Catskill Craftsmen 2008 User Manual

Assembly Instructions

Model 2008

The Grand Island with Wine Rack

GENERAL:

1. 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 EST and we’ll send you the prepaid part via UPS usually that same

day! You may also email us [e-mail].

2. 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.

3. Tools required: Phillips screwdrivers, medium and small; medium at blade screwdriver and a hammer.

4. This unit uses the Bastion System; a simple yet rugged compression fastening system. We have a

video online at www.catskillcraftsmen.com illustrating the proper installation of this system.

5. Directions (left/right, front/back) are given as facing the front of an assembled upright unit.

CABINET PARTS MODEL 2008

Drop Leaf (1)

P/N DL-2007

Table Top (1)

P/N TT-2007

Drawer Front (1)

P/N DF-2007

21 15/16 x 9 x 3/4

Drawer Back (1)

P/N DBK-2007

21 1/8 x 7 x 3/4

Front Right/Back Left Legs (2)

P/N L-2007FR/BL

Front Left/Back Right Legs (2)

P/N L-2007FL/BR

Wine Rack Pipes (7)

P/N WRP-2008

15 7/8 x 5/8

Glide Support Braces (2)

P/N GS-2007

13 x 2 x 3/4

Drawer Side Left (1)

P/N DS-2007L

14 x 7 x 3/4

Drawer Bottom (1)

P/N DBOT-2007

20 1/4 x 14 5/8 x 5.2 mm

Drawer Side Right (1)

P/N DS-2007R

14 x 7 x 3/4

Top Back Brace (1)

P/N B-2007/TB

22 1/8 x 7 3/4 x 3/4

Top Side Braces (2)

P/N B-2007/TS

13 x 9 x 3/4

Wine Rack Braces (2)

P/N WRB-2008

22 1/8 x 1 1/2 x 3/4

Shelf (1)

P/N SS-2007

HARDWARE MODEL 2008

(Used to attach
hinges/supports)

5/8” Phillips Flat Head #8 Screw (26)

(used on “L” Bracket)

5/8” Phillips Flat Head #6 Screw (8)

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

3/4” Long 3/16” DIA. Steel Pin (16)

(used to attach glides)

7/16” Pan Head #6 Screw (8)

L-Bracket (4)

DRAWER HANDLE - 17 7/8” CHROME TUBE SET (1)

(TUBE/PIPE, PIPE HOLDER, SET SCREWS

SIDE HANDLE - 13” CHROME TUBE SET (2)

(TUBE/PIPE, PIPE HOLDER, SET SCREWS

P/N DHDL-2007

P/N SHDL-2007

Drop Leaf Support (2)

Bastion Set Screw (16)

Bastion Post (16)

Bastion Barrel Nut (16)

Caster Socket (4)

Hinge (3)

Locking Wheel Caster (2)

Non-Locking Wheel Caster (2)

14” FULL EXTENSION GLIDE SET (1)

P/N GLIDE - 2007

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)

Illustration Bas. 1

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.

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.

STEP 1

Table top L-Bracket holes

ASSEMBLE SIDE PANELS

A. Each side panel consists of two (2) legs, one
(1) top side brace and one (1) Glide Support
Brace. When assembled, diagonal legs will be

the same (i.e. Front Right/Back Left & Front

Left/Back Right). Side panels are identical when
assembled -- the Drawer Glides will determine

left and right sides.

B. Take each of the 4 legs and install two (2)
Bastion Posts per leg, on the side of the leg
which also has two (2) pin holes for the Glide
Support Sticks. Locate post holes. Tap Posts in
with hammer until threads engage wood; turn
Posts down until the solid shaft hits the wood
(All threads are into wood), then back Posts out
until the holes in the Posts are perpendicular to
the long length of the leg (about 1/2 turn).

C. Lay out Front Left leg and one (1) top side

brace as in Illustration 1A. Note the three pilot
holes for the table top sticks are along the top
inside of the top side brace.

not used
in front legs

bottom shelf hole

Towel bar holes

Nut access holes

TOP SIDE BRACE

Bastion Post

Left Front Leg

Illustration 1A

Glide Support Steel Pin Holes

D. Take the top side brace and drop two barrel­shaped bronze bastion nuts into the nut access
holes as in illustration 1A. Threaded end-of the
nuts face out. Insert front left leg posts into the

holes in the ends of the brace, through the side
of the barrel nuts, until the holes in the posts

can be seen through the threaded end of the
nuts. Insert the Set Screws into the nuts and
tighten down. The tip of the set screw will seek

the center of the bastion post as it is tightened,
leaving a tight joint. If the joint is loose, check to

make sure the set screw is not cross-threaded
or that the post is out too far (not threaded

into leg deep enough.) See previous page for
Bastion illustrations for clarication of assembly.

E. Insert two 3/4” pins into each end of the glide

support brace. Position brace such that the pilot

holes for attaching the glide are towards the
bottom edge. Insert brace pins into the holes
on the inside of the left front leg as in illustration

1B (4 pilot holes out) with pilot holes off-center

toward the bottom of the leg.

GLIDE SUPPORT BRACE

Left Front Leg

Illustration 1B

Left Front Leg

Pilot holes go on

the bottom edge

F. Attach Back Left leg in same manner as in
illustration 1C.

G. Repeat for other side panel.

Left Back Leg

Illustration 1C

STEP 2

Push down on the black tab and pull out

ATTACH DRAWER GLIDES TO GLIDE SUPPORT STICKS

A. Take the Drawer Glides, extend them to their fullest. See illustration 4. The Glide has 3 parts.
Remove the furthest extended part (1) (smallest) by pushing the black plastic lever down – then pull
part out, separating it. This part will attach to the Drawer Side later. Attach the largest parts (2&3) to
the Glide Support Stick using holes as illustrated. Attach with 7/16 #6 pan head screws. About 1 1/4”

of this glide will overlap the Front Leg. See illustration 2B.

B. Repeat with the other side.

(1) (2) (3)

This side goes against glide support brace

Gets attached to the Drawer Side Gets attached to the Glide Support Brace

(1) (2) & (3)

Tab faces out

This shows back side of Glide. Part (1) is separated from Parts (2) & (3).

This side of Part (3) goes against the Glide Support Brace. Screw holes are blackened.

Illustration 2A

Bastion Post

Positions for Top

Back Brace

Illustration 2B

This end of the glide overlaps front leg 1 1/4”

& the bottom edge drops below the

glide support brace

Right Front Leg

PREPARE SIDE ASSEMBLIES fOR BACK BRACES

The top back brace utilizes the bastion system for attachment. Place the bastion posts into their

positions on the back legs only of both side assemblies.

STEP 3
ATTACH THE BACK BRACE
AND BOTTOM SHELf

A. The Top Back Brace attaches 1 1/4”

down on the legs, allowing clearance for

the hinges and drop leaf supports. Attach
the back brace with bastions to the right
and left side assembly. Before tightening

the bastions, attach the back wine rack
brace, making sure the off-center pipe

holes are toward the top of the unit.
(See illustration 3B) Use two steel pins
for each side. After the back wine rack

brace is in position, tighten the top back
brace’s bastions. See illustration 3A.

B. Insert the metal wine rack pipes into
the back wine rack brace. Attach the front

wine rack brace to the left leg, off-center
pipe holes at the top, and insert the
metal wine rack pipes into position,
working left to right, nally attaching

the front wine rack brace to the right leg.
See illustration 3C.

Illustration 3A

C. While holding the wine rack in position,

attach the bottom shelf to the inside of all
four legs using the 1 1/4” #8 screws.
See illustration 3D.

Illustration 3C

Illustration 3D

Illustration 3B

Make sure the Pipe holes are positioned
off-center, toward the top for both the
front and back wine braces.

STEP 4

Make sure the round

TABLE TOP PREPARATION

A. Invert table top on smooth, at surface. Attach the 4 L-Brackets with 5/8” #6 screws, using the

round hole as shown in Illustration 4B.

B. Attach the 3 hinges with 5/8” #8 screws. Attach
drop leaf supports with 5/8” #8 screws

as shown in illus. 4A.

hole is used to attach
the L-Bracket to the

Illustration 4C

bottom of the table top

Illustration 4B

You must use the smaller hole, furthest from the edge
for L-bracket attachment, as shown in illustration 4C.

Illustration 4A

STEP 5
ATTACH TABLE TOP

A. With the top still inverted, invert the leg

assembly onto the top as shown. Secure top

to leg assembly with 5/8” #6 screws through

L-brackets.

STEP 6
ATTACH CASTERS

A. With unit still inverted, tap Caster

Sockets into holes in leg ends until
seated then tap in the Casters.

STEP 7
ATTACH TOWEL BARS

Note: Unit should still be inverted

See Illustrations. Screw brass towel bar posts into the top side braces and the drawer front using

1 1/4” #8 screws. Attach pipe holder by sliding supports over posts and secure with tiny set screws

using allen wrench provided. Slide towel bar through holes in supports and secure in place with
set screws. Bar should be equidistant on either side of the supports. Tap end caps into place. See
Illustration 7C.

Pipe Holder

Set Screw Hole

Standoff use optional.
If used, it must be placed
on Post prior to the
Pipe Holder!

Illustration 7A

BOTTOM VIEW

Set Screw Hole

Allen Wrench

Set Screw

Illustration 7B

Illustration 7C

STEP 8
ASSEMBLE DRAWER

A. Attach the drawer back to the drawer sides with 1 1/4” #8 screws. Slide in drawer bottom, best side

up. Attach front using the Bastion System. Holes in the posts will be parallel to the long edge of the
drawer front. See illustration.

B. Attach the drawer glide to the drawer sides with 7/16” Pan Head #6 screws in the places indicated
in the illustration. Black plastic lever will face outward. Glide will be up against the back of the drawer

front.

STEP 9
fINAL STEPS

A. Upright unit. Slide drawer into bas. Glides will automatically lock into place.

Holes along the
bottom edge of the
drawer sides are not
used in this model.

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 .

Catskill Craftsmen, Inc.

15 West End Ave.

Stamford, NY 12167-1296

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: 2008

Name _______________________________

Address _____________________________

City ________________________________

State ___________ Zip ________________

Please make checks payable to Catskill Craftsmen
Inc. 15 West End Ave., Stamford, NY 12167-1296