CATSKILL 2005 User manual

CRAFTSMEN, INC.
Assembly Instructions
Model 2005
Model 2005
A. Assembly uses the Bastion System; a simple, yet rugged compression
fastening system.
B. This unit is made of solid North American hardwood and has a factory
applied oil finish. See the enclosed booklet for care instructions.
C. Directions (left/right, front/back) are given as if facing the front of an
assembled unit.

CABINET PARTS
Drop Leaf (1)
P/N DL-2005
Table Top (1)
P/N TT-2005
Drawer Front (1)
P/N DF-2005
28” x 10” x 3/4”
Drawer Back (1)
P/N DBK-2005
27 1/8” x 8” x 3/4”
Drawer Side Right (1)
P/N DS-2005R
18” x 8” x 3/4”
Drawer Side Left (1)
P/N DS-2005L
18” x 8” x 3/4”
Glide Support Braces (2)
P/N GS-2005
17” x 2” x 3/4”
Shelf (1)
P/N SS-2005
Top Side Braces (2)
P/N B-2005/TS
17” x 10” x 3/4”
Top Back Brace (1)
P/N B-2005/TB
28 1/8” x 8 3/4” x 3/4”
Drawer Bottom (1)
P/N DBOT-2005
Front Left/Back Right Legs (2)
P/N L-2005FL/BR
Front Right/Back Left Legs (2)
P/N L-2005FR/BL
Table Top Sticks (2)
15 3/4” x 3/4” x 3/4”

HARDWARE
Drop Leaf Hinges (3)
P/N HINGE-2005
1 1/4” Phillips Flat Head #8 Screw (18)
7/16” Pan Head #6 Screw (8)
3/4” Long 3/16” DIA. Steel Pin (8)
5/8” Phillips Flat Head #8 Screw (26)
Wheel Insert-2005 (4)
3” Wheel Caster (2)3” Locking Wheel Caster (2)
Drop Leaf Support (2)
Bastion Set Screw (16)
PN: BSS1429
Bastion Post (16)
PN: BPost1429
Bastion Barrel Nut (16)
PN: BNut1429
Full Ext Glide Set (1)
Towel Bar Post (6)
Standoffs (6)
Pipe Holder (6)
Set Screw (12)
24” Chrome Tube (1)
16” Chrome Tube (2)
End Caps (6)
1 1/4” Phillips Flat Head #8 Screw (6)
PREPACK

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 ½ 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 damage
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
ASSEMBLE SIDE PANELS
A. Each side panel consists of two (2) legs, one (1) top
side brace and one (1) Glide Support Brace. When
assembled, diagonal legs will be the same (i.e. Front
Right/Back Left & Front Left/Back Right). Side panels are
identical when assembled -- the Drawer Glides will
determine left and right sides.
B. Take each of the 4 legs and install two (2) Bastion
Posts per leg, on the side of the leg which also has two
(2) pin holes for the Glide Support Sticks. Locate post
holes. Tap Posts in with hammer until threads engage
wood; turn Posts down until the solid shaft hits the wood
(All threads are into wood), then back Posts out until the
holes in the Posts are perpendicular to the long length of
the leg (about 1/2 turn).
C. Lay out Front Left leg and one (1) top side brace as in
Illustration 1A. Note the three pilot holes for the table top
sticks are along the top inside of the top side brace.
D. Take the top side brace and drop two barrel-shaped
bronze bastion nuts into the nut access holes as in
illustration 1A. Threaded end-of the nuts face out. Insert
front left leg posts into the holes in the ends of the brace,
through the side of the barrel nuts, until the holes in the
posts can be seen through the threaded end of the nuts.
Insert the Set Screws into the nuts and tighten down. The
tip of the set screw will seek the center of the bastion post
as it is tightened, leaving a tight joint. If the joint is loose,
check to make sure the set screw is not cross-threaded
or that the post is out too far (not threaded into leg deep
enough.) See previous page for Bastion illustrations for
clarification of assembly.
E. Insert two 3/4” pins into each end of the glide support
brace. Position brace such that the pilot holes for
attaching the glide are towards the bottom edge. Insert
brace pins into the holes on the inside of the left front leg
as in illustration 1B (4 pilot holes out) with pilot holes
off-center toward the bottom of the leg.
F. Attach Back Left leg in same manner as in illustration
1C.
G. Repeat for other side panel.
Table top stick holes
Nut access holes
bottom shelf hole
TOP SIDE BRACE
Bastion Post
GLIDE SUPPORT BRACE
Glide Support Steel Pin Holes
Illustration 1A
Illustration 1B
Illustration 1C
Towel bar holes
not used
in front legs
Left Front Leg
Pilot holes go on
the bottom edge
Left Front Leg
Left Front Leg
Left Back Leg

This end of the glide overlaps front leg 1 1/4”
& the bottom edge drops below the
glide support brace
2A
2A.
2B.
Illustration 2B
7/16” #6 pan head screws. About 1 1/4” of this glide will overlap the front leg. See illustration 2B.
Right Front Leg
You may have to slide part 2 in and out to expose pilot holes.

STEP 3
ATTACH TOP BACK BRACE
You may find it easiest to attach the Top Back Brace and shelves by inverting the island.The Top Back
Brace is located 1 1/4” down on the legs. This allows clearance for hinges and the drop leaf supports. Attach the
Top Back Brace to the left and right side panels with bastions.
STEP 4
TABLE TOP PREPARATION
Invert Table Top on smooth flat surface. Attach the 2 Table Top Sticks to the bottom of the table top
with 1 1/4” #8 screws, 2 per stick countersunk holes on top of the stick are up so that screw head is flush with top of
stick when tightened down. Attach the 3 hinges with 5/8” #8 screws large part of hinges go on Drop Leaf. Attach Drop
Leaf Supports with 5/8” #8 screws.
Illustration 3
Illustration 4
The 3 counter sunk holes
on the Table Top Sticks
Face in.

STEP 5
ATTACH LEGS TO TABLE TOP
With Top still inverted, secure top to leg assembly with 1 1/4” #8 screws through Table Top Sticks.
Three screws per stick.
STEP 6
ATTACH CASTERS & BOTTOM SHELF
With unit still upside down, tap caster sockets into holes in leg ends until seated, then tap in casters.
Hit on metal part of caster to seat. Locking casters usually go on the front, non-locking casters on the back. Use 1
1/4” #8 screws to attach shelf to the inside of the 4 legs. Keep unit upside down for step 7.
Illustration 6
Illustration 5

STEP 7
7.
7A 7B.
7C.
7A
7B
7C
Standoff must be placed on
post prior to the Pipe Holder.
End Cap
See illustration 7A and 7B. Screw Brass Towel Bar Posts into the Top Side
Braces and the Drawer Front using 1 1/4” #8 Screws. Slide Standoffs over Posts. Attach
Pipe Holders by sliding Supports over Posts and secure with tiny Set Screws using Allen
Wrench provided. Set Screws should face down. Slide Towel Bar through holes in
Supports and secure in place with Set Screws. Bar should be equidistant on either side of
the Supports. Tap End Caps into place. See ilustration 7C.

STEP 8
DRAWER ASSEMBLY
Attach Drawer Back to Drawer Sides using 1-1/4” Phillips Flat Head #8
screws. 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 the
Glide inserts to the drawer sides so that the front of the glide insert touches the
drawer front, using 7/16” Phillips Pan Head #6 Screws.
Illustration 8
STEP 9
FINAL STEP
After you have the drawer assembled simply upright the unit and attach the
drawer to the cart by sliding it into the Glide Rails. Drawer glides will lock into place.

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.
Catskill Craftsmen, Inc.
15 West End Ave.
Stamford, NY 12167-1296
CRAFTSMEN, INC.
BUTCHER BLOCK OIL COUPON
CRAFTSMEN, INC.
NAME _____________________________________
ADDRESS __________________________________
__________________________________________
CITY ______________________________________
STATE _________________________ ZIP _______
Please make checks payable to: Catskill Craftsmen Inc.
15 West End Ave. Stamford, NY 12167-1296
Please send me _____# of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $6.95
each. My Check or Money Order is enclosed
for a total of $______________.
Item Code: 2005
012208