C R A F T S M E N, I N C. Assembly Instructions Model 1521 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.
Parts List Model 1521 Not used on this model Back Panel (1) P/N BP-1521 Top & Bottom Front Braces (2) P/N B34 1/4 / 2 1/2 /BOT-1521 Left Side Panel (1) P/N LFT/SP/HDL-1521 Top Right Drawer Side (1) P/N Top DS-1521/R Top Left Drawer Side (1) P/N Top DS-1521/L Lower Left Drawer Side (2) P/N Low DS-1521/L Lower Right Drawer Side (2) P/N Low DS-1521/R Drop Leaf (1) P/N DL-1521 Right Side Panel (1) P/N RGHT/SP/HDL-1521 Top Drawer Front (1) P/N DF-1521 Top Drawer Back (1) P/N DBK-1521 Top Drawer Botto
Hardware List Model 1521 To ease assembly, sort and count the hardware before getting started. 1 3/4” Phillips Flat Head Bolt (8) 3/16” Flat Washer (11) Nickel Handle (5) 1 1/4” Phillips Flat Head #8 Screw (24) 5/8” Phillips Flat Head #8 Screw (20) 5/8” Phillips Flat Head #7 Screw (4) Bundled and labeled separately.
STEP 1A IMPORTANT - There is a right and a left side panel. Lay them out as shown below in Illustration 1. Pay close attention to the glides, that they are properly positioned when attaching to the side panels. Review Step 1B for specific instructions on the full extention glides.
STEP 1B IMPORTANT - Please read these instructions carefully! 1. Remove the drawer side section of the glide by pressing the black lever and sliding the steel inner glide section all the way out of the glide assembly. Set this inner section aside as it will be used later on the lower drawer sides. 2. Next, identify the holes to be used for attaching each glide to the side panel.
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 2 A. Attach the Top 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. 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.
STEP 3 Perform a similar drawer assembly as Step 2 for the lower drawers. A. Using 1-1/4” #8 screws, attach the drawer back to the drawer sides as shown below. B. Slide the drawer bottom into the slots. C. Insert Bastion Posts into the drawer front and tighten into position. D. Insert Barrel Nuts into the holes on the drawer sides, and slide the drawer front into place. Tighten with the set screws. Use hand screwdriver or hex wrench. E. Attach the full extention glides to the drawer sides.
STEP 4 A. Tap/insert ONE 1 1/2” pin into each end of the door. DON’T OVERDRIVE PINS! Pins should stick up about 1/2” when seated. B. Attach the magnet plate (may be stuck to magnet in the hardware pack!) with a 1/2” #4 screw to the top of the door. Bumps go toward the wood, and the plate should be vertical. C. Attach door handle with 1” truss head machine screws. 2 Used in this step 1” Truss Head Machine Screw 2 Used in this step 1 1/2” Long 3/16” DIA.
STEP 6 A. Tap/insert 3/4” pin into each long edge of the center divider. DON’T OVERDRIVE PINS! Pins should stick up about 1/4” when seated. B. Attach the magnet with 1/2” #4 screws to the top of the door. C. Attach full extention glides to the center divider as shown. Note that the glides should slide out towards the same edge with the attached magnet. D. Tap 1” steel pins into the left side of the center divider to be used as shelf supports in a later step. 4 Used in this step 3/4” Long 3/16” DIA.
STEP 7 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 8 which shows side panels attached to back panel. NOTE: Make sure you position the side panels according to Drawer Glides (left or right).
STEP 9 A. Fit a washer onto the bottom door pin and slide the pin into the bottom front brace. B. Slide the Top Front Brace into place and secure the brace using 1 3/4” machine screws and nuts as in illustration 9A & 9B. C. Tap 1” pins into Side Panel as in illustration 9B. These will hold the shelves. IMPORTANT! - To guarantee proper positioning, loosen the screws holding in the full extension drawer glides, and shift the glides back against the back panel. Retighten the screws.
STEP 10 Invert unit, or lay the unit on its back to insert the wheels. Have a friend help with this step as the unit can be heavy and awkward to move. 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.
STEP 11 A. Upright unit. B. Attach Towel Bars to the Side Panels with 1 1/4” #8 screws from inside each Side Panel. Place a washer over each screw. ILLUSTRATION 11 STEP 12 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 12A. B.
STEP 13 Slide the lower drawers into place. To initially seat the glides, it will take some force. Once the glides are properly seated, the drawers should pull out and slide in with ease. ILLUSTRATION 13 STEP 14 A. Tilt the bottom shelf and set down onto the pins. B. Fit the middle shelf into the cart and rest it on the pins. Edge banding should face out.
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. Illustration 15B shows completed 1521.
9/10/11 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 or visit us online at www.catskillcraftsmen.com. C R A F T S M E N, I N C.
