CATSKILL 1480 User manual

Assembly Instructions
Model 1480DOR
The Empire Work Center
GENERAL:
1. You have purchased model 1480.
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 [email protected].
3. Read the assembly instructions and the enclosed brochure before beginning assembly. Assembly is easy
if you read and follow the instructions step by step. See our website for assembly tips and videos:
www.catskillcraftsmen.com
4. The only tools needed are a hammer and a screwdriver. A power screwdriver is recommended. Where
possible we have packaged some of the screws in separate labeled packages. A friend is recommended to assist
with the assembly. Some parts are large and awkward to hold in place.
5. Glides are sometimes pre-packed with screws. These are not used.
6. Instructions (left/right, top/bottom) are given as you face an assembled unit.
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: [email protected].
3. Read the assembly instructions and the enclosed brochure before beginning assembly. Assembly is
easy if you read and follow the instructions step by step. See our website for assembly tips and videos:
www.catskillcraftsmen.com
4. The only tools needed are a hammer, a small and a medium Phillips head screwdriver and a medium
at blade screwdriver. A pencil is also needed. A power screwdriver will speed assembly, but is not
required. Place a few drops of vegetable oil on the threads of wood screws before screwing into the
solid hardwood parts.
5. Glides are sometimes pre-packed with screws. These are not used.
6. Instructions (left/right, top/bottom) are given as you face an assembled unit.

(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”
(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”
CABINET PARTS
(2) Pull Out Cutting Board Tops
22” x 19 1/2” x 3/4”
BOTTOM VIEW
Not To Scale
BOTTOM VIEW

(2) Left Door-1480DOR
22 1/4” x 16 5/8” x 3/4”
(2) Right Door -1480DOR
22 1/4” x 16 5/8” x 3/4’
(1) Top Back Brace-1480DOR
33 7/16” x 7 3/8” x 3/4”
(2) Top Side Brace-1480DOR
22 1/4” x 5 1/8” x 3/4”
(4) Mid/Bot Side Brace-1480DOR
22 1/4” x 2 1/4” x 3/4”
(1) Drawer Front-1480DOR
33 1/4” x 5 3/16” x 3/4”
(2) Drawer Glide Support-1480DOR
22 1/4” x 1 1/2” x 3/4”
(2) Front/Back Bottom Brace-1480DOR
33 7/16” x 2” x 3/4”
(1) Top Front Brace-1480DOR
33 7/16” x 2” x 3/4”
(1) Drawer Back-1480DOR
32 7/16” x 4 3/8” x 3/4”
(1) Left Drawer Side-1480DOR
21 1/4” x 4 3/8” x 3/4”
(1) Right Drawer Side-1480DOR
21 1/4” x 4 3/8” x 3/4”
(4) Cutting Board Glide Support-1480DOR
19” x 3/4” x 3/4”
(2) Right Leg-1480DOR
32 1/2” x 4” x 7/8”
(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”
(2) Cutting Board Front-1480DOR
21 3/4” x 2” x 3/4”
(Inside View)
(Inside View)
(Inside View)
(Inside View)
(Inside View)
(Outside View)
(Inside View)
(Inside View)
(Outside View)
(Inside View)
(Inside View)
(Inside View)
(Inside View)
(Inside View)
(Outside View)
(Inside View) (Inside View)

HARDWARE
1 3/4” Phillips Flat Head Bolt (12)
1 1/4” Phillips Flat Head #8 Screw (12)
3/4” Long 3/16” DIA. Steel Pin (20)
(Brace Ends and Glide Suports)
1 1/2” Long 3/16” DIA. Steel Pin (18)
(Shelf Supports and Doors)
Caster Socket (4)
5/8 Wooden
Disk (12)
1/2” Flat Washer (16)
10-24 Hex
Nut (12)
Bastion
Set Screw (10)
Bastion Post (10) Bastion
Barrel Nut (10)
“L” Bracket (4)
5/8” Phillips Flat Head #6 Screw (8)
”L” Bracket Screws
7/16” Phillips Pan Head #6 Screw (24)
Glide Screws
18” Full Ext Glide Sets (3)
Bar Handle (8)
MSKRU M5-25 For Handles (16)
Caster with Stops (2)Caster (2)
1 3/4” Phillips Flat Head #8 Screw (12)
2 1/2” Phillips Flat Head #8 Screw (6)
Allen Wrench
5/8” Pan Head
Screw (8)
1/2” Phillips
Flat Head
#4 Screw (4)
Magnet Plate (4)
Magnet (4)
MAGNET PACK
(Drawer Back &
Cutting Board Glide Support)
(Attaches Cutting
Board Side Rails)
(Attaches Cutting
Board Fronts)
Note: Not to scale

WRONG!
Post needs to be screwed deeper.
WRONG!
Post needs to be backed out.
CORRECT!
Set screw secures post properly.
Step 1
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. B) Align threaded end of Post
with hole in wood, tap on slotted end with hard hammer until threads enter, then tighten
down using a flat head screw driver or the provided allen wrench (See the Illus. Bas. 3 for
alternate seating methods). DO NOT TRY TO HAMMER THE POST ALL THE WAY IN AS IT
WILL STRIP THE POST HOLE. C) When solid shaft of Post hits wood, back out
approximately 1 turn until the hole in the posts is properly aligned as per step by step
directions. For example: the holes in the posts on the inside of the drawer front will be
parallel with the long length of the drawer front when properly seated.
3. A) Place a Barrel Nut into the nut access hole, so that the threads in the nut face out.
The small notches on either side of the nut opening, indicate the location of the holes
through the sides of the nut. B) Insert the posts through the end of the braces (or drawer
sides); through the holes in the sides of the nut. When properly aligned, you will see the hole
in the post inside the barrel nut. Post hole should be slightly off-center toward the wood.
4. Insert the Set Screw into the threaded end of the nut and tighten down. The tip of the Set
Screw will seek the center of the hole in the Post as it is tightened down, forcing the Nut
toward the main shaft of the Post. This is what tightens the wooden parts together. Set
screws should thread easily – DON’T CROSS THREAD! If Set Screw doesn’t thread easily,
check position of the hole in Post.
5. If the wooden parts are not tight against each other, the Post needs to be screwed a half
turn at a time until wood joints are tight.
Illustration Bas. 1
Step 2
Illustration Bas. 2 Illustration Bas. 3
TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS
See video on our website!
If you have any questions regarding assembly or missing or damaged
parts, call our customer support number:
607-652-7321 or 888-732-7321.
Customer Support Hours are 8am-5pm Mon. - Fri. Eastern Time zone.
Allen Wrench Provided

STEP 1
Slide Out Cutting Board Assembly - Part 1
2 Pull Out Cutting Board Tops, 2 Cutting Board Fronts, 4 Cutting Board Sides.
STEP 2
Slide Out Cutting Board Assembly - Part 2
A. Take all of the glides and detach the inserts by fully extending the glides and pressing down on the
black tab and pulling them out.
B. Attach Glide Inserts to the sides of the Slide Out Cutting Boards using two (2) 7/16” #6 Pan Head
Screws.
C. Attach handles to the
Cutting Board Top
using machines
screws. Glide
should be almost
1/8” to the front
edge of the
sides.
2 1/2” #8 Screws
1 3/4” #8 Screws
glide holes toward
the outside and
off center up
Counter Sink Up
Cutting Board Front
Tip: Dip screw tips in cooking oil
to ease turning into hardwood.
Lay Pull Out Cutting Board Top on its
back so holes face up. Then attach
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.) Now attach the
Cutting Board Side Rails to the Top
so that the glide holes face out
and the counter sunk holes
face up, using 1 3/4”
#8 screws.
7/16” #6
Pan Head Screws
about 1/8”
from drawer
front
Note: Holes in glides sometimes vary.
Just make sure glides are about 1/8 inch
from front edge of the sides against inside
of Drawer Front.
Push down on the black tab and pull out
Gets attached to the Drawer Side Gets attached to the Glide Support Brace

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 scews, 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 ush with the
inside of the Drawer Front when mounted.
1 1/4” #8 Screws
7/16” #6 Pan Head Screws
Bastion Post
(Holes in posts will be horizontal with top/bottom
long edges of drawer front when seated)
M5-25

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
Front/Back Bottom Brace (2)
Top Front Brace
Drawer Glide Support Brace (2)
STEP 5
Leg Preparation
Insert Bastion Posts into the 2 sets of Legs
as illustrated. Tighten the Bastion down all
the way, then back it out abot 1 turn so that
the hole in the Bastion Post is perpendicular
to the long edge of the leg. See illustration
or video on Bastion System at www.
catskillcraftsmen.com
Right Leg Left Leg
Inside View
Bottom Bottom

Back Panel Assembly
Top Back Brace
Bottom Brace
3/4” Pin Note pin hole in center
3/4” Pin
Make sure washer is on the door pin
1 1/2” Pin
AA
AA
Back Panel Assembly
Top Back Brace
Bastion Post
3/4” Pin
Bastion Post
Left Back Leg
Right Back Leg
BB
Bottom Brace
Note pin hole in center
STEP 6
Front and Back Panel
Assembly
A. The Back Panel Assembly
consists of a Right and Left
Rear Leg, 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.
Insert the Pins in the top
of the doors into the
Top Back Brace as
illustrated.
B. Fasten the Legs to the one side top/bottom, then the other side using the Bastion Posts and Pins
already inserted in steps 4 and 5. Insert Barrel Nuts into the Nut Access Holes and tighten down with
Set Screws.
C. Repeat the entire process for the Front Panel Assembly.

Back Panel Assembly
1/2” Phillips Flat Head #4 Screw
Front Panel Assembly
1/2” Phillips Flat Head #4 Screw
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 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 agains the wood.

7/16” #6 Pan Head Screws
1 1/4” #8 Screws
5/8” Pan Head Screws
(Rounded)
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 at! 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. Be sure to insert
3 Washers between the Glide Support and the Top Back Brace as illustrated below.
D. Attach the Cutting Board Glides using 7/16” #6 Pan Head Screws to the Cutting Board Glide
Support so that they extend to the outside of the cart. The front edge of the Glide is about 1/8” from
the front edge of the Glide Support as in the illustration. Two holes in the Glide Support are not used.

STEP 9
Brace Prep
A. When positioned properly the 6 pilot holes in the Glide Support Sticks will be closer to the bottom
edge. The Glide will overhang the Glide Support Sticks on the front edge by about an 1/8 of an inch
and slightly on the bottom. Only 2 of the 6 pilot holes will be used.
B. 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 overhang the front
edge of the Glide Support Stick by 1/8 inch. See Illustration 9A.
C. Attach Bottom Side Braces (illustration 9B), Middle Side Braces, (illustration 9C) Top Side Braces
and drawer glide support sticks (illustration 9D) to the back assembly using 1 3/4 machine screws
and nuts. Position braces as illustrated.
Note: This step requires access to both sides of the back panel in order to insert the machine screws
(bolts) from the front & attach the nuts/braces on the inside with help. The easiest way is to invert the
top on a table to that one side overhangs the table top giving you access from the bottom to the holes
in one of the legs. This allows you to insert the bolts through the holes in the front of the leg, through
the leg, into the ends of the bottom, middle and top braces. Secure with a nut. Repeat with the other
6” to allow you access to the bolt holes. With a friend, you can stand the back panel upright and work
Illustration 9A
Pilot Holes are closer to the bottom Bottom of glide overhangs support stick
front edge
of glide
overhangs
support sticks
1 3/4 machine screws
Hex Nut
Illustration 9B
1 3/4 machine
screws from
back side
Hex Nut
Illustration 9C
Note: See our
assembly video at
www.catskillcraftsmen.com
for tips on assembling this
cart alone.

1 3/4 machine
screws from back side
Hex Nut
Drawer Glide Supports
Illustration 9D
Illustration 9E
TIP: Place a towel or tablecloth
(movable) on the table, that will
allow you to rotate the Back
Assembly without scratching the
tabletop.
Illustration 9F
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. Make sure Glide is
positioned to the bottom of the
support stick as illustrated in
9E and 9F.
Make sure the glides are to the bottom!!!

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
Illustration 10B
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.

Lay Top upside-down on at smooth surface and screw on the “L” brackets using 5/8” #6 at
head screws as in illustration. Attach the “L” bracket to the top using the hole, not the slot on the
“L” bracket. Then ip assembled unit upright and attach the Top to the assembled unit using 5/8”
#6 at head screwsthrough the “L” brackets into the pilot holes in the top side brace
5/8” #6 Flat Head Screws
STEP 12
Tabletop
STEP 11
Castors and Shelf Pins
A. Upright the unit.
B. Insert (10) 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 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.
Then tap in the 5/8 Wooden
Plugs into the holes in the Legs.
Tip: Give Drawer/Boards a hard
shove inward to seat.
STEP 13
Insert Shelves
Slide in the Bottom
Shelf and t it over
the Bottom Pins.
Then slide in the
Middle Shelf
(with edge
banding) and
t it over the
middle set of
Pins.

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 . oz.) bottle, which is
sufcient for two applications, simply
send $7.95 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.
Catskill Craftsmen, Inc.
15 West End Ave.
Stamford, NY 12167-1296
BUTCHER BLOCK OIL COUPON
Please send me______ # of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $7.95
per bottle. My check or money order is
enclosed for a total of $_______________.
Item code: 1480
Name _______________________________
Address _____________________________
City ________________________________
State ________________ Zip ___________
Please make checks payable to Catskill Craftsmen Inc.
15 West End Ave., Stamford, NY 12167-1296
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 direct-
ly from Catskill Craftsmen’s factory. For
one eight ounce (8 . oz.) bottle, which
is sufcient 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 .
Catskill Craftsmen, Inc.
15 West End Ave.
Stamford, NY 12167-1296
BUTCHER BLOCK OIL COUPON
Please send me______# of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $6.95
per bottle. My check or money order is
enclosed for a total of $____________.
Item code: 1480DOR
Name _______________________________
Address _____________________________
City ________________________________
State ___________ Zip ________________
Please make checks payable to Catskill Craftsmen
Inc. 15 West End Ave., Stamford, NY 12167-1296