CATSKILL 64024 User manual

Assembly Instructions
Model 64024
The Deep Storage WorkCenter
A. These units are Ready-to-Assemble. Catskill uses positive fastening methods such as wood screws
and in some places hidden Bastion fasteners. You will need some standard household tools: hammer
and Phillips small and medium screwdrivers. A power screwdriver is recommended for some applica-
tions. Where possible, we have packaged some of the screws in separate labeled packages. Note label
for screws and when they are to be used in assembly in the instructions.
B. Directions (left/right, front/back) are given as facing the front of an assembled upright unit.
C. A friend is recommended to assist with assembly as this will ease the process. Some of the parts are
large and awkward to hold in place, and an extra pair of hands will help.
D. Visit www.catskillcraftsmen.com to view our assembly video and care products.

Inside
PARTS 64024
P/N: B-27/2/64024/BF
Bottom Front Brace (1)
Inside View
P/N: B-27/2/64024/TF
Top Front Brace (1)
P/N: DOOR-64024L
Left Door (1)
P/N: DOOR-64024R
Right Door (1)
INSIDE
P/N: SIDE SHELF-64024
Side Shelf (8)
P/N: 64024/BOT
Bottom Shelf (1)
EDGE BANDING
P/N: 64024/MID
Middle Shelf (1)
Inside View Inside View
P/N: L-31/5/RF/64024 P/N: L-31/5/LF/64024
Front Legs (2)
P/N: L-31/5/LB/64024 P/N: L-31/5/RB/64024
Back Legs (2)
P/N: DS-18R 64024
Right
Drawer Side (1)
P/N: DS-18L 64024
Left
Drawer Side (1)
P/N: TT 64024
Table Top (1)
P/N: DBOT 64024
Drawer Bottom (1)
P/N: DBK 64024
Drawer Back (1)
P/N: DF 64024
Drawer Front (1)
Inside View
P/N: BP 64024
Back Panel (1)
Inside View
P/N: SP 64024
Side Panel (2)

Hardware 64024
Caster Socket (4)
P/N: SET SCREW
Bastion Set Screw (10)
P/N: B-NUT
Bastion Barrel Nut (10)
P/N: B-POST
Bastion Post (10)
5/8” Wooden Disk (12)
(Packed with Hardware)
P/N: SPACER
Plastic Spacer (4)
(Goes between cabinet
drawer glide & side panel)
Butterfly
Brackets (4)
IMPORTANT NOTE ON SCREWS: Separate screws
into piles with a note on use as some are very similar.
DO NOT use the larger diameter 5/8” #8 screws to
attach the drawer glides. Screws for the glides have
flat heads & are much smaller in diameter. Double Check!!
Drawer Glide (1 Set )
Drawer
Cabinet
P/N: WHEEL 2L (LOCKING)
Locking Wheel Casters (2)
P/N: WHEEL 2 (NON-LOCKING)
Wheel Casters (2)
P/N: HANDLE 64024
Nickel Handle (3)
1 1/2” Phillips Flat Head #8 Screw (16)
5/8” Pan Head Screw (4)
3/4” Long 3/16” DIA. Steel Pin (4)
1” Long 3/16” DIA. Steel Pin (40)
1 1/2” Long 3/16” DIA. Steel Pin (4)
Magnet Plate (2)
Magnet (2)
1/2” Phillips Flat Head #4 Screw (2)
(Used on Magnet Plate)
(Used on Magnet)
Magnet Pack
(Door pins)
(Shelf pins)
(Brace pins)
1” Truss Head Machine Screw (6)
(used on door/
drawer handles)
1” Phillips Flat Head #6 Screw (4)
(used to attach cabinet
drawer glides)
5/8” Phillips Flat Head #8 Screw (8)
(used to attach
butterfly bracket)
5/8” Phillips Flat Head #6 Screw (4)
(used on drawer glides -
packed separately)
3/16” Flat Washer (2)

STEP 1
Assemble Drawer
A. Attach the drawer back to the drawer sides with four 1 1/2” #8 screws. There are left and right 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 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 post hits the wood. Back
post out about 1/2 turn until the hole/screwdriver slot in the end of the post is parallel and in direct line
with the long edges of the Drawer Front. Dip threads in cooking oil to east turning.
D. Insert the barrel nuts into the nut access holes on the inside of the drawer side with the threaded
end of the nut facing out. Take the drawer front and carefully insert the posts into the ends of the brace
sides, through the sides of the nut until seated. Push nut snug up against the wood in the nut access
hole toward the inside drawer front. Hole should be slightly off-center toward the drawer front. Insert the
set screw and tighten down with a Phillips screwdriver. See illustration. The ends of the sides should
be tight against the inside drawer front. See Bastion video on our website www.catskillcraftsmen.com
E. Attach the drawer handle with the M 8-32 Pan Head Machine Screws.
F. Attach the drawer glides (left and right) to the Drawer Sides using two 5/8” #6 screws per side.
Wheels go toward drawer back and are up.
Illustration 1

STEP 2
Attach Posts To Legs
A. There are 2 right legs and 2 left legs. Diagonal legs are the same (Example: Right Front /Left
Back). See Illustration 2 below which shows the legs paired (inside view) for the front and back panels
respectively. Notice that the position of the posts in the front legs differ from those in the back legs. This
difference will mean that there are some holes that are not used on all legs.
B. Take all 4 legs and lay out in pairs as in Illustration 2. Each pair of legs should be mirror images of
each other! Make sure the bottoms of the legs (hole in each of legs for caster is bottom) are down as
they are in the illustration.
C. On the Front Legs, posts will go into holes #1 and #5 counting down from the top. On the Back Legs,
posts will go into holes #1 and #3. On the Front Legs, hole #3 is not used. On the Back Legs, holes #4
and #5 are not used.
D. To seat posts, tap the slotted end of posts with hammer until threads just enter holes; then tighten
down (see “Tips On How The Bastion System Works” for alternative methods) until the solid shaft of
the post hits the wood, then back at least 1 full turn so that the hole in the post is perpendicular to the
length of leg/wood grain. Screw posts into all 4 legs. Double check with Illustration 2.
(A)
(B)
(B)
(B)
(B)
(A)
(A)
Posts
TOP
RIGHT LEFT
FRONT LEGS
(A)
(B)
(B)
(B)
(B)
(A)
(A)
(A)
(B)
(B)
(B)
(B)
(A)
(A)
Posts
NOT USED
Posts
TOP
LEFT RIGHT
BACK LEGS
Posts
INSIDE VIEW
(A) Thru holes
used to attach
Side Panels
(B) Pin holes
for pins that
support Side
Shelves Sets
of 2
Note: Only the post holes are used
on Back Legs.
NOT USED
NOT USED
NOT USED
Pins
Pins
Illustration 1
(A)
(B)
(B)
(B)
(B)
(A)
(A)
Illustration 2

STEP 3
Assemble Cabinet Back
A. Take the Back Panel and the Back Legs, lay out as in illustration 3. The Back Panel cannot be installed
improperly since the top and bottom hole measurements are the same distance top to bottom.
Nut Access Holes
Nut Access Holes
Illustration 2
Illustration 2A
Inside View
Nut Access Holes
Nut Access Holes
Illustration 2
Illustration 2A
Inside View
B. Drop a Barrel Nut, open
end up, into each of the
large nut access holes in
the Back Panel. There are
small indented marks on
the lip of the open end of
the Barrel Nut. This shows
the alignment of the holes
through the sides of the
Back Panel. Continue
seating Post until Post goes
thru the sides of the Barrel
Nut and the hole in the post
can be seen through the
threaded end of the nut.
When the back panel is ush
against the inside of the leg,
the hole in the post should
be offset toward the side of
the access hole adjacent
to the post. Insert the Set
Screw and tighten down
with Phillips screwdriver. Set
Screws should thread easily.
DO NOT CROSS THREAD
OR FORCE. As you tighten
the Set Screw down, the
tip of the screw will seek
the center of the hole in the
post, thereby pulling the side
of the Barrel Nut against the
inside edge of the access
hole and toward the leg. If
the nut is loose and does
not tighten down against the
wood after the Set Screw
is tightened then you will
need to remove the leg(s)
and tighten the Bastion Post
down another 1/2 turn, then
repeat above.
C. Attach Right Leg to Back
Panel in the same manner.
Illustration 3A shows the
assembled Back Panel.
Illustration 3
Illustration 3A

STEP 4
Assemble Cabinet Front
A. Prep doors by inserting 1 1/2” pin in the top/bottom of each door. Attach the magnet plates to hte
top of each door using pilot holes in door and small at head screw in the magnet pack. Bumps on the
magnet plate face the wood.
B. Take the 2 Front Braces (Illustration 4) and tap/insert one 3/4” pin into each end of each brace. Take
the 2 doors and tap/insert one 1 1/2” pin into each end of each door. With pins in place lay out Braces,
Doors and Front Legs as illustrated in Illustration 4A.
C. Place 1 washer on each bottom door pin. Push door pins into the Bottom and Top Front Braces until
seated. Drop Barrel Nuts into the nut access holes in the legs. Next, attach this door assembly to the
Left Back Leg with Bastions/Pin. Then attach the Right Back Leg in the same manner (as shown in Step
2). Illustration 4B shows an assembled cabinet front.
Washer Washer
This Hole is Not Used
Note: Assemble top brace/doors/bottom brace before attaching legs!
Door Pin Holes (Inside View)
Post Hole
Pin Hole Magnet Block
Top Front Brace
Bottom Front Brace
Pin Hole
Post Hole
Illustration 3
Door Pin Holes
Illustration 4
Illustration 4A

D. Invert the Front Cabinet Assembly. Attach the magnet plates to the inside top of the doors using
at head 1/2” #4 screws. Stick the magnets to the magnet plates on the Doors. The Magnet should be
positioned over the wooden block on the bottom of the Top Front Brace. Secure the Magnets with the
two Round Head Screws in the magnet packet. Center screws in the slots in the magnet. This will allow
adjustment later, if needed. The block is soft wood, so no pilot holes are needed.
Door Pin Holes (Inside View)
Post Hole
Pin Hole Magnet Block
Top Front Brace
Bottom Front Brace
Pin Hole
Post Hole
Illustration 3
Door Pin Holes
Washer Washer
This Hole is Not Used
Note: Assemble top brace/doors/bottom brace before attaching legs!
Illustration 4B
Illustration 4C

STEP 5
Attach Front Assembly to Back Assembly with Side Panels
A. This step is easier with 2 persons! Take the front assembly and attach the 2 side panels with three
1 1/4” screws per side. Push screws through the three holes on the front face of each leg, aligning
the screws with the pilot holes in the long edges of the panels. Start all three into the pilot holes, then
tighten them down. Repeat with the other side panel. Illustration 5 shows side panels in place attached
to the front assembly.
Illustration 5

B. Take the back
assembly and attach
it to the side panels
using three 1 1/2”
#8 screws as above.
Illustration 5A shows
back panel assembly
going into place.
Illustration 5B shows
cabinet assembly at
this point.
Illustration 4B
Illustration 4A
Attach back panel with 1 1/2”
Phillips Flat Head #8 Screws
Illustration 5A
Illustration 5B