Sauder Costa 419958 User manual

Need help? Visit Sauder.com to view video assembly tips or chat with a live rep.
Prefer the phone? Call 1-800-523-3987.
Share your journey!
sauder.com
NOTE: THIS INSTRUCTION
BOOKLET CONTAINS IMPORTANT
SAFETY INFORMATION.
PLEASE READ AND KEEP FOR
FUTURE REFERENCE.
English pg 1-33
Français pg 34-37
Español pg 38-41
Lot # 393894 09/26/16
Purchased: __________________
Be sure to give us a ring before
making any returns. 1-800-523-3987
Knick-knack
paddywhack,
give your stu a home.
Hutch
Costa Collection | Model 419958

Part Identification
Hardware Identification
Assembly Steps
Français
Español
Safety
Warranty
No. 2 Phillips Screwdriver
Tip Shown Actual Size
Hammer
Not actual size
Nail Holder (provided)
2-3
4
5-33
34-37
38-41
42
43
Table of Contents Assembly Tools Required
A RIGHT END (1)
B LEFT END (1)
C BOTTOM (1)
D RIGHT UPRIGHT (1)
E LEFT UPRIGHT (1)
F BRACE (1)
G SMALL UPRIGHT (2)
H SHELF (1)
I ADJUSTABLE SHELF (2)
J BOTTOM MOLDING (1)
K TOP MOLDING (1)
L SHELF MOLDING (1)
M ADJUSTABLE SHELF MOLDING (2)
N VERTICAL BRACE (1)
O CENTER BACK (1)
P BACK (2)
Q UPPER BACK (2)
R NARROW BACK (1)
S SMALL NARROW BACK (2)
T TOP (1)
U DOOR (2)
V GRILLE (2)
Part Identification
Electric drill with 3/16" bit
(ONLY in indicated step)
419958 www.sauder.com/servicesPage 2
Tape Measure

åWhile not all parts are labeled, some of the parts will have a label or an inked letter on the edge
to help distinguish similar parts from each other. Use this part identification to help identify similar parts.
Now you know
our ABCs.
Part Identification
A
B
C
D
E
F
G
G
H
I
I
J
K
L
M
M
N
O
P
P
Q
Q
R
S
S
T
U
U
V
V
419958www.sauder.com/services Page 3

Hardware Identification
åScrews are shown actual size. You may receive extra hardware with your unit.
BLACK 1-1/8" MACHINE SCREW - 2
21S
SAFETY BRACKET - 1
1G METAL BRACKET - 6 4G
BLACK 9/16" LARGE HEAD SCREW - 23
1S
PIVOT HINGE - 2
15H
12F TWIST-LOCK®FASTENER - 16
METAL PIN - 24
1R
TAPE CARD - 2
4M
BLACK 1/2" FLAT HEAD SCREW - 8
11S
WOOD DOWEL - 6
15F
NAIL - 28
1N
16S BLACK 1-7/8" PAN HEAD SCREW - 1
HIDDEN CAM - 14
1F CAM DOWEL - 10 2F
CAM COVER - 12
33P RUBBER SLEEVE - 10 2R
BLACK 1-15/16" FLAT HEAD SCREW - 8
113S
13H HINGE - 4 KNOB SET - 2
136K
CLIP - 8
67G
CAM SCREW - 4
8F
419958 www.sauder.com/servicesPage 4

Step 1 Look for this icon. It means a
video assembly tip is available at
www.sauder.com/services/tips
Do not tighten the TWIST-LOCK® FASTENERS in this step.
(16 used)
12F
12F
å Assemble your unit on a carpeted floor or on the empty
carton to avoid scratching your unit or the floor.
å To begin assembly, push a SAUDER TWIST-LOCK®
FASTENER (12F) into the large holes in the BOTTOM (C).
Repeat this step for the ENDS (A and B) and
UPRIGHTS (D, E, and G).
C
419958www.sauder.com/services Page 5

Step 2
Insert the metal end of the CAM
DOWEL into the HIDDEN CAM.
Arrow
å Push ten HIDDEN CAMS (1F) into the BRACE (F), SHELF (H),
and ADJUSTABLE SHELVES (I). Then, insert the metal end
of a CAM DOWEL (2F) into each HIDDEN CAM.
(10 used)
Arrow
1F
2F
Do not tighten the HIDDEN CAMS in this step.
Arrow
1F
2F
F
H
I
I
419958 www.sauder.com/servicesPage 6

Step 3
å Push four HIDDEN CAMS (1F) into the edges of the
ENDS (A and B).
A
B
Hole
Arrow
The arrow in the HIDDEN
CAMS must point toward the
hole in the edge of the board.
419958www.sauder.com/services Page 7
Arrow
1F
(4 used)

å Fasten the UPRIGHTS (D and E) to the TOP (T). Tighten
four TWIST-LOCK® FASTENERS.
å Slide the CENTER BACK (O) into the grooves of the
UPRIGHTS (D and E).
Step 4
How to use the SAUDER TWIST-LOCK®FASTENER
1. Insert the dowel end of the FASTENER into the hole of the
adjoining part.
NOTE: The dowel end of the FASTENER must remain fully
inserted in the hole of the adjoining part while locking
the FASTENER.
2. Tighten the FASTENER with a Phillips screwdriver as tight
as possible.
Dowel end
O
D
E
T
Finished surface
Groove
Surface with holes
419958 www.sauder.com/servicesPage 8
Just think. The sooner
you do this, the sooner
you do something else.
These holes must be here.
Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution
Meet Part (T). This component has
been engineered to be lighter, stronger,
faster… well ok. Not technically faster.
But definitely makes for a sturdier
Hutch that’s easier to assemble and
friendlier to the environment.

å Fasten the SHELF (H) to the UPRIGHTS (D and E). Use
four BLACK 1-15/16" FLAT HEAD SCREWS (113S).
å Fasten the SHELF MOLDING (L) to the SHELF (H).
Tighten four HIDDEN CAMS.
Step 5
These edges must be even.
D
E
BLACK 1-15/16" FLAT HEAD SCREW
(4 used in this step)
113S
H
Start Tighten
Arrow
Minimum
190 degrees
Caution
Risk of damage or
injury. HIDDEN CAMS
must be completely
tightened. HIDDEN
CAMS that are not
completely tightened
may loosen, and parts
may separate. To
completely tighten:
Arrow
Maximum
210 degrees
Surface with HIDDEN CAMS
419958www.sauder.com/services Page 9
L

å Fasten the SMALL UPRIGHTS (G) to the SHELF (H).
Tighten four TWIST-LOCK® FASTENERS.
Step 6
Finished edge
Surface with TWIST-LOCK® FASTENERS
G
G
H
419958 www.sauder.com/servicesPage 10

Step 7
1R
å Insert six METAL PINS (1R) into the SHELF (H).
å Place the BACKS (R and S) onto the METAL PINS (1R).
å Insert six METAL PINS (1R) into the long edges of the
BACKS (R and S).
H
R
S
S
Finished surface Finished surface Finished surface
419958www.sauder.com/services Page 11
(12 used)

å Fasten the BOTTOM (C) to the SMALL UPRIGHTS (G).
Use four BLACK 1-15/16" FLAT HEAD SCREWS (113S).
å NOTE: Be sure the METAL PINS in the BACKS (R and S)
insert into the holes in the BOTTOM.
Step 8
C
G
G
R
S
S
Surface with TWIST-LOCK® FASTENERS
419958 www.sauder.com/servicesPage 12
BLACK 1-15/16" FLAT HEAD SCREW
(4 used in this step)
113S
Notched edge

Step 9
å Slide the BOTTOM MOLDING* (J) onto the notched edge
of the BOTTOM (C).
å *U.S. Patent No. 5,499,886
Notched edge
Slide the BOTTOM MOLDING (J) onto the notched edge.
C
J
419958www.sauder.com/services Page 13

å Insert two WOOD DOWELS (15F) into the edge of the
SHELF (H).
å First, fasten the LEFT END (B) to the TOP (T). Tighten
two TWIST-LOCK® FASTENERS. Then, fasten the LEFT
END (B) to the SHELF (H) and BOTTOM (C). Tighten two
TWIST-LOCK® FASTENERS.
å NOTE: Be sure the WOOD DOWELS insert into the holes
in the END.
Step 10
C
H
T
15F
B
Arrow
Minimum
190 degrees
Maximum
210 degrees
419958 www.sauder.com/servicesPage 14

å Insert two METAL PINS (1R) into the BOTTOM (C).
å Place the VERTICAL BRACE (N) onto the METAL PINS (1R).
å Insert two METAL PINS (1R) into the short edge of the
VERTICAL BRACE (N).
Step 11
1R
N
Finished surface
419958www.sauder.com/services Page 15
C
(4 used)

å Insert two WOOD DOWELS (15F) into the short edges of
the BRACE (F).
å Fasten the BRACE (F) to the LEFT END (B). Tighten the
HIDDEN CAM.
å NOTE: Be sure the METAL PINS in the VERTICAL BRACE (N)
insert into the holes in the BRACE (F).
Step 12
Arrow
Minimum
190 degrees
Maximum
210 degrees
15F
15F
F
N
419958 www.sauder.com/servicesPage 16
B
Surface with HIDDEN CAMS

å Insert two WOOD DOWELS (15F) into the edge of the
SHELF (H).
å First, fasten the RIGHT END (A) to the TOP (T). Tighten two
TWIST-LOCK® FASTENERS. Then, fasten the RIGHT END (A)
to the SHELF (H), BOTTOM (C) and BRACE (F). Tighten two
TWIST-LOCK® FASTENERS and one HIDDEN CAM.
å NOTE: Be sure the WOOD DOWELS in the SHELF (H)
and BRACE (F) insert into the holes in the END.
Step 13
Arrow
Minimum
190 degrees
Maximum
210 degrees
15F
F
A
C
H
T
419958www.sauder.com/services Page 17

å Push two RUBBER SLEEVES (2R) over the posts of the
PIVOT HINGES (15H).
å Fasten two PIVOT HINGES (15H) to the TOP MOLDING (K).
Use two BLACK 9/16" LARGE HEAD SCREWS (1S).
å Fasten six METAL BRACKETS (4G) to the TOP MOLDING (K).
Use six BLACK 9/16" LARGE HEAD SCREWS (1S).
å NOTE: Be sure the BRACKETS are even with the edges of
the TOP MOLDING.
Step 14
K
BLACK 9/16" LARGE HEAD SCREW
(8 used in this step)
1S
4G
4G
15H
2R
These two holes must be
closer to the front edge.
419958 www.sauder.com/servicesPage 18

å Fasten the TOP MOLDING (K) to the TOP (T).
Use six BLACK
9/16" LARGE HEAD SCREWS (1S).
å NOTE: Start each screw a few turns before tighten any of them.
Step 15
K
The posts on the PIVOT
HINGES should be pointing up.
T
419958www.sauder.com/services Page 19
Side Step: Make
nachos. (Optional, but
recommended.)
BLACK 9/16" LARGE HEAD SCREW
(6 used in this step)
1S
Do not lift on the BRACE (F) until the
BACKS are fastened.
Caution
F

Step 16
å NOTE: You will need a Tape Measure in this step. Each BACK will use eight NAILS in this step.
å Carefully lay your unit onto its front edges. We have provided a Nail Holder tool to use in this step for proper placement of the
NAILS. We will refer to parts of this tool as the bead, oset edge, and nail slot which is important to follow for proper assembly.
å Diagram 1. Place a BACK (Q) into the lower edge of the LEFT END (B) with the top edge of the BACK (Q) against the
bottom surface of the TOP (T).
å Diagram 2. Place the bead of the Nail Holder down between the BACK (Q) and LEFT END (B) 1-1/2" from the corner.
Place a NAIL (1N) into the nail slot of the Nail Holder. Tap the NAIL through the BACK and into lower edge of the LEFT
END. Remove the Nail Holder from the NAIL and completely tap the NAIL in with your hammer. Finish fastening the BACK
to the LEFT END with the hammer and Nail Holder placing NAILS approximately 5-1/2" apart.
å Diagram 3 and 4. To fasten the remaining two edges of the BACK (Q) place the oset edge of the Nail Holder down.
Place a NAIL into the nail slot of the Nail Holder. Tap the NAIL through the BACK and into edge of LEFT UPRIGHT (E) and
SHELF (H). Remove the Nail Holder from the NAIL and completely tap the NAIL in with your hammer. Finish fastening the
BACK to the LEFT END with the hammer and Nail Holder placing NAILS approximately 5-1/2" apart.
å Repeat this step for the remaining BACK (Q) fastening it to the RIGHT END (A), RIGHT UPRIGHT (D) and SHELF (H).
Q
Q
Bead
Nail slot
Nail
Holder
1-1/2"
1-1/2"
B
NAIL
(16 used in this step)
1N
D
E
A
T
1.
2.
3.
4.
H
Lower edge
Unfinished
surface
Unfinished
surface
419958 www.sauder.com/servicesPage 20
Place packing material
under the BRACE (F)
for suppport.
F
Oset edge
Oset edge
Oset edge
Bead
Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution