Catskill Craftsmen 1537 User Manual

CRAFTSMEN, INC.

Assembly Instructions

Model 1537

Cuisine Island with Microwave Rack

GENERAL:

1. You have purchased model 1537. Overall dimensions of an assembled unit with drop leaf up
is 31 1/2” x 27 1/2” x 53” height. This cart is made of the finest Northeastern Hardwood and
matching veneer.

2. Should you need assistance or need to replace a damaged or missing part, DO NOT
RETURN THE UNIT TO THE STORE where you purchased it, simply give us a call and we’ll
send you the prepaid part via UPS usually that same day!

3. Read the assembly instructions and the enclosed brochure before beginning assembly.
Assembly is very easy if you read and follow the instructions step by step.

4. The only tools needed are a hammer, a small and a medium Phillips head screwdriver and
medium flat blade screwdriver. A pencil is also needed. A power screwdriver will speed
assembly, but is not required. Place a few drops of vegetable oil on the threads of wood screws
before screwing into hardwood parts.

CABINET PARTS

TOPTOP TOP

Table Top (1)

EDGE BANDING
GOES OUT

Plain Side Panel (1) Handle Side Panel (1)

Rack Side Panels (2)

Rack Top (1)

Drawer Dowel (1)

Back Panel (1)

Left Door (1)

Drawer Front (1)

Door Spacer (1)

Drawer Bottom (1)

Right Door (1)

13 3/8”

Middle Shelf (1)

13 13/16”

Bottom Shelf (1)

Drawer Side Left (1)

Drawer Side Right (1)

Table Top Stick (2)

Drawer Back (1)

Bottom Brace (1)

Top Brace (1)

HARDWARE

1 3/4” Phillips Flat Head Bolt (8)

1 1/2” Phillips Flat Head #8 Screw (2)

Cam Posts (2)

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

1” Truss Head Machine Screw (6)

5/8” Pan Head Screw (2)

5/8” Phillips Flat Head #8 Screw (3)

1/2” Phillips Flat Head #4 Screw (1)

3/4” Long 3/16” DIA. Steel Pin (4)

Caster Socket (4)

Nickel Handle (3)

Towel Bar Post (2)

Hinge (2)

Cam (2)

5/8 Wooden Disk (2)

1” Long 3/16” DIA. Steel Pin (8)

1 1/2” Long 3/16” DIA. Steel Pin (4)

3/16” Flat Washer (2)

10-24 Hex Nut (8)

Magnet Plate (1)

Locking Wheel Caster (2)

Non Locking Wheel Caster (2)

Magnet (1)

Polished
Nickel Towel
Bar (1)

STEP A

1. Attach the Rack Top to the top ends of the Side Panels using 1 1/4” #8 wood screws. MAKE
SURE YOU HAVE THE RACK TOP! The only difference between the Rack Top and the Cabinet Top
is that the Cabinet Top has 4 small pilot holes on the bottom side plus the 4 throughholes; whereas,
the Rack Top only has the 4 through holes. NOTE: On the Rack Top the countersunk (reamed out)
through holes face up and the countersunk holes/pilot holes on the Cabinet Top face down.
The countersunk holes allow the screw heads to be flush with the wood surface when tightened down.

2. Turn this assembly upside down so that the Rack Top is on a smooth flat surface. Attach the
Cabinet Top with four 1 1/4” #8 wood screws. With the unit upside down at this point, the 4 pilot holes
should be up.

3. Leave this assembly UPSIDE DOWN and go to STEP 1. Looking ahead to STEPS 3 & 4,
the bottom of the Cabinet Top IS THE BOTTOM OF THE CART TOP ATTACHED TO THE RACK IN
STEP A4 ABOVE.

NOTE: The cart cabinet will be constructed
upside down using the bottom of the Cart
Top as the base.

8 Used in this step

1 1/4” Phillips Flat Head #8 Screw

ILLUSTRATION A

RACK TOP

CABINET TOP

PILOT HOLES HIDDEN

STEP 1

4 Used in this step

Attach a table top stick to the
top of each side panel using
1 1/4” #8screws. The countersunk
holes (reamed out) in the
stick are positioned as in
illustration 1. Sticks should
be flush with top of panel.

ILLUSTRATION 1

1 1/4” Phillips Flat Head #8 Screw (12)

STEP 2

A. Lay back panel flat on a smooth surface with holes up.
B. Decide at this point if you want the handle/towel bar on
the right or the left side of the cabinet as they are
interchangeable. We placed the handle/towel bar on the
right for these instructions.
C. 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 finger, align nut
with bolt and tighten.
D. Look ahead to step 5 which shows side panels
attached to back panel.

NOTE: Back panel is flush with bottom of side
panels. Back panel is 1” shorter than side
panels which leaves gap for drop leaf hinges.

4 Used
in this step

1 3/4” Phillips Flat Head Bolt (8)

4 Used
in this step

10-24 Hex Nut (8)

ILLUSTRATION 2

STEP 4

Invert assembled rack on a smooth flat surface and
make a large (X) mark over each of the pilot
holes in the bottom. Make marks about
1 1/2” long. These marks will help you align
the cabinet with the pilot holes in step 5.

NOTE: Use holes circled on illustration.
The four outside holes are not used.

ILLUSTRATION 4

STEP 5

A. Turn the side/back assembly ( from step 2 )
upside down ( invert ) on top of the inverted table top.
B. Drop two 1 1/4” # 8 screws into the holes in
each of the table top sticks.
C. Using the (+) marks from step 4 as a guide,
insert the tips of the screws into the pilot
holes in the unit top and finger tighten.
When all 4 screws are properly aligned,
tighten down.
D. Tap two 1” pins into each side panel.
These pins will hold the bottom shelf.
See illustration5

4 Used in this step

1 1/4” Phillips Flat Head #8 Screw (12)

4 Used in this step

1” Long 3/16” DIA. Steel Pin (8)

ILLUSTRATION 5

STEP 6

A. Attach the drawer back to the drawer sides with
two 1 1/2” #8 screws. The drawer back leaves a 1”
gap at the top to allow drop leaf support clearance.
Make sure parts are aligned as in illustration 6A.
B. Insert drawer bottom into the slots in the drawer
sides, best side to inside of drawer. Slide down
until seated in the slot in the drawer back.
See illustration 6B.
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 guide rings/head exposed. See illustration 6C.
D. Insert the posts into holes in the drawer side
until seated against the front ends of the drawer
sides. Insert cams so that slot in the cam fits over
the post and turn with Phillips screwdriver until
seated. Don’t over-torque! See illustration 6D.
E. Attach drawer handle with the two handle
screws ( no illustration ).

ILLUSTRATION 6A

ILLUSTRATION 6C

Below line in wood

Cam Posts (2)

2 used
in this step

1 1/2” Phillips Flat Head #8 Screw (2)

2 used
in this step

1” Truss Head Machine Screw (6)

2 used
in this step

Cam (2)

ILLUSTRATION 6B

ILLUSTRATION 6D

STEP 7

Take drawer, insert the drawer
dowel thru the hole in the
drawer back, invert drawer
and place in cabinet cavity.
Insert/turn drawer dowel
into the 1/2” dia. hole in
the back panel.

STEP 8

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 (4)

ILLUSTRATION 7

ILLUSTRATION 8

STEP 9

A. Take the top front brace ( with magnet block ), insert the pins in the brace
ends into the slots on the inside of the front legs and slide down until the
brace rests on the bottom of the drawer front. The pin holes for the door
pins will be up.

B. Twist drawer dowel into the 1/2” dia.
hole on the inside of the brace under
the magnet block.

C. BEFORE securing brace with
1 3/4” machine screws/hex nuts,
raise brace approximately 1/8”
before tightening ( or use a
couple of dull kitchen knives
as spacers between the brace
and the top edge of the
drawer front. ) This will allow
the drawer to open easily

Hex Nut

ILLUSTRATION 9A

Inside Brace

Nut Access Hole

ILLUSTRATION 9B

Side Panel Leg

Countersunk Hole in Leg
( disk goes in this hole to
hide bolt head! )

1 3/4” Phillips Flat Head Bolt (8)

2 Used
in this step

10-24 Hex Nut (8)

2 Used
in this step

STEP 10

Attach handle/towel bar to side panel with 1 1/4” #8 screws from inside side panel.

NOTE: Put washers in between the screws and the Side Panel so the
screws don’t pull through the Side Panel.

2 Used in this step

1 1/4” Phillips Flat Head #8 Screw (12)

2 Used
in this step

3/16” Flat Washer (2)

ILLUSTRATION 10

STEP 11

A. Tap/insert ONE 1 1/2” pin
into each end of both doors.
DON”T OVERDRIVE PINS!
pins should stick up about 1/2”
when seated.
B. Attach the doorspace to the
left door with 5/8” #8 screws.
The spacer has a space at the
top to allow magnet clearance
and is almost flush with the
bottom of the door.
C. Attach the magnet plate
(may be stuck to magnet!)
with the small flat head screw
to the top of the right door.
D. Attach door handles with 1”
truss head machine screws.

ILLUSTRATION 11

4 used in
this step

1 1/2” Long 3/16” DIA. Steel Pin (4)

2 used
in this step

1” Truss Head Machine Screw (6)

Magnet Plate (1)

3 used in this step

5/8” Phillips Flat Head #8 Screw (23)

2 used in this step

1/2” Phillips Flat Head #4 Screw (1)

STEP 12

A. Install doors by inserting pins in
the door tops into the holes in
the long edge top front brace.
B. Place one washer on
each of the door pins in
the door bottoms.
C. Take the bottom front
brace, align pins in door
bottoms with holes along
top long edge of brace
( are washers on pins ? )
and secure brace with
1 3/4” bolts/hex nuts as before.

2 Used
in this step

10-24 Hex Nut (8)

ILLUSTRATION 12

2 Used
in this step

3/16” Flat Washer (2)

2 Used
in this step

1 3/4” Phillips Flat Head Bolt (8)

STEP 13

A. Stick magnet to magnet plate on right door.
B. 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 in place with your thumb, and open the right
door. The magnet will be in the correct position on the block.
C. Secure magnet with the two round head screws in the magnet packet. Center screws in the slot in
the magnet . This will allow adjustment later, if needed.

2 Used
in this step

ILLUSTRATION 13

5/8” Pan Head Screw (2)

Magnet (1)

STEP 14

A. Insert and tap caster sockets with
hammer until the teeth grab the wood.
DON’T POUND SOCKET FLAT
OR CASTER SHFT WILL
NOT ENTER.
B. Insert casters and seat by
pushing straight downward
with heel or 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 back, but can go diagonally
or on the front if cart is moved
a lot.

ILLUSTRATION 14

STEP 15

A. Upright Unit. Take care when
you upright the unit so that the
drop leaf is support with your
hand. Take bottom shelf
( no edge banding )
and place it on the
set of back pins.
Close doors and
shelf will drop into place.
B. Decide on position of middle
shelf, then tap two 1” pins into
each side panel, making sure
the pins on both sides are in
the same relative position. To
remove a pin, use pliers or
claw hammer.
C. Place middle shelf, edge
banding out, on pins.
D. Tap remaining wooden disks
into sides.

ILLUSTRATION 15

012208

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 $5.95 along
with the completed coupon to the
address below.

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 $5.95.
My Check or Money Order is enclosed for a
total of $______________.
Item Code: 1537

NAME _____________________________________

ADDRESS __________________________________

__________________________________________

CITY ______________________________________

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