Catskill Craftsmen 1538 User Manual

CRAFTSMEN, INC.

Assembly Instructions

Model 1538

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. A power screwdriver is recommended. Where possible, we have
packaged some of the screws in separate 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 recommended to assist with assembly as this will ease the process. Some of the
parts are large and awkward to hold in place, an extra pair of hands will help.

Model 1538

Parts List Model 1538

Knife Rack Face (1)

P/N KR-1538

Back Panel (1)

P/N BP-1538

Center Shelf (1)

P/N CS-1538

Side Panel (2)

P/N SP/HDL-1538

Top Front Brace (1)

P/N B-34 1/4 / 2 1/2 /TF-1538

Bottom Front Brace (1)

P/N B34 1/4 / 2 1/2 /BOT-1538

Drop Leaf (1)
P/N DL-1538

Bottom Shelf (1)

P/N BS-1538

Drawer Front (1)

P/N DF-1538

Drawer Back (1)

P/N DBK-1538

Table Top (1)
P/N TT-1538

Glide Support (2)

P/N GLDSUP-1538

Left Door (2)

P/N DOR-1538L

Knife Rack Side (2)
P/N KR-SIDE-1538

Drawer Bottom(1)

P/N DB-1538

Right Drawer Side (1)

P/N DS-1538/R

Left Drawer Side (1)

P/N DS-1538/L

Right Door (2)

P/N DOR-1538R

1 3/4” Phillips Flat Head Bolt (8)

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

3/16” Flat Washer (8)

5/8” Phillips Flat Head #8 Screw (20)

5/8” Phillips Flat Head #6 Screw (12)

Nickel Handle (6)

Bastion Post (2)

10-24 Hex Nut (8)

Bastion Set Screw (2)

5/8” Phillips Flat Head #5 Screw (4)

5/8” Phillips Flat Head #4 Screw (4)

5/8” #6 Pan Head Screw (8)

1” Truss Head Machine Screw (12)

1 1/2” Long 3/16” DIA. Steel Pin (8)

1” Long 3/16” DIA. Steel Pin (14)

3/4” Long 3/16” DIA. Steel Pin (4)

“L” Bracket (4)

Polished Nickel Towel Bar (1)

Hinge (2)

P/N Drop Leaf Support (2)

5/8 Wooden Disk (8)

Drawer

Bastion Barrel Nut (2)

Cabinet

Drawer Glide (1 Set )

Magnet Plate (4)

Magnet (4)

Towel Bar Post (2)

Locking Wheel Casters (2)

Caster Socket (4)

Wheel Casters (2)

STEP 1

A. Tap/insert ONE 1 1/2” pin into each end of all the doors. DON’T OVERDRIVE PINS! Pins should
stick up about 1/2” when seated.
B. Attach the magnet plate (may be stuck to magnet!) with the 1/2” #4 screw to the top of the doors.
Bumps go toward the wood.
C. Attach door handles with 1” truss head machine screws.

ILLUSTRATION 1

STEP 2

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.

ILLUSTRATION 2

STEP 3

A. Assemble Knife Rack by inserting four brass colored 1 1/4” #8
Screws through the countersunk (reamed out) holes in the Knife
Rack into the pilot holes in the long edges of the Knife Rack
Sides. Tighten untill Seated. Sides will be flush with the bottom
of the face leaving a space at the top.

ILLUSTRATION 3

STEP 4

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

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

ILLUSTRATION 4

STEP 5

A. Attach a Glide Support Stick to the top of each Side Panel using 1 1/4” #8 screws. The
countersunk holes (reamed out) in the stick are positioned as in illustration 5 so that the glide holes
are toward the lower edge. Sticks should be flush with top of panel.
B. Attach the cabinet glide of the Drawer Glides to the Glide Support Stick using 5/8” #6 flat head
screws. Left glide to left Side Panel, right glide to right Side Panel. 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 glides so that the end with the wheel comes
flush with the front edge of the Glide Support Stick.
C. Attach the “L” brackets to the top of the glide supports using 5/8” #6 screws. Use hole rather than
slot.

5/8” #6 Screw

TOP TOP

1 1/4” #8 Screw

5/8” #6 Screw

ILLUSTRATION 5

STEP 6

A. Lay Back Panel flat 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 finger, align nut with bolt and tighten.
C. Look ahead to step 7 which shows side panels attached to back panel.

NOTE: Make sure you position the side panels according to Drawer Glides (left or right).
And that the Back Panel is 1 1/4” shorter than the Side Panel at the top.

ILLUSTRATION 6

STEP 7

A. Invert cabinet assembly from step 6.
B. Take the Top Front Brace ( with magnet blocks ), insert the pins in the brace ends into the slots on
the inside of the front legs of the Side
Panel and slide down until the brace
is aligned with the set of holes in
the Side Panel as illustrated.
C. Secure brace with 1 3/4”
machine screws and hex
nuts as in step 6.

ILLUSTRATION 7

STEP 8

A. Install Doors by fitting the pins in the top of the door into the holes in the Top Front Brace.
B. Place washers on the pins on the bottom of the doors, then fit the Bottom Front Brace onto the
pins and secure the brace using 1 3/4” machine screws and nuts as in illustration 8A.
C. Tap two 1” pins into the back panel, two into the holes on the inside of the Bottom Front Brace
and two into each Side Panel as in illustration 8B. These will hold the Bottom Shelf.

ILLUSTRATION 8A

1” Pins1” Pins

ILLUSTRATION 8B

STEP 9

A. Stick magnet to magnet plate on a door.
B. With all other doors open, close the 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 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.
D. Repeat these steps for all the doors.

ILLUSTRATION 9

STEP 10

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 10

STEP 11

A. Upright unit.
B. Determine if you want the Knife Rack on the left or right Side Panel. The Handle/Towel Bar will go
on the other. Then attach the Knife Rack to the Side Panel with two 1 1/4” x #8 screws from inside the
panel. Place a washer over the screw so that so that the head won’t pull through the side panel.
C. Attach Towel Bar to the other Side Panel with 1 1/4” #8 screws from inside the Side Panel. Place a
washer over each screw.

ILLUSTRATION 11

STEP 12

A. Angle the Bottom Shelf as necessary to pass it
through the opening in the cabinet top until it
rests on the pins installed in step 8.

ILLUSTRATION 12

STEP 13

A. Choose at which height you want the
middle shelf to be from the two sets of holes
in the Back & Side Panels. Then tap 1” pins
into the 6 holes in the Back & Side Panels.
B. Fit the middle shelf into the cart and rest
it on the pins.

ILLUSTRATION 13

STEP 14

A. Assemble top by placing the top and the drop leaf upside down on a smooth flat 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. See illustration 14B.
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 holes in the “L” brackets. Secure top to “L”
brackets with 5/8” #8 screws, allowing approximately 3/16” space between inside face of Knife Rack
and end of Cart Top .

ILLUSTRATION 14A

ILLUSTRATION 14B

STEP 15

A. Slide the Drawer into the front of the cart.
B. Tap in the 5/8 wooden plugs into the holes on the legs.
C. Install Middle Shelf simply by sliding it in.
D. Illustration 15B shows completed 1538.

ILLUSTRATION 15A

ILLUSTRATION 15B

121207

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: 1538

NAME _____________________________________

ADDRESS __________________________________

__________________________________________

CITY ______________________________________

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

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

ALTERNATIVE METHODS

Set screw secures post properly.

CORRECT!

FOR SEATING POSTS

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.