Catskill Craftsmen 63036 User Manual

CRAFTSMEN, INC.

Assembly Instructions

Model 63036

The Big Island

GENERAL:

1. You have purchased model 63036. The overall dimension of an assembled unit is 36 x 30
x 34 1/2 height. 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 and wellsend you the prepaid part via UPS usually that same day!

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. The only tools needed are a hammer, a small and a medium Phillips head screwdriver and
medium flat blade screwdriver. A pencil is also needed. A power screwdriver will speed
assembly, but is not required. Place a few drops of vegetable oil on the threads of wood screws
before screwing into hardwood parts.

BB

Bottom Brace (2)

P/N-B-27-2-63036

Not Used

CABINET PARTS

TB

Top Brace (2)

P/N-B-27-2-TF-63036

Not Used

FD

False Drawer Front (1)

P/N-D/F-26 7/8-4 1/2-63036F

DBK

Drawer Back (1)

P/N-DBK-24 7/16-4 1/2-63036

DF

Drawer Front (1)

P/N-DF-26 7/8-4 1/2-63036

BS

Bottom Shelf (1)

P/N-BS-63036

MS

Edge Banding On Each Side

Middle Shelf (1)

P/N-MS-63036

SP

Side Panel (2)

P/N-SP-63036HDL

LS RS

Left Drawer Side (1)

P/N-DS-63036L

TS

Table Top Stick (2)

P/N-TTS-23 11/16-63036

DB

Drawer Bottom (1)
P/N-DBOT-63036

Right Drawer Side (1)

P/N-DS-63036R

LD RD

Left Door (2)

P/N-DOR-R-PANEL-L63036

TT

Table Top (1)

P/N-TT-63036

Right Door (2)

P/N-DOR-R-PANEL-R63036

HARDWARE

10-24 Hex Nut (8)

1 3/4 Phillips Flat Head Bolt (8)

Nickel Handle (6)

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

2 Phillips Flat Head #8 Screw (6)

1 Truss Head Machine Screw (12)

3/4 Long 3/16 DIA. Steel Pin (12)

1 Long 3/16 DIA. Steel Pin (4)

1 1/2 Long 3/16 DIA. Steel Pin (8)

Use on drawer glides

5/8 #8 Pan Head Screw (10)

3/16 Flat Washer (8)

5/8 Wooden Disk (12)

Metal Shelf Pin (4)

Towel Bar Post (4)

Magnet (4)

Screws for magnet

included in magnet packet.

Magnet Plate (4)

Screws for magnet included in magnet packet.

Bastion Post (2)

Bastion Set Screw (2)

Bastion Barrel Nut (2)

Caster Socket (4)

Non-Locking Wheel Caster (2)Locking Wheel Caster (2)

Polished
Nickel Towel
Bar (2)

STEP 1

Gets attached to the drawer side Gets attached to the Table Top Stick

STEP 2

Push down on the black tab and pull out

1 1/4 #8 Screw

TS

SP

Glides Extend Toward the Front of the Cart

SP

5/8 #6 Screw

TS

Use these holes to attach to Table Top Stick

Repeat for other Side Panel

STEP 3

1 Pin

Choose at which height you

SP SP

want the middle shelf

2 #8 Screws

Metal Shelf Pin

1 1/4 #8 Screw

Washer

TT

STEP 4

BB BB

Not Used

TB TB

Not Used

1 Pan Head Machine Screw

3/4 Pin

STEP 5

Make sure that you Install the
False Drawer Front on the back of
the cart. The Drawer glides that
you installed in step 2 will
extend out to the front of
the cart.

Not Used

Not Used

FD

FD

Back of Cart

Make sure the glides

extend out this side

Front of Cart

STEP 6

1 3/4 Machine Screw

TB

Nut

STEP 7

1 1/2 Pin

LD LDRD RD

TB

FD

1 Pan Head Machine Screw

1/2 #4 Screw

STEP 8

RDLD

RD LD

STEP 9

1 3/4 Machine Screw

Washer

Nut

BB

BB

STEP 10

Magnet

A. Stick magnet to magnet plate on the right door.
B. With left door open, close the right 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 right 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 with left Door and Doors on back side.

STEP 11

MS

BS

STEP 12

1 1/4 #8

DBK

LS RSDB

Set Screw

1 Machine Screw

DF

See next page for instructions on how the bastion fastening system works.

Barrel Nut

5/8 #6

Use the first and seventh hole

to attach glide to drawer side

Bastion Post

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.

Illustration Bas. 1

WRONG!

Post needs to be screwed deeper.

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.

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

WRONG!

Post needs to be backed out.

CORRECT!

Set screw secures post properly.

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.

102109

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: 63036

NAME ______________________________________

ADDRESS __________________________________

___________________________________________

CITY ______________________________________

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