Sauder Costa 419961 User manual

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Prefer the phone? Call 1-800-523-3987.
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NOTE: THIS INSTRUCTION
BOOKLET CONTAINS IMPORTANT
SAFETY INFORMATION.
PLEASE READ AND KEEP FOR
FUTURE REFERENCE.
English pg 1-23
Français pg 24-26
Español pg 27-29
Lot # 395001 09/27/16
Purchased: __________________
Be sure to give us a ring before
making any returns. 1-800-523-3987
For things 'n such.
Hutch
Costa Collection | Model 419961

Table of Contents Assembly Tools Required
Part Identification
Hardware Identification
Assembly Steps
Français
Español
Safety
Warranty
Hammer
Not actual size
No. 2 Phillips Screwdriver
Tip Shown Actual Size
3
4
5-23
24-26
27-29
30
31
Nail holder (provided)
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Electric drill with 3/16" bit
(ONLY in indicated step)

Part Identification
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.
A END (2)
B FRONT LEG (2)
C END MOLDING (2)
D VALANCE (1)
E ADJUSTABLE SHELF (2)
F ADJUSTABLE SHELF MOLDING (2)
G BACK (1)
H LEFT REAR LEG (1)
I BRACE (1)
J RIGHT REAR LEG (1)
K TOP (1)
A
A
B
B
C
C
D
E
E
F
F
G
H
I
J
K
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Hardware Identification
åScrews are shown actual size. You may receive extra hardware with your unit.
SAFETY BRACKET - 1
1G
BLACK 9/16" LARGE HEAD SCREW - 4
1S BLACK 2-1/4" FLAT HEAD SCREW - 1 26S
12F TWIST-LOCK®FASTENER - 6
METAL PIN - 8
1R
BLACK 9/16" FLAT HEAD SCREW - 4
32S
CAM SCREW - 24
8F
WOOD DOWEL - 2
15F
NAIL - 12
1N
HIDDEN CAM - 24
1F
CAM COVER - 16
33P RUBBER SLEEVE - 8 2R
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CLIP - 3
67G

Step 1 Look for this icon. It means a
video assembly tip is available at
www.sauder.com/services/tips
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 ENDS (A) and
VALANCE (D).
Do not tighten the TWIST-LOCK® FASTENERS in this step.
12F
A
A
D
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Step 2
å Push twenty-four HIDDEN CAMS (1F) into the edges of the
ENDS (A), BRACE (I), and ADJUSTABLE SHELVES (E).
The arrow in the HIDDEN
CAM must point toward the
hole in the edge of the board.
Hole
Hole
Arrow Arrow
1F
Arrow
1F
Arrow
(24 used)
A
A
I
E
E
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Step 3
8F
8F
8F
å Turn twenty CAM SCREWS (8F) into the LEGS (B, H, and J)
and SHELF MOLDINGS (F).
B
B
H
J
F
F
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Remember:
Righty tighty.
Lefty loosey.
(20 used)

Step 4
å Turn four BLACK 9/16" FLAT HEAD SCREWS (32S) into
the ENDS (A) until the shoulders of the SCREWS rest on
the surfaces of the ENDS.
å NOTE: Do not overtighten the SCREWS.
å Slide the END MOLDINGS (C) onto the ENDS (A). Line
up the grooves in the MOLDINGS over the heads of the
SCREWS in the ENDS.
å NOTE: If the MOLDINGS come up o of the SCREWS,
remove them and slide them on again.
These edges
should be even.
These edges
should be even.
BLACK 9/16" FLAT HEAD SCREW
(4 used in this step)
32S
Apply pressure with your hands
as you guide the MOLDINGS over
the SCREWS and onto the ENDS.
Apply pressure with your hands
as you guide the MOLDINGS over
the SCREWS and onto the ENDS.
Shoulder
Shoulder
A
A
C
C
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Step 5
These surfaces
should be even.
Edge with
TWIST-LOCK®
FASTENERS
å Fasten the LEGS (B and J) to an END (A). Tighten six HIDDEN CAMS.
B
J
A
Surface with HIDDEN CAMS
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This END (A) will
become the right
END (A).

å Fasten the LEGS (B and H) to the END (A). Tighten six
HIDDEN CAMS.
Step 6
These surfaces
should be even. Edge with
TWIST-LOCK®
FASTENERS
B
H
A
Surface with HIDDEN CAMS
12
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Now might be a
good time to refresh
your drink.
This END (A) will
become the left
END (A).

å Fasten the left END (A) to the TOP (K). Tighten two
TWIST-LOCK® FASTENERS.
å Fasten the VALANCE (D) to the TOP (K). Tighten two
TWIST-LOCK® FASTENERS.
Step 7
A
Surface with HIDDEN CAMS
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.
For support, place packing
foam and magazines here.
Dowel end
K
D
Surface with TWIST-LOCK® FASTENERS
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Meet Part (K). 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 Push a WOOD DOWEL (15F) into the RIGHT REAR LEG (J).
å Fasten the BRACE (I) to the RIGHT REAR LEG (J). Tighten
the HIDDEN CAM.
å NOTE: Be sure the WOOD DOWEL inserts into the edge
of the BRACE.
Step 8
15F
I
Surface with HIDDEN CAMS
J
12
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å Push a WOOD DOWEL (15F) into the
LEFT REAR LEG (H) .
å Fasten the left END (A) to the TOP (K). Tighten two
TWIST-LOCK® FASTENERS.
å Fasten the BRACE (I) to the LEFT REAR LEG (H) . Tighten
the HIDDEN CAM.
å NOTE: Be sure the WOOD DOWEL inserts into the edge
of the BRACE.
Step 9
15F
H
IFor support, place packing
foam and magazines here.
A
K
12
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Hey! It's starting to look
like something!

å Fasten an ADJUSTABLE SHELF MOLDING (F) to an
ADJUSTABLE SHELF (E). Tighten three HIDDEN CAMS.
å Repeat this for the remaining ADJUSTABLE SHELF (E)
and SHELF MOLDING (F).
å To prepare for the next step, place the ADJUSTABLE
SHELVES (E) exactly as shown below. This is done to
support the BACK attachment in the next step.
å NOTE: The ADJUSTABLE SHELF must not be higher than
the lower edge of the REAR LEG.
Step 10
1
2
Surface with HIDDEN CAMS
E
E
E
F
F
The CAM SCREWS should be
closer to this edge.
View shown
without the LEFT
END for clarity.
F
For support, place packing
foam and magazines here.
Lower edge of REAR LEG
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Step 11
2.
1.
å NOTE: You will need a tape measure in this step.
å Unfold the BACK (G) and lay it over the lower edges of the REAR LEGS (H and J) as shown in diagrams #1 and #2. The
back should be against the TOP (K).
å Diagram 3 and 4. Place the bead of the nail holder down between the BACK (G) and REAR LEGS (J and H) 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
REAR LEGS. Remove the nail holder from the nail and completely tap the nail in with your hammer. Finish fastening the
BACK to the REAR LEGS with the hammer and nail holder placing nails approximately 5-1/2" apart.
å Diagram 5. Fasten the BACK (G) to the BRACE (F). Use three CLIPS (67G) and three BLACK 9/16" LARGE HEAD
SCREWS (1S).
å NOTE: The CLIPS should wrap around the edges of the BACKS and the teeth of the CLIPS should bite into the BRACES as
you tighten the screws.
5.
67G
BLACK 9/16" LARGE HEAD SCREW
(3 used in this step)
1S
NAIL
(12 used in this step)
1N
Lower edge
Lower edge
J
H
4.
2"
Bead
3.
2"
Bead
G
K
(3 used)
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H
J
F
Bead
Nail slot
nail
holder
Oset edge

å Your Hutch was made to fasten to the 419960 Library
Base and the 420040 Lateral File.
å Go to step 13 if your 419960 Library Base or the 420040
Lateral File is assembled.
å Go to step 14 if your 419960 Library Base or the 420040
Lateral File is not assembled.
Step 12
419960 Library Base
420040 Lateral File
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Step 13
å NOTE: Use these
templates only if
your 419960 Library
Base or the 420040
Lateral File is
assembled.
å Cut out the two
templates along the
dashed lines and go
to step 15.
LEFT EDGE OF TOP
RIGHT EDGE OF TOP
BACK EDGE OF TOP
LEFT TEMPLATE RIGHT TEMPLATE
BACK EDGE OF TOP

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Step 14
å If you purchased the 419960 Library Base or the
420040 Lateral File, open the box, locate the
TOP and place it on packing foam or magazines
flat on the floor.
å With a drill and 3/16" drill bit, finish drilling
through the holes shown.
419960 Library Base Top (J)
420040 Later File Top (K)
Drill through these
two small holes.
Drill through these
two small holes.
Drill through these
two small holes.
Drill through these
two small holes.
CAUTION
Make sure you
have packing
foam or throw
away material
underneath the
tops near the drill
area.

Step 15
Drill through
the two circles
closest to the
outside edge.
Drill through
the two circles
closest to the
outside edge.
Drill through these four
circles farthest away
from the outside edge.
419960 Library Base
420040 Lateral File
å Use masking tape to hold the correct template edges to the corners
of the 419960 Library Base top or 420040 Lateral File top.
å Use an electric drill with a 3/16" drill bit to drill through the four
circles in the templates and through the top of the Library base or
Lateral File.
RIGHT TEMPLATE
RIGHT TEMPLATE
LEFT TEMPLATE LEFT TEMPLATE
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