Catskill Craftsmen 1521 User Manual

Assembly Instructions

Model 1521

Mid-Sized Drawer Island

GENERAL:

1. You have purchased model 1521.

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 Eastern and we’ll send you the prepaid part via UPS
usually that same day! You may also email us: [e-mail].

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:
www.catskillcraftsmen.com. Click the instructions tab in the top blue bar.

4. The only tools needed are a hammer, Phillips head screwdriver and a pencil. A power screwdriver will

speed assembly, but is not required.

5. Glides are sometimes pre-packed with screws. These are not used.

6. Instructions (left/right, top/bottom) are given as you face an assembled unit.

Parts List Model 1521

Not used on this model

Drop Leaf (1)
P/N DL-1521

Back Panel (1)

P/N BP-1521

Top & Bottom Front Braces (2)
P/N B34 1/4 / 2 1/2 /BOT-1521

Table Top (1)
P/N TT-1521

Left Side Panel (1)

P/N LFT/SP/HDL-1521

Top Right Drawer Side (1)

P/N Top DS-1521/R

Top Left Drawer Side (1)

P/N Top DS-1521/L

Lower Left Drawer Side (2)

P/N Low DS-1521/L

Lower Right Drawer Side (2)

P/N Low DS-1521/R

Right Side Panel (1)

P/N RGHT/SP/HDL-1521

Top Drawer Front (1)

P/N DF-1521

Top Drawer Back (1)

P/N DBK-1521

Top Drawer Bottom (1)

P/N TDB-1521

Middle Drawer Front (1)

P/N Mid DF-1521

Door (1)

P/N Dr-1521

Center Divider (1)

P/N DIV-1521

Left Side View

Lower Drawer Back (2)

P/N Low DBK-1521

Lower Drawer Bottom (2)

P/N LBS-1521

Glide Support (2)

P/N GLDSUP-1521

Bottom Drawer Front (1)

P/N Bot DF-1521

Bottom Shelf (1)

P/N BS-1521

Middle Shelf (1)

P/N MS-1521

Hardware List Model 1521

To ease assembly, sort and count the hardware before getting started.

(Cabinet Assembly)

1 3/4” Phillips Flat Head Bolt (8)

(Drawer Backs

Table Top Sticks)

Nickel Handle (5)

10-24 Hex Nut (8)

3/16” Flat Washer (13)

1 1/4” Phillips Flat Head #8 Screw (20)

(Attaches Hinges

Drop Leaf Supports)

5/8” Phillips Flat Head #8 Screw (20)

(Top Drawer Glides That

Attach to Table Top Sticks)

5/8” Phillips Flat Head #7 Screw (4)
Bundled and labeled separately.

(Used to Attach L Brackets / Top

Drawer Glides to the Drawer Sides)

5/8” Phillips Flat Head #6 Screw (12)

(used to attach spice

rack and towel bar)

1” Phillips Flat Head #8 Screw (4)

(Full Extention Glide Screws)

5/8 Wooden Disk (8)

Drawer

Cabinet

Drawer Glide (1 Set )

Full Extention

Drawer Glide (2 Sets)

Polished Nickel Towel Bar (2)

Bastion Post (10)

Bastion Set Screw (10)

Bastion Barrel Nut (10)

“L” Bracket (4)

3/8” Phillips Pan Head #8 Screw (20)

(Attaches Handles

to Door / Top Drawer)

1” Truss Head Machine Screw (6)

(Attaches Handles

to Large Drawers)

1/2” Truss Head M4x10 screw (4)

(Door Pin)

1 1/2” Long 3/16” DIA. Steel Pin (2)

(Shelf Pin)

1” Long 3/16” DIA. Steel Pin (8)

(Brace Pin)

3/4” Long 3/16” DIA. Steel Pin (8)

Hinge (2)

P/N Drop Leaf Support (2)

Magnet (1)

Magnet Plate (1)

Bundled with screws used

for attaching to cart.

Towel Bar Post (4)

Caster Socket (4)

Locking Wheel

Casters (2)

Wheel

Casters (2)

STEP 1A -
Important - Please Read These Instructions Carefully!

Attach Glides to Side

Panels

1. Remove the drawer side
section of the glide by pushing
the black lever down and
sliding the steel inner glide
section all the way out of the
glide assembly. Set this inner
section aside as it will be used
later on the lower drawer
sides.

2. Next, identify the holes to be
used for attaching each glide

to the side panel. IMPORTANT

as shown below, the full
extention glides are only
attached to the right side panel
and to the center divider as
shown in Step 6.

Attach glides using 3/8” #6 pan
head screws. In step 10 you
will loosen these screws to

slide the glides ush with the

back panel once it is attached.

Push this lever down, then
slide the inner glide section
out of the glide assembly.

Face of
Glide

Use these three (3) holes to attach the glide to the side panel.

Backside
of Glide

FRONT OF CART

TOP

This edge will attach to back

panel in the next step.

STEP 1B

IMPORTANT - There is a right and a left side panel. Lay them out as shown below. Pay close

attention to the glides so that they are properly positioned when attaching to the side panels. Review

Step 1A for specic instructions on the full extention glides.

8 Used
in this step

1-1/4” Phillips Flat Head #8 Screw

4 Used
in this step

5/8” Phillips Flat Head #7 Screw

5/8” #7 Screw

TOPTOP

1 1/4” #8 Screw

4 Used
in this step

5/8” Phillips Flat Head #6 Screw

6 Used
in this step

3/8” Phillips Pan Head #8 Screw

5/8” #6 Screw

Leg Slot

3/8” #8 Pan Head
Screw

When attached, this
edge will be flush
behind the leg slot.

3/8” #8 Pan Head
Screw

Left Side PanelRight Side Panel

PLEASE NOTE - Some pieces are interchangeable with other units we manufacture, and thus some

pilot holes may not be used. It is important to note the proper holes required for assembly in each step.

1. The Bastion fastening system consists of a steel post (threaded on one end with a

TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS

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.

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.

Illustration Bas. 1

Post needs to be screwed deeper.

WRONG!

RIGHT!

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

Allen Wrench Provided

See video on our website!

If you have any questions regarding assembly or missing or damaged

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 2

2

4

A. Attach the Top 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 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 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” #6 screws per side.
Wheels go toward Drawer Back and are up. The end with no wheels should touch the Drawer Front.

4 Used
in this step

1-1/4” Phillips Flat Head #8 Screw

4 Used
in this step

1” Truss Head Machine Screw

4 Used
in this step

5/8” Phillips Flat Head
#5 Screw

BASTION ASSEMBLY INSTRUCTIONS

3

1

DO NOT USE POWER SCREW DRIVER FOR THIS STEP.
USE HAND SCREW DRIVER ONLY.

1. Screw Bastion post into drawer front. Screw until all threads are hidden, then back
out a full turn such that the hole in the post will face left to right.

2. Place the barrel nut into the side brace hole.

3. Slide the side brace onto the post such that the post also slides into the barrel nut.

4. Screw the set screw into place, tightening such that the side brace and drawer
front pull together tightly.

1-1/4” #8 Screw

5/8” #5 Screw

1” Truss Head Machine Screw
Use flat washers if necessary to tighten

STEP 3

Perform a similar drawer assembly as Step 2 for the lower drawers.

A. Using 1-1/4” #8 screws, attach the drawer back to the drawer sides as shown below.

B. Slide the drawer bottom into the slots.

C. Insert Bastion Posts into the drawer front and tighten into position.

D. Insert Barrel Nuts into the holes on the drawer sides, and slide the drawer front into place.

Tighten with the set screws. Use hand screwdriver or hex wrench.

E. Attach the full extention glides to the drawer sides. See step 1B to locate the correct part of the
glide for this step.

F. Using 1/2” Truss head screws with two washers each, attach the handle to the drawer front.

FOR TIPS ON HOW THE BASTION SYSTEM WORKS SEE LAST PAGE!

8 Used
in this step

1-1/4” Phillips Flat Head #8 Screw

Bastion Post

8 Used
in this step

3/8” Phillips Pan Head #8 Screw

This end goes flush against
the drawer front.

Use these holes to attach to
the drawer side.

3/8” #8 Pan Head
Screw

Note: On one side the black lever is up and
on the other side the lever is down.

Barrel Nut &
Set Screw

1-1/4” #8 Screw

4 Used
in this step

1/2” Truss Head M4x10 Screw

1/2” Truss Head M4x10 Screw

STEP 4

A. Tap/insert ONE 1 1/2” pin into each end of the door. DON’T OVERDRIVE PINS! Pins should stick

up about 1/2” when seated.

B. Attach the magnet plate (may be stuck to magnet in the hardware pack!) with a 1/2” #4 screw to
the top of the door. Bumps go toward the wood, and the plate should be vertical.

C. Attach door handle with 1” truss head machine screws. Use washers if necessary to tighten.

2 Used
in this step

1” Truss Head Machine Screw

2 Used
in this step

1 1/2” Long 3/16” DIA. Steel Pin

* Use flat washers to tighten handle if necessary.

STEP 5

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.

4 Used
in this step

3/4” Long 3/16” DIA. Steel Pin

STEP 6

A. Tap/insert 3/4” pin into each long edge of the center divider. DON’T OVERDRIVE PINS! Pins

should stick up about 1/4” when seated.

B. Attach the magnet with 1/2” #4 screws to the top of the door.

C. Attach full extention glides to the center divider as shown. Note that the glides should slide out
towards the same edge with the attached magnet.

D. Tap 1” steel pins into the left side of the center divider to be used as shelf supports in a later step.

4 Used
in this step

3/4” Long 3/16” DIA. Steel Pin

4 Used
in this step

1” Pin

1” Long 3/16” DIA. Steel Pin

Left Side View

This side forms the right
inside of the door cavity.

3/4” Pin

The finished
edge faces the
front of the cart

Right Side View

Not Used

This side is the left inside
of the door cavity.

Not Used

Note: Look ahead to Step 8

6 Used
in this step

3/8” Phillips Pan Head #6 Screw

STEP 7

A. Lay Back Panel at on a smooth surface with holes up.

B. Attach Side Panels with 1 3/4” machine screws (bolts) and hex nuts. After inserting bolts(s) 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 nger, align nut with bolt and tighten.

C. Look ahead to step 8 which shows side panels attached to back panel.

4 Used
in this step

1 3/4” Phillips Flat Head Bolt

4 Used
in this step

10-24 Hex Nut

STEP 8

A. Place the center divider pins

into the holes int he back panel.

B. Take the Bottom Front Brace
and insert the pin in the right
end of the brace into the slot in
the top of the right front leg and
slide down as in the illustration.
The pin in the left end of the
brace will be outside the slot at

this time. Loosely secure the

right side of teh brace with 1 3/4
in. machine screw/nut. Align the
bottom pin in the divider with the
hole (closest to the left side) on
the inside of the brace. Spread
the left side panel until the pin
in the left end of the brace can
enter the slot and secure
brace with 1 3/4 in.
machine screw/nut.
Tighten right side bolt/nut.

10-24 Hex Nut

Not used if present

Left
Side

2 Used
in this step

Not used if present

Slot

Door Pin Hole Not Used

2 Used
in this step

1 3/4” Phillips Flat Head Bolt

STEP 9

2 Used
in this step

1 3/4” Phillips Flat Head Bolt

2 Used
in this step

1 3/4” Phillips Flat Head Bolt

4 Used
in this step

1” Long 3/16” DIA. Steel Pin

A. Fit a washer onto the bottom door pin and slide
the pin into the bottom front brace.

B. Slide the Top Front Brace into
place and secure the brace using
1 3/4” machine screws and nuts as
in illustration 9A & 9B.

C. Tap 1” pins into Side Panel as in illustration 9B.

These will hold the shelves.

IMPORTANT! - To guarantee proper positioning,

loosen the screws holding in the full extension
drawer glides, and shift the glides back against the
back panel. Retighten the screws.

2 Used
in this step

1 3/4” Phillips Flat Head Bolt

ILLUSTRATION 9A

4 Used
in this step

1” Long 3/16” DIA. Steel Pin

2 Used
in this step

10-24 Hex Nut

STEP 10

Invert unit, or lay the unit on its back to insert the
wheels. Have a friend help with this step as the unit
can be heavy and awkward to move.

A. 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.

ILLUSTRATION 9B

STEP 11

A. Upright unit.

B. Attach Towel Bars
to the Side Panels with
1” #8 screws from

inside each Side Panel.

STEP 12

A. Assemble top by placing the top and the drop leaf upside down on a smooth at surface. Install

hinges using 5/8 #8 screws. The longer part of the hinge goes on the drop leaf with the short part on

the cart top. Fasten the drop leaf supports using 5/8 #8 screws. Attach Drop Leaf Supports with 5/8

inch #8 screws. See illustration 12A.

B. Make a large ( X ) mark over each of the 4 pilot holes in the bottom. Make marks about 1/2-1” long.
These marks will help you align the cabinet with the pilot holes in the bottom of the Top.

C. Place the Cart Top on the cabinet. Open the outside doors. Maneuver the Cart Top so that the (X)
marks/pilot holes in the bottom of the Top align with the slots in the “L” brackets. Secure top to “L”

brackets with 5/8” #6 screws.

ILLUSTRATION 12A

ILLUSTRATION 12B

STEP 13

Slide the lower drawers into
place. To initially seat the glides,

it will take some force. Once the

glides are properly seated, the
drawers should pull out and slide
in with ease.

STEP 14

A. Tilt the bottom shelf and set
down onto the pins.

B. Fit the middle shelf into the
cart and rest it on the pins.
Edge banding should face out.

STEP 15

A. Slide the top drawer into the front of the cart.

B. Retighten all 1 3/4 in. machine screws and nuts. Tap in the 5/8 wooden plugs into the holes on the
legs.

C. Illustration 15B shows completed 1521.

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 direct­ly from Catskill Craftsmen’s factory. For
one eight ounce (8 . oz.) bottle, which
is sufcient 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.

BUTCHER BLOCK 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: 1521

Name _______________________________

Address _____________________________

City ________________________________

State ___________ Zip ________________

Catskill Craftsmen, Inc.

15 West End Ave.

Stamford, NY 12167-1296

Please make checks payable to Catskill Craftsmen

Inc. 15 West End Ave., Stamford, NY 12167-1296