Sauder Costa 420654 User manual

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Don't sweat the
small stu anymore.
NOTE: THIS INSTRUCTION
BOOKLET CONTAINS IMPORTANT
SAFETY INFORMATION.
PLEASE READ AND KEEP FOR
FUTURE REFERENCE.
English pg 1-29
Français pg 30-33
Español pg 34-37
Lot # 396101 01/30/17
Purchased: __________________
Be sure to give us a ring before
making any returns. 1-800-523-3987
Hutch
Costa Collection | Model 420654

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
5-29
30-33
34-37
38
39
Electric drill with 3/16" bit
(ONLY in indicated step)
Tape Measure
Nail holder (provided)
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Masking Tape

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 RIGHT END (1)
B LEFT END (1)
C END MOLDING (2)
D FRONT LEG (2)
E SHELF (1)
F ADJUSTABLE SHELF (1)
G CENTER SHELF (1)
H RIGHT REAR LEG (1)
I LEFT REAR LEG (1)
J RIGHT UPRIGHT (1)
K LEFT UPRIGHT (1)
L SMALL UPRIGHT (2)
M DIVIDER (1)
N RIGHT BACK (1)
O LEFT BACK (1)
P BACK (1)
Q BRACE (1)
R RIGHT BRACE (1)
S LEFT BRACE (1)
T TOP (1)
A
B
C
C
D
D
E
F
G
H
I
J
K
L
L
M
N
O
P
Q
R
S
T
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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 - 8
1S
12F TWIST-LOCK®FASTENER - 19
METAL PIN - 4
1R
BLACK 9/16" FLAT HEAD SCREW - 4
32S
CAM SCREW - 18
8F
WOOD DOWEL - 4
15F
NAIL - 16
1N
16S BLACK 1-7/8" PAN HEAD SCREW - 1
HIDDEN CAM - 18
1F
CAM COVER - 14
33P
GLUE - 1
54M
RUBBER SLEEVE - 4
2R
BLACK 1-15/16" FLAT HEAD SCREW -10
113S
CLIP - 7
67G
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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 B). Repeat this step for the SHELF (E),
CENTER SHELF (G), UPRIGHTS (K and J), SMALL
UPRIGHTS (L), and DIVIDER (M).
A
B
Do not tighten the TWIST-LOCK® FASTENERS in this step.
(19 used)
12F
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Step 2
A
B
R
S
å Push eighteen HIDDEN CAMS (1F) into the edges of the
ENDS (A and B) and BRACES (R and S).
The arrow in the HIDDEN
CAM must point toward the
hole in the edge of the board.
Hole
Hole
Arrow Arrow
Arrow
1F
1F
1F
Arrow
Arrow (18 used)
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Step 3
8F
8F
å Turn fourteen CAM SCREWS (8F) into the LEGS (D, H, and I).
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Remember:
Righty tighty.
Lefty loosey.
(14 used)
D
D
H
I

Step 4
A
B
å Flip the ENDS (A and B) over.
å Turn four BLACK 9/16" FLAT HEAD SCREWS (32S) into
the ENDS (A and B) 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 and B).
Line up the grooves in the MOLDINGS over the heads of
the SCREWS in the ENDS.
å NOTE: If the MOLDING comes up o of the SCREWS,
remove it and slide it on again. Center the END
MOLDINGS (C) on the ENDS (A and B).
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.
Shoulder
Shoulder
Apply pressure with your hands
as you guide the MOLDINGS over
the SCREWS and onto the ENDS.
C
C
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Step 5
å Fasten the LEGS (D and H) to the RIGHT END (A). Tighten six
HIDDEN CAMS.
å NOTE: Be sure to position the LEGS and END exactly as shown.
Surface with
HIDDEN CAMS
These surfaces should be even.
These surfaces should be even.
1
2
Edge with
TWIST-LOCK®
FASTENERS
A
D
This CAM
SCREW should
be here.
H
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Step 6
å Fasten the LEGS (D and I) to the LEFT END (B). Tighten six
HIDDEN CAMS.
å NOTE: Be sure to position the LEGS and END exactly as shown.
Surface with
HIDDEN CAMS
These surfaces should be even.
These surfaces should be even.
1
2
Edge with
TWIST-LOCK®
FASTENERS
B
D
This CAM
SCREW should
be here.
I
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Step 7
Finished edge
å Fasten the SMALL UPRIGHTS (L) to the TOP (T).
Tighten two TWIST-LOCK® FASTENERS. 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
L
L
T
Surface with TWIST-LOCK® FASTENER
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Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution

å Fasten the CENTER SHELF (G) to the SMALL UPRIGHTS (L).
Use four BLACK 1-15/16" FLAT HEAD SCREWS (113S).
Step 8
Finished edge
Surface with
TWIST-LOCK®
FASTENERS
G
L
L
BLACK 1-15/16" FLAT HEAD SCREW
(4 used in this step)
113S
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å Fasten the UPRIGHTS (J and K) to the TOP (T)
and CENTER SHELF (G). Tighten eight
TWIST-LOCK® FASTENERS.
Step 9
Finished edge
Finished edge
G
Surface with
TWIST-LOCK®
FASTENERS
Surface without
TWIST-LOCK®
FASTENERS
J
K
T
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Step 10
Fill the holes 1/4 to 1/2 full with GLUE.
Inspect the parts thoroughly before
assembling. Disassembly of glued
parts is extremely dicult.
Caution
!
54M
15F
15F
å First, fill the holes in one short edge of the
BRACE (Q) 1/4 to 1/2 full with GLUE (54M). Then,
insert two WOOD DOWELS (15F) into the holes. Wipe
away the excess GLUE.
å Now, fill the holes in the other short edge of the
BRACE (Q) 1/4 to 1/2 full with GLUE. Then, insert two
WOOD DOWELS (15F) into these holes. Wipe away the
excess GLUE.
Q
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å First, fill the holes in the UPRIGHTS (J and K). Then,
fasten the BRACE (Q) to the UPRIGHTS (J and K) by fully
inserting the WOOD DOWELS in the BRACE into the
holes in the UPRIGHTS.
Step 11
Fill the holes 1/4 to 1/2 full with GLUE.
Inspect the parts thoroughly before
assembling. Disassembly of glued
parts is extremely dicult.
Caution
!
54M
Q
Surface without holes
J
K
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Notch

å Fasten the DIVIDER (M) to the TOP (T). Tighten the
TWIST-LOCK® FASTENER.
Step 12
Finished edge
Surface with
TWIST-LOCK®
FASTENER
MT
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Step 13
Finished edge
Surface with
TWIST-LOCK®
FASTENER
å Fasten the SHELF (E) to the RIGHT UPRIGHT (J). Tighten
two TWIST-LOCK® FASTENERS.
å Fasten the SHELF (E) to the DIVIDER (M).
Use two BLACK
1-15/16" FLAT HEAD SCREWS (113S).
M
E
BLACK 1-15/16" FLAT HEAD SCREW
(2 used in this step)
113S
J
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Step 14
å Fasten the RIGHT BRACE (R) to the RIGHT UPRIGHT (J)
and the LEFT BRACE (S) to the LEFT UPRIGHT (K). Use
four BLACK 1-15/16" FLAT HEAD SCREWS (113S).
J
R
K
S
BLACK 1-15/16" FLAT HEAD SCREW
(4 used in this step)
113S
Surface without holes
Surface without holes
420654 www.sauder.com/servicesPage 18
Don't worry. It isn't
Rome. This can be built
in a day.

å Fasten the RIGHT END (A) to the TOP (T), SHELF (E)
and RIGHT BRACE (R). Tighten four TWIST-LOCK®
FASTENERS and one HIDDEN CAM.
å Fasten the LEFT END (B) to the TOP (T) and LEFT
BRACE (S). Tighten two TWIST-LOCK® FASTENERS and
one HIDDEN CAM.
Step 15
R
S
T
E
A
B
Surface with
HIDDEN CAMS
Surface
without
HIDDEN
CAMS
1
2
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Step 16
å Carefully lay your unit onto its front edges.
å Slide the BACK (P) into the grooves of the UPRIGHTS (J and K).
å Fasten the BACK (P) to the BRACE (Q). Use three CLIPS (67G) and three BLACK 9/16" LARGE HEAD SCREWS (1S).
å NOTE: The CLIPS should wrap around the edge of the BACK and the teeth of the CLIP should bite into the BRACE and
BACK as you tighten the screws.
Unfinished surface
4.
67G
BLACK 9/16" LARGE HEAD SCREW
(3 used in this step)
1S
Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution
420654 www.sauder.com/servicesPage 20
P
J
K
Q