Catskill Craftsmen 15445 Instructions / Assembly
Contents
1. CATSKILL C RA T S ME N Assembly Instructions Model 15445 Heart of the Kitchen Island with Drop Leaf READ ME FIRST You have purchased a fine piece of domestic hardwood furniture with finely matched non warping hardwood veneer panels and shelves Because this is a quality product we have engineered all parts for a near perfect fit All parts are secured with positive fastening hardware At first blush when you see all of the parts and pieces of hardware you may feel that assembly is very difficult In fact assembly is very easy if you follow the instructions step by step in order A partner will cut assembly time considerably Here are a few general rules to keep in mind 1 Because we sell to a large cross section of the populace we encounter people with various assembly skills and abilities For this reason we try to over simplify some steps however should you encounter any assembly difficulty please give us a call at 607 652 7321 Mon Fri 8am 4 30 pm EST and someone will help you What s easy for us may not be easy for you 2 Our basic assembly hardware is called bastion hardware which consists of a post that is screwed into the wooden parts a barrel nut that has holes thru the sides and an open threaded end that accepts a set screw Pins hold panels in place and keep braces from turning Bastion fasteners join the front oback panel assemblies Heads on set screws sometimes vary 3 TOOLS NEEDED Medi2. IMPORTANT Middle Side Brace must be Note Some people find it assembled with the off center holes towards the inside of easier to place the leg flat s the cart rounded edge on the on 5 face with the holes _ outside of cart If the brace is up See assembly video fard inside ssembled with holes towards of cart the outside of the cart the center shelf will not fit BACK FRONT Linh LL Illustration 4B STEP 5 Back Assembly A Lay the left side unit as in illustration 5 and attach the top Back Brace using the bastion post pins Now Inside View fit the Back Panel between the Bottom Back Brace and Middle Back Brace using 3 4 steel pins and then attach it to the side unit using bastion posts pins See illustration 5 B Attach the Left Cabinet Glide to the Glide Support Brace with 5 8 7 flat head screws 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 the glides so that the end with the wheel Illustration 5 STEP 6 Front Assembly A Tap 1 1 2 pins into the ends of the doors and fit both doors between the Middle Front Brace and Bottom Front Brace using pins as shown in illustration 5 but put washers on pins on the bottom of the doors B Now attach the braces to the side unit using bastion posts p
3. 67 1296 ke am am amp amp amp aD D D D D D D D D D D D D D D D ED c 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 AS IT Lad 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 WRONG The small notches on either side of the nut opening indicate the location of the holes Post needs to be backed out through the sides of the nut B Insert the posts through the end of the braces or drawer
4. es 5 8 Phillips Flat Head 5 Screw 4 Caster Socket 4 Cari ES SY Attach Handle Bracket 4 1 Phillips Flat Head 6 Screw 4 1 ae ee ee es a Magnet Pack Gp Dnne tit 1 2 Phillips Flat 5 8 Pan Head 6 Head 4 Screw 2 screw 4 ye rD Plate Locking Wheel Caster 2 Non Locking Wheel Caster 2 STEP 1 Drawer Assembly A Attach the Drawer Back to the Drawer Sides with four 1 1 4 8 screws There are left and right sides Make sure the slots that run the length of the Slides 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 Screw the cam posts into the two outside holes on the inside face of the drawer front until seated Only 3 8 of this post goes into the wood leaving the 4 larger guide rings head exposed See illustration 1C Visit our website www catskillcraftsmen com for a video on cams D Insert the posts into holes in the drawer sides until seated against the front ends of the drawer sides Insert cams so that the arrow on the outside face of the cam points to the post The slot in the cam fits over the post Turn with Phillips screwdriver until seated Don t over torque See Illustration 1C See our video online at www catskillcraftsmen com E Attach the drawer ha
5. he outside of cart If the brace is assembled with holes towards the outside of the cart the center shelf will not fit fard inside of cart Illustration 3 Not Used on Top or Middle Back Braces Jol PIN HOLE _ POST HOLE Bottom Front Middle Back Bottom Back amp Top Back Brace 4 PIN HOLE POST oe Bottom Side Brace 2 PIN a PIN HOLE 1 Middle Side Brace 2 Not Used ee Middle Front Brace 1 POST HOLE PIN HOLE PIN HOLE PIN HOLE Glide Support Brace 2 POST HOLE PIN HOLE Top Side Brace 2 STEP 4 Assemble Cabinet Sides We recommend using a second person to help with alignment A Lay a Right Back Left Front Leg on its back and attach the Top Side Brace to the upper left corner using the bastion posts and steel pins Also attach the Middle Side Brace and Bottom Side brace in like manner Now slip in the Side Rods into the big holes and fit in the Glide Support Brace into the upper right side so the holes are down and toward the bottom of the brace Then fit the side panel on the right side of the back leg using 3 4 pins Make sure that the holes in the braces face the side panel and glide support This should now look like illustration 4A B Now take a Left Back Right Front Leg and fit it onto the assembled unit using bastion post pins Now it should look like illustration 4B C Assemble the other side by repeating steps A amp B
6. ing 5 8 8 screws Brace and glide removed in illustration 10A to show placement of L Bracket Illustration 7 A Make sure the round hole is used to attach the L Bracket to the Leg Illustration 10B A Mark a cross over the pilot holes as illustrated in Illustration 10B This helps to line up the pilot holes when placing the top on the cabinet STE P 1 1 This step can also be accomplished without the unit upright Top Assembly A Invert cabinet onto top and secure cabinet to the top using 5 8 7 screws through the L brackets on the legs or place cart top on top of cabinet as in illustration 11 B Insert tap 1 pins into legs and drop side shelves onto pins 4 pins for each side shelf C Slide middle shelf into place on top of side panels though one side Insert drawer SS lt gt gt Illustration 11 STEP 12 Magnet Block Assembly A Attach the magnet plates may be stuck to magnet with 1 2 Phillips flat head 4 screws to the inside top of both doors The countersunk hole in the plate faces out bumps go toward wood See illustration 12B B Attach metal door handles with 1 8 32 truss head machine screws as in illustration 12A C Stick magnet to magnet plate on right door D With left door open close the right door The magnet should be positioned over the wooden block on the bottom of the Top Front Brace Hold the magnet i
7. ins as in illustration 5 6 Illustration 6 STEP 7 Main Assembly A Attach the right cabinet glide to the glide support brace on the right side unit using the same holes as in step 5B B Take the right side assembly and attach it to the main unit using the bastion system NOTE There are 3 posts in the back legs only 2 in the front legs top holes not used on front legs Not Used Illustration 7 STEP 8 Bottom Assembly fy Ld f vA A With unit still on its side place bottom shelf into the bottom of the cart as In illustration 8 Secure by tapping 1 pins 6 in each bottom side brace and 1 each for the front back bottom braces Illustration 8 STEP 9 Caster Towel Bar Assembly A Tap wheel sockets into 3 8 holes in leg bottoms Hammer until socket is seated B Locking wheels in front tap in wheels with a hammer hitting on solid fixed metal until wheel is seated See illustration 9 C Upright and attach the handle Towel bars to the Top Side Braces using 1 8 screws from inside the Top Side Brace Illustration 9 STEP 10 Top Assembly A Upright unit and attach an L Bracket to the top inside of each leg using 5 8 7 Phillips head screws The screws go through the round hole in the L Bracket Attach the drop leaf supports and hinges to the Table Top and Drop Leaf us
8. n place with your thumb and open the right door The magnet will be in the correct position on the block E Secure magnet with the two round head screws in the magnet packet as in illustration 12 C Center screws in the slots in the magnets This will allow adjustment later if needed There are no pilot holes as blocks are soft wood F Repeat with left door Illustration 12A Illustration 12B 12 For continued beauty and long life of your Catskill Craftsmen cart we recommend Catskill Craftsmen s Butcher CATSKILL Block Oil CRA F TS MEN INC no BUTCHER BLOCK OIL COUPON you would like to purchase Butcher Please send me of bottle s of the Block Oil directly from Catskill Craftsmen s factory we offer a reduced price For one eight ounce 8 fl oz Catskill Craftsmen Butcher Block Oil at 6 95 bottle which is sufficient for two My Check or Money Order is enclosed for a total of applications simply send 6 95 along Item Code 15445 with the completed coupon to the NAME address below or visit us online at www catskillcraftsmen com for other DH ordering options CITY Catskill Craftsmen Inc STATE ZIP Please make checks payable to Catskill Craftsmen Inc 15 West End Ave Stamford NY 12167 1296 CATSKILL 15 West End Ave CRAFTSMEN INC Stamford NY 121
9. ndle with one 7 8 Truss head machine screws F Attach the drawer glides left and right to the Drawer Sides using two 5 8 5 screws per side packed separately Wheels go toward Drawer Back and are up Glides are flush with front ends of drawer sides and stick out about 3 4 in back FOR TIPS ON HOW THE CAM SYSTEM WORKS SEE LAST PAGE or visit us online at www catskillcraftsmen com and view our video Illustration 1D F We 6 gt 1 Illustration 1A Illustration 1B Illustration 1C STEP 2 Attach Posts to Legs A There are 2 Right Legs and 2 Left Legs Diagonal legs are the same Example Right Front Left Back For identification purposes look at illustration 2 which shows the inside view of a pair of legs B Take all 4 legs and lay out in pairs as in illustration 2 The posts will go inside edge hole 1 top hole 3 down from top and hole 6 last On the front legs use holes 3 and 6 only Put a few drops of vegetable oil into these holes or dip post threads to ease screwing of posts into place C Attach two posts to the inside flat face of each leg using the top and bottom outside holes as illustrated FOR TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS SEE LAST PAGE NOTE The holes in the po
10. rop Leaf 1 34 x 11 x 3 4 Side Panel 2 16 5 8 x 14 5 10 x 7 10 Drawer Bottom 1 18 3 4 x 12 3 4 x 1 4 SS Nickel Side Rods 6 15 x 3 8 Diameter ae Polished Nickel Towel Bar 2 8 7 8 x 3 8 Diameter Left Back Right Back Right Front 2 Left Front 2 31 x5 x 3 4 31 x 5 x 3 4 NOT TO SCALE EO DNN Drawer back O 11 1 1 4 Phillips Flat Head 8 Screw 4 Bastion Post 18 Bastion Set Screw 18 9 gt N gt Drop Leaf Hinges se 5 8 Phillips Flat Head 8 Screw 20 3 16 Flat Washer 2 Bastion Barrel Nut 18 Brace ends Under Door Pins l 3 4 Long 3 16 DIA Steel Pin 46 Shelf supports 1 Long 3 16 DIA Steel Pin 14 1 Doors 1 1 2 Long 3 16 DIA Steel Pin 4 T FECA Drawer Front Cam Posts 2 Gp Drawer handle anil 1 Truss Head Machine Screw 2 Eak DAWET CE Cam 2 a 81 Door Handles 7 8 Truss Head Machine Screw 4 G For L Brackets amp paii Attach Glides to Cabinet Door Drawer Handle 3 5 8 Phillips Flat Head 7 Screw 12 Note 8 are loose packed 4 are with the glide pack J lt P Sette Drawer Sid
11. 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 Ifthe 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 Step 1 ALTERNATIVE METHODS FOR SEATING POSTS Step 2 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
12. sts on the inside edges will be perpendicular to the long edges of the leg when properly seated as pictured in illustration 2 The holes in the posts on the flat surfaces will be parallel with the short Only on Back Legs not used on front leg assembly v4 Left Back Right Front Right Back Left Front Illustration 2 edges of the legs when properly seated STEP 3 Brace Guide Identify and group like braces together A The Middle Front Bottom Front Middle Back and Bottom Back Braces are exactly the same except the Middle Front Brace has a magnet block attached Brace size 20 1 2 long x 2 wide B The Top Side Braces are 14 3 8 long x 4 5 8 wide The Middle Side Braces are identical are 14 3 8 long x 2 wide with no holes on the flat surfaces The Bottom Side Braces are identical are 14 3 8 long x 2 wide but have pin holes and nut access holes on inside flat face The Glide Support Braces are 14 3 8 x 1 1 2 wide with 2 pin holes on each end amp 4 holes on bottom inside C Insert tap 3 4 steel pins into the ends of ALL braces If tight DON T OVERDRIVE PINS About 3 8 of pin will stick out when seated Since the diameter of holes pins vary from time to time some pins will be looser than others This is nota problem IMPORTANT Middle Side Brace must be assembled with the off center holes towards the inside of the cart rounded edge on t
13. um sized flat blade screwdriver a medium sized and small Phillips screwdriver a hammer and a small amount of vegetable oil or liquid soap to ease screwing screws wherever hardwood is involved A tape measure will help you identify the parts We include an allen wrench when set screws have hex heads A power screwdriver with flat phillips heads will soeed assembly on most applications except drawer glides and magnets plates 4 All Parts are described as if you were facing the front side of assembled unit Table Top 1 34 x 18 x 3 4 E Back Panel 1 20 7 16 x 15 1 16 x 7 16 D 2 Bottom Front Top Back Middle Back amp Bottom Back Braces 4 20 1 2 x 2 x 3 4 Bottom Side Brace 2 14 3 8 x 2 x 3 4 Middle Side Brace 2 14 3 8 x 2 x 3 4 Middle Front Brace 1 20 1 2 x 2 x 3 4 Glide Support Brace 2 14 3 8 x 1 1 2 x 3 4 Top Side Brace 2 14 3 8 x 4 5 8 x 3 4 jp Left Door 1 Right Door 1 15 x 10 x 3 4 15 x 10 x 3 4 S N o o o o Bottom amp Middle Shelf 2 28 7 16 x 14 1 4 x 7 16 Drawer Front 1 20 5 16 x 4 1 2 x 3 4 Drawer Back 1 19 9 16 x 3 1 2 x 3 4 Drawer Side Right 1 12 1 4 x 3 1 2 x 3 4 Drawer Side Left 1 12 1 4 x 3 1 2 x 3 4 Side Shelf 2 14 5 16 x 4 x 3 4 D
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