Assembly Instructions Model 54238 Butcher Block WorkCenter PLUS with Drop Leaf GENERAL: 1. You have purchased model 54238. 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 54238 Center Shelf (1) P/N CS-54238 Small Middle Shelf (2) P/N SMS-54238 Divider Panel (2) P/N DP-54238 Drop Leaf (1) P/N DL-54238 Table Top (1) P/N TT-54238 Bottom Shelf (1) P/N BS-54238 Top Front Brace (1) P/N B-38/2 7/16/TF-54238 Drawer Bottom (1) P/N DBOT-54238 Glide Support Stick (2) P/N GLDSUP-54238 Bottom Front Brace (1) P/N B-38/2 7/16/BOT-54238 Drawer Front (1) P/N DF-54238 31” Drawer Back (1) P/N DBK-54238 Left Drawer Side (1) P/N DS-54238L Right Drawer Side (1) P/N
Hardware for 54238 Retainer Rods for Spice Rack (2) 1 3/4” Phillips Flat Head Bolt (8) Drawer (8 are bronze for spice rack) 1 1/4” Phillips Flat Head #8 Screw (16) (Used to attach drawer back) P/N Drop Leaf Support (2) 1 1/2” Phillips Flat Head #8 Screw (2) Drawer Glide (1 Set ) (Used to attach drop leaf hardware) 5/8” Phillips Flat Head #8 Screw (26) (8 Used on “L” Brackets and 4 used for Drawer glides) Cabinet 3/16” Flat Washer (8) Bastion Post (2) 5/8” Phillips Flat Head #7 Screw (12) 10-24 He
STEP 1 1/2” #4 Flat Head Screw (Included in magnet pack) The counter sunk hole 5/8” #8 goes out so the bumps A. Tap/insert ONE 1 1/2” pin into each end of all the doors. DON’T OVERDRIVE PINS! Pins should go toward the wood. 7/8” Truss Head Screw 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.
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 Washer Slide top front brace down into position to secure doors. Fasten with 1 3/4” bolts and nuts as shown.
STEP 9 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 . This will allow adjustment later, if needed. D. Repeat these steps for all the doors.
STEP 11 A. Upright unit. B. Determine if you want the Spice Rack on the left or right Side Panel. The Handle/Towel Bar will go on the other. Attach the Spice Rack to the Side Panel with two 1” #8 screws from inside the panel. Place a washer over the screw so that so that the head won’t pull through the side panel. C. Attach Towel Bar to the other Side Panel with 1” #8 screws from inside the Side Panel. Place a washer over each screw. STEP 12 A.
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. C. On the Inside face of the Top Front Brace there is a hole adjacent to each of the magnet blocks for the outside doors. Tap one 1” pin into each hole. D. Choose the height you want your middle shelves, then tap the 2” pins in accordingly on the Cabinet Dividers. For Side Panels, use the metal shelf pins.
STEP 15 A. Slide the Drawer into the front of the cart. Make sure drawer moves freely, then retighten all bolts/nuts. B. Tap in the 5/8 wooden plugs into the holes on the legs. C. Install Small Middle and Center Shelves simply by sliding them in, edge banding out. D. Illustration 15B shows completed 54238.
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