CATSKILL 53220 User manual

Assembly Instructions
Model 53220
Butcher Block Island with Flat Panel Doors
GENERAL:
1. You have purchased model 53220.
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.
4. Tools required: Phillips screwdrivers, medium and small; medium at blade screwdriver and a hammer.
5. Drawer glides are sometimes pre-packed with screws, these are not used.
6. Directions (left/right, front/back) are given as facing the front of an assembled upright unit.

Parts List Model 53220
Drawer Bottom (1)
P/N DBOT-53220
Small Middle Shelf (2)
P/N SMS-53220
Center Shelf (1)
P/N CS-53220
Bottom Shelf (1)
P/N BS-53220
Left Center Door (1)
P/N DOR-53220/LC
Left Door (1)
P/N DOR-53220/LO
Right Door (1)
P/N DOR-53220/RO
Right Center Door (1)
P/N DOR-53220/RC
Side Panel (2)
P/N SP/HDL-53220
Divider Panel (2)
P/N DP-53220
Back Panel (1)
P/N BP-53220
Glide Support (2)
P/N GLDSUP-53220
Drawer Front (1)
P/N DF-53220
Left Drawer Side (1)
P/N DS-53220L
Right Drawer Side (1)
P/N DS-53220R
Bottom Front Brace (1)
P/N B-38/2 1/2/BOT-53220
Drawer Back (1)
P/N DBK-53220
Top Front Brace (1)
P/N B-38/2 1/2/TF-53220
Spice Rack Side Left (1)
P/N SR-53220L
Spice Rack Side Right (1)
P/N SR-53220R
Spice Rack Shelves (2)
P/N SRS-53220
31”
Table Top (1)
P/N TT-53220

Hardware for 53220
1 3/4” Phillips Flat Head Bolt (8)
1 1/4” Phillips Flat Head #8 Screw (20)
7/8” Truss Head Machine Screw (8)
5/8” Pan Head Screw (8)
3/4” Long 3/16” DIA. Steel Pin (4)
1” Long 3/16” DIA. Steel Pin (26)
1 1/2” Long 3/16” DIA. Steel Pin (8)
Caster Socket (4)
5/8 Wooden Disk (8)
Nickel Handle (6)
Towel Bar Post (2)
Wheel Casters (2)
Locking Wheel Casters (2)
Magnet Plate (4)
Magnet (4)
3/16” Flat Washer (8)
10-24 Hex Nut (8)
(Used on “L” Brackets
& cabinet glides)
1/2” Phillips Flat Head #4 Screw (4)
(Used on Magnet Plate)
(Used on Magnet)
2” Long 3/16” DIA. Steel Pin (8)
Bastion Set Screw (2)
Bastion Post (2)
Bastion Barrel Nut (2)
“L” Bracket (4)
Drawer Glide (1 Set )
Drawer
Cabinet
Polished Nickel Towel Bar (1)
5/8” Phillips Flat Head #7 Screw (12)
Retainer Rods for Spice Rack (2)
1” Phillips Flat Head #8 Screw (4)
Magnet Pack
(use 8 bronze screws
for spice rack)
5/8” Phillips Flat Head #5 Screw (4)
(Used on Drawer Glides)
(Used to attach towel
bar & spice rack)
(used on door handles)
(Divider pins)
(Door pins)
(Shelf pins)
(Brace pins)
1” Truss Head Machine Screw (4)
(used on
drawer handles)

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.
STEP 2
A. Take the 2 front braces and tap/insert one 3/4” steel pin into each end of both braces until seated.
About 3/8” will stick out when seated. OK if loose.
B. Insert two 1” pins in bottom brace as shown.
1” Pin
3/4” Pin
Not used Not used
Top Front Brace
Insert Bottom Front Brace

STEP 3
Assemble Spice Rack
STEP 4
A. Attach the Drawer Back to the Drawer Sides with four 1 1/4” #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. Tighten posts down until the solid shaft of the posts hits the
wood. Back post out until the hole/screwdriver slot in end of post is parallel and in direct line with the
long edges of the Drawer Front.
D. Insert the barrel nuts into the nut access holes on the inside of the Drawer Sides with the threaded
ends of the nuts facing out. Take the Drawer Front and carefully insert the posts into the ends of the
Drawer Sides, through the sides of the nuts until seated. Push nut snug up against the wood in the
nut access hole toward the inside of Drawer Front. Hole
should be slightly off-center toward the Drawer Front.
Insert the set screw and tighten down. The ends of
the sides should be tight against the inside
Drawer Front.
E. Attach the drawer handles with
1” Truss head machine screws.
F. Attach the drawer
glides (left and right)
to the Drawer Sides
using two 5/8” #5
screws per side.
Wheels go toward
Drawer Back and are
up. The end with no
wheels should touch
the Drawer Front.
Insert retainer
rods into holes
Fasten Shelves with
1 1/4” Phillips Flat Head
#8 Screw (Bronze)
Pilot holes in shelves
go toward back
1 1/4” #8
1” Truss Head Screw
5/8” #5
See next page to learn how the bastion fastening system works.
Also see our video on the Bastion Fastening System at www.catskillcraftsmen.com

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 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 ush with top of panel.
B. Attach the cabinet glide of the Drawer Glides to the Glide Support Stick using 5/8” #7 at head screws.
Left glide to left Side Panel, right glide to right Side Panel. The glides look almost alike however, the right
glide (as you face the cart) has a rolled lip at the top of the glide that keeps the drawer glide wheel in
place. Line up the holes in the glides so that the end with the wheel comes ush with the front edge of the
Table Top Stick.
C. Attach the “L” brackets to the top of the glide supports using 5/8” #7 screws. Use the long slot rather
than the hole/slot. The hole will be used to attach the table top. The “L” brackets should be ush with the
top of the glide support sticks.
Note: Glides are marked right/left with imprint behind wheel.
TOPTOP
5/8” #7 Screw
1 1/4” #8 Screw
5/8” #7 Screw

STEP 6
A. Lay Back Panel at 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 nger, align nut with bolt and tighten.
C. Look ahead to step 7 which shows side panels attached to back panel.
E. Insert 1” pins into back panel as shown.
STEP 7
Bottom Brace Assembly
A. Secure bottom brace
with 1 3/4” bolts/nuts
as shown.
B. Insert 1” pins into
the side panel as
shown.
1 3/4” Bolts
1” Pin
Nut
1 3/4” Bolts
1” Pin
Nut
Note: Wheel on glide is
to the front of the unit

STEP 8
Door Assembly
Insert a washer on
each bottom door pin.
Slide top front brace down into position to secure doors. Fasten with 1 3/4” bolts and nuts as shown.
1 3/4” Bolts
Washer
Nut

STEP 9
Magnet
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.
No pilot holes as softwood.
5/8” Pan Head Screws
easier to lay the unit
on its back.