Assembly Instructions Model 1480DOR Empire Island GENERAL: 1. You have purchased model 1480DOR. 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 Eastern and we’ll send you the prepaid part via UPS usually that same day! You may also email us: info@catskillcraftsmen.com. 3. Read the assembly instructions and the enclosed brochure before beginning assembly.
CABINET PARTS BOTTOM VIEW (1) Table Top-1480 44” x 26” x 1 1/4” (1) Bottom Shelf-1480 39 3/16” x 22 1/8” x 7/16” (1) Middle Shelf-1480DOR (Edge Banded) 39 3/16” x 21 7/16” x 7/16” Not To Scale BOTTOM VIEW (2) Pull Out Cutting Board Tops 22” x 19 1/2” x 3/4” (1) Drawer Bottom-1480 31 9/16” x 21 3/4” x 1/4” (2) Side Panel Inserts-1480 20 9/16” x 22 11/16” x 1/4”
(2) Right Leg-1480DOR 32 1/2” x 4” x 7/8” (4) Cutting Board Glide Support-1480DOR 19” x 3/4” x 3/4” (Inside View) (Inside View) (2) Left Leg-1480DOR 32 1/2” x 4” x 7/8” (4) Cutting Board Side Rail-1480DOR 18” x 1 1/4” x 3/4” (Inside View) (Inside View) (2) Cutting Board Front-1480DOR 21 3/4” x 2” x 3/4” (Inside View) (1) Top Back Brace-1480DOR 33 7/16” x 7 3/8” x 3/4” (Inside View) (1) Top Front Brace-1480DOR 33 7/16” x 2” x 3/4” (2) Top Side Brace-1480DOR 22 1/4” x 5 1/8” x 3/4” (Inside View) (In
HARDWARE 1 3/4” Phillips Flat Head Bolt (12) Note: Not to scale 18” Full Ext Glide Sets (3) MSKRU M5-25 For Handles (16) (Drawer Back & Cutting Board Glide Support) 10-24 Hex Nut (12) 1 1/4” Phillips Flat Head #8 Screw (12) 1/2” Flat Washer (16) (Attaches Cutting Board Side Rails) Allen Wrench 1 3/4” Phillips Flat Head #8 Screw (12) (Attaches Cutting Board Fronts) 2 1/2” Phillips Flat Head #8 Screw (6) 5/8 Wooden Disk (12) ”L” Bracket Screws 5/8” Phillips Flat Head #6 Screw (8) Bastion Post (10)
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 Slide Out Cutting Board Assembly - Part 1 2 Pull Out Cutting Board Tops, 2 Cutting Board Fronts, 4 Cutting Board Sides. Lay Pull Out Cutting Board Top on its back so holes face up. Then attach Counter Sink Up the Cutting Board Front to the Top, so that the counter sunk holes face up, using 2 1/2” #8 screws (the curved edge should face outward).
STEP 3 Drawer Assembly 2 Drawer Sides, 1 Drawer Back, 1 Drawer Front, 1 Drawer Bottom Attach Drawer Back to Drawer Sides using 1 1/4” #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 Handles using Pan Head M5-25 Machine Screws. Screw the Glide Inserts to the Drawer Sides using 7/16” Phillips Pan Head #6 Screws. Glide inserts will be almost flush with the inside of the Drawer Front when mounted.
STEP 4 Brace Preparation Insert 3/4” Pins into each end of the Top and Bottom Braces and Drawer Glide Supports. OK if Pins are loose. Top Back Brace Top Front Brace Front/Back Bottom Brace (2) Drawer Glide Support Brace (2) STEP 5 Right Leg Left Leg Leg Preparation Insert Bastion Posts into the 2 sets of Legs as illustrated. Tighten the Bastion down all the way, then back it out about 1 turn so that the hole in the Bastion Post is perpendicular to the long edge of the Leg.
STEP 6 Back Panel Assembly Front and Back Panel Assembly 3/4” Pin 1 1/2” Pin Top Back Brace A A. The Back Panel Assembly consists of a Right and Left Rear Legs, Top Back Brace, Bottom Brace, a Left Door and a Right Door. Insert 1 1/2 inch Pins into the top and bottom of the Right and Left Doors. Be sure to add a Washer over the Pins on the bottom of the doors. Insert the Bottom Door Pins into the holes in the bottom brace as illustrated.
STEP 7 Attach Magnet Plates Using 1/2” Phillips Flat Head #4 screws from your Magnet Pack attach the Magnet Plates to the small pilot holes at the top of the Doors. Bumps on Plate go against wood.
STEP 8 Insert Caster Sleeves and Cutting Board Glides A. Insert the Caster Sleeves into the holes in the bottom of the Legs and tap in with a hammer until the teeth grabs the wood - don’t pound flat! Repeat for the front assembly. B. Attach the Magnets to the bottom inside edge of the Glide Supports using the round head screws included in the Magnet Pack. C. Attach the Glide Supports to the Top Back Brace using 1 1/4” #8 screws.
STEP 9 Brace Prep A. Attach the Drawer Glides to the Glide Support Sticks using two 7/16” #6 screws. Slide top part of glide to expose pilot holes in glide support sticks. The front edge of the glide will overhangthe front edge of the Glide Support Stick by 1/8 inch. See Illustration 9A. Illustration 9A The Glide Sticks have 6 holes - only 2 are used. The pilot holes should be facing down and the glide is slightly below the long edge of the stick when positioned properly. B.
Hex Nut 1 3/4 machine screws from back side Illustration 9D TIP: Place a towel or tablecloth (movable) on the table, that will allow you to rotate the Back Assembly without scratching the tabletop. Drawer Glide Supports Illustration 9E C. Insert the Side Panels into the slots of the Bottom/ Middle Side Braces. Best side out! (Illustration 9F) E. Attach the Drawer Glide Supports. Start by aligning the 2 Pins in each end of the Sticks into the pin holes in the leg.
STEP 10 Attach Front Assembly 2 Person Job!! A. Attach the front assembly to the sides using Pins and 1 3/4” Machine Screws/Nuts. B. Insert the castors into the caster sockets. 1 3/4 machine screws Illustration 10A Tip: Don’t try to align all the pins at the same time. Better to work from one end toward the other. i.e. insert Pins on right sides lowering Front Assembly and align Pins on left side until all Pins are seated.
STEP 11 Castors and Shelf Pins A. Upright the unit. B. Insert (6) 1 1/2” pins into the pin holes at the bottom (1 in each leg and 1 in each bottom brace). The Middle Shelf has 3 adjustable heights, determine which height to use and insert the 1 1/2” pins into the appropriate holes in the legs, as the Middle Shelf is adjustable. 1 1/2” pin STEP 12 Tabletop Lay Top upside-down on flat smooth surface and screw on the “L” brackets using 5/8” #6 flat head screws as in illustration.
STEP 13 Insert Shelves Slide in the Bottom Shelf and fit it over the Bottom Pins. Then slide in the Middle Shelf (with edge banding) and fit it over the middle set of Pins. STEP 14 Add Drawer and Cutting Boards Slide the Drawer into the front of the cart then slide the Slide Out Cutting Boards into the sides of the cart. Drawer will push in halfway and seem to stop. It is O.K. to apply greater pressure to align ball bearings properly then glides will work smoothly.
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