembled pieces will be flush or offset to create a reveal. As a general example, these instructions will show how to connect a 11⁄2″ x 31⁄2″ stretcher (the actual dimensions of a nominal 2×4 board) to a 31⁄2″ x 31⁄2″ leg (the actual dimensions of a nominal 4×4 post), with a 1/4″ reveal. If your materials are of different dimensions or your situation calls for a different reveal, you will need to calculate the measurements for your drilling locations.
NOTICE:
It’s a good idea to label the inside and outside faces of the stretcher and the faces of the leg to which the stretchers will be attached. This will help avoid confusion and help ensure that you drill holes in the correct faces of your workpieces.

Locate and mark the center on the end of the stretcher. This is where you will drill the 9/16″ diameter hole for the bolt. In our example scenario, it will be 13⁄4″ from the top and bottom and 3/4″ in from each face.
Use a square to extend the horizontal centerline from the end onto the inside face of the stretcher. Then calculate how far from the end of the stretcher the hole for the cross dowel needs to go. To do this, subtract the thickness of the leg from 43⁄4″. In this case, the leg is 31⁄2″, so the equation would be 43⁄4″ – 31⁄2″ = 11⁄4″. Then measure 11⁄4″ in from the end of the stretcher and make a vertical mark on the inside face. This marks the location for the 7/8″ diameter hole for the cross dowel. NOTICE:
Because of the diameter of the washer, the through hole in the leg must be centered at least 3/4″ from the edge of the leg. Otherwise, the washer will extend beyond the edge of the leg.
If you’re mounting stretchers at the same height on adjacent faces of the legs, be sure to vertically offset the drilling locations for the bolts and cross dowels. Otherwise, the holes in the leg will intersect and it will be impossible to install the hardware for both stretchers.
Switch to the leg to mark the drilling location for the through hole for the bolt. Accuracy is crucial: For the hardware to work, this hole must align exactly with the hole in the end of the stretcher. In our example, the top of the stretcher is flush with the top of the leg, but the outside face of the stretcher
is set back 1/4″ from the outside face of the leg. As a result, the horizontal mark for the through hole will be the same distance from the top of the leg as from the top of the stretcher (13⁄4″); but, for the vertical mark, the 1/4″ setback will need to be added to the 3/4″ distance for the vertical mark on the stretcher. Adding 1/4″ to 3/4″ equals 1″, so measure 1″ in from the outside face of the leg and make a vertical mark. NOTICE:
It is very important that the holes for the bolt and cross dowel are straight and square to their reference surfaces. Rockler has created the adjustable XL Cross Dowel Jig (62757, sold separately) to make accurate drilling easier with a handheld drill. Otherwise, we recommend using a drill guide, such as Rockler’s Portable Drill Guide (52885, sold separately), to drill the holes. Or, you can create shop-made drilling guides.
Use a 9/16″ diameter drill bit (55227, sold separately) to drill a through hole in the leg at the marked location and, in our example scenario, a 2″ deep stopped hole in the end of the stretcher (11⁄4″ to reach the cross dowel and an extra 3/4″ to keep the bolt from bottoming out in the hole).
Switch to a 7/8″ diameter Forester bit and drill a 17⁄16″ deep hole for the cross dowel on the inside face of the stretcher. Note that, depending on variations in material thickness, this hole might go all the way through.
With the slotted end facing you, fit the cross dowel into the hole you just drilled in the stretcher.
Position the stretcher against the leg so that the end-grain hole in the stretcher aligns with the through hole in the leg.
Insert the bolt in the through hole in the leg and fit it into the end-grain hole in the stretcher. Use a flat-head screwdriver to rotate the cross dowel until you are able to thread the bolt into it.
CAUTION:
After installation, periodically check all hardware to make sure it hasn’t come loose during use, and retighten as necessary. Non-permanent blue thread locker also could be used to help prevent loosening.
Use a 13/16″ wrench to tighten the bolt and bring the parts securely together.

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