CATSKILL Grand Americana 1428 User manual

CRAFTSMEN, INC.
Assembly Instructions
Model 1428
Grand Americana
Model 1428
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 screwdriver while a power screwdriver is recommended. Where possible, we
have packaged some of the screws in seperate labeled packages. To keep hardware separate
after packets are open, we suggest you place each type of screw into separate containers. Note
labels 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 reccommended to assist with assembly as this will ease the process. Some of the
parts are large and awkward to hold in place, and extra pair of hands are a huge help.

Parts List
Model 1428
(4) Caster Insert Sleeves
Part #: CIS1428
(2)Left Front / Right Back Leg
30” x 2.5” x 2.5”
Part #: Leg-1428LFRB
(2) Right Front / Left Back Leg
30” x 2.5” x 2.5”
Part #: Leg-1428RFLB
(2) Center/Bottom Front Brace
41” x 2” x 3/4”
Part #: CBFB1428
(1) Top Back Brace
41” x 4-3/4” x 3/4”
Part #: TBB1428
(4) Back/Side Panels
19-7/16” x 11-7/8” x 5/32”
Part #: BSP1428
(2) Center/Bottom Back Brace
41” x 2” x 3/4”
Part #: CBBB1428
(2) Center Vertical Braces
11-9/16” x 2” x 3/4”
Part #: CVB1428
(4) Top/Bottom Side Glide Support Sticks
19-7/16” x 2” x 3/4”
Part #: TBSGSS1428
(1) Center Bottom Glide Support Stick
22-1/16” x 2” x 3/4”
Part #: CBGSS1428
(4) Center/Bottom Side Braces
19-1/2” x 2” x 3/4”
Part #: CBSB1428
(2) Top Side Braces
19-1/2” x 5-1/2” x 3/4”
Part #: TSB1428
(3 sets) 20” Drawer Glide
Part #: GL-20-1428
(4) 3” Locking Casters
Part #: WHEELS1428
(1) Top Drawer Front
40-13/16” x 5-3/8” x 3/4”
Part #:TDF1428
(1) Top Drawer Back
40” x 4-1/4”” x 3/4”
Part #: TDB1428
(1) Top Drawer Left Side
17” x 4-1/4” x 3/4”
Part #:TDLS1428
(1) Top Drawer Right Side
17” x 4-1/4” x 3/4”
Part #:TDRS1428
(2) Bottom Drawer Left Side
18” x 8” x 3/4”
Part #:BDLS1428
(2) Bottom Drawer Right Side
18” x 8” x 3/4”
Part #:BDRS1428
(2) Bottom Drawer Fronts
19-1/4” x 11-7/16” x 3/4”
Part #:BDF1428
(2) Bottom Drawer Backs
18-1/2” x 8” x 3/4”
Part #:BDB1428
(1) Top Drawer Bottom
39-1/8” x 17-5/8” x 5.2mm
Part #: TDBottom1428
(2) Bottom Drawer Bottom
18-5/8” x 17-5/8” x 5.2mm
Part #: BDBottom1428

(1) Table Top
48” x 26” x 1-3/4”
Part #: TT-1428
(1) Middle Shelf
43-1/2” x 22” x 7/16”
Part #: MS-1428
(4) Clamshell Handles
Part #: Handle-1428
(8) Clamshell Handle Screws
Part #: CHScrews-1428
(48) 3/4” Steel Pins
Part #: PIN3/4
(12) 1-1/4” #8 Screws
Part #: 1-1/4#8-1428
(4) L Brackets
Part #: Lbracket-1428
(20) 5/8” #6 Screws
Part #: 5/8#6-1428
(12) 5/8” #5 Screws
Part #: 5/8#5-1428
(6) 1” Steel Pins
Part #: PIN1
(36)
(36)
(36)
(1) drop leaf
48” x 10” x 1-3/4”
Part #: DL-1428
Drop Leaf Support (2)
(26) 5/8” #8 Screws
Part #: 5/8#8-1428

WRONG!
Post needs to be screwed deeper.
WRONG!
Post needs to be backed out.
CORRECT!
Set screw secures post properly.
Step 1
TIPS ON HOW THE BASTION FASTENING SYSTEM WORKS
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 (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 and align hole in shaft.
3. Place the Barrel Nut into the designated hole in the brace or drawer side, threaded side up, making sure the hole
for the Post is aligned in the proper direction. Insert the Post into the designated hole, right into the Barrel Nut, where
you should be able to see the entire Post hole. See Illustration Bas. 1 to compare the alignment of the Post hole in
the Barrel Nut.
4. Insert the Set Screw into the threaded end of the nut and tighten down. 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. Nuts 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 in another half turn or so.
Illustration Bas. 1
Step 2
Illustration Bas. 2 Illustration Bas. 3

1Begin assembly by laying out all of the pieces and checking against the parts list
on the previous pages.Tap Caster sleeves for the caster wheels into the bottom of
the legs using a standard hammer. Do not insert wheels yet. Assemble the Back
Assembly by laying out the Back Right and Left Legs, Back Top Brace, Back
Center Brace, Back Bottom Brace, Back Vertical Brace and the Back Bottom
Panels as well as the necessary Bastions Posts and 3/4” Steel Pins as shown in
Illustration 1A. Note: Back Center and Back Bottom Braces are slotted whereas
the Front Center and Front Bottom Braces are not.
Tap the 3/4” Steel Pins into place on the Back Vertical Brace and attach to the
Back Center and Back Bottom Braces. Slide one of the Back Bottom Panels into
place, and attach the left leg to the Back Center and Bottom Braces using the
Bastions and 3/4” Steel Pins.
Next, attach the Back Top Brace to the left leg using the two Bastions.
Repeat the procedure to attach the right leg to compete Back Assembly.
Finally, tap the 1” steel pin into the center pilot hole on the Back Center Brace.
This will be used later to support the middle shelf.
BACK ASSEMBLY
Back Right Leg
Back Top Brace
Back Center Brace
Back Bottom Brace
Back
Vertical
Brace Back Bottom Panel
Back Bottom Panel
Back Left Leg
This hole not used on this brace Caster Sleeve
Caster Sleeve
Illustration 1A

Front Right Leg
Front Center Brace
Front Bottom Brace
Front
Vertical
Brace
Front Left Leg
2Tap Caster sleeves into the bottom of the legs. Do Not insert wheels yet. Assemble
the Front Assembly by laying out the Front Right and Left Legs, Front Center Brace,
Front Bottom Brace, Front Vertical Brace as well as the necessary Bastions and 3/4”
Steel Pins as shown in Illustration 2A. Note: Front Center and Front Bottom Braces
are not slotted.
Tap the 3/4” Steel Pins into place on the Front Vertical Brace and attach to the Front
Center and Front Bottom Braces. Attach the leg to the Front Center and Bottom
Braces using the Bastions and Steel Pins.
Repeat the procedure to attach the other leg to compete Front Assembly.
Use Illustration 2B to properly orientate the legs and braces.
Finally, tap the 1” steel pin into the center pilot hole on the Front Center Brace. This
will be used later to support the middle shelf.
Illustration 2A
FRONT ASSEMBLY
Front Right Leg
Front Center Brace
Front Bottom Brace
Front
Vertical
Brace
Front Left Leg
Reverse/Inside view of the Front Assembly
Illustration 2B
Front View of the Front Assembly
1” Pin taps into center
hole on backside of
Front Center Brace
These holes not
used in assembly

Back Assembly
Top Side Brace
Center
Side
Brace
Bottom
Side
Brace
Top Side Brace
Center
Side
Brace
Bottom
Side
Brace
3Lay the Back Assembly on a smooth flat surface as in Illustration 3A. Screw the Bastion
Posts into the legs and Back Vertical Brace as shown in the Bastion Fastening Instructions
on Page 3. When properly seated, the screwdriver slot in the post ends will be
perpendicular to the length of the legs. Tap the 3/4” Steel Pins into the legs and Back
Vertical Brace. Tap 1” Steel Pins into the Center Side Braces to be used later to support the
center shelf. Slide the Side Braces and Center Drawer Glide Support Stick into place,
tightening the set screws.
Next, tap two 3/4” Steel Pins into each end of the four Drawer Glide Support Sticks as
shown in llustration 3A. insert one end of these sticks into the legs as illustrated while
making sure that the small pilot holes for the drawer glides are toward the bottom edge and
face toward the inside of the cart.
Finally slide the Bottom Side Panels into place, best side out.
SIDE PANEL ASSEMBLY
Drawer
Glide
Support
Stick
Drawer
Glide
Support
Stick
Drawer
Glide
Support
Stick
Drawer
Glide
Support
Stick
Center
Drawer
Glide
Support
Stick
Bottom
Side
Panel
Bottom
Side
Panel
These holes not
used in assembly
Illustration 3A
1” Pins taps into holes
on Center Side
Braces
holes toward
bottom edge

Back Assembly
Front Assembly
4Upright Back Assembly with Braces, etc. Attached from Step 3. Caster holes in
legs should be facing down as shown in Illustration 4A. Attach Bastion Posts and
tap in 3/4” Steel Pins into front legs and Front Vertical Brace. Working Right to
left, slide the bastion posts and 3/4” Steel Pins into the Side Braces, waiting to
tighten set screws until the Center Drawer Glide Support Stick and the Left Side
Braces are all seated properly.
Drawer Glide Support Sticks should also be inserted into the Front Assembly,
using the previously inserted 3/4” Steel Pins.
ATTACHING FRONT ASSEMBLY
Illustration 4A

5Attach the Cabinet drawer glides for both bottom drawers and the top drawer to the
drawer support sticks using the 5/8” #6 screws. Note: refer to the label included with
screw pack to make sure the appropriate screws are used for this step.
ATTACH DRAWER GLIDES
Note the holes used to attach
the drawer glides to the cart.
Glide overlaps leg by 1 1/4”

Straight on view of cart with front cutaway
6Make sure 1” Steel Pins were firmly tapped into place in the pilot holes on each of the
center braces in previous steps.
Then, take the center shelf and dip it down into the unit, putting one end down near the
bottom drawer support stick as shown in Illustration 6A. This will allow the other end to
clear the opposite top drawer support stick while resting on the pins in the front and
back center braces. Back the shelf up until both ends are above the steel pin supports
on each side center brace as shown in Illustration 6B. Then settle the shelf down onto
the pins as shown in Illustration 6C.
INSERT SHELF
Top Drawer
Support Stick
Bottom Drawer
Support Stick
Shelf
Illustration 6A Illustration 6B
Illustration 6C

ASSEMBLE DRAWERS
A. Attach the Drawer Back to the Left
and Right Drawer Sides with four 1 ¼”
#8 Screws. 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,
C. Take two (2) Bastion Posts for the top
drawer, four (4) Bastion Posts for the
bottom drawers, align the threaded ends
of the Posts with the post holes located
near the ends of the inside Drawer
Front. Tighten Posts down until the
solid shaft of the Post hits the wood.
Back Post out 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.
D. Insert the Bastion Nuts (B-Nuts) into
the nut access holes on the inside of the
Drawer Sides with the threaded end
facing out. Take the Drawer Front and
carefully insert the Posts into the ends of
the Brace Sides, through the sides of the
B-Nut until seated. Push Nut snugly
against the wood in the nut access hole
toward the Drawer Front. Hole should be
slightly off-center toward the Drawer
Front. Insert the Set Screw and tighten
down. The Drawer Sides should be tight
against the Drawer Front.
E. Attach the Drawer Handle with 8-32
Truss-Head screws.
Attach the Drawer Glides (left and Right)
to the Drawer Sides using two 5/8” #5
Flat Head Screws per glide. Wheels go
toward Drawer Back and are up. DO
NOT INSERT DRAWERS INTO
CABINET AT THIS TIME.
Illustration 7A
Illustration 7B
Illustration 7C
Top Drawer Front
Illustration 7E
Illustration 7F
Illustration 7D
Bottom Drawer Fronts
7

TABLE TOP PREPARATION
Invert Table Top on smooth flat surface. 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.

8Attach the 4 L-Brackets to the top side braces with 5/8” # 6 screws. Note the
orientation of the L-Brackets in Illustration 8A. The single slot side should attach
to the Top Side Braces while the slot and hole side should attach to the Butcher
Block Top, also using 5/8” #6 screws. Note: As the Butcher Block top is heavy and
somewhat awkward to maneuver, it is highly recommened to have a friend assist
in positioning the Top for attachment.
ATTACH BUTCHER BLOCK TOP

9Tap the wheel casters into place. Note: It is highly recommended to have a friend
assist in setting the cart upright once the casters have been tapped into place.
INSERT WHEEL CASTERS

10
INSERT DRAWERS
Slide the drawers into place. Your Grand Americana is now ready to use.
BUTCHER BLOCK OIL COUPON
REDUCED
PRICE TO OUR
CUSTOMERS!
CRAFTSMEN, INC.
NAME _____________________________________
ADDRESS __________________________________
__________________________________________
CITY ______________________________________
STATE _________________________ ZIP _______
Please make checks payable to: Catskill Craftsmen Inc.
15 West End Ave. Stamford, NY 12167-1296
Catskill Craftsmen, Inc.
15 West End Ave.
Stamford, NY 12167-1296
CRAFTSMEN, INC.
Please send me _____# of bottle(s) of the
Catskill Craftsmen Butcher Block Oil at $6.95.
My Check or Money Order is enclosed for a
total of $______________.
Item Code: 1428
rev. 11/17/11
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. If you
prefer to use MasterCard or Visa please visit
us online at www.catskillcraftsmen.com