CATSKILL 1522 User manual

Assembly Instructions
Model 1522
Drawer Cart with Side Drop Leaf
GENERAL:
1. You have purchased model 1522.
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:
www.catskillcraftsmen.com
4. The only tools needed are a hammer and a screwdriver. A power screwdriver is recommended. Where
possible we have packaged some of the screws in separate labeled packages. A friend is recommended to assist
with the assembly. Some parts are large and awkward to hold in place.
5. Glides are sometimes pre-packed with screws. These are not used.
6. Instructions (left/right, top/bottom) are given as you face an assembled unit.

Parts List Model 1522
Side Panel (1)
P/N: SP - 1522 R
TOP TOP
Table Top (1)
P/N: TT -1522
Drop Leaf (1)
P/N: DL-1522
Side Panel (1)
P/N: SP - 1522 L
TOP
Back Panel (1)
P/N: BP - 1522
Bottom Shelf (1)
P/N: BS-1522
13 7/8” x 9 7/16”
Middle Shelf (1)
P/N: MS-1522
13 1/2” x 9 7/16”
Edge Banding Door (1)
P/N: DR-1522
Center Divider (1)
P/N: DIV-1522
Left Side View
Drawer Front (3)
P/N: DF-1522
Left Drawer Side (3)
P/N: DS-1522L
Right Drawer Side (3)
P/N: DS-1522R
Drawer Bottom (3)
P/N: DBOT-1522
Drawer Back (3)
P/N: DBK-1522
Top & Bottom Front Braces (2)
P/N: B27x2-1522

1 3/4” Phillips Flat Head Bolt (8)
1 1/4” Phillips Flat Head #8 Screw (12)
1” Truss Head Machine Screw (2)
5/8” Phillips Flat Head #8 Screw (4)
3/4” Long 3/16” DIA. Steel Pin (8)
1” Long 3/16” DIA. Steel Pin (8)
1 1/2” Long 3/16” DIA. Steel Pin (2)
Hinge (2)
Caster Socket (4)
5/8 Wooden Disk (8)
Nickel Handle (4)
Wheel
Casters (2)
Locking Wheel
Casters (2)
Magnet Plate (1)
Magnet (1)
3/16” Flat Washer (15)
10-24 Hex Nut (8)
Bastion Set Screw (12)
Bastion Post (12)
Bastion Barrel Nut (12)“L” Bracket (4)
P/N Drop Leaf Support (1)
Full Extention
Drawer Glide (3 Sets)
1/2” Truss Head M4x10 screw (6)
3/8” Phillips Pan Head #8 Screw (30)
5/8” Phillips Flat Head #6 Screw (16)
Hardware List Model 1522
To ease assembly, sort and count the hardware before getting started.
Bundled with screws used
for attaching to cart.
(Cabinet Assembly)
(Drawer Backs)
(Attaches Drop Leaf Supports)
(Used to Attach L Brackets and Hinges)
(Full Extention Glide Screws)
(Attaches Handles
to Door )
(Attaches Handles
to Large Drawers)
(Door Pin)
(Shelf Pin)
(Brace Pin)

STEP 1
Attach Glides to Right
Side Panel
A. Remove the drawer side
section of the glide by pushing
the black lever down and sliding
the steel inner glide section all the
way out of the glide assembly. Set
this inner section aside as it will
be used later on the lower drawer
sides.
B. Next, identify the holes to be
used for attaching each glide to
the side panel. IMPORTANT as
shown below, the full extension
glides are only attached to the
right side panel and to the center
divider as shown in step 6.
C. Attach glides using 3/8” #8 pan
head screws. In step 10 you will
loosen these screws to slide the
glides ush with the back panel
once it is attached.
Push this lever down, then
slide the inner glide section
out of the glide assembly.
FRONT OF CART
Face of
Glide
Backside
of Glide
Use these three (3) holes to attach the glide to the side panel.
This edge will attach to back
panel in a later step.
TOP
3/8” #8 Pan
Head Screw
When attached, this
edge will be flush
behind the leg slot
Right Side Panel

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 2
Assemble 3 Drawers
A. Using 1 1/4” #8 screws, attach the drawer back to the drawer sides as shown below.
B. Slide the drawer bottom into the slots.
C. Insert Bastion Posts into the drawer front and tighten into position.
D. Insert Barrel Nuts into the holes on the drawer sides, and slide the drawer front into place. Tighten
with the set screws. Use hand screwdriver or hex wrench.
E. Attach the full extension glides to the drawer sides. See step 1 to locate the correct part of the glide
for this step.
F. Using 1/2” Truss head screws with two washers each, attach the handle to the drawer front.
FOR TIPS ON HOW THE BASTION SYSTEM WORKS SEE PREVIOUS PAGE.
This end goes flush against
the drawer front.
Use these holes to attach to
the drawer side.
1-1/4” #8 Screw
1/2” Truss Head Screw
3/8” #8 Pan Head
Screw
12 Used
in this step
1-1/4” Phillips Flat Head #8 Screw
1/2” Truss Head Screw
6 Used
in this step
12 Used
in this step
3/8” Phillips Pan Head #8 Screw
Barrel Nut &
Set Screw
Bastion Post
Note: On one side the black lever is up and
on the other side the lever is down.

STEP 3
A. Tap/insert one 1 1/2” pin into each end of the door. DON’T OVERDRIVE PINS! Pins should stick up
about 1/2” when seated.
B. Attach the magnet plate (may be stuck to magnet in the hardware pack!) with a 1/2” #4 screw to
the top of the door. Bumps go toward the wood, and the plate should be vertical.
C. Attach door handle with 1” truss head machine screws. Use washers if necessary to tighten.
1” Truss Head Machine Screw
2 Used
in this step
2 Used
in this step
1 1/2” Long 3/16” DIA. Steel Pin
* Use flat washers to tighten handle if necessary.
STEP 4
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.
4 Used
in this step
3/4” Long 3/16” DIA. Steel Pin

STEP 5
A. Tap/insert 3/4” pin into each long edge of the center divider. DON’T OVERDRIVE PINS!
Pins should stick up about 1/4” when seated.
B. Attach the magnet with 1/2” #4 screws to the top of the door.
C. Attach full extension glides to the center divider as shown.
Note that the glides should slide out towards the same edge with the attached magnet.
D. Tap 1” steel pins into the left side of the center divider to be used as shelf supports in a later step.
4 Used
in this step
The finished
edge faces the
front of the cart
3/4” Long 3/16” DIA. Steel Pin
4 Used
in this step
1” Long 3/16” DIA. Steel Pin
3/4” Pin
Left Side View
1” Pin
This side forms the right
inside of the door cavity.
3/8” #8 Pan
Head Screw
Center Divider
9 Used
in this step
3/8” Phillips Pan Head #6 Screw
Center Divider
Right Side View

2 Used
in this step
1 3/4” Phillips Flat Head Bolt
10-24 Hex Nut
2 Used
in this step
Slot
Left
Side
Door Pin Hole Not Used
STEP 5
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 bolt(s) through
the holes in the Side Panels and through the holes in the long edges of the Back Panel place a hex
nut on the tip of your nger. Align the nut with the bolt and tighten.
C. Look ahead
to step 6 which
shows the side
panels attached
to the back panel.
10-24 Hex Nut
4 Used
in this step
1 3/4” Phillips Flat Head Bolt
4 Used
in this step
STEP 6
A. Place the center divider pins
into the holes in the back panel.
B. Take the bottom front brace and
insert the pin in the right end of the
brace into the slot in the top of the
right front leg. The pin in the left
end of the brace will be outside
the slot at this time. Loosely
secure the right side of the brace
with 1 3/4 in. machine screw/nut.
Align the bottom pin in the divider
with the hole (closest to the left
side) on the inside of the brace.
Spread the left side panel until the
pin in the left end of the brace can
enter the slot and secure brace
with 1 3/4 in. machine screw/nut.
Tighten right side bolt/nut.

2 Used
in this step
1 3/4” Phillips Flat Head Bolt
4 Used
in this step
1” Long 3/16” DIA. Steel Pin
10-24 Hex Nut
2 Used
in this step
STEP 7
A. Fit a washer onto the bottom door pin and
slide the pin into the bottom front brace.
B. Slide the Top Front Brace into place and
secure the brace using 1 3/4” machine screws
and nuts as in illustration 7A & 7B.
C. Tap 1” pins into the Left Side Panel as in
Illustration 7B. These will hold the shelves.
D. Attach the L Brackets to the Back Panel
and the Top Front Brace using 5/8 #6 screws.
Use the slot rather than the hole. The hole will
attach to the table top. The L Brackets should
be ush with the top of the back panel and the
Top Front Brace.
STEP 8
Invert the unit or lay the unit on its back to insert
the wheels. Have a friend help with this step as the
unit can be heavy and awkward to move.
A. Insert and tap caster sockets with hammer until
the teeth grab the wood. DON’T POUND SOCKET
FLAT OR CASTER SHAFT WILL NOT ENTER.
B. Insert casters and seat by pushing straight
downward with heel of your hand, or tap into place
with a hammer. Don’t be afraid to give them a
good downward whack on the solid metal part of
the caster!
C. Locking wheels usually go on the front.

STEP 9
A. Assemble top by placing the top and the drop leaf upside down on a smooth at surface. Install
hinges using 5/8” #8 screws. The longer part of the hinge goes on the drop leaf with the short part on
the cart top. Fasten the drop leaf supports using 5/8” #8 screws. Attach Drop Leaf Supports with 5/8”
#8 screws. See illustration 9A.
B. Make a large (X) mark over each of the 4 pilot holes in the bottom. Make marks about 1/2-1” long.
These marks will help you align the cabinet with the pilot holes in the underside of the tabletop.
C. Place the cart top on the cabinet. Open the door. Maneuver the cart top so that the (X) marks/pilot
holes in the underside of the tabletop align with the hole in the “L” brackets. Secure top to “L” Brakes
with 5/8” #6 screws.
5/8” Phillips Flat Head #8 Screw
5/8” Phillips Flat Head #6 Screw

STEP 10
Slide the drawers into
place. To initially seat
the glides, it will take
some force. Once the
glides are properly
seated, the drawers
should pull out and
slide in with ease.
STEP 11
A. Tilt the bottom shelf and set down onto the pins.
B. Fit the middle shelf into the cart and rest it on the pins. Edge banding should face out.
C. Retighten all 1 3/4” machine screws. Tap 5/8” wooden disks into holes on the legs.

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: 1522
Name _______________________________
Address _____________________________
City ________________________________
State ________________ Zip ___________
Please make checks payable to Catskill Craftsmen Inc.
15 West End Ave., Stamford, NY 12167-1296