Sauder Costa 422983 User manual

sauder.com
Hutch
Costa Collection | Model 422983
NOTE: THIS INSTRUCTION
BOOKLET CONTAINS IMPORTANT
SAFETY INFORMATION.
PLEASE READ AND KEEP FOR
FUTURE REFERENCE.
English pg 1-32
Français pg 33-36
Español pg 37-40
Lot # 534197 10/29/19
Purchased: __________________
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BEFORE MAKING ANY RETURNS TO THE STORE.
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CONTACT US FIRST
BEFORE MAKING ANY RETURNS TO THE RETAILER.
Visit sauder.com/service to order replacement parts, view video assembly tips, or chat with a live rep.
Prefer the phone? Give us a ring at 1-800-523-3987.
Customer Service is available Monday-Friday - 8:30 a.m. to 5 p.m. EST (except holidays)
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Part Identification
Hardware Identification
Assembly Steps
Français
Español
Safety
Warranty
No. 2 Phillips Screwdriver
Tip Shown Actual Size
Hammer
Not actual size
2-3
4
5-32
33-36
37-40
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)
T2 TOP (1)
U DOOR (2)
V GRILLE (2)
Part Identification
Nail Holder (provided)
Electric drill with 3/16" bit
(ONLY in indicated step)
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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.
Masking Tape

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
T2
U
U
V
V
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Now you know
our ABCs.

åScrews are shown actual size. You may receive extra hardware with your unit.
Hardware Identification
BLACK 9/16" LARGE HEAD SCREW - 22
1S BLACK 1/2" FLAT HEAD SCREW - 8 11S
BLACK 1-1/8" MACHINE SCREW - 2
21S BLACK 1-15/16" FLAT HEAD SCREW - 8
113S
TAPE CARD - 2
4M NAIL - 28 1N CAM COVER - 12 12P
KNOB SET - 2
167K
METAL BRACKET - 6
4G PIVOT HINGE - 2 15H
WOOD DOWEL - 6
15F 13H HINGE - 4
CLIP - 8
67G
7F TWIST-LOCK®FASTENER - 16HIDDEN CAM - 14 1F CAM DOWEL - 10 2F CAM SCREW - 4 8F
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METAL PIN - 24
1R RUBBER SLEEVE - 10 2R FURNITURE TIPPING
RESTRAINT KIT - 1
97

Step 1
Do not tighten the TWIST-LOCK® FASTENERS in this step.
(16 used)
7F
7F
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 (7F) into the large
holes in the ENDS (A and B), BOTTOM (C),
and UPRIGHTS (D, E, and G).
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A
B
C
D
E
G
G
Look for this icon. It means a video assembly tip is
available at www.sauder.com/service/tips
Find the numbered video or scan the QR code. 2

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
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1

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.
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Arrow
1F
(4 used)
1

å Fasten the UPRIGHTS (D and E) to the TOP (T2).
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
T2
Finished surface
Groove
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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 (T2). 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.
2

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 surfaces
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
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L
1

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
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2

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
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(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
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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).
Notched edge
Slide the BOTTOM MOLDING (J) onto the notched edge.
C
J
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The groove
is closer to
this edge.

å Insert two WOOD DOWELS (15F) into the edge of the SHELF (H).
å First, fasten the LEFT END (B) to the TOP (T2). 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 LEFT END.
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 10
C
H
T2
15F
B
Arrow
Minimum
190 degrees
Maximum
210 degrees
1R
N
Finished surface
(4 used)
422983 www.sauder.com/servicePage 14
2

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 11
Arrow
Minimum
190 degrees
Maximum
210 degrees
15F
15F
F
N
B
Surface with HIDDEN CAMS
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1

å Insert two WOOD DOWELS (15F) into the edge of the SHELF (H).
å First, fasten the RIGHT END (A) to the TOP (T2). 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 RIGHT END.
Step 12
Arrow
Minimum
190 degrees
Maximum
210 degrees
15F
F
A
C
H
T2
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2

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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 edge of the
TOP MOLDING.
Step 13
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.
18

å Fasten the TOP MOLDING (K) to the TOP (T2). Use six
BLACK 9/16" LARGE HEAD SCREWS (1S).
å NOTE: Start each screw a few turns before tightening
any of them.
Step 14
K
The posts on the PIVOT
HINGES should be pointing up.
T2
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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

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Step 15
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 (T2).
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 the edges of the 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
T2
1.
2.
3.
4.
H
Lower edge
Unfinished
surface
Unfinished
surface
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

Step 16
B
NAIL
(12 used in this step)
1N
2.
1.
å NOTE: You will need a Tape Measure in this step. Each back will use six NAILS in this step.
å Unfold the BACKS (P) and lay them into the lower edges of the ENDS (A and B) as shown in diagrams #1 and #2.
å Fasten the BACKS (P) to the BRACE (F) and VERTICAL BRACE (N). Use eight CLIPS (67G) and eight 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. Follow diagrams #3 and #4
å Fasten the remaining edges of the BACKS (P) to the ENDS (A and B) and BOTTOM (C) using the Nail Holder and
NAILS (1N). The NAILS along the short edge of the BACKS (P) should be placed 1" from the fold line and approximately
2" from the corners. The NAILS along the long edge of the BACKS should be placed approximately 7" from the corners.
Lower edge
Lower edge
FN
P
P
Unfinished surface
Unfinished surface
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3.
Fold line Fold line
4.
67G
67G
67G
A
Oset edge
Oset edge
Bead
Bead
C
7"
1"
1"
7"
BLACK 9/16" LARGE HEAD SCREW
(8 used in this step)
1S