Catskill Craftsmen 51843 User Manual

Assembly Instructions

Model 51843

Butcher Block Island with Flat Doors and Drop Leaf

GENERAL:

1. You have purchased model 51843. This unit is 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 except when attaching
drawer glides. 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. 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.

C. Check our website for assembly videos and tips.

D. If you have any questions regarding assembly or missing/damaged parts, please call our customer
support number 607-652-7321 or toll free 888-732-7321 Monday - Friday 7am-4pm EST. If you prefer,
you may also email us [e-mail].

Parts List Model 51843

Right Drawer Side (1)

P/N DS-51843/R

Small Middle Shelf (2)

P/N SMS-51843

Drawer Front (1)

P/N DF-51843

Top Front Brace (1)

P/N B-38/2 1/2/TF-51843

Center Shelf (1)

P/N CS-51843

Left Drawer Side (1)

P/N DS-51843/L

Drawer Back (1)
P/N DBK-51843

Glide Support (2)

P/N GLDSUP-51843

Bottom Front Brace (1)

P/N B-38/2 1/2/BOT-51843

Door Spacer (1)

P/N DORS/21 9/16 51843

Spice Rack Retainer Rods (2)

P/N SRS-51843

Drawer Bottom (1)

P/N DBOT-51843

Spice Rack Left Side

(1) P/N: SR - 51842L

Spice Rack Right Side (1)

P/N: SR - 51843R

Spice Rack Shelves (2)

P/N SRS-51843

Divider Panel (2)

P/N DP-51843

Left Outside Door (1)

P/N DOR-51843LO

Left Center Door (1)

P/N DOR-51843LC

Right Center Door (1)

P/N DOR-51843RC

Right Outside Door (1)

P/N DOR-51843RO

Side Panel (2)
P/N SP-51843

Drop Leaf (1)

P/N DL-51843

Table Top (1)

P/N TT-51843

Bottom Shelf (1)

P/N BS-51843

Back Panel (1)

P/N BP-51843

29 3/4”

Hardware for 51843

1 3/4” Phillips Flat Head Bolt (8)

Retainer Rods for Spice Rack (2)

Note: Use the 8 Bronze screws
to assemble the spice rack

1 1/4” Phillips Flat Head #8 Screw (16)

(Used to attach

drawer back)

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

(Used to attach door spacer

& drop leaf supports)

5/8” Phillips Flat Head #8 Screw (29)

(Used to attach cabinet

glides & “L” Brackets)

5/8” Phillips Flat Head #7 Screw (12)

(Used on Drawer Glides)

5/8” Phillips Flat Head #5 Screw (4)

(Used to attach Spice

Rack & Towel Bar)

1” Phillips Flat Head #8 Screw (4)

(Used to attach handles)

10-24 Hex Nut (8)

3/16” Flat Washer (8)

Drawer

Drawer Glide (1 Set )

Nickel Handle (6)

“L” Bracket (4)

Cabinet

5/8 Wooden Disk (8)

Bastion Post (2)

Bastion Set Screw (2)

Bastion Barrel Nut (2)

7/8” Truss Head Machine Screw (12)

(DIvider
Panel Pins)

2” Long 3/16” DIA. Steel Pin (8)

(Door Pins)

1 1/2” Long 3/16” DIA. Steel Pin (8)

(Shelf Pins)

1” Long 3/16” DIA. Steel Pin (26)

(Brace Pins)

3/4” Long 3/16” DIA. Steel Pin (4)

Magnet Pack

(Used on Magnet

Included in magnet pack)

5/8” Pan Head Screw (6)

(Used on Magnet Plate

Included in magnet pack)

1/2” Phillips Flat Head #4 Screw (3)

P/N Drop Leaf Support (2)

Polished Nickel Towel Bar (1)

Hinge (3)

Caster Socket (4)

Towel Bar Post (2)

Magnet Plate (3)

Magnet (3)

Locking Wheel Casters (2)

Wheel Casters (2)

1/2” #4 Flat Head Screw

STEP 1

7/8” Truss Head Screw

1/2” #4 Flat Head Screw

5/8” #8

The counter sunk hole

goes out so the bumps

go toward the wood.

1 1/2” Pin

Flush at bottom, space at top to clear magnet

(Included in magnet pack)

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 7/8” truss head
machine screws.

D. Attach door spacer
with three 5/8” Phillips
Head #8 screws.

(Included in magnet pack)

7/8” Truss Head Screw

5/8” #8

The counter sunk hole
goes out so the bumps

go toward the wood.

1 1/2” Pin

Flush at bottom, space at top to clear magnet

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.

B. Insert two 1” pins in bottom brace as shown.

Insert

STEP 3

Assemble Spice Rack

Not used Not used

1” Pin

Top Front Brace

3/4” Pin

Bottom Front Brace

Pilot holes in shelves

go toward back

Fasten Shelves with
1 1/4” Phillips Flat Head
#8 Screw (Bronze)

Insert retainer
rods into holes

STEP 4

1 1/4” #8

1” Truss Head Screw

5/8” #5

A. Attach the Drawer Back to the Drawer Sides with two 1 1/2” #8 screws. There are left and right
drawer 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 7/8” 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.

1” Truss Head Screw

1 1/2” #8

Note: Drawer Back is shorter than

the Drawer Sides to allow clearance

for Drop Leaf Supports

5/8” #5

See next page to learn how the bastion fastening system works.

Also see our video on the Bastion Fastening System at www.catskillcraftsmen.com

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

TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS

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

Set screw secures post properly.

CORRECT!

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 5

5/8” #7 Screw

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 1 so that the glide holes

are toward the lower edge. Sticks should be ush with top of panel.

B. Attach the cabinet glide of the Drawer Glides to the Glide Support Stick using 5/8” #7 at 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 ush

with the front edge of the Table Top Stick. Only 2 holes in the glide support are used.

C. Attach the “L” brackets to the top of the glide supports using 5/8” #7 screws. Use the long slot

rather than hole/slot. The hole will be used to attach the table top. The “L” brackets should be ush

with the top of the glide support sticks.

Note: Glides are marked right/left with imprint behind wheel.

1 1/4” #8 Screw

TOP

TOP

5/8” #7 Screw

STEP 6

1 3/4” Bolts

1” Pin

Nut

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 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. Back panel has 1 1/4” space at the top.

C. Look ahead to step 7 which shows side panels attached to back panel.

D. Insert 1” pins into back panel as shown.

1 3/4” Bolts

Note: Wheel on glide is
to the front of the unit

Nut

STEP 7

Bottom Brace
Assembly

A. Slide bottom front brace
into position using the pins
int he brace ends, slots in
legs and secure bottom
brace with 1 3/4” bolts/nuts
as shown.

B. Insert 1” pins into
the side panels as shown.

1” Pin

1” Pin

Nut

1 3/4” Bolts

STEP 8

Door Assembly

A. Make sure
washers are
placed on the
pins at the
bottom of the
doors, then slide
the doors down
into the pins.

Washer

B. Slide top front brace down into position to secure doors. Fasten with 1 3/4” bolts and nuts as
shown. Make sure washers are on the pins in the door bottoms.

Nut

1 3/4” Bolts

STEP 9

Magnet

No pilot holes as softwood.

5/8” Pan Head Screws

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 pan 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, except the door with the door spacer.

STEP 10

Install Casters

Install Casters: Locking wheels normally go on the front.

Tap in wheel sleeves until teeth bite wood. Don’t atten

or wheel stem won’t go in!

Locking

STEP 11

Towel Bar and
Spice Rack

Decide which side to put the spice rack on then put the towel bar on the other side.

Attach side handle/towel bar using 1” Phillips Flat Head #8 screws. Place a washer over the screw to
keep screwheads from pulling through the side panels. Attach the spice rack in the same way using
the pilot holes in the top shelf. The holes in the bottom shelf are not used.

Washer

1” #8

1” #8

STEP 12

Dividers will slide between

Insert Bottom Shelf

Install Divider Panel

A. Tap eight 1” pins
(4 pairs of 2) into back panel.

B. Tap one 1” pin into the
holes beside the two
outside magnet blocks
in the top front brace
(2 pins).

C. Tap 2 pairs of
1” pins into the bottom
front brace.

D. Tap a pair of
1” pins into
each side panel.

1”

pin

1” Pin

the two 1” pins

Slide Divider Panels Into Place

A. Slide each panel down using a set/pair of pins as illustrated on the top front brace. The magnet
block takes the place of one pin.

Install Shelf Support Pins

2” long into/through divider panels as illustrated. Make sure these pins align with shelf support pins in
side panels.

Note: Use the four extra 2” pins
if you want the middle shelf at a
different height than side shelves.

Edge Banding Out

Make sure you put the pins

in the side panel at the

same height as the pins

in the Divider Panel

2” Pin

1” Pin

1”

pin

STEP 13

Drop Leaf Assembly

A. Invert Table Top on a smooth at surface and make a large (X) mark over each of the 4 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 the bottom of the Top.

B. Attach hinges/drop leaf supports with 5/8” #8 screws. Place the Cart Top on the cabinet.

C. 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” #7 screws.

5/8” #8

Marking an X with a pencil on the pi­lot holes under the tabletop will help
to line up the pilot holes with
the L Brackets in step 14.

STEP 14

Fasten the table top with
5/8” #7 screws up through
the “L” Brackets.

5/8” #7

STEP 15

A. Slide panels
into place on pins with
edge banding out.

B. Re-tighten screws
and tap wooden
5/8” plugs into holes
in legs.

C. Insert Drawer. Drop
Leaf must be up to
insert drawer.

5/8” wooden disk

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: 51843

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