C R A F T S M E N, I N C. Assembly Instructions Model 2005 A. Assembly uses the Bastion System; a simple, yet rugged compression fastening system. B. This unit is made of solid North American hardwood and has a factory applied oil finish. See the enclosed booklet for care instructions. C. Directions (left/right, front/back) are given as if facing the front of an assembled unit.
CABINET PARTS Drawer Front (1) P/N DF-2005 28” x 10” x 3/4” Drawer Back (1) P/N DBK-2005 27 1/8” x 8” x 3/4” Drop Leaf (1) P/N DL-2005 Table Top (1) P/N TT-2005 Drawer Side Left (1) P/N DS-2005L 18” x 8” x 3/4” Drawer Side Right (1) P/N DS-2005R 18” x 8” x 3/4” Shelf (1) P/N SS-2005 Glide Support Braces (2) P/N GS-2005 17” x 2” x 3/4” Table Top Sticks (2) 15 3/4” x 3/4” x 3/4” Drawer Bottom (1) P/N DBOT-2005 Top Side Braces (2) P/N B-2005/TS 17” x 10” x 3/4” Front Right/Back Left Legs (2) P/N L-200
HARDWARE Set Screw (12) End Caps (6) Standoffs (6) Pipe Holder (6) Drop Leaf Hinges (3) P/N HINGE-2005 Towel Bar Post (6) 1 1/4” Phillips Flat Head #8 Screw (6) PREPACK 1 1/4” Phillips Flat Head #8 Screw (18) Full Ext Glide Set (1) Drop Leaf Support (2) 5/8” Phillips Flat Head #8 Screw (26) 16” Chrome Tube (2) 7/16” Pan Head #6 Screw (8) 24” Chrome Tube (1) 3/4” Long 3/16” DIA.
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.
STEP 1 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.
2A. 7/16” #6 pan head screws. About 1 1/4” of this glide will overlap the front leg. See illustration 2B. 2B. 2A You may have to slide part 2 in and out to expose pilot holes.
STEP 3 ATTACH TOP BACK BRACE You may find it easiest to attach the Top Back Brace and shelves by inverting the island.The Top Back Brace is located 1 1/4” down on the legs. This allows clearance for hinges and the drop leaf supports. Attach the Top Back Brace to the left and right side panels with bastions. Illustration 3 STEP 4 TABLE TOP PREPARATION Invert Table Top on smooth flat surface.
STEP 5 ATTACH LEGS TO TABLE TOP With Top still inverted, secure top to leg assembly with 1 1/4” #8 screws through Table Top Sticks. Three screws per stick. Illustration 5 STEP 6 ATTACH CASTERS & BOTTOM SHELF With unit still upside down, tap caster sockets into holes in leg ends until seated, then tap in casters. Hit on metal part of caster to seat. Locking casters usually go on the front, non-locking casters on the back. Use 1 1/4” #8 screws to attach shelf to the inside of the 4 legs.
STEP 7 7. 7A 7B. See illustration 7A and 7B. Screw Brass Towel Bar Posts into the Top Side Braces and the Drawer Front using 1 1/4” #8 Screws. Slide Standoffs over Posts. Attach Pipe Holders by sliding Supports over Posts and secure with tiny Set Screws using Allen Wrench provided. Set Screws should face down. 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 ilustration 7C. 7C.
STEP 8 DRAWER ASSEMBLY Attach Drawer Back to Drawer Sides using 1-1/4” Phillips Flat Head #8 screws. Then insert Drawer Bottom into slots (Best side up). Put bastion posts into Drawer Front & secure to Drawer Sides using barrel nuts & set screws. Attach the Glide inserts to the drawer sides so that the front of the glide insert touches the drawer front, using 7/16” Phillips Pan Head #6 Screws.
012208 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. C R A F T S M E N, I N C.
