Catskill Craftsmen 1580 User Manual

CRAFTSMEN, INC.

Assembly Instructions

Model 1580

Deluxe Wine Island with Drop Leaf

GENERAL:

1. You have purchased model 1580. Overall dimensions of an assembled unit is 33 wide
x 27.5 deep (with drop leaf up) x 34.5 high. 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 at
607-652-7321 from 7:30 - 4:00 PM Eastern time and well send you the prepaid part via UPS
usually that same day! Please have model number and part description ready when you call.
You can also make a parts request on our website: www.catskillcraftsmen.com/customer_service

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. Tools required: Phillips screwdrivers, medium and small; medium flat blade screwdriver
and hammer.

CABINET PARTS

TOP

P1

Handle Side Panel (2)

TOP

P3

Back Panel (1)

Drawer Bottom (1)

D1

Drawer Front (1)

Drop Leaf (1) Table Top (1)

B2

Bottom Brace (1)

B1

Top Brace (1)

Drawer Back (1)

D4

Drawer Side Left (1)

Table Top Stick (2)

Drawer Dowel (1)

Wine Rack Front Brace (3)

Wine Rack Back Brace (3)

T2

D7

D2

D3

Drawer Side Right (1)

Stemware Holder (5)

Wine Rack Dowel (24)

Wine Rack Side Brace (6)

CABINET HARDWARE

1-3/4 Phillips Flat Head Machine Screw (8)

Hinge (2)

1-1/2 Phillips Flat Head #8 Screw (2)

1-1/4 Phillips Flat Head #8 Screw (24)

1 Phillips Flat Head #8 Screw (5)

1 Truss Head Machine Screw (2)

5/8 Phillips Flat Head #8 Screw (20)

3/8 Pan Head #8 Screw (30)

3/4 Long 3/16 DIA. Steel Pin (9)

Cam Posts (2)

Cam (2)

Towel Bar Post (4)

Bastion

Set Screw (6)

5/8 Wooden

Plug (8)

10-24 Hex Nut (8)

Bastion

Barrel Nut (6)

Bastion Post (6)

Locking Wheel Caster (2)

Drop Leaf Support (2)

Caster Socket (4)

Non-Locking Wheel Caster (2)

Nickel

Handle (1)

Polished

Nickel Towel

Bar (2)

Full Extention

Wine Rack

Glides (6)

STEP 1

Attach TableTop Support Stick to the side Panel using
1-1/4 Phillips flat head #8 screws. Make sure the counter
sunk holes face out and down on the support stick when
assembling. Repeat for other side panel.

Repeat to other Side Panel

1-1/4 #8 Screw

T2

P2

4 Used
in this step

1-1/4 Phillips Flat Head #8 Screw

STEP 2 - IMPORTANT - Please read these instructions carefully!

1. Remove the wine rack shelf section
of the glide by pressing the black lever
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 Wine Rack Shelf.

2. Next, identify the holes to be used for
attaching each glide to the side panel.
IMPORTANT it is at this point that you
determine front, back left and right of the
assembled cart. Note that the glide must
extend out towards the front of the cart,
therefore, select a right side panel, and
make sure all glides are attached to the
cart so they extend in the same direction.

Face of
Glide

Press this lever then slide the
inner glide section out of the
glide assembly.

Attach glides using 3/8 #8 pan head

screws. But do not tighten down the
screws. You must attach the back
panel in the next step, then shift the
glides all the way back so they are
flush with the back panel before
tightening into place. This will insure
that they are all even.

Repeat for the left side panel making
sure that the glides extend in the correct
direction. When properly attached, the
side panels should appear to be mirror
images of each other.

Properly attached
wine rack glides.

18 Used
in this step

3/8 Pan Head #6 Screw

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

Backside
of Glide

FRONT OF CART

This side will attach to back

panel in the next step.

STEP 3

A. Attach the Towel bars to the side panels
using 1-1/4 #8 screws.

B. Lay back panel flat on a smooth surface with holes up.

C. Attach side panels to the back panel with 1-3/4 machine
screws (bolts) and hex nuts. After inserting bolts 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. MAKE SURE THE GLIDES
EXTEND OUT THE FRONT SIDE OF THE CART.

D. Look ahead to step 5 which shows side panels
attached to back panel.

1 1/4 Screw

IMPORTANT NOTE:

Back panel is flush with
bottom of side panels. Back
panel is 1 shorter than side
panels which leaves gap for
drop leaf supports at the top.

REMEMBER TO MAKE SURE
THE GLIDES EXTEND OUT THE
FRONT SIDE OF THE CART.

Towel Bar Post

1 3/4 Machine Screw

1 3/4 Phillips Flat Head Bolt

Nut

4 Used
in this step

Towel Bar

4 Used
in this step

1-1/4 Phillips Flat Head #8 Screw

4 Used
in this step

10-24 Hex Nut

IMPORTANT NOTE:

STEPS 4 - 10 WILL BE ACCOMPLISHED WITH THE
UNIT TOP UPSIDE DOWN ( INVERTED ), BUILDING
UPWARD TOWARD THE BOTTOM/CASTER END!
BE CAREFUL AS PART DESCRIPTIONS ARE BASED
ON AN UPRIGHT, COMPLETED UNIT!

STEP 4

Assemble the table 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.

20 Used in this step

5/8 Phillips Flat Head #8 Screw

Invert table top 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.

STEP 5

A. Turn the side/back assembly ( from step 3 )
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.

4 Used in this step

1 1/4 Phillips Flat Head #8 Screw

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.

ILLUSTRATION 6A

ILLUSTRATION 6B

ILLUSTRATION 6C

Below line in wood

Cam Posts
2 used in this step

2 used
in this step

1 1/2 Phillips Flat Head #8 Screw

2 used
in this step

1 Truss Head Machine Screw

2 used
in this step

Cam

ILLUSTRATION 6C

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)

STEP 9

A. Take the top front brace with the holes facing the bottom of the cart,
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.

B. Twist drawer dowel into the 1/2 dia.
hole on the inside of the front brace.

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
when unit is uprighted.

D. Take the bottom front brace,
insert the pins in the brace ends
into the slots on the inside of the
front legs and slide down until
the brace is flush with the bottom
of the side panels. Secure the
bottom brace with 1-3/4 machine
screws/hex nuts.

BE SURE TO USE THE
CORRECT BRACE AND
THAT THE HOLES
ALONG THE EDGE FACE
THE BOTTOM OF THE
CART - THESE WILL BE
USED TO ATTACH THE
STEMWARE HOLDERS.

Inside Brace

Hex Nut

Nut Access Hole

Side Panel Leg

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

1 3/4 Phillips Flat Head Bolt

4 Used
in this step

10-24 Hex Nut

4 Used
in this step

STEP 10

A. Insert one 3/4 pin into the end of each stemware holder. Orient holder as shown in the
illustration and put pins into holes in the back panel.

B. Attach the stemware holders to the bottom edge of the top front brace using 1 #8 screws.

C. Insert and tap caster sockets with hammer until the teeth grab the wood.
DONT POUND SOCKET FLAT OR CASTER SHAFT WILL NOT ENTER.

D. 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! Locking casters are usually most functional when placed on the
front of the cart.

5 used
in this step

1 Phillips Flat Head #8 Screw

5 used in this step

3/4 Long 3/16 DIA. Steel Pin

STEP 11

A. Attach rack front to the rack sides using bastions. (see bastion assembly
instructions below for added information.
B. Insert wine bottle support dowels into rack front and back.
C. Secure rack back to sides using 1-1/4 #8 screws (4 used in this step).
D. Attach inner rack glide to rack sides using 3/8 #6 pan head screws.
Rack glide should be flush with the rack front.

4 Used in this step

1-1/4 Phillips Flat Head #8 Screw

4 Used
in this step

3/8 Pan Head #6 Screw

Open end of

glide faces

the back

3

1

2

4

BASTION ASSEMBLY INSTRUCTIONS

1. Screw Bastion post into wine rack front. Screw until all
threads are hidden, then back out a half turn (or the depth of
a finger nail) 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 wine rack front pull together tightly.

STEP 12

A. Upright Unit. Take care when you upright the unit so that the drop leaf
is supported with your hand.

B. Slide wine racks into place. The wine rack will be properly seated in
the glides once it has been pushed all the way in - it may take extra force
to push the rack in initially. Once properly seated the wine rack should
then glide smoothly.

C. Tap wooden disks into sides.

012009

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.

Mail this coupon along with

payment to:

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 $5.95.
My Check or Money Order is enclosed for a
total of $______________.
Item Code: 1580

NAME ______________________________________

ADDRESS __________________________________

___________________________________________

CITY ______________________________________

STATE _________________________ ZIP _______
Please make checks payable to: Catskill Craftsmen Inc.