Assembly Instructions Model 51843 Butcher Block Island with Flat Doors and Drop Leaf GENERAL: 1. You have purchased model 51843. This unit is 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 except when attaching drawer glides. Where possible, we have packaged some of the screws in separate labeled packages.
Parts List Model 51843 Drawer Front (1) P/N DF-51843 Left Drawer Side (1) P/N DS-51843/L Right Drawer Side (1) P/N DS-51843/R Drawer Back (1) P/N DBK-51843 Top Front Brace (1) P/N B-38/2 1/2/TF-51843 Glide Support (2) P/N GLDSUP-51843 Bottom Front Brace (1) P/N B-38/2 1/2/BOT-51843 Small Middle Shelf (2) P/N SMS-51843 Center Shelf (1) P/N CS-51843 Spice Rack Retainer Rods (2) P/N SRS-51843 Drawer Bottom (1) P/N DBOT-51843 Left Outside Door (1) P/N DOR-51843LO Spice Rack Right Side (1) P/N: SR - 5
Side Panel (2) P/N SP-51843 Drop Leaf (1) P/N DL-51843 Table Top (1) P/N TT-51843 Bottom Shelf (1) P/N BS-51843 29 3/4” Back Panel (1) P/N BP-51843
Hardware for 51843 Retainer Rods for Spice Rack (2) 1 3/4” Phillips Flat Head Bolt (8) Note: Use the 8 Bronze screws to assemble the spice rack 1 1/4” Phillips Flat Head #8 Screw (16) (Used to attach drawer back) Nickel Handle (6) 10-24 Hex Nut (8) 1 1/2” Phillips Flat Head #8 Screw (2) (Used to attach door spacer & drop leaf supports) 5/8 Wooden Disk (8) 3/16” Flat Washer (8) 5/8” Phillips Flat Head #8 Screw (29) (Used to attach cabinet glides & “L” Brackets) 5/8” Phillips Flat Head #7 Screw (12)
STEP 1 1/2” #4 Flat Head Screw (Included in magnet pack) A. Tap/insert ONE 1 1/2” pin into each end of all the doors. DON’T 7/8” Truss Head Screw stick up about 1/2” when seated. 5/8” #8 1/2” #4 Flat Head Screw (Included in magnet pack) 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. The counter sunk hole goes out so the bumps OVERDRIVE PINS! go toward the wood.
STEP 4 1 1/4” #8 A. Attach the Drawer Back to the Drawer Sides with two 1 1/2” #8 screws. There are left and right drawer 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.
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 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” #7 flat head screws. Left glide to left Side Panel, right glide to right Side Panel.
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 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. Back panel has 1 1/4” space at the top. C. Look ahead to step 7 which shows side panels attached to back panel. D. Insert 1” pins into back panel as shown.
STEP 8 Door Assembly A. Make sure washers are placed on the pins at the bottom of the doors, then slide the doors down into the pins. Washer B. Slide top front brace down into position to secure doors. Fasten with 1 3/4” bolts and nuts as shown. Make sure washers are on the pins in the door bottoms.
STEP 9 Magnet No pilot holes as softwood. 5/8” Pan Head Screws 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 pan head screws in the magnet packet. Center screws in the slot in the magnet.
STEP 10 Install Casters Install Casters: Locking wheels normally go on the front. Tap in wheel sleeves until teeth bite wood.
STEP 11 Towel Bar and Spice Rack Decide which side to put the spice rack on then put the towel bar on the other side. Attach side handle/towel bar using 1” Phillips Flat Head #8 screws. Place a washer over the screw to keep screwheads from pulling through the side panels. Attach the spice rack in the same way using the pilot holes in the top shelf. The holes in the bottom shelf are not used.
STEP 12 Insert Bottom Shelf Dividers will slide between the two 1” pins Install Divider Panel A. Tap eight 1” pins (4 pairs of 2) into back panel. B. Tap one 1” pin into the holes beside the two outside magnet blocks in the top front brace (2 pins). 1” Pin C. Tap 2 pairs of 1” pins into the bottom front brace. D. Tap a pair of 1” pins into each side panel.
Slide Divider Panels Into Place A. Slide each panel down using a set/pair of pins as illustrated on the top front brace. The magnet block takes the place of one pin. Install Shelf Support Pins 2” long into/through divider panels as illustrated. Make sure these pins align with shelf support pins in side panels. Note: Use the four extra 2” pins if you want the middle shelf at a different height than side shelves.
STEP 13 Drop Leaf Assembly 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 1/2” long. These marks will help you align the cabinet with the pilot holes in the bottom of the Top. B. Attach hinges/drop leaf supports with 5/8” #8 screws. Place the Cart Top on the cabinet. C. 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.
STEP 14 Fasten the table top with 5/8” #7 screws up through the “L” Brackets.
STEP 15 A. Slide panels into place on pins with edge banding out. B. Re-tighten screws and tap wooden 5/8” plugs into holes in legs. C. Insert Drawer. Drop Leaf must be up to insert drawer.
For continued beauty and long life of your Catskill Craftsmen cart, we recommend Catskill Craftsmen’s Butcher Block Oil. Our Butcher Block Oil is available directly from Catskill Craftsmen’s factory. 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 are accepted online .
