Catskill Craftsmen 1428 User Manual

CRAFTSMEN, INC.

Assembly Instructions

Model 1428

Grand Americana

A. These units are Ready-To-Assemble. Catskill uses positive fastening methods such as wood
screws and in some places hidden Bastion Fasteners. You will need some standard household
tools: hammer and screwdriver while a power screwdriver is recommended. Where possible, we
have packaged some of the screws in seperate labeled packages. To keep hardware separate
after packets are open, we suggest you place each type of screw into separate containers. Note
labels for screws and when they are to be used in assembly in the instructions.

B. Directions (left/right, front/back) are given as facing the front of an assembled upright unit.

C. A friend is reccommended to assist with assembly as this will ease the process. Some of the
parts are large and awkward to hold in place, and extra pair of hands are a huge help.

Model 1428

(2) Right Front / Left Back Leg

30” x 2.5” x 2.5”

Part #: Leg-1428RFLB

Parts List Model 1428

(2)Left Front / Right Back Leg

30” x 2.5” x 2.5”

Part #: Leg-1428LFRB

(1) Top Back Brace

41” x 4-3/4” x 3/4”

Part #: TBB1428

(2) Center/Bottom Front Brace

41” x 2” x 3/4”

Part #: CBFB1428

(2) Center/Bottom Back Brace

41” x 2” x 3/4”

Part #: CBBB1428

(2) Bottom Drawer Fronts

19-1/4” x 11-7/16” x 3/4”

Part #:BDF1428

(2) Bottom Drawer Left Side

18” x 8” x 3/4”

Part #:BDLS1428

(1) Top Drawer Left Side

17” x 4-1/4” x 3/4”
Part #:TDLS1428

(2) Bottom Drawer Backs

18-1/2” x 8” x 3/4”

Part #:BDB1428

(2) Bottom Drawer Right Side

18” x 8” x 3/4”

Part #:BDRS1428

(1) Top Drawer Right Side

17” x 4-1/4” x 3/4”
Part #:TDRS1428

(1) Top Drawer Front

40-13/16” x 5-3/8” x 3/4”

Part #:TDF1428

(2) Bottom Drawer Bottom
18-5/8” x 17-5/8” x 5.2mm

Part #: BDBottom1428

(4) Back/Side Panels

19-7/16” x 11-7/8” x 5/32”

Part #: BSP1428

(1) Center Bottom Glide Support Stick

22-1/16” x 2” x 3/4”

Part #: CBGSS1428

(2) Center Vertical Braces

11-9/16” x 2” x 3/4”

Part #: CVB1428

(2) Top Side Braces

19-1/2” x 5-1/2” x 3/4”

Part #: TSB1428

(4) Top/Bottom Side Glide Support Sticks

19-7/16” x 2” x 3/4”

Part #: TBSGSS1428

(4) Center/Bottom Side Braces

19-1/2” x 2” x 3/4”

Part #: CBSB1428

(1) Top Drawer Back

40” x 4-1/4”” x 3/4”

Part #: TDB1428

(1) Top Drawer Bottom

39-1/8” x 17-5/8” x 5.2mm

Part #: TDBottom1428

(4) L Brackets

Part #: Lbracket-1428

(8) Clamshell Handle Screws

Part #: CHScrews-1428

(6) 1” Steel Pins

Part #: PIN1

(48) 3/4” Steel Pins

Part #: PIN3/4

(4) Caster Insert Sleeves

Part #: CIS1428

(4) 3” Locking Casters

Part #: WHEELS1428

(3 sets) 20” Drawer Glide

Part #: GL-20-1428

(20) 5/8” #6 Screws

Part #: 5/8#6-1428

(12) 1-1/4” #8 Screws

Part #: 1-1/4#8-1428

(12) 5/8” #5 Screws

Part #: 5/8#5-1428

(26) 5/8” #8 Screws

Part #: 5/8#8-1428

Hinge (3)

(4) Clamshell Handles

Part #: Handle-1428

Drop Leaf Support (2)

(1) Middle Shelf

43-1/2” x 22” x 7/16”

Part #: MS-1428

(36)

(36)

(36)

(1) Table Top

48” x 26” x 1-3/4”

Part #: TT-1428

(1) drop leaf

48” x 10” x 1-3/4”

Part #: DL-1428

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 & holes through the sides); and a Set Screw (Phillips slot on one end, pointed on
the other)

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
WILL STRIP THE POST HOLE. C) When solid shaft of Post hits wood, back out
approximately ½ 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.

Illustration Bas. 1

WRONG!

Post needs to be screwed deeper.

WRONG!

Post needs to be backed out.

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

Step 1

Step 2

Illustration Bas. 3

Set screw secures post properly.

CORRECT!

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.

1

BACK ASSEMBLY

Begin assembly by laying out all of the pieces and checking against the parts list
on the previous pages.Tap Caster sleeves for the caster wheels into the bottom of
the legs using a standard hammer. Do not insert wheels yet. Assemble the Back
Assembly by laying out the Back Right and Left Legs, Back Top Brace, Back
Center Brace, Back Bottom Brace, Back Vertical Brace and the Back Bottom
Panels as well as the necessary Bastions Posts and 3/4” Steel Pins as shown in
Illustration 1A. Note: Back Center and Back Bottom Braces are slotted whereas
the Front Center and Front Bottom Braces are not.

Tap the 3/4” Steel Pins into place on the Back Vertical Brace and attach to the
Back Center and Back Bottom Braces. Slide one of the Back Bottom Panels into
place, and attach the left leg to the Back Center and Bottom Braces using the
Bastions and 3/4” Steel Pins.

Next, attach the Back Top Brace to the left leg using the two Bastions.

Repeat the procedure to attach the right leg to compete Back Assembly.

Finally, tap the 1” steel pin into the center pilot hole on the Back Center Brace.
This will be used later to support the middle shelf.

Back Left Leg

Caster Sleeve

Back Bottom Panel

Back Top Brace

Back Center Brace

Back

Vertical

Brace

This hole not used on this brace

Back Bottom Panel

Back Bottom Brace

Back Right Leg

Caster Sleeve

Illustration 1A

2

FRONT ASSEMBLY

Tap Caster sleeves into the bottom of the legs. Do Not insert wheels yet. Assemble
the Front Assembly by laying out the Front Right and Left Legs, Front Center Brace,
Front Bottom Brace, Front Vertical Brace as well as the necessary Bastions and 3/4”
Steel Pins as shown in Illustration 2A. Note: Front Center and Front Bottom Braces
are not slotted.

Tap the 3/4” Steel Pins into place on the Front Vertical Brace and attach to the Front
Center and Front Bottom Braces. Attach the leg to the Front Center and Bottom
Braces using the Bastions and Steel Pins.

Repeat the procedure to attach the other leg to compete Front Assembly.

Use Illustration 2B to properly orientate the legs and braces.

Finally, tap the 1” steel pin into the center pilot hole on the Front Center Brace. This
will be used later to support the middle shelf.

Front Left Leg

These holes not

used in assembly

Front Right Leg

Front View of the Front Assembly

1” Pin taps into center

hole on backside of
Front Center Brace

Front Center Brace

Front

Vertical

Brace

Illustration 2A

Front Bottom Brace

Reverse/Inside view of the Front Assembly

Front Right Leg

Front Left Leg

Front Center Brace

Front

Vertical

Brace

Front Bottom Brace

Illustration 2B

SIDE PANEL ASSEMBLY

3

Lay the Back Assembly on a smooth flat surface as in Illustration 3A. Screw the Bastion
Posts into the legs and Back Vertical Brace as shown in the Bastion Fastening Instructions
on Page 3. When properly seated, the screwdriver slot in the post ends will be
perpendicular to the length of the legs. Tap the 3/4” Steel Pins into the legs and Back
Vertical Brace. Tap 1” Steel Pins into the Center Side Braces to be used later to support the
center shelf. Slide the Side Braces and Center Drawer Glide Support Stick into place,
tightening the set screws.

Next, tap two 3/4” Steel Pins into each end of the four Drawer Glide Support Sticks as
shown in llustration 3A. insert one end of these sticks into the legs as illustrated while
making sure that the small pilot holes for the drawer glides are toward the bottom edge and
face toward the inside of the cart.

Finally slide the Bottom Side Panels into place, best side out.

Top Side Brace

Top Side Brace

Back Assembly

Bottom
Side
Panel

Bottom
Side
Brace

Drawer
Glide
Support
Stick

Center

Side

Brace

holes toward

bottom edge

1” Pins taps into holes

on Center Side

These holes not

used in assembly

Braces

Center
Drawer
Glide
Support
Stick

Drawer
Glide
Support
Stick

Bottom
Side
Panel

Bottom
Side
Brace

Center

Side

Brace

Drawer
Glide
Support
Stick

Drawer
Glide
Support
Stick

Illustration 3A

ATTACHING FRONT ASSEMBLY

4

Upright Back Assembly with Braces, etc. Attached from Step 3. Caster holes in
legs should be facing down as shown in Illustration 4A. Attach Bastion Posts and
tap in 3/4” Steel Pins into front legs and Front Vertical Brace. Working Right to
left, slide the bastion posts and 3/4” Steel Pins into the Side Braces, waiting to
tighten set screws until the Center Drawer Glide Support Stick and the Left Side
Braces are all seated properly.

Drawer Glide Support Sticks should also be inserted into the Front Assembly,
using the previously inserted 3/4” Steel Pins.

Back Assembly

Front Assembly

Illustration 4A

ATTACH DRAWER GLIDES

5

Attach the Cabinet drawer glides for both bottom drawers and the top drawer to the
drawer support sticks using the 5/8” #6 screws. Note: refer to the label included with
screw pack to make sure the appropriate screws are used for this step.

Glide overlaps leg by 1 1/4”

Note the holes used to attach
the drawer glides to the cart.

INSERT SHELF

6

Top Drawer
Support Stick

Make sure 1” Steel Pins were firmly tapped into place in the pilot holes on each of the
center braces in previous steps.

Then, take the center shelf and dip it down into the unit, putting one end down near the
bottom drawer support stick as shown in Illustration 6A. This will allow the other end to
clear the opposite top drawer support stick while resting on the pins in the front and
back center braces. Back the shelf up until both ends are above the steel pin supports
on each side center brace as shown in Illustration 6B. Then settle the shelf down onto
the pins as shown in Illustration 6C.

Straight on view of cart with front cutaway

Illustration 6A

Shelf

Bottom Drawer
Support Stick

Illustration 6C

Illustration 6B

Illustration 7C

Top Drawer Front

Illustration 7A

Illustration 7B

7

A. Attach the Drawer Back to the Left
and Right Drawer Sides with four 1 ¼”
#8 Screws. 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,

C. Take two (2) Bastion Posts for the top
drawer, four (4) Bastion Posts for the
bottom drawers, align the threaded ends
of the Posts with the post holes located
near the ends of the inside Drawer
Front. Tighten Posts down until the
solid shaft of the Post hits the wood.
Back Post out until the hole/screwdriver
slot in the end of the Post is parallel and
in direct line with the long edges of the
Drawer Front.

ASSEMBLE DRAWERS

Illustration 7D

Bottom Drawer Fronts

Illustration 7F

Illustration 7E

D. Insert the Bastion Nuts (B-Nuts) into
the nut access holes on the inside of the
Drawer Sides with the threaded end
facing out. Take the Drawer Front and
carefully insert the Posts into the ends of
the Brace Sides, through the sides of the
B-Nut until seated. Push Nut snugly
against the wood in the nut access hole
toward the Drawer Front. Hole should be
slightly off-center toward the Drawer
Front. Insert the Set Screw and tighten
down. The Drawer Sides should be tight
against the Drawer Front.

E. Attach the Drawer Handle with 8-32
Truss-Head screws.

Attach the Drawer Glides (left and Right)
to the Drawer Sides using two 5/8” #5
Flat Head Screws per glide. Wheels go
toward Drawer Back and are up. DO
NOT INSERT DRAWERS INTO
CABINET AT THIS TIME.

TABLE TOP PREPARATION

Invert Table Top on smooth flat surface. Attach the 3 hinges with 5/8” #8 screws large part of

hinges go on Drop Leaf. Attach Drop Leaf Supports with 5/8” #8 screws.

ATTACH BUTCHER BLOCK TOP

8

Attach the 4 L-Brackets to the top side braces with 5/8” # 6 screws. Note the
orientation of the L-Brackets in Illustration 8A. The single slot side should attach
to the Top Side Braces while the slot and hole side should attach to the Butcher
Block Top, also using 5/8” #6 screws. Note: As the Butcher Block top is heavy and
somewhat awkward to maneuver, it is highly recommened to have a friend assist
in positioning the Top for attachment.

INSERT WHEEL CASTERS

9

Tap the wheel casters into place. Note: It is highly recommended to have a friend
assist in setting the cart upright once the casters have been tapped into place.

INSERT DRAWERS

rev. 5/6/13

10

Slide the drawers into place. Your Grand Americana is now ready to use.

For continued beauty and long life of your
Catskill Craftsmen cart, we recommend
Catskill Craftsmen’s Butcher Block Oil.
If you would like to purchase Butcher
Block Oil directly from Catskill Craftsmen’s
factory, we offer a reduced price. 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. If you prefer to use
MasterCard or Visa please visit us online at
www.catskillcraftsmen.com

Catskill Craftsmen, Inc.

15 West End Ave.

CRAFTSMEN, INC.

Stamford, NY 12167-1296

CRAFTSMEN, INC.

BUTCHER BLOCK OIL COUPON

Please send me _____# of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $6.95.
My Check or Money Order is enclosed for a
total of $______________.
Item Code: 1428

NAME _____________________________________

ADDRESS __________________________________

__________________________________________

CITY ______________________________________

STATE _________________________ ZIP _______
Please make checks payable to: Catskill Craftsmen Inc.
15 West End Ave. Stamford, NY 12167-1296