Assembly Instructions Model 54228 Butcher Block Island with Raised Panel Doors and Drop Leaf GENERAL: 1. You have purchased model 54228. 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 EST 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.
Parts List Model 54228 Center Shelf (1) P/N CS-54228 Small Middle Shelf (2) P/N SMS-54228 Drop Leaf (1) P/N DL-54228 Side Panel (2) P/N SP/HDL-54228 Table Top (1) P/N TT-54228 Bottom Shelf (1) P/N BS-54228 Glide Support (2) P/N GLDSUP-54228 Drawer Bottom (1) P/N DBOT-54228 29” Drawer Front (1) P/N DF-54228 Drawer Back (1) P/N DBK-54228 Top Front Brace (1) P/N B-38/2 1/2/TF-54228 Bottom Front Brace (1) P/N B-38/2 1/2/BOT-54228 Divider Panel (2) P/N DP-54228 Back Panel (1) P/N BP-54228 Left Dra
Hardware for 54228 Drawer 1 3/4” Phillips Flat Head Bolt (8) (8 are bronze for spice rack) 1 1/4” Phillips Flat Head #8 Screw (16) P/N Drop Leaf Support (2) Cabinet Drawer Glide (1 Set ) (attach drawer back) 1 1/2” Phillips Flat Head #8 Screw (2) (Used on “L” Brackets and cabinet glides) 5/8 Wooden Disk (8) Bastion Post (2) 5/8” Phillips Flat Hed #7 Screw (12) Bastion Set Screw (2) (Used on Cabinet Glides) 5/8” Phillips Flat Head #5 Screw (4) (Attaches towel bar & spice rack) 3/16” Flat Washer (8
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 7/8” truss head machine screws. 1/2” #4 Flat Head Screw (Included in magnet pack) 5/8” #8 7/8” Truss Head Screw The counter sunk hole goes out so the bumps go toward the wood. STEP 2 A.
STEP 3 Pilot holes in shelves go toward back Assemble Spice Rack Fasten Shelves with 1 1/4” Phillips Flat Head #8 Screw (Bronze) Insert retainer rods into holes 1 1/4” #8 STEP 4 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.
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(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. The back banel is flush with bottom of side panels.The back panel is 1 1/4” shorter than the side panels, leaving room at the top for drop leaf supports and hinges. D.
STEP 8 Door Assembly Washer Slide top front brace down into position to secure doors. Fasten with 1 3/4” bolts and nuts as shown.
STEP 9 Magnet Note: You may find it easier to lay the unit on it’s back. 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.
STEP 10 A. Lay the cart on it’s back. 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. STEP 11 A. Upright unit. B. Determine if you want the Spice Rack on the left or right Side Panel.
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 steps 2, 6, and 8. 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. Edge banding toward front of unit. 2” Pins C.
STEP 14 Drop Leaf Assembly A. Assemble top by placing the top and 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 14A. 5/8” #8 ILLUSTRATION 14A Marking an X with a pencil on the pilot holes under the tabletop will help to line up the pilot holes with the L Brackets in step 15.
STEP 15 A. 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” #7 screws. 5/8” #7 STEP 16 A. Slide the drawer into the front of the cart. If necessary, adjust top front brace so that drawer moves freely. Then retighten all bolts/nuts. B. Tap in the 5/8 wooden plugs into the holes on the legs. C.
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 .
