Catskill Craftsmen 54238 Instructions / Assembly
Contents
1. No pilot holes as softwood 5 8 Pan Head Screws STEP 10 A Lay the cart on it s back Insert and tap caster sockets with hammer until the teeth grab the wood DON T POUND SOCKET FLAT OR CASTER SHAFT WILL NOT ENTER B Insert casters and seat by pushing straight downward with heel of your hand or tap into place with a hammer Don t be afraid to give them a good downward whack on the solid metal part of the caster C Locking wheels usually go on front STEP 11 A Upright unit B Determine if you want the Spice Rack on the left or right Side Panel The Handle Towel Bar will go on the other Attach the Spice Rack to the Side Panel with two 1 8 screws from inside the panel Place a washer over the screw so that so that the head won t pull through the side panel C Attach Towel Bar to the other Side Panel with 1 8 screws from inside the Side Panel Place a washer over each screw STEP 12 A Angle the Bottom Shelf as necessary to pass it through the opening in the cabinet top until it rests on the pins installed in step 8C STEP 13 A Tap 1 pins into the 4 sets of holes in the Back Edge banding toward front of unit Panel B Just above t2. 5 8 Phillips Flat Head 5 Screw 4 ED tt 1 Phillips Flat Head 8 Screw 4 L KN Used to attach door handles 7 8 Truss Head Machine Screw 8 Gb A Used to attach drawer handles 1 Truss Head Machine Screw 4 divider panel pin for shelves 2 Long 3 16 DIA Steel Pin 8 LY a0 iy 1 1 2 Long 3 16 DIA Steel Pin 8 LY shetty 1 Long 3 16 DIA Steel Pin 22 LY rave pin 3 4 Long 3 16 DIA Steel Pin 4 Used to attach towel bar and spice rack L Magnet Pack 0 J te Oo Magnet 4 Magnet Plate 4 EP DEE Used on Magnet Plate 1 2 Phillips Flat Head 4 Screw 4 aam 5 8 Pan Head Screw 8 Used on Magnet 5 8 Wooden Disk 8 Bastion Set Screw 2 wii ID D Bastion Barrel Nut 2 Polished Nickel Towel Bar 1 L Bracket 4 Towel Bar Post 2 Nickel Handle 6 D ea Metal Shelf Pin 4 Caster Socket 4 Locking Wheel Casters 2 Wheel Casters 2 STEP 1 A Tap insert ONE 1 1 2 pin into each end of all the doors DON T OVERDRIVE PINS Pins should stick up about 1 2 when seated B Attach the magnet plate ss a may be stuck to magnet with the 1 2 4 screw F 7 to the top of the doors Bumps go toward the wood C Attach door handles with 7 8 truss head
3. 4238R Divider Panel 2 P N DP 54238 Drawer Bottom 1 P N DBOT 54238 Drop Leaf 1 P N DL 54238 Table Top 1 PIN TT 54238 lo g D o Pe ze Glide Support Stick 2 P N GLDSUP 54238 lo Side Panel 2 P N SP HDL 54238 ja Left Door 1 P N DOR 54238LO Left Center Door 1 P N DOR 54238LC Right Center Door 1 P N DOR 54238RC Right Door 1 P N DOR 54238RO Spice Rack Side Left 1 P N SR 54238L Back Panel 1 P N BP 54238 Spice Rack Side Right 1 P N SR 54238R Spice Rack Shelves 2 P N SRS 54238 31 Hardware for 54238 ED B 1 3 4 Phillips Flat Head Bolt 8 OD Retainer Rods for Spice Rack 2 ED BNS 8 are bronze for spice rack eee Drawer 1 1 4 Phillips Flat Head 8 Screw 16 Used to attach ED AAA drawer back P N Drop Leaf Support 2 Y 1 1 2 Phillips Flat Head 8 Screw 2 ED Pua EERS Nen SIE 5 8 Phillips Flat Head 8 Screw 26 p a 3 16 Flat Washer 8 CO kiii HD 8 Used on L Brackets 7 2 and 4 used for Drawer glides O Bastion Post 2 5 8 Phillips Flat Head 7 Screw 12 10 24 Hex Nut 8 GE Used on Drawer Glides
4. K OIL COUPON Please send me of bottle s of the Catskill Craftsmen Butcher Block Oil at 6 95 per bottle My check or money order is enclosed for a total of Item code 54238 Name Address City State Zip Please make checks payable to Catskill Craftsmen Inc 15 West End Ave Stamford NY 12167 1296
5. POU ad CATSKILL CRAFTSMEN Assembly Instructions Model 54238 Butcher Block WorkCenter PLUS with Drop Leaf GENERAL 1 You have purchased model 54238 2 Should you need assistance or need to replace a damaged or missing part simply give us a call M F at 607 652 7321 from 7 30 am 4 30 pm EST and we ll send you the prepaid part via UPS usually that same day You may also email us info catskillcraftsmen com 3 Read the assembly instructions and the enclosed brochure before beginning assembly Assembly is easy if you read and follow the instructions step by step See our website for assembly tips and videos 4 Tools required Phillips screwdrivers medium and small medium flat blade screwdriver and a hammer 5 Drawer glides are sometimes pre packed with screws these are not used 6 Directions left right front back are given as facing the front of an assembled upright unit Parts List Model 54238 Center Shelf 1 P N CS 54238 Small Middle Shelf P N SMS 54238 2 Bottom Shelf 1 P N BS 54238 Top Front Brace 1 P N B 38 2 7 16 TF 54238 Bottom Front Brace 1 P N B 38 2 7 16 BOT 54238 Drawer Front 1 P N DF 54238 Drawer Back 1 P N DBK 54238 fa 4 Left Drawer Side 1 P N DS 54238L Right Drawer Side 1 P N DS 5
6. S IT WRONG Post needs to be screwed deeper WILL STRIP THE POST HOLE C When solid shaft of Post hits wood back out approximately turn until the hole in the posts is properly aligned as per step by step directions For example the holes in the posts on the inside of the drawer front will be parallel with the long length of the drawer front when properly seated 3 A Place a Barrel Nut into the nut access hole so that the threads in the nut face out The small notches on either side of the nut opening indicate the location of the holes through the sides of the nut B Insert the posts through the end of the braces or drawer sides through the holes in the sides of the nut When properly aligned you will see the hole in the post inside the barrel nut Post hole should be slightly off center toward the wood CORRECT Set screw secures post properly 4 Insert the Set Screw into the threaded end of the nut and tighten down The tip of the Set Screw will seek the center of the hole in the Post as it is tightened down forcing the Nut toward the main shaft of the Post This is what tightens the wooden parts together Set screws should thread easily DON T CROSS THREAD If Set Screw doesn t thread easily check position of the hole in Post 5 If the wooden parts are not tight against each other the Post needs to be screwed a half turn at a time until wood joints are tight Illustration Bas 2 Illustration Bas 3
7. Step 1 TA I OO D CO TY ALTERNATIVE METHODS FOR SEATING POSTS Allen Wrench Provided See video on our website If you have any questions regarding assembly or missing or damage parts call our customer support number 607 652 7321 or 888 732 7321 Customer Support Hours are 8am 5pm Mon Fri Eastern Time zone STEP 5 A Attach a Glide Support Stick to the top of each Side Panel using 1 1 4 8 screws The countersunk holes reamed out in the stick are positioned as in illustration 1 so that the glide holes are toward the lower edge Sticks should be flush with top of panel B Attach the cabinet glide of the Drawer Glides to the Glide Support Stick using 5 8 7 flat head screws Left glide to left Side Panel right glide to right Side Panel The glides look almost alike however the right glide as you face the cart has a rolled lip at the top of the glide that keeps the drawer glide wheel in place Line up the holes in the glides so that the end with the wheel comes flush with the front edge of the Table Top Stick Only 2 holes in the glide support are used C Attach the L brackets to the top of the glide supports using 5 8 7 screws Use hole rather than slot Note Glides are marked right left with imprint behind wheel 5 8 7 Screw TOP a TOP 11 4 8 Screw g SS A 5 8 7 Screw S Po
8. d z STEP 6 A Lay Back Panel flat on a smooth surface with holes up B Attach Side Panels with 1 3 4 machine screws bolts and hex nuts After inserting bolts thru the holes in the Side Panels thru the holes in the long edges of the Back Panel place a hex nut on the tip of your finger align nut with bolt and tighten Back panel has 1 1 4 space at the top C Look ahead to step 7 which shows side panels attached to back panel D Insert 1 pins into back panel as shown 1 3 4 Bolts OT f 6 6 LA i LA 6 i y o o o o o pi Note Wheel on glide is to the front of the unit STEP 7 Bottom Brace Assembly A Secure bottom brace with 1 3 4 bolts nuts as shown B Insert 1 pins into the side panels as shown 1 3 4 Bolts STEP 8 Door Assembly 1 3 4 Bolts STEP 9 A Stick magnet to magnet plate on a door B With all other doors open close the a door The magnet should be positioned 4 i over the wooden block on the bottom of the o top front brace Hold the magnet in place with your thumb and open the door The magnet will be in the correct position on the block C Secure magnet with the two pan head screws in the magnet packet Center screws in the slot in the magnet This will allow adjustment later if needed D Repeat these steps for all the doors
9. he Bottom shelf on the inside ra of the Bottom Front Brace there are two sets of holes 2 Pins Tap 1 pins into these holes C On the Inside face of the Top Front Brace there is a hole adjacent to each of the magnet blocks for the outside doors Tap one 1 pin into each hole D Choose the height you want your middle shelves then tap the 2 pins in accordingly on the Cabinet Dividers For Side Panels use the metal shelf pins E Slide the Cabinet Dividers between the sets of pins in the Back Panel and the pins in the Front Braces until dividers rest on the Bottom Shelf Make sure the edge banding faces out pad Pins 9 Divider l in place gt NOTE Eight 2 pins are provided in case you want the center middle shelf amp the side middle shelves at different heights ILLUSTRATION 14A MAN STEP 14 A Invert Table Top on a smooth flat surface and make a large X mark over each of the 4 pilot holes in the bottom P Make marks about 1 1 2 long These marks will help you align the cabinet with the pilot holes in the bottom of the Top B Attach hinges drop leaf supports with 5 8 8 screws Place the Cart Top on the cabinet V C Open the ou
10. machine screws STEP 2 A Take the 2 front braces and tap insert one 3 4 steel pin into each end of both braces until seated About 3 8 will stick out when seated OK if loose B Insert two 1 pins in bottom brace as shown Not used Not used Top Front Brace Insert Bottom Front Brace STEP 3 Pilot holes in shelves Assemble Spice Rack go toward back Fasten Shelves with 1 1 4 Phillips Flat Head 8 Screw Bronze Insert retainer rods into holes STEP 4 A Attach the Drawer Back to the Drawer Sides with two 1 1 2 8 screws There are left and right drawer sides Make sure the slots that run the length of the Sides are aligned with the slot in the Drawer Back to accept the Drawer Bottom B Slide in Drawer Bottom best side up to inside of drawer C Take the 2 bastion posts align the threaded end of the posts with the post holes located near the ends of the inside of the Drawer Front Tighten posts down until the solid shaft of the posts hits the wood Back post out until the hole screwdriver slot in end of post is parallel and in direct line with the long edges of the Drawer Front D Insert the barrel nuts into the nut access holes on the inside of the Drawer Sides with the threaded ends of the nuts facing out Take the Drawer Front and carefully insert the posts into the ends of the Drawer Sides through the sides of the nuts until seated Push nut snug up against the wood in the
11. nut access hole toward the inside of Drawer Front Hole should be slightly off center toward the Drawer Front Insert the set screw and tighten down The ends of the sides should be tight against the inside Drawer Front E Attach the drawer handles with 1 Truss head machine screws F Attach the drawer glides left and right to the Drawer Sides using two 5 8 5 screws per side Wheels go toward Drawer Back and are up The end with no wheels should touch the Drawer Front if Note Drawer Back is shorter than 11 2 8 the Drawer Sides to allow clearance Pa for Drop Leaf Supports See next page to learn how the bastion fastening system works Also see our video on the Bastion Fastening System at www catskillcraftsmen com TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS 1 The Bastion fastening system consists of a steel post threaded on one end with a hole through the shaft on the other end a Barrel Nut cylindrical barrel shaped with threaded open end amp holes through the sides and a Set Screw Phillips slot on one end pointed on the other Illustration Bas 1 2 To attach Posts A Dip threads of Post in vegetable oil B Align threaded end of Post with hole in wood tap on slotted end with hard hammer until threads enter then tighten down using a flat head screw driver or the provided allen wrench See the Illus Bas 3 for alternate seating methods DO NOT TRY TO HAMMER THE POST ALL THE WAY IN A
12. tside doors Maneuver the Cart Top so that the X marks pilot holes b in the bottom of the Top align with the holes in the L brackets Secure top to L brackets with 5 8 7 screws ILLUSTRATION 14B STEP 15 A Slide the Drawer into the front of the cart Make sure drawer moves freely then retighten all bolts nuts B Tap in the 5 8 wooden plugs into the holes on the legs C Install Small Middle and Center Shelves simply by sliding them in edge banding out D Illustration 15B shows completed 54238 of W ha LC l l T 1 1 1 1 1 1 1 1 e ILLUSTRATION 15A ILLUSTRATION 15B For continued beauty and long life of your Catskill Craftsmen cart we recommend Catskill Craftsmen s Butcher Block Oil Our Butcher Block Oil is available direct ly from Catskill Craftsmen s factory For one eight ounce 8 fl oz bottle which is sufficient for two applications simply send 6 95 along with the completed coupon to the address below Visit us online at www catskillcraftsmen com to browse our assortment of butcher block care products Visa and Mastercard are accepted online KILE ven sd CRAFTSMEN N C Stamford NY 12167 1296 m aa CATSKILL CRAFTS MEN IN C BUTCHER BLOC
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