Page 1
CRAFTSMEN, INC.
Assembly Instructions
Model 1481
The Mini Empire Island
READ ME FIRST!!!
Assembly will be much easier if you have two
people and a power screwdriver.
You have purchased a fine piece of domestic
hardwood furniture with finely matched
non-warping plywood 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 glance you may feel that assembly is
very difficult. In fact, assembly is very easy if you
follow the instructions step by step in order.
Having 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,
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.
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 a hole
thru the sides and an open threaded end that
accepts a set screw. Pins hold panels in place and
keep braces from turning. Machine Screws join
the front/back panel assemblies to the sides.
Heads on set screws sometimes vary.
3) TOOLS NEEDED: Medium-sized flat blade
screwdriver, a medium-sized and a 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.
4) All Parts are described as if you were facing the
front side of assembled unit.
Page 2
CABINET PARTS
TT
(1) Table Top-1481
30” x 26” x 1”
B1
(4) Front/Back Brace-1544
20 1/2” x 2” x 3/4”
B2
(3) Bot/Mid Side Brace-1480
22 1/4” x 2 1/4” x 3/4”
LD
(1) Left Door-1481
22 1/4” x 10 5/32” x 3/4”
(2) Cutting Board Glide Support-1481
26 3/8” x 3/4” x 3/4”
RD
(1) Right Door-1481
22 1/4” x 10 5/32” x 3/4”
GS
CBT
B3
(1) Top Side Brace-1480
22 1/4” x 5 1/8” x 3/4”
B4
(1) Top Side Brace Handle-1481
22 1/4” x 5 1/8” x 3/4”
B5
(2) Drawer Glide Support Brace-1480
22 1/4” x 1 1/2” x 3/4”
CBR
(2) Cutting Board Rail-1480
18” x 1 1/4” x 3/4”
CBF
(1) Cutting Board Front-1480
21 3/4” x 2” x 3/4”
(1) Pull Out Cutting Board Top-1480
22” x 19 1/2” x 3/4”
DF
(1) Drawer Front-1481
20 5/16” x 5 3/16” x 3/4”
DBK
(1) Drawer Back-1481
19 1/2” x 4 3/8” x 3/4”
FLL
LDS
(1) Left Drawer Side-1481
21 1/4” x 4 3/8” x 3/4”
RDS
(1) Right Drawer Side-1481
21 1/4” x 4 3/8” x 3/4”
FRL
(2) Front Left/Back Right Leg-1481
32 1/2” x 4” x 1”
(2) Front Right/Back Left Leg-1481
32 1/2” x 4” x 1”
Page 3
SP
(1) Side Panel-1480
20 9/16” x 22 5/8” x 1/4”
MS
LSP
(1) Large Side Panel-1481
25 11/16” x 22 5/8” x 1/4”
Edge Banding
(1) Middle Shelf-1481
26 3/8” x 21 3/4” x 7/16”
BS
BP
(1) Back Panel-1481
27 11/16” x 20 7/16” x 7/16”
DB
(1) Bottom Shelf-1481
26 3/8” x 22 3/16” x 7/16”
(1) Drawer Bottom-1481
18 5/8” x 21 3/4” x 3/16”
Page 4
HARDWARE
18” Full Ext Glide (4)
2 1/2” Phillips Flat Head #8 Screw (3)
1 3/4” Phillips Flat Head #8 Screw (6)
1 3/4” Phillips Flat Head Bolt (10)
1 1/4” Phillips Flat Head #8 Screw (8)
HDL-MS-25 Screw (10)
Magnet (2)
Magnet Plate (2)
Bar Handle (5)
10-24 Hex Nut (10)
Bastion Post (10)
Bastion Barrel Nut (10)
Bastion Set Screw (10)
4 bronze screws found
in magnet pack
7/16” #6 Pan Head Screw (28)
Found in magnet pack
1/2” Phillips Flat Head #4 Screw (2)
1 1/2” Long 3/16” DIA. Steel Pin (12)
3/4” Long 3/16” DIA. Steel Pin (24)
Washer (2)
“L” Bracket (4)
Caster Socket (4)
5/8 Wooden Disk (12)
Caster with Stops (2) Caster (2)
Page 5
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!
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-4pm Mon. - Fri. Eastern Time
Page 6
STEP 1
Take all of the glides and detach the inserts by fully extending the glides and pressing
down on the black tab and pulling them out.
Push down on the black tab and pull out
Gets attached to the Drawer Side Gets attached to the Glide Support Brace
STEP 2
Drawer Assembly
2 Drawer Sides, 1 Drawer Back, 1 Drawer Front, 1 Drawer Bottom
Attach Drawer Back to Drawer Sides using 1 1/4” #8 screws, then insert Drawer
Bottom into slots. Put bastion posts into Drawer Front & secure to Drawer Sides using barrel
nuts & set screws. When seated, hole in bastion post will be parallel long edge of Drawer
Front. Attach handle using HDL-M5-25 Screws. Screw the Glide Inserts to the drawer sides
using 7/16” Pan Head #6 screws.
1 1/4” #8 Screws
DBK
LDS
DB
RDS
Barrel nut & set screw
HLD-M5-25
DF
7/16” #6 Pan Head Screws
Bastion Post
See previous page for tips on how to use the bastion fastening system
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STEP 3
Slide Out Cutting Board Assembly
1 Pull Out Cutting Board Top, 1 Cutting Board front, 2 Cutting Board Sides.
Lay Pull Out Cutting Board Top on its back so holes face up. Then attach the Cutting
Board Front to the top, with best side facing out, so that the counter sunk holes face up, using
2 1/2” #8 screws. Now attach the Cutting Board Side Rails to the top so that the glide holes
face out and the countersunk holes face up, using 1 3/4” #8 screws.
glide holes towards
the outside
CBR
1 3/4” #8 Screws
2 1/2” #8 Screws
CBF
CBT
CBR
STEP 4
Slide Out Cutting Board Assembly Part 2
2 Slide Out Cutting Boards
Attach Glide Inserts to the sides of the Slide Out Cutting Boards and attach handles to
the front of the board using HDL-M5-25 screws.
7/16” #6 Pan Head Screws
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STEP 5
Bastion Post & Pin Assembly
4 Legs, 4 Front/Back Braces, 3 Mid/Bot Side Braces, 2 Doors, 1 Back Panel, 2 Top Side
Braces, 2 Glide Support Braces
Tap 3/4” Pins into the ends of all the Braces and the back panel using a hammer, it is ok if pins
are loose. Tap the 1 1/2” Pins into the ends of the Doors with a hammer. The Back Right Leg and the
Front Left Leg are identical, as are the Back Left Leg and the Front Right Leg. Group them together
so that you have 2 sets of opposite legs, one set for the front, one set for the back. For the Front
Legs, screw bastion posts into the third hole from the top and the bottom hole as illustrated. When
seated, holes in posts should be perpendicular with the long edge of the leg. For the Back Legs,
screw bastion posts into the top hole and in the bottom hole as illustrated. The bottom of the leg is the
end with the large hole in it. Tap 1 1/2” pins into the holes the near the bottom end. For the middle
holes you have to choose the height where you want the middle shelf, then tap in 1 1/2” pins.
Bastion Post
1 1/2” Steel Pin
B1
Four of this brace
B3
FLL BRLFRL BLL
Choose from the three holes, the
height where you want the middle shelf.
This can always be changed later.
Front Legs
3/4” Pin
BP
Back Legs
Attach magnet plate so that the bumps face the wood
1 1/2” Pin
1/2” #4
RD LD
B4
B5
Two of this brace
Page 9
STEP 6
Back Assembly
1 Front Left/Back Right Leg, 1 Back
Panel, 1 Front Right/Back Left Leg, 2
Front/Back Braces, 1 Cutting Board
Glide Support
Attach the Back Panel to the
Front/Back Braces using 3/4” Steel
Pins.
Then attach the braces to the
legs using the bastion posts and set
screws.
Then attach the Cutting Board Glide
Support to the legs using 1 1/4” #8 screws
making sure the holes on the edge face
the bottom.
Inside View
B1
BLL BRLBP
Barrel nut & set screw
B1
B1
BLL BRLBP
BP
B1
Make sure that the holes on the edge
are facing the bottom of the cart
B1
1 1/4” # 8 Screw
GS
BP
BRLBLL
B1
B1
B1
Page 10
STEP 7
Front Assembly
1 Front Left/Back Right Leg, 1 Left
Door,
1 Right Door, 1 Front Right/Back Left
Leg, 2 Front/Back Braces, 1 Cutting
Board Glide Support
Inside View
B1
Attach the Doors to the
Front/Back Braces using 1 1/2” Steel
Pins making sure to put washers on
the pins on the bottom of the door.
Then attach the braces to the
legs using the bastion posts and set
screws.
Then attach the Cutting Board
Glide Support to the legs using 1 1/4” #8
screws making sure the holes on the edge
face the bottom.
Now attach the magnets to the
bottom edge of the Cutting Board
Glide Support with 7/16” #6 Pan Head
Screws (Bronze).
FRL
Washer
FLL
RD LD
B1
FRL
Barrel nut & set screw
B1
RD LD
B1
FLL
Make sure that the holes on the edge
are facing the bottom of the cart
B1
GS
7/16” #6 Pan
Head Screw
(Bronze)
FRL
RD LD
B1
FLL
Page 11
STEP 8
Main Assembly
1 Back Assembly, 1 Front
Assembly, 3 Mid/Bot Side
Braces, 2 Glide Support
Braces, 2 Top Side Braces, 1
Large Side Panel Insert, 1
Small Side Panel Insert
Now you have to decide which
side of the cart you want the
pullout cutting board to come
out of.
Nut
The illustration shows the
cutting board coming out of
the left side of the cart. You
can have it come out of the
right simply by reversing the
pieces shown. Attach the
braces to the back assembly
using 1 3/4” machine screws
and nuts. Then insert the side
panels into the slots in the
braces. Then attach the front
assembly in the same manner.
Then attach the handles to
brace B4 and the doors using
HDL-M5-25 screws.
Make sure holes go toward the bottom of the cart
LSP
B2
B4
B5
B5
B3
SP
B2
1 3/4” Machine Screw
Make sure you use B3 here (with no handle holes)
above the pullout cutting board.
B2
HDL-M5-25
B4
B5
B3
LSP
This step is much easier if two
people work together.
B2
B2 B2
SP
Page 12
STEP 9
Glide Assembly
Use the Second
hole and the fourth
hole on the glide
support
Use the Fourth hole
and the eleventh
hole on the glide to
attach to support.
Front
7/16” #6 Pan head screw
Use the Sixth hole
and the thirteenth
hole on the glide
Tap the caster sockets into the holes in the bottom
of the leg with a hammer so the teeth bite into the
wood, but not too hard. Then tap the casters into the
caster sockets until seated. Put the locking casters
in the front of the cart.
Use the first small
pilot hole and the
third small pilot hole
on the glide support.
Page 13
STEP 10
Table Top Assembly
Attach “L” brackets to the Table Top using 7/16” #6
flat head screws. Use round hole in the “L” bracket
not the slot Then attach the table top to the cart
using the same screws into the pilot holes in the Top
TT
7/16” #6 Flat Head Screws
TT
Page 14
STEP 11
Shelf Assembly
Attach “L” brackets to the Table Top using 7/16” #6 flat head screws. Use round hole in the
“L” bracket not the slot Then attach the table top to the cart using the same screws into the
pilot holes in the Top Side Brace.
Edge Banding goes
toward outside
MS
BS
Page 15
STEP 12
Finishing Touches
Pull/extend the metal glides from the cabinet and insert the drawer and the pull out cutting
board. Drawer will push in halfway and seem to stop, it is ok to apply greater pressure to
align ball bearings properly, then glides will work smoothly. Then tap in the wooden plugs into
the big holes in the legs.
Page 16
11/24/09
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. Visit us online at
www.catskillcraftsmen.com to browse our
selection of butcher block care products.
MasterCard and Visa accepted online.
Catskill Craftsmen, Inc.
CRAFTSMEN, INC.
15 West End Ave.
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: 1481
NAME _____________________________________
ADDRESS __________________________________
__________________________________________
CITY ______________________________________
STATE _________________________ ZIP _______
Please make checks payable to: Catskill Craftsmen Inc.
15 West End Ave. Stamford, NY 12167-1296
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