PROTEUS PROTEUS PROTEUS PROTEUS PROTEUS PROTEUS PROTEUS

PROTEUS

PROTEUS

The key

to a superb

workplace

KC AUG 08

Assembly instructions

General Guidelines

Please read these notes before starting to assemble your proteus units

THE BASIC COMPONENTS OF THE PROTEUS SYSTEM consist of two aluminium extrusions (the leg and beam extrusions) which are connected together with joining brackets to construct various forms of work benches, tables, storage units, etc. Plastic trim is then fitted to the finished construction to enhance its good looks.

LEG

BRACKET

BEAM

THE ORDER OF ASSEMBLY IS IMPORTANT for all constructions:

Fasten the joining brackets to the leg extrusions

Construct the end frames

Join the end frames and beam extrusions to complete the cube

Fix the trim and worktop

POSITIONING THE JOINING BRACKETS ON THE LEG is done in one of two ways :

With each kit is included a small section of the beam extrusion which acts as a spacer. When placed over the joining bracket during assembly it enables you to precisely predict the final position of the beam on the leg when the assembly is complete. This method is particularly useful when a beam is required to be flush with the end of a leg extrusion.

ALLEN KEY

BRACKET

SPACER

LEG

Use a measuring tape or make a spacer from stiff card or wood to space the joining bracket a given distance from another joining bracket or the end of the leg.

THE 5mm ALLEN KEY (HEXAGON WRENCH) in your assembly kit has a ball end on the longer leg which enables the key to be rotated at an oblique angle to the screw it is tightening. This feature allows the key to be rotated fully when used in a confined area. Many ratchet screw driver tool sets contain 5mm Allen key bits which can be very useful when assembling the Proteus.

When assembling a bench or table ensure that the slot is uppermost.

WHEN FITTING GLASS OR OTHER SMOOTH MATERIALS such as a smooth MDF work top for example, without using screws or other fixings we offer a white silicon rubber cord to provide the grip necessary to avoid easy displacement, the cord fits into the slot in one of the narrow sides of the beam.

SPECIAL ASSEMBLY NOTES AND PRECAUTIONS

Both the beam and leg sections feature special webs which are intended to collapse locally under pressure from the conical end of the grub screw. The result is a permanent and secure position for each grub screw which is designed to prevent collapse of a structure under load in the event of one or more grub screws working loose over a period of time.

It is essential that the grub screws are clamped up tight. Use the ball end of the Allen key to initially tighten the grub screw, then when you are satisfied that the components are located in the correct position, always fully tighten the grub screws with the short leg of the Allen key in the screw head using additional leverage of the long leg (possibly another 1 1 / 2 turns or so).

For the reasons described above it is important to locate each component carefully before tightening fully because a small adjustment (less than 5mm or 3 / 16 ”) will be difficult afterwards. Large realignments will present no problem.

Construction Details

Workbench or Table Extension

Matboard Storage Unit PD02 & PD07

Adding a Matboard Storage Unit Extension PR02 & PR07

Matboard Storage Unit with Extension

Covering the Worktop with Fabric

Fitting Cantelever Matcutter Supports

Workbench or Table

SECTION 1

You should have :

ITEM

TOOLS

ITEM

QTY

QTY

Joining Bracket

Put a grub screw backwards into each of the joining brackets - do not place grub screws in the other holes at this stage.

GRUB SCREW

ITEM

Attach the joining brackets to the legs.

At this stage you need to decide the format of your bench/table. Here are a few ideas :

QTY

JOINING BRACKET

We will assume for the purposes of these instructions, that the style on the left is required. Using the spacer, fit two brackets to the top of each leg ensuring the brackets are fitted the correct way round - with the flat faces towards each other.

Attach joining brackets to the bottom of the legs, using a tape measure, or self made spacer to position them accurately to your requirements.

Put grub screws in each of the two large holes in every bracket, only screw them in by 2 or 3 turns.

Make the end frames

Fit two short beams between two leg assemblies ensuring the small groove in the beam is uppermost. Pulling the two legs together closing any gaps between the end of the beam and the legs - tighten all the grub screws using the long end of the allen key first then the short end to lock them.

SHORT BEAM

Repeat for the second frame.

LEG

LEG

SHORT BEAM

Join the end frames

Place one end frame on the floor with the brackets pointing upwards, position a long beam over each bracket, ensuring the small groove in the beam is uppermost. Place the other end frame over the beams and tighten the grub screws ensuring there are no gaps between the beam end and the legs.

Fit the moulded leg-end caps.

Workbench or Table Extension

SECTION 2

When ordering an extension unit to an existing standard bench, order one end frame with the same order prefix as the bench. e.g. Order a PA01 end frame to extend a PA03 bench. Then order the beams and brackets bearing in mind the leg is 4cm (1 9 / 16 ”) square.

Plastic trim is also available seperately.

Assemble the end frame as in Section 1;

Attach the joining brackets to the legs on the side of the bench being extended;

Position the beams and end frame then tighten the grub screws ensuring there are no gaps between the ends of the beams and the legs.

Single Matboard Storage Unit

NOTE:

SECTION 3

If you are assembling an extension unit with a standard unit – go to section 5

You should have :

TOOLS

ITEM

PD02 PD07

ITEM

PD02 PD07

Joining Bracket

Dividing Rod Support

ITEM

QTY

Put a grub screw backwards into each of the joining brackets - do not place grub screws in the other holes at this stage.

Using the spacer, fit two brackets to the top of each leg ensuring the brackets are fitted the correct way round - with the flat faces towards each other.

Attach joining brackets to the bottom of the legs, again using the spacer, position them as shown.

Put grub screws in each of the two large holes in every bracket, only screw them in by 2 or 3 turns.

FOR L.H. END FRAME

FOR R.H. END FRAME

Make the end frames

Lay the two legs for the LH end frame on the floor together and two of the set of four beams. Slide a fixing channel in the top beam - take note of the relative positions of the brackets in the drawing and the diamond hole in the fixing channel.

Fix the legs over the brackets and tighten all the grub screws using the long end of the allen key. Ensure there are no gaps between the ends of the beams and the legs, then lock the grub screws using the short end of the allen key.

TOP

L.H. FRAME

Repeat for the RH frame.

Remember to ensure the groove in the beam is on top.

BOTTOM

Repeat for the RH frame.

Remember to ensure the groove in the beam is on top.

TOP

R.H. FRAME

BOTTOM

Join the end frames

Position the beams (set of 3) on the end frames as shown, again ensuring the groove in the beam is at the top. Tighten the grub screws ensuring there are no gaps between the beam ends and the legs.

Carefully trim the leg-end caps as shown. Keeping your fingers behind the blade at all times.

Fitting the base channels

Place the unit in its final position, once the base channels are fitted the unit can be dragged but not lifted.

Slide the base channels in place starting from the outside working towards the centre. Ensure the set of holes in the edges are towards the front of the unit.

The two channels on the outside fit tight to the inside of the beam leaving a small gap at the back of the channel.

GAP

Fitting the dividing rod supports & dividing rods

Fit the dividing rod supports inside the top beams as

shown, using the cap screws and washers.

Note:- ensure the fixing channel is pushed to the back of the unit.

Offer each rod up into the slot (this may be a tight fit this stops the rods rattling when in use).

Pull the rods down and push into the holes in the base channels.

SECTION 4

Adding a Matboard Storage Unit Extension

• NOTE:

If you are assembling an Matboard Storage unit with an extension unit

• go to section 5

You should have :

TOOLS

ITEM

PR02 PR07

ITEM

PR02 PR07

Beam with holes

Joining Bracket

Dividing Rod Support

long Cap screw

ITEM

QTY

Put a grub screw backwards into each of the joining brackets - do not place grub screws in the other holes at this stage.

Attach the Joining brackets to the legs

BACK LEG

FRONT LEG

Using the spacer, fit the joining brackets to the top of each leg

NOTE:- Ensure the joining brackets are fitted the correct way round.

Put grub screws in each of the two large holes in every bracket, only screw them in by 2 or 3 turns.

Make the Centre frame

Assemble the frame using the beam with holes and the other single beam of the same length. ensure the beam with holes is assembled the correct way round (see diagram)

FRONT LEG

Tighten all the grub screws using the long end of the allen key. ensure there are no gaps between the ends of the beams and the legs, then lock the grub screws using the short end of the allen key.

HOLES TOWARDS

THE BACK

BACK LEG

Change the frame on your existing unit

TAPE OR

STRING

Remove the worktop from your existing unit then:-

Either Remove the dividing rods and dividing rod supports from your existing unit

TIMBER

Or Hold the dividing rod supports in place with a length of timber fixed to the unit with strong tape or string.

Remove the screws and washers attaching the dividing rod supports to the end frames.

REMOVE SCREWS AND

WASHERS

TIMBER

SIDE TO BE EXTENDED

Release the grub screws to remove the end frame and replace it with the centre frame.

NOTE:- Rod supports are not show for clarity.

Complete the frame work

Using the set of 3 beams assemble the unit as shown. Ensure all grub screws are tightened fully and there are no gaps between the beam ends and legs.

Fitting the leg-end caps

Carefully trim the leg-end caps as shown, keeping your fingers behind the blade at all times.

Fitting the base channels

Slide the base channels in place starting from the outside working towards the centre. Ensure the set of holes in the edges are towards the front of the unit.

The two channels on the outside fit tight to the inside of the beam leaving a small GAP gap at the back of the channel.

DIVIDING ROD

SUPPORT

BEAM

LONG CAP

SCREW

NUT WASHER

BEAM

WASHER

Place the dividing rod supports as shown, using the short cap

screws and washers removed earlier, to hold the supports to the end of the unit.

Offer each rod up into the slot (this may be a tight fit this stops the rods rattling when in use).

Pull the rods down and push into the holes in the base channels.

DIVIDING ROD

SUPPORT

AM BE

D RO G SHORT CAP N DI RT SCREW VI PO D P U S LEG

SECTION 5

Matboard Storage Unit with Extension

NOTE:

If you are adding an extension to an existing Matboard Storage Unit

• go to section 4. For a Parts List refer to the beginning of:

Section 3 – Matboard Storage unit PD02 & PD07 Section 4 – Matboard Storage unit extension PR02 & PR07

Put a grub screw backwards into each of the joining brackets - do not place grub screws in the other holes at this stage.

Attach the joining brackets to the legs

Using the spacer, fit two brackets to the top of 4 legs ensuring the brackets are fitted the correct way round - with the flat faces towards each other.

Attach joining brackets to the bottom of the legs, using the spacer. Position them as shown in the diagram. These will make the left & right hand end frames

FOR L.H. END FRAME

FOR R.H. END FRAME

BACK LEG

FRONT LEG

Using the spacer, fit the joining brackets to the other two legs as shown, these will make the centre frame.

NOTE:- Ensure the joining brackets are fitted the correct way round.

Put grub screws in each of the two large holes in every bracket, only screw them in by 2 or 3 turns.

FOR CENTRE FRAME

Make the end frames

Lay the two legs for the LH end frame on the floor together and two of the set of four beams. Slide a fixing channel in the top beam - take note of the relative positions of the brackets in the drawing and the diamond hole in the fixing channel.

Fix the legs over the brackets and tighten all the grub screws using the long end of the allen key. Ensure there are no gaps between the ends of the beams and the legs, then lock the grub screws usingthe short end of the allen key.

TOP

L.H. FRAME

Remember to ensure the groove in the beam is on top.

Repeat for the RH frame.

TOP

R.H. FRAME

BOTTOM

BOTTOM

Make the Centre frame

FRONT LEG

Assemble the frame using the beam with holes and the other single beam of the same length. ensure the beam with holes is assembled the correct way round (see diagram)

HOLES TOWARDS

THE BACK

Tighten all the grub screws using the long end of the allen key. ensure there are no gaps between the ends of the beams and the legs, then lock the grub screws using the short end of the allen key.

BACK LEG

CENTRE FRAME

Assemble the frame work

R.H. END

FRAME

Using the remainder of the beams assemble the framework as shown. Start from one end frame and attach 3 beams, then the centre frame,3 beams and then the remaining end frame. Ensure all grub screws are tightened fully and there are no gaps between the beam ends and legs.

L.H. END

FRAME

CENTRE

FRAME

Fitting the leg-end caps

Carefully trim the leg-end caps as shown, keeping your fingers behind the blade at all times.

Fitting the base channels

Slide the base channels in place starting from the outside working towards the centre. Ensure the set of holes in the edges are towards the front of the unit.

The two channels on the outside fit tight to the inside of the beam leaving a small GAP gap at the back of the channel.

DIVIDING ROD

SUPPORT

BEAM

LONG CAP

SCREW

NUT WASHER

BEAM

WASHER

Place the dividing rod supports as shown, using the short cap

screws and washers removed earlier, to hold the supports to the end of the unit.

Offer each rod up into the slot (this may be a tight fit this stops the rods rattling when in use).

Pull the rods down and push into the holes in the base channels.

DIVIDING ROD

SUPPORT

AM BE

D RO G SHORT CAP N DI RT SCREW VI PO D P U S LEG

Covering the worktop with fabric

SECTION 6

Worktops can be covered with many types of worksurface, the Proteus covering (PN01/2/3) is a grey non woven fabric which will not fray or unravel and can be moulded around worktop corners.

Proteus worktop fabric has a smooth upper surface and slightly rougher underside to key into adhesives. Use double sided carpet tape, carpet/flooring adhesive or staples.

Cut the fabric larger than the worktop allowing about 10cm

(4”) overhang on all four sides. Apply tape or adhesive around the edges and to the middle of the worktop.

TOP

APPLY

DOUBLE SIDED TAPE OR ADHESIVE

ALSO APPLY

AROUND EDGE ON UNDERSIDE

Fold the sides of the fabric down and pinch the flap made

in each corner, trim with scissors.

PINCH

Fold the fabric to the underside, again pinch and trim. A

few staples in the underside will ensure the fabric is held in place whilst the adhesive cures.

PINCH

UNDERSIDE

Fitting the Worktop

SECTION 7

It is advisable to fit one piece worktops cut from 18mm ( 3 / 4 ”) MDF. When deciding on the size of your worktop make allowances for any overhangs you require.

The worktop clips are hooked into the slot on the inside of the beam and screwed into the underside of the worktop. Position one clip near to each corner of the top and space any others accordingly. Matboard storage units also have worktop fixing holes in the dividing rod supports.

If you are fitting multiple piece worktops, use the joining plate (PI01) to fix adjoining worktops as shown. This will prevent a step along the join.

JOINING PLATE

Fitting Cantilever Matcutter Supports

SECTION 8

You should have :

ITEM

QTY

ITEM

QTY

Beam End Cap

Joining Bracket

TOOLS

ITEM

QTY

Put a grub screw backwards into each of the joining brackets - do not place grub screws in the other holes at this stage.

Attach the joining brackets to the legs

Decide upon the height required for the supports and fit the brackets on two adjacent legs accordingly.

Note: the flat faces of the bracket should face each other.

Attach the beams to the brackets

Assemble the two beams on to the brackets and fasten with the grubscrews.

Fit the beam end caps.

When placing a matcutter directly on to the supports (ie. when not extending the worktop across them) place the rubber pads on the beams to support the right hand edge of the cutter.