Catskill Craftsmen 54238 User Manual

Assembly Instructions

Model 54238

Butcher Block WorkCenter PLUS with Drop Leaf

GENERAL:

1. You have purchased model 54238.

2. 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].

3. 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.

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

5. Drawer glides are sometimes pre-packed with screws, these are not used.

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

Parts List Model 54238

Center Shelf (1)

P/N CS-54238

Bottom Shelf (1)

P/N BS-54238

Top Front Brace (1)

P/N B-38/2 7/16/TF-54238

Bottom Front Brace (1)

P/N B-38/2 7/16/BOT-54238

Drawer Front (1)

P/N DF-54238

Small Middle Shelf (2)

P/N SMS-54238

Divider Panel (2)

P/N DP-54238

Drawer Bottom (1)

P/N DBOT-54238

Drop Leaf (1)

P/N DL-54238

Table Top (1)

P/N TT-54238

Glide Support Stick (2)

P/N GLDSUP-54238

31”

Left Drawer Side (1)

P/N DS-54238L

Left Door (1)

P/N DOR-54238LO

Drawer Back (1)
P/N DBK-54238

Right Drawer Side (1)

Left Center Door (1)

P/N DOR-54238LC

P/N DS-54238R

Side Panel (2)

P/N SP/HDL-54238

Right Center Door (1)

P/N DOR-54238RC

Right Door (1)

P/N DOR-54238RO

Back Panel (1)
P/N BP-54238

Spice Rack Side Left (1)

P/N SR-54238L

Spice Rack Shelves (2)

P/N SRS-54238

Spice Rack Side Right (1)

P/N SR-54238R

Hardware for 54238

1 3/4” Phillips Flat Head Bolt (8)

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

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

(Used to attach
drop leaf hardware)

(8 are bronze for spice rack)

(Used to attach
drawer back)

Retainer Rods for Spice Rack (2)

Drawer

P/N Drop Leaf Support (2)

Cabinet

Drawer Glide (1 Set )

5/8” Phillips Flat Head #8 Screw (26)

(8 Used on “L” Brackets
and 4 used for Drawer glides)

5/8” Phillips Flat Head #7 Screw (12)

(Used on Drawer Glides)

5/8” Phillips Flat Head #5 Screw (4)

(Used to attach towel bar
and spice rack)

1” Phillips Flat Head #8 Screw (4)

(Used to attach
door handles)

7/8” Truss Head Machine Screw (8)

(Used to attach
drawer handles)

1” Truss Head Machine Screw (4)

(divider panel
pin for shelves)

2” Long 3/16” DIA. Steel Pin (8)

(door pin)

1 1/2” Long 3/16” DIA. Steel Pin (8)

3/16” Flat Washer (8)

5/8 Wooden Disk (8)

Bastion Set Screw (2)

Polished Nickel Towel Bar (1)

“L” Bracket (4)

Towel Bar Post (2)

Bastion Post (2)

10-24 Hex Nut (8)

Bastion Barrel Nut (2)

Nickel Handle (6)

Metal Shelf Pin (4)

(shelf pin)

1” Long 3/16” DIA. Steel Pin (22)

(brace pin)

3/4” Long 3/16” DIA. Steel Pin (4)

Magnet Pack

Magnet (4)

1/2” Phillips Flat Head #4 Screw (4)

5/8” Pan Head Screw (8)

Magnet Plate (4)

(Used on Magnet Plate)

(Used on Magnet)

Hinge (3)

Locking Wheel Casters (2)

Caster Socket (4)

Wheel Casters (2)

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.

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.

Not used Not used

1” Pin

Bottom Front Brace

Insert

STEP 3

Assemble Spice Rack

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

Top Front Brace

3/4” Pin

Pilot holes in shelves

go toward back

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 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.

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

Post needs to be screwed deeper.

Post needs to be backed out.

WRONG!

WRONG!

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 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.

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 hole rather than
slot.

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. 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

Washer

Slide top front brace down into position to secure doors. Fasten with 1 3/4” bolts and nuts as shown.

Nut

1 3/4” Bolts

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 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.

No pilot holes as softwood.

5/8” Pan Head Screws

STEP 10

A. Lay the cart on it’s back. 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.

STEP 11

A. Upright unit.

B. Determine if you want the Spice Rack on the left or right Side Panel. The Handle/Towel Bar will go
on the other. Attach the Spice Rack to the Side Panel with two 1” #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” #8 screws from inside the Side Panel. Place a
washer over each screw.

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 8C.

STEP 13

A. Tap 1” pins into the 4 sets of holes in the Back
Panel. B. Just above the Bottom shelf on the inside
of the Bottom Front Brace there are two sets of holes.
Tap 1” pins into these holes.

C. On the Inside face of the Top Front Brace there is
a hole adjacent to each of the magnet blocks for the
outside doors. Tap one 1” pin into each hole.

D. Choose the height you want your middle
shelves, then tap the 2” pins in accordingly
on the Cabinet Dividers. For Side Panels,
use the metal shelf pins.

E. Slide the Cabinet Dividers between the
sets of pins in the Back Panel and the pins
in the Front Braces until dividers rest on
the Bottom Shelf. Make sure the edge
banding faces out.

NOTE: Eight 2” pins are provided in case
you want the center middle shelf & the
side middle shelves at different heights.

Edge banding toward front of unit.

2” Pins

1” Pins

Divider
in place

5/8” #8

ILLUSTRATION 14A

STEP 14

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.

5/8” #7

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.

ILLUSTRATION 14B

STEP 15

A. Slide the Drawer into the front of the cart. Make sure drawer moves freely, then retighten all bolts/nuts.

B. Tap in the 5/8 wooden plugs into the holes on the legs.

C. Install Small Middle and Center Shelves simply by sliding them in, edge banding out.

D. Illustration 15B shows completed 54238.

ILLUSTRATION 15A

ILLUSTRATION 15B

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: 54238

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