Catskill Craftsmen 64238 User Manual

CRAFTSMEN, INC.

Assembly Instructions

Model 64230-64238

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

C. 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.

Model 64238 has Drop Leaf
Basic assembly is the same for both models with additional instructions for the drop leaf.

Model 64230

Model 64238

Parts List
Model 64230

Model 64230

Center Shelf (1)
P/N CS-64230/38
20 3/8” x 23 5/16”

Bottom Shelf (1)

P/N BS-64230/38

37 7/8” x 23 13/16” x 7/16”

Small Middle Shelf (2)

P/N SMS-64230/38

7 15/16” x 23 5/16”

Table Top (1)

P/N TT-64230

42” x 30”

Drawer Bottom (1)

P/N DBOT-64230/38

34 5/8” x 16 3/4”

Left Door (1)

P/N DOR-64230/38LO

Left Center Door (1)

P/N DOR-64230/38LC

Right Center Door (1)

P/N DOR-64230/38RC

Right Door (1)

P/N DOR-64230/38RO

Model 64230

38” x 31” x 3/4”

Model 64238

38” x 29 3/4” x 3/4”

Divider Panel (2)

P/N DP-64230/38

Back Panel (1)
P/N BP-64230
P/N BP-64238

Top Front Brace (1)

P/N B-38/2 7/16/BOT-64230/38

Bottom Front Brace (1)

P/N B-38/2 7/16/TF-64230/38

Drawer Front (1)

P/N DF-64230/38

Drawer Back (1)

P/N DBK-64230

Side Panel (2)

P/N SP/HDL-64230/38

Left Drawer Side (1)

P/N DS-64230/38/L

16 1/4” x 3 1/4”

Right Drawer Side (1)

P/N DS-64230/38/R

16 1/4” x 3 1/4”

Knife Rack Face (1)

P/N KR-64230/38

10 3/8” x 16 3/8”

Glide Support Stick (2)

P/N GLDSUP-64230/38

23 5/8” x 3 1/2”

Knife Rack Side (2)

P/N KR-SIDE-64230/38

9 1/4” x 1 1/2”

Table Top and Drawer Back are Replaced With
These Parts in Model 64238

Drawer Back (1)
P/N DBK-64238

Drop Leaf (1)

P/N DL-642338

42” x 10”

Table Top (1)

P/N TT-64238

42” x 28”

Hardware for 64230

Drawer

3/16” Flat Washer (8)

1 3/4” Phillips Flat Head Bolt (8)

(4 are brass for knife rack)

1 1/4” Phillips Flat Head #8 Screw (20)

(Used for attaching “L”

Brackets to cabinet )

5/8” Phillips Flat Head #8 Screw (4)

(4 Used on “L” Brackets

and 4 used for Drawer glides)

5/8” Phillips Flat Head #6 Screw (8)

(Used on Drawer Glides)

5/8” Phillips Flat Head #5 Screw (4)

(Used on Magnet Plate)

1/2” Phillips Flat Head #4 Screw (4)

(Used on Magnet)

5/8” Pan Head Screw (8)

“L” Bracket (4)

Magnet (4)

10-24 Hex Nut (8)

Cabinet

Drawer Glide (1 Set )

5/8 Wooden Disk (8)

Bastion Post (2)

Bastion Set Screw (2)

Magnet Plate (4)

Bastion Barrel Nut (2)

Polished Nickel Towel Bar (1)

1” Truss Head Machine Screw (12)

2” Long 3/16” DIA. Steel Pin (8)

1 1/2” Long 3/16” DIA. Steel Pin (8)

1” Long 3/16” DIA. Steel Pin (22)

3/4” Long 3/16” DIA. Steel Pin (4)

Hardware for 64238

Hinge (3)

P/N Drop Leaf Support (2)

Nickel Handle (6)

Towel Bar Post (2)

Metal Shelf Pin (4)

Caster Socket (4)

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

5/8” Phillips Flat Head #8 Screw (26)

Locking Wheel Casters (2)

Wheel Casters (2)

STEP 1

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 1” truss head machine screws.

ILLUSTRATION 1

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.

ILLUSTRATION 2

STEP 3

A. Assemble Knife Rack by inserting four brass colored 1 1/4” #8
Screws through the countersunk (reamed out) holes in the Knife
Rack into the pilot holes in the long edges of the Knife Rack
Sides. Tighten untill Seated. Sides will be flush with the bottom
of the face leaving a space at the top.

ILLUSTRATION 3

STEP 4

A. Attach the Drawer Back to the Drawer Sides with four 1 1/4” #8 screws. There are left and
right 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.

NOTE: On the 64238 the Drawer Back only has one hole and uses 1 1/2” #8 screws to attach as in
illustration 4B.

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.

FOR TIPS ON HOW THE BASTION SYSTEM WORKS SEE LAST PAGE!

Model 64230 Model 64238

ILLUSTRATION 4A ILLUSTRATION 4B

STEP 5

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 flush with top of panel.
B. Attach the cabinet glide of the Drawer Glides to the Glide Support Stick using 5/8” #6 flat 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 flush
with the front edge of the Table Top Stick.
C. Attach the “L” brackets to the top of the glide supports using 5/8” #6 screws. Use hole rather than
slot.

5/8” #6 Screw

TOP TOP

1 1/4” #8 Screw

5/8” #6 Screw

ILLUSTRATION 5

STEP 6

A. Lay Back Panel flat on a smooth surface with holes up.
B. Attach Side Panels with 1 3/4” machine screws (bolts) and hex nuts. After inserting bolts(s) 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.
C. Look ahead to step 7 which shows side panels attached to back panel.

NOTE: Back panel is flush with bottom of side panels. On the 64238 the back panel is 1 1/4”
shorter than side panels which leaves room at the top for drop leaf supports and hinges.

ILLUSTRATION 6

STEP 7

A. Invert cabinet assembly from step 6.
B. Take the Top Front Brace ( with magnet blocks ), insert the pins in the brace ends into the slots on
the inside of the front legs of the Side
Panel and slide down until the brace
is aligned with the set of holes in
the Side Panel as illustrated.
C. Secure brace with 1 3/4”
machine screws and hex
nuts as in step 6.

ILLUSTRATION 7

STEP 8

A. Install Doors by fitting the pins in the top of the door into the holes in the Top Front Brace.
B. Place washers on the pins on the bottom of the doors, then fit the Bottom Front Brace onto the
pins and secure the brace using 1 3/4” machine screws and nuts as in illustration 8A.
C. Tap two 1” pins into the back panel, two into the holes on the inside of the Bottom Front Brace
and two into each Side Panel as in illustration 8B. These will hold the Bottom Shelf.

ILLUSTRATION 8A

1” Pins1” Pins

ILLUSTRATION 8B

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 round 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.

ILLUSTRATION 9

STEP 10

A. 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.

ILLUSTRATION 10

STEP 11

A. Upright unit.
B. Determine if you want the Knife Rack on the left or right Side Panel. The Handle/Towel Bar will go
on the other. Then attach the Knife Rack to the Side Panel with two 1 1/4” x #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 1/4” #8 screws from inside the Side Panel. Place a
washer over each screw.

ILLUSTRATION 11

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 8.

ILLUSTRATION 12

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.

Metal shelf pins

1” Pins

Edge banding toward front

ILLUSTRATION 13

STEP 14 ONLY 64230

A. Invert Table Top on a smooth flat surface and
make a large ( X ) mark over each of the 4
pilot holes in the bottom. Make marks about
1/2-1” long. These marks will help you
align the cabinet with the pilot holes in the
bottom of the Top.
B. Place the Cart Top on the cabinet. 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”
#8 screws, allowing approximately 3/16”
space between inside face of Knife Rack
and end of Cart Top .

ILLUSTRATION 14A

STEP 14 64238 ONLY

A. Assemble 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. See illustration 14B.
B. Make a large ( X ) mark over each of the 4 pilot holes in the bottom. Make marks about 1/2-1” long.
These marks will help you align the cabinet with the pilot holes in the bottom of the Top.
C. Place the Cart Top on the cabinet. 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” #8 screws, allowing approximately 3/16” space between inside face of Knife Rack
and end of Cart Top .

ILLUSTRATION 14B

ILLUSTRATION 14C

STEP 15

A. Slide the Drawer into the front of the cart.
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.
D. Illustration 15B shows completed 64230.

ILLUSTRATION 15A

ILLUSTRATION 15B

120409

Model 64230 Model 64238

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
$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 accepted online.

CRAFTSMEN, INC.

BUTCHER BLOCK OIL COUPON

Please send me _____# of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $6.95.
My Check or Money Order is enclosed for a
total of $______________.
Item Code: 64230/38

NAME _____________________________________

ADDRESS __________________________________

__________________________________________

CRAFTSMEN, INC.

Catskill Craftsmen, Inc.

15 West End Ave.

Stamford, NY 12167-1296

CITY ______________________________________

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

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.

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

CORRECT!

Set screw secures post properly.

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.