Sauder Costa 428724 User manual

sauder.com
Hutch
Costa Collection | Model 428724
NOTE: THIS INSTRUCTION
BOOKLET CONTAINS IMPORTANT
SAFETY INFORMATION.
PLEASE READ AND KEEP FOR
FUTURE REFERENCE.
English pg 1-22
Français pg 23-25
Español pg 26-28
Lot # 548256 10/15/20
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.
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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
5-22
23-25
26-28
29-30
31
Nail holder (provided)
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Electric drill with 3/16" bit
(ONLY in indicated step)
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 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)
K2 TOP (1)
A
A
B
B
C
C
D
E
E
F
F
G
H
I
J
K2
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åScrews are shown actual size. You may receive extra hardware with your unit.
Hardware Identification
BLACK 9/16" LARGE HEAD SCREW - 3
1S
37F 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
75P
RUBBER SLEEVE - 8
2R
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CLIP - 3
67G
FURNITURE TIPPING RESTRAINT KIT - 1
97
105P TWIST-LOCK®
FASTENER COVER - 4

Step 1
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 (37F) into the large holes in the ENDS (A)
and VALANCE (D).
Do not tighten the TWIST-LOCK® FASTENERS in this step.
37F
A
A
D
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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
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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1

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
JF
F
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Remember:
Righty tighty.
Lefty loosey.
(20 used)
1

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 as shown in the upper diagram.
å Fasten the LEGS (B and H) to the other END (A). Tighten six HIDDEN CAMS as shown in the lower diagram.
B
J
A
Surface with HIDDEN CAMS
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This END (A)
will become the
right END (A).
These surfaces
should be even. Edge with
TWIST-LOCK®
FASTENERS
B
H
A
Surface with HIDDEN CAMS
This END (A)
will become the
left END (A).
1
2
1

å Fasten the right END (A) to the TOP (K2). Tighten two
TWIST-LOCK® FASTENERS.
å Fasten the VALANCE (D) to the TOP (K2). Tighten two
TWIST-LOCK® FASTENERS.
Step 6
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
K2
D
Surface with TWIST-LOCK® FASTENERS
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2

Step 7
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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.
15F
I
Surface with HIDDEN CAMS
J
1

å Push a WOOD DOWEL (15F) into the LEFT REAR LEG (H).
å Fasten the left END (A) to the TOP (K2). 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.
å Using your hammer, gently tap a TWIST-LOCK®
FASTENER COVER (105P) onto each visible TWIST-LOCK®
FASTENER.
Step 8
15F
H
IFor support, place packing
foam and magazines here.
A
K2
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Hey! It's starting to look
like something!
(4 used)
105P
2
1
2
1

Step 9
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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.
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
1

Step 10
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 (K2).
å Diagrams 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
K2
(3 used)
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H
J
F
Bead
Nail slot
Nail
holder
Oset edge
Unfinished
surface

Step 11
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å Your Hutch was made to fasten to the 428192 Library
Base and the 428191 Lateral File.
å Go to Step 13 if your 428192 Library Base or the 428191
Lateral File is assembled.
å Go to Step 14 if your 428192 Library Base or the 428191
Lateral File is not assembled.
428192 Library Base
428191 Lateral File

Step 12
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å If you purchased the 428192 Library Base or
the 428191 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.
428192 Library Base Top (J)
428191 Lateral 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.

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Step 13
å NOTE: Use these
templates only
if your 428192
Library Base or the
428191 Lateral File
is assembled.
å Cut out the two
templates along the
dashed lines and go
to Step 14.
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
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.
428192 Library Base
428191 Lateral File
å Use masking tape to hold the correct template edges to the corners
of the 428192 Library Base top or 428191 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

Step 15
428192 Library Base
428191 Lateral File
å Remove the templates.
å Turn four CAM SCREWS (8F) into the holes in the top of
your Library Base or Lateral File.
å With the help of another person, carefully lift your HUTCH
and place it over the CAM SCREWS (8F). Tighten four
HIDDEN CAMS.
8F
Pro Tip: Lift with your
legs. And, you know,
your arms.
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(4 used)
1