CATSKILL 7222 User manual

Assembly Instructions
Model 7222
Drop Leaf Cabinet Cart
GENERAL:
1. You have purchased model 7222. Overall dimensions of an assembled unit is 40” x 20” x 34.25”
when drop leaves are up.
2. Should you need assistance or need to replace a damaged or missing part, DO NOT RETURN
THE UNIT TO THE STORE where you purchased it, simply give us a call at 607-652-7321 from
7:30 - 4:00 PM Eastern time and we’ll send you the prepaid part via UPS usually that same day!
3. Read the assembly instructions and the enclosed brochure before beginning assembly.
Assembly is very easy if you read and follow the instructions step by step.
4. Tools required: Phillips screwdrivers, medium and small; medium at blade screwdriver and a
hammer.

CABINET PARTS
B1
Top Front Brace (1)
P/N B-15 7/8-1 1/4-TF
B2
Top Back Brace (1)
P/N B-15 7/8-5 3/8-TB
B3
Bottom Front/Bottom Back Brace (2)
P/N B-15 7/8-2-BFBBTB
B4
Middle Back Brace (1)
P/N B-15 7/8-2-MB
B5
Middle Front Brace (1)
P/N B-15 7/8-2-MF
BP
Back Panel (1)
P/N BP-7222
15 13/16-15 1/16
D1
Drawer Front (1)
P/N DF-7221 15 11/16-3 7/8
D2
Drawer Back (1)
P/N DBK-7221/L 13 3/8-3
D3
Drawer Side/Left (1)
P/N DS-7221/L 14 7/8-3
D4
Drawer Side/Right (1)
P/N DS-7221/R 14 7/8-3
D5
Drawer Bottom (1)
P/N DBOT-7221 12 1/2-13 1/2
RD
Right Door (1)
P/N DOR-7222R 15-7 3/4
LD
Left Door (1)
P/N DOR-7222L 15-7 3/4
DS
Door Spacer (1)
P/N DORS 1644 14 5/16-1 3/4
SV
Shelf (2)
P/N S-7222
15 13/16-15 13/16
SP
Side Panel (2)
P/N SP 7222
T2
Drop Leaf (2)
P/N DL-7222 21-12 3/4
T1
Cart Top (1)
P/N TT-7221 21-18 1/2
Glide Support Sticks (2)
P/N GSS 7222 15 7/8-1 1/2

CABINET HARDWARE
1 3/4” Phillips Flat Head Bolt (12)
1 1/4” Phillips Flat Head #8 Screw (8)
3/4” Truss Head Machine Screw (6)
5/8” #6 Pan Head Screw (2)
5/8” Phillips Flat Head #8 Screw (12)
3/4” Long 3/16” DIA. Steel Pin (14)
1” Long 3/16” DIA. Steel Pin (8)
1 1/2” Long 3/16” DIA. Steel Pin (4)
Hinge (4)
Caster Socket (4)
Wheel Casters (2)
Locking Wheel Casters (2)
Magnet Plate (1)
Magnet (1)
3/16” Flat
Washer (2)
10-24 Hex Nut (12)
5/8” Phillips Flat Head #6 Screw (20)
5/8” Phillips Flat Head #5 Screw (4)
1/2” Phillips Flat
Head #4 Screw (1)
Bastion Set Screw (2)
Bastion Post (2)
Bastion Barrel Nut (2)
Drawer Glide (2 Sets )
Drawer
Cabinet
P/N Drop Leaf Support (2)
1 3/4” Phillips Flat Head #8 Screw (2)
Handle (3)
( 4 are used on Cabinet Side
Glides. They may be packed
in a separate bag.)
( Used on Drawer Side Glides )
“Z” Bracket (2)
5/8” Wooden
Disk (12)
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.
(Cabinet Bolt)
(Attaches Cabinet
to Top - Front)
(Door Pin)
(Shelf Pin)
(Brace & Brace Panel Pin)
(Handle Screw)
(Drop Leaf Supports)
May be bronze in color
NOTE: Handles may be
packed with screws -
discard those and use the
screws in the hardware pack.

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
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
WRONG!
Post needs to be screwed deeper.
RIGHT!
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.
ALTERNATIVE
METHODS FOR
SEATING POSTS

STEP 1
Drawer Assembly
Tap in post with a hammer to start and screw down with a screwdriver or with a small allen wrench
until the shoulder of the post hits the wood. Then unscrew until the hole is parallel with the groove on
the bottom of the Drawer Front.
To understand how the bastion fastening system
works see “Tips on how the Bastion System Works”
or visit www.catskillcraftsmen.com and click
on our instructional video.
Either
D1
1 1/4” #8
1” Machine Screw 5/8” #5
D1
D2
D3 D4
D5
Set Screw
Barrel Nut
Drawer Bottom Slot
STEP 2
Top Assembly 5/8” #8
T1
T2 T2
SP
5/8” #6
1 1/4” #8
G1
SP
G1
Leg disc clearance holes
Left Side
Right Side
Either
D1
1 1/4” #8
1” Machine Screw 5/8” #5
D1
D2
D3 D4
D5
Set Screw
Barrel Nut
Drawer Bottom Slot

STEP 3
Glide Assembly
The glides look almost alike
however, they are labeled CR
for Cabinet Right and CL for
Cabinet Left.
5/8” #6
T1
T2 T2
SP
5/8” #6
1 1/4” #8
G1
SP
G1
Leg disc clearance holes
Left Side
Right Side
STEP 4
Brace
Preparation
B4
B3
BP
B2
3/4” Pin
B5
B3
1” Pin
Note: Ok if pins
are loose

Step 5
Main Assembly
TIP: Place the nut on the tip of your nger
and hold it against the inside of the hole as
you screw in the bolt from the other side.
Step 6
Door Assembly
1/2” #4
RD 5/8” #8
1 1/2” Pin
LD
DS
INSIDE VIEW OF DOORS
B4
BP
B3
B2
Nut
SPSP
1 3/4” Machine Screws
Side Panel Leg
Inside Brace
Countersunk Hole in Leg
( disk goes in this hole to
hide bolt head! )
Nut Access Hole
Hex Nut
B4
BP
B3
B2
Nut
SPSP
1 3/4” Machine Screws
Side Panel Leg
Inside Brace
Countersunk Hole in Leg
( disk goes in this hole to
hide bolt head! )
Nut Access Hole
Hex Nut

Step 7
Front Assembly
B3
B2
BP
B4
SP SP
Washer
RDLD
B3
SP
1 3/4” Machine Screws
B5
B1
Step 8
Door Magnet
1. Stick magnet to magnet plate on
right door.
2. With left door open, close the right
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 right door. The magnet will be in
the correct position on the block. Mark
holes with pencil thru slots, make pilot
holes with a nail or screw.
3. Secure magnet 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. NOTE: No pilot holes
in block, as it is softwood!
5/8” #6 Pan Head Screw
SP
1” Machine screw

SP
5/8” #8
1 3/4” #8
SP
SP
Invert the Cart Base and posi-
tion onto the Cart top. Fit the “Z”
brackets into the slot across the
top back brace. Align the holes
in the top front brace with the
pilot holes at the front of the cart
top. Attach the top front brace to
the cart top with 1-3/4” #8 Wood
Screws. Tighten the “Z” brackets
to complete top attachment with
5/8” #8 screw.
NOTE: The holes for the “Z”
brackets are further apart than
those for the Top Back Brace
Step 9
Attach Top
SP
5/8” #8
1 3/4” #8
SP
SP

Step 10
Main Assembly
SP
SV
SV
5/8” Wooden Disk
SP
SP

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: 7222
Name_______________________________
Address _____________________________
City ________________________________
State ___________ Zip ________________
Please make checks payable to Catskill Craftsmen
Inc. 15 West End Ave., Stamford, NY 12167-1296