Gorilla Playsets 01-0003-AP 870780002248 0870780002248 1000341500
Gorilla Playset Installation Instructions and Manuals
TM
playsets
TM playsets
Timber Shield Post Option BOXES: W-1, 120
Chateau II
Model: 1500AW
(BOXES: 1501, 1503N, 1507, 1530 & Slide Box)
Amber Post Option BOXES: 1520-2bx, 1522,
*51-0003-W*
51-0003-W
Copyright © 2016 Gorilla Playsets All Rights Reserved
190 Etowah Industrial Court Canton, GA 30114
www.gorillaplaysets.com
Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our "Quick Response Center" located at:
www.gorillaplaysets.com/support
DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECTLY. THE RETAILER DOES NOT STOCK COMPONENTS.
PLEASE RETAIN ALL INSTRUCTIONS FOR FUTURE REFERENCE. KEEP THEM IN A SAFE PLACE WHERE YOU CAN REFER TO THEM AS NEEDED. CHECK FOR REVISED INSTRUCTIONS AT:
www.gorillaplaysets.com/manuals
GORILLA PLAYSETS WARRANTY 2016
Gorilla Playsets® ("Gorilla") warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
Gorilla warrants all remaining products, including but not limited to its , Free Standing Swing Set, Free Standing Tire Swing, See-Saw, Children's Picnic Table with Umbrella, Play-Zee-BoTM, Cedar Toy Chest and spring riders to be free from defects in workmanship and materials, under normal use and conditions, for a period of 1 year.
Cosmetic imperfections and natural tendencies of wood such as peeling, splintering, warping, seasonal checking or cracking, knots or knot holes, etc. are normal characteristics of all outdoor wooden play equipment and are not covered by this warranty. Checks or cracks in wood components that do not affect the intended function of the part, piece or overall swing set are not covered under this warranty.
Wood rot or decay that develops because the product was installed in an area with poor drainage is not covered under this warranty. Lumber that has been damaged by wood boring bees, or conditions that develop as a result of faulty or improper installation of the product, are not covered by this warranty. Fading of stain, discoloration or mold on any wood part or accessory is not covered by this warranty. Cracks in plastic components, surface rust on hardware and chips on powder coated materials are not considered defects in material as long as they do not affect the functionality or structural integrity of the part or component.
It is the owner's responsibility to maintain the swing set. This includes but is not limited to staining and sealing the lumber as needed and regular inspection to be sure all hardware is tight. Instructions for proper maintenance can be found on Gorilla's website. Imperfections or conditions that develop because of a failure to properly maintain the swing set are not covered by this warranty.
Gorilla will, at its discretion, replace any above ground part within the stated warranty period that is defective in workmanship or materials. This decision is subject to verification of the defect, which, at Gorilla's discretion, may be accomplished by submitting photographs or by delivery of the defective part to Gorilla Playsets · 190 Etowah Industrial Ct. · Canton, GA 30114 · 1-800-882-0272 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase. In addition, within the first 30 days from the date of purchase, Gorilla will replace any parts discovered to be missing from or damaged in the original packaging.
This warranty is valid only if the product is used for the purpose for which it was designed and installed at a residential, single-family dwelling. This warranty is void if the product is used in a commercial, institutional or multi-family setting. This warranty does not cover normal wear and tear or (a) products that have been damaged by acts of God and/or nature, negligence, misuse or accident; (b) products that have been modified or repaired by unauthorized persons; (c) the cost of labor; or (d) the cost of shipping any replacement product or part.
GORILLA DISCLAIMS ALL OTHER REPRESENTATIONS AND WARRANTIES OF ANY KIND, EXPRESSED, IMPLIED, STATUTORY OR OTHERWISE, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. GORILLA WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty is non-transferable and does not extend to the owners of the product subsequent to the original purchaser. Some states do not allow limitations on implied warranties or exclusion of incidental or consequential damages, so these restrictions may not be applicable to you. This warranty gives you specific legal rights. You may also have other rights which vary from state to state.
IMPORTANT SAFETY GUIDELINES
This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set.
As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury. Gorilla recommends you follow all tool manufacturers' safety guidelines. Always wear eye protection and safety gloves to prevent injury. In several phases of construction two people may be required for lifting and securing of lumber. While the play set is being constructed, please keep children off the equipment until the project is complete. Bolts and screw heads should be checked regularly for tightness. The ground ladder, rope ladder, slide, swings and other areas where children spend a majority of their playtime should be checked more frequently.
Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used.
WEIGHT LIMITS FOR GORILLA PLAYSETS
· FORT PLATFORMS: 800 LBS. TOTAL WEIGHT
· SWING BELT: 225 LBS.
· TANDEM SWINGS: 70 LBS. PER CHILD. UP TO 140 LBS. TOTAL WEIGHT.
· TRAPEZE: 125 LBS.
· FULL BUCKET SWING/ HALF BUCKET SWING: 50 LBS.
· HEAVY DUTY TODDLER BUCKET SWING: 85 LBS.
· INFANT SWING: 35 LBS.
· TIRE SWING: 125 LBS. TOTAL WEIGHT
· ROPE LADDER: 75 LBS.
· ROCK WALL: 150 LBS.
· CLIMBING RAMP: 150 LBS.
· MONKEY BARS: 175 LBS.
· ALL SLIDES: 150 LBS.
Gorilla recommends that the weight limits for all components must not be exceeded. Failure to adhere to these and other safety guidelines could result in damage to the play set and injury to the users.
WARRANTY REGISTRATION
- CHATEAU II -
Gorilla PlaysetsTM manufactures the finest quality products that are designed for outstanding strength and durability. We back our products with an unparalleled warranty. In the unlikely event that you will need to contact us about covered repairs, we must have a valid Warranty Registration on file.
3 EASY WAYS TO REGISTER
OPTION 1
Fax this completed form to: (800) 880-3300
OR
Mail this completed form to: Gorilla Playsets
190 Etowah Industrial Court Canton, GA 30114
OPTION 2
Complete the online registration form at: http://www.gorillaplaysets.com/register
OPTION 3
Scan this QR Code with your smartphone to complete the
form using your phone:
Where did you buy this product?
Date of Purchase
Store
Store City
Store State
Your registration information: Name:_______________________________________________________ Email: ______________________________________
Address: __________________________________________________________________________________________________
Street
City
State
Zip
Please select your age
How old are your children?
18-30 31-40
2-3 4-5
41-50 51+
6-7 8+
How would you rate the quality of this
product?
Excellent Above Average Average Below Average Poor
Would you recommend this product to friends & family?
Yes
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Comments: ________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________
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IMPORTANT PLEASE READ
Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years.
As your swing set acclimates to its new environment, natural characteristics of the wood can show in the form of checks, or "cracks" in the lumber. In almost all cases this is normal and it will not affect the structural integrity of your play set and is not covered under warranty.
KEEPING YOUR PLAYSET LIKE NEW
MUST DO's The following owner responsibilities are crucial to the safety, integrity and aesthetic appeal of your swing set and may affect the warranty if not adhered to.
WITHIN 60 DAYS · Check and tighten Hex Bolts/T-nuts, Carriage Bolts/Lock-nuts, and Lag Screws within the first 60 days and then twice annually once before each season and then once during the season.
WITHIN 90 DAYS · Apply a sealant or semi-transparent stain with sealant within the first 90 days of owning the swing set. Our own Stain/sealant is available online here: http://www.gorillaplaysets.com/Playground-Sealant-p/10-0003.htm
Oil based stain or water based stain may be used. Should you choose to use other stain we suggest asking the product covering specialists at any number of specialty paint stores or home improvement centers for a product that would work best for your local environment. ** TIP while the set is new, take a small board from to the store with you so they can color match the tint of the stain or sealant.
SEASONAL REMINDERS · If your area experiences regular snowfall, remove your fabric tarp/canopy to avoid stretching, sagging or tearing of the material. Store it inside, folded up, and it will be as good as new when winter is over. · If your area experiences extremely cold temperatures, remove swing belts and other pliable features to prolong the lifespan of these play activities.
OTHER TIPS · Spray swing hangers with Pam, Mazola or olive oil to stop squeaking; do not use petroleum based products such as WD-40 or motor oil. · To repel yellow jackets and wasps, use a cotton ball and dab interior wooden corners underneath the play set deck with a liquid dish soap. Avoid using insecticides. · To speed up the slide wipe the center of slide with wax paper every 2 - 3 weeks.
For additional safety and maintenance guidelines, please visit our website.
IMPORTANT DOCUMENTS
CUSTOMER MUST READ AND RETAIN
Please go to the following links and read important SAFETY information prior to using your new play structure.
http://www.gorillaplaysets.com/Swing-Set-Safety-s/85.htm
https://www.gorillaplaysets.com/Maintenance-s/129.htm
http://www.gorillaplaysets.com/manuals.html (Click on your specific model)
http://www.gorillaplaysets.com/Warranty-s/82.htm
NOTE: Your children's safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious injury. Please review these safety rules regularly with your children.
WARNING:
Children must NOT use this play set until it has been completely assembled and inspected by an adult to
ensure it has been properly installed.
Gorilla Playsets 190 Etowah Industrial Court
Canton, GA. 30114
Model 1500AW shown. See cover of manual for the image of your model when it is completed.
Timber Shield Post Option BOXES: W-1, 120
Models: 1500AW 1500AWF 1500AWC 1500AWCF
Amber Post Option BOXES: 1520-2bx, 1522,
(BOXES: 1501, 1503N, 1507, 1530, 1518*, 1525* & Slide Box)
*1518 only included with 1500AWC and 1500AWCF Clubhouse models
*1525 only included with 1500AWF and 1500AWCF Treehouse models
REV: 2.23.2016
TABLE OF CONTENTS
Safety Guidelines.....................................................................................Pages 3-6 Leveling Fort, General Information and Definitions........................................Pages 6-8 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading........................................................................................Pages 9-13 Site Plan, Required Tool List and Kit Contents...............................................Pages 14-15 Hardware, Lumber and Accessory Checklists.........................................Pages 16-32 Adding T-Nuts to Corner Posts...................................................................... Step 1 Framing Fort....................................................................................... Steps 2-9 Mounting Deck.......................................................................................... Step 10 Rock Wall Assembly/Installation............................................................ Steps 11-15 Ladder Assembly/Installation..................................................................... Steps 16-17 Center Post, Panel Slat and Roof Support Installation................................. Steps 18-20A Swing Beam Assembly......................................................................... Steps 21-28 Roof Assembly....................................................................................... Steps 29-31 Hanging Swings and Safety Board....................................................... Steps 32-33 Picnic Table Assembly and Installation.................................................... Steps 34-36 Rope Ladder Assembly/Installation............................................................... Step 37 Slide, Telescope and Climbing Rope..................................................... Steps 38-40 Tic Tac Toe Assembly/Installation........................................................... Steps 41-42 Safety Handles and Flag Kit.......................................................................... Steps 43-44 Sandbox Seats/Name Plate, Plastic Sunburst, Ground Stakes and Steering Wheel........................................................................................ Steps 45-48 Appendix: Chimney and Dormer instructions, etc.................................................Page 83
PLEASE READ OWNER'S MANUAL CAREFULLY BEFORE STARTING ASSEMBLY!
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Safety and Maintenance Tips for Your New Play Set:
NOTE: Your children's safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with your children.
· This play set is designed for the use of 4 occupants who have a combined weight not exceeding 800 pounds on the elevated floor, 3 occupants who have a combined weight of 425 pounds on the swing area, for a total Unit capacity of 7 occupants who have a combined weight of 1225. (This weight does not include any picnic table area(s).) · On-site adult supervision is required. · Teach children not to walk close to, in front of, behind, or between moving swings or other moving playground equipment. · Teach children to sit in and never stand on swings · Teach children not to twist the chains and ropes and not to loop them over the swing beam, since this may reduce the strength of the chain or rope. · Teach children not to jump from swings or other playground equipment in motion. · Teach children not to push empty seats. The seat may hit them and cause serious injury. · Teach children to sit in the center of the swings with their full weight on the seats. · Teach children not to use the equipment in a manner other than intended. · Teach children to always go down slides feet first. Never slide headfirst. · Teach children to look before they slide to make sure no one is at the bottom. · Teach children to never run up a slide, as this increases their chances of falling. · The parents should have the children dress appropriately with well-fitting shoes. Loose clothing such as scarves and ponchos should not be worn. Always take off, tie up or tuck in cords and drawstrings on children's clothing. These things can get caught on playground equipment and strangle a child. · Teach children not to climb when the equipment is wet. · Teach children to never jump from a fort deck. They should always use the ladder, ramp or slide. · Teach children to never crawl or walk across the top of monkey bars or swing beam. · Teach children to never crawl on top of a fort roof or on the outside of a tube slide. · Verify that any suspended climbing ropes, chains, or cables are secured at both ends and that they cannot be looped around an adult hand. · Teach children not to attach items to the playground equipment that are not specifically designed for use with the equipment, such as, but not limited to, jump ropes, clothesline, pet leashes, cables and chain as they may cause a strangulation hazard. · Teach children to never wrap their legs around swing chain. · Teach children to never slide down the swing chain. · Teach children to remove their bike or other sports helmet before playing on the playgound equipment. · Teach children to NEVER look at the sun or other bright light through any accessory such as but not limited to a telescope, periscope or binoculars.
WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to insure it has been properly installed and the swing beam legs are anchored.
3
Safety and Maintenance Tips for Your New Play Set:
(continued)
Playgrounds should be inspected on a regular basis. If any of the following conditions are noted, they should be removed, corrected, or repaired immediately to prevent injuries.
· Hardware that is loose, worn or that has protrusions or projections. · Exposed equipment footings. · Scattered debris, litter, rocks, or tree roots. · Splinters, large cracks, and decayed wood components. · Deterioration and corrosion on structural components, which connect to the ground. · Missing or damaged equipment components, such as handholds, guardrails, swing seats. · Check all nuts and bolts twice monthly during the usage season and tighten as required. (But not so tight that you crack the wood) We recommend you check the swing beam and hardware often due to wood expansion and contraction. It is particularly important that this procedure be followed at the beginning of each season. · Remove plastic swing seats and take indoors or do not use when the temperature drops below 32°F. Reinstall swings and other swing equipment at the beginning of the usage season. · Oil all metallic moving parts monthly during the usage period. · Check all coverings for bolts and sharp edges twice monthly during usage season to be certain they are in place. Replace when necessary. It is especially important to do this at the beginning of each new season. · Check swing seats, ropes, cables and chains monthly during usage season for evidence of deterioration. Replacement should be made of any swing seat that has developed cracks in the plastic seats. Ropes, cables and chains should be removed and replaced if excessive wear is found. Contact us for warranted replacement parts. · Swing chains, rings, ropes, etcetera should always be fastened to a rotating swing hanger. NEVER attach a chain, ring, rope, etcetera to a stationary hanger such as but not limited to an eye bolt. Severe wear could occur leading to an injury. · For rusted areas on metallic members such as monkey bars, hand supports brackets, etc.; sand and repaint, using a non lead-based paint meeting the requirements of Title 16 C.F.R. Part 1303. These requirements are available at: http://www.cpsc.gov/ · Inspect wood parts monthly. The grain of the wood sometimes will lift in the dry season causing splinters to appear. Light sanding may be necessary to maintain a safe playing environment. If you are treating your play set with stain regularly, it will help prevent severe checking/splitting and other weather damage. · Once or twice a year, depending on your climate conditions, you must apply some type of protection (sealant) to the wood of your unit. Prior to the application of sealant, lightly sand any "rough" spots on your set. Please note this is a requirement of your warranty. · Creating and maintaining the play set on a level location is very important. As your children play, your play set will slowly dig its way into the soil, and it is very important that it settles evenly. Make sure the play set is level and true once each year or at the beginning of each play season. · Twice a month during the usage season rake the playground protective surfacing materials to prevent compaction and maintain appropriate depths. Replace the protective surfacing materials as required. · Disposal Instructions: When the play set is no longer desired, it should be disassembled and disposed of in such away that no unreasonable hazards will exist at the time the play set is discarded.
4
Play Set Surfacing Recommendations:
Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf
1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
Certain manufactured synthetic surfaces also are acceptable; however, test data on shock absorbing performance should be requested from the manufacturer.
Asphalt and concrete are unacceptable. They do not have any shock absorbing properties. Similarly, grass and turf should not be used. Their ability to absorb shock during a fall can be reduced considerably through wear and environmental conditions.
Certain loose-fill surfacing materials are acceptable. Surfacing materials are acceptable, such as the types and depths shown in the table.
Fall Heights and Materials
Type Of Material
6 in. depth
Double-Shredded bark mulch Wood Chips Fine Sand
6' Fall Height 6' Fall Height 5' Fall Height
Shredded Tires* Fine Gravel
10-12' Fall Height 6' Fall Height
9 in. depth
10' Fall Height 7' Fall Height 5' Fall Height
N/A 7' Fall Height
12 in. depth
11' Fall Height 12' Fall Height 9' Fall Height
N/A 10' Fall Height
*This data is from tests conducted by independent testing laboratories on a 6-inch depth of uncompressed shredded tire samples produced by four manufacturers. The tests reported critical heights, which varied from 10 feet to greater than 12 feet. It is recommended that persons seeking to install shredded tires as a protective surface request test data from the supplier showing the critical height of the material when it was tested in accordance with ASTM F1292.
It should be recognized that all injuries due to falls cannot be prevented no matter what surfacing material is used.
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2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6' in all directions from the perimeter of the equipment.
Swings should have a fall zone extending a minimum of 6' from the outer edge of the support structure on each side. The fall zone in front and back of the swing should extend out a minimum distance of twice the height of the swing as measured from the ground to the top of the swing support structure.
LEVELING YOUR FORT DURING ASSEMBLY
· Complete the steps which will be the basic frame of the fort. {i.e. four corner posts with base (sand box boards) and deck supports} · Position in the most level area chosen for the play set, keeping in mind the location and size of the swing beam, ladder, slides, etc. that extend off the fort. · Once the frame is in the final position, check for vertical and horizontal levelness to determine which side(s) will need to be dug into the ground to level the play set. · With a shovel, score the ground around the outside edges of the sandbox boards on the `high' side of the fort. This is the area that will be dug in. Make sure to score deep enough; the scored lines will be your digging template. · Push the frame off and away from the scored area, far enough to dig and remove dirt to reach the appropriate depth. · Dig a channel along the scored line(s) for the base of the fort (corner post and sandbox boards) to rest into. Dig the channel(s) to the same level depth. The bottom of the channel(s) should be level to each other so your frame doesn't teeter or rock because the channel(s) are uneven. · Once you have removed enough grass and dirt, slide/push the frame into the channel(s). Place a level on the vertical and horizontal boards of the frame to determine if enough soil, or too much, was removed. · Repeat this process until the basic frame is plumb and level and in its final position before completing the rest of the assembly. · Measure to make sure fort is square.
Important: if you require a channel depth of more than 6", then we recommend you have your play set area professionally graded before completing assembly.
Example Play area:
Side View of Playset Frame (Grade is the Slanted Line)
The diagonal measurements should be the same from corner post to corner post. If not, adjust corner posts so that the distance is equal.
= Area to be scored and channeled for levelness
6
General Info to Review Before Installation
· Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly.
· Identify all of the parts for your play set. Empty each box and lay out boards so you can see each part. Your instruction book will have detailed drawings that will make it easy for you to recognize individual parts. Keep all hardware and metal parts separate from wooden pieces.
· After everything is laid out, check carefully to ensure all parts are present. Make sure there are no broken boards.
· Find an area to sort your hardware. It is best to open the hardware on a solid surface so that you do not lose any pieces in the grass. This will save time and familiarize you with all the different pieces in the hardware bag.
· Important note: Wood has some natural defects such as knots, surface cracks, etc... We reject parts that are structurally defective. We use a high quality lumber in our structures; however, you should inspect each part for splinters or rough spots and sand them smooth to prevent injury.
· After familiarizing yourself with all of the components, read all instructions thoroughly. Reading instructions after you have studied the parts will help you understand the installation process, and help to eliminate unnecessary mistakes.
· Pay close attention to the diameter and length of each bolt and screw.
· Never tighten hardware completely at first. It helps to have some adjustment for bolt alignment while you are attaching parts together. After everything is square, tighten each joint.
· After the main unit is assembled it is critical that the floor is level and square. If the main frame is not level, the walls and floor will be out of square.
· After you complete installation, make sure every bolt, screw, and nut is tight, and every board is secure. Wood will expand and contract with the seasons.
· Place the set on level ground, not less than 6 feet from any structure or obstruction such as a fence, garage, house, overhanging branches, laundry lines, or electrical wires.
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This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set.
Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board. In the procedures you will be instructed to attach the boards with the holes offset up or with the holes offset down. This refers to which side of the board the hole/holes should be closer to. Offset holes up= hole/holes will be closer to the top of the board. Offset holes down= hole/holes will be closer to the bottom of the board. Note: some parts do not have offset holes, but instead the holes are on center. Therefore there will not be any reference on how to offset these parts. EXAMPLE OF OFFSET HOLES UP
EXAMPLE OF OFFSET HOLES DOWN
Counter-sunk holes - Many of the parts that will be used have counter-sunk holes. A counter-sunk hole is one that surrounds one side of a through hole, but does not extend through the wood it's self. When using a counter-sunk hole the bolt will be inserted through the through hole and either the head of the bolt and washer or nut and washer will occupy the counter sunk hole.
Counter-Sunk Hole Through Hole
Lag Screws- Lag screws are used in the construction of our play sets to enhance the structural integrity of the unit. There will not be predrilled holes in the post for lag screw installation. Lag screws are self-tapping, though if you are using a manual socket wrench it may be advantageous to pre-drill a hole first. Instructions for this are provided on a separate page in the front of the manual. Be sure to tighten the lags completely when driving them in by hand. Power tools such as a heavy duty impact driver or large power drill should have enough torque to drive in the lag screws, but make sure not to over tighten as this can cause the threads to "strip out" in the post.
8
Common Installation Practice Installing T-nuts
When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood.
Corner Post
T-nut
Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.
This picture shows the T-nut inserted and installed flush to the wood.
Flush (Correct)
This picture shows an end view of the T-nut installed flush to the wood.
WARNING: DO NOT EMBED THE TOP OF THE T-NUT INTO THE FACE OF THE WOOD
Cross Section end view, you are looking at an X-ray view of the post and T-nut. The barrel of the T-nut is in the corner post the line is the face of the wood.
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HOW A T-NUT WORKS
THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS.
THE T-NUT HAS A BARREL SHAPED END WHICH GOES INTO THE HOLE IN THE CORNER POST. THE T-NUT ALSO HAS AN FLANGE SHAPED END WITH TEETH. THE TEETH PENETRATE INTO THE CORNER POST WOOD TO PREVENT THE T-NUT FROM SPINNING WHEN YOU TIGHTEN THE HEX HEAD BOLT.
SHOWN BELOW YOU WILL SEE THE T-NUT IS HAMMERED INTO THE CORNER POST ON THE BACK SIDE. THE BOARD IS BEING ATTACHED ON THE FRONT SIDE OF THE CORNER POST.
CORNER POST
CORNER POST WASHER
BOARD YOU ARE ATTACHING TO CORNER POST. HEX HEAD BOLT
WASHER
T-NUT FLANGE IS HERE.
T-NUT
A
BACK SIDE OF CORNER POST
CROSS SECTION VIEW OF BOARD, CORNER POST AND FASTENERS.
BOARD YOU ARE ATTACHING TO CORNER POST.
FRONT SIDE OF CORNER POST HEX HEAD BOLT
T-NUT DETAILS
TEETH
FLANGE SHAPED END WITH TEETH
THREADS ON INSIDE OF BARREL .
BARREL
DETAIL A
SHAPED
SCALE 2 : 1
END GOES
INTO HOLE IN
CORNER POST.
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BOARD IDENTIFICATION
1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" · The 2 is the thickness of the board. "Nominal Lumber" at a home center will measure 1-
1/2" for the thickness. We "remill" that lumber to 1-3/8" thick. · The 4 is the width of the board. "Nominal Lumber" at a home center will measure 3-
1/2" for the width. We "remill" that lumber to 3-3/8" wide. Note: sometimes the width will be smaller than 3-3/8" because: A) We need the width of the part to fit into a certain area of the play set. B) We need the designation to be simple. · The 3600 is the length of the board. It means the board is 36 inches long. If the code were 3625 then the board is 36-1/4" in length. · The "BPB" abbreviation stands for "Bottom Panel Board". The wood part bill of materials in the instructions has a description which will match the abbreviation closely. · In the event that there is no tag on a wood part measure the part then: A)Use the measurements and compare them to the wood list at the front of the instructions to identify it. B)Look at the holes on the wood part and compare them to the pictures in the wood list. C)Look to see if the holes are centered or if they are offset up or offset down. This should help you identify any parts that have missing tags. In the event that you cannot identify a board please email us for assistance.
36" LENGTH
3
3 8
"
WIDTH
2-4-3600-BPB
1
3 8
"
THICKNESS
TAG
11
PRE-DRILL LAG SCREW DIRECTIONS
Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole.
Pay attention to the DIAMETER of the lag screw you are installing. Your playset may come with two different diameter lag screws. Each diameter will require a different size drill bit. When installing lag screws DO NOT OVERTIGHTEN.
LAG SCREW DIAMETER 5/16" DIAMETER 3/8" DIAMETER
DRILL BIT SIZE 9/64" 11/64"
Example: 3/8" diameter x 3-1/2" lag screw
2 x 4 board
This would be like the 2 x 4 board installation shown below. Place the board into position. Spot Drill through the holes in the 2 x 4 board into the corner posts with an 11/64" drill bit. Remove the 2 x 4 board. Continue to drill the holes to a total depth of 2-5/16" as shown at the right. Install the 2 x 4 board.
Example 5/16" diameter x 3-1/2" lag screw
This would be like the 2 x 4 board installation shown below. Place the board into position. Spot Drill through the holes in the 2 x 4 board into the corner posts with an 9/64" drill bit. Remove the 2 x 4 board. Continue to drill the holes to a total depth of 2-5/16" as shown at the right. Install the 2 x 4 board.
Corner Post
3
7 16
"
2
5 16
"
Example 3/8" diameter x 5" lag screw This would be like the 4 x 4 board installation shown below. Place the board into position. Spot drill through the holes in the 4 x 4 board into the corner posts with an 11/64" drill bit. Remove the 4 x 4 board. Continue to drill the holes to a total depth of 2-13/16" as shown at the right. Install the 4 x 4 board.
Corner Post 4 x 4 board
Corner Post Corner post
2 x 4 board 4 x 4 board
2
13 16
"
4
15 16
"
12
SWING BEAM LOADING
Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs.
Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs. 2) The maximum allowable swinging weight at the Trapeze position is 125 lbs. 3) The MAXIMUM SWING BEAM LOAD IS 425 lbs.
MAXIMUM SWING BEAM LOAD IS 425 LBS.
150 LBS MAX SWINGING WEIGHT
125 LBS MAX SWINGING WEIGHT
150 LBS MAX SWINGING WEIGHT
THIS END OF SWING BEAM IS ATTACHED TO PLAY SET.
TRAPEZE BAR
SWING BELT
SWING BELT
13
REV A: 8/29/2012
Please familiarize yourself with the manual, parts/components and general
1500 cSEoRnIsEStruction process of your new playset before getting started.
CHATEAU
7 HEIGHT - 11' - 18"
SITE PLAN:
19'-
3 8
"
Rope Ladder
10'-1
1 8
"
9'-10
1 8
"
Swing Belts (2) Trapeze (1)
2'-8
1 16
"
3'-11
1 2
"
7'-3
13 16
"
5'-10"
3'-1
5 16
"
Ladder
14'-2
5 8
"
3'-2"
Rock Wall
Wave Slide
Playset height: 11 feet - 2 inches Swing Beam height: 7 feet - 7-1/2 inches Deck height: 5 feet Approximate assembly time: 6-8 hours (6) foot unobstructed safety perimeter around playset recommended
14
REQUIRED TOOL LIST:
___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8", 3/16", 3/8", 7/64", 9/64", 11/64" ___ ½" Wrench and Socket ___ ½" Deep Well Socket ___ 9/16" Deep Well Socket ___ 9/16" Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel ___ Masking Tape or Marker (See Step 37)
KIT CONTENTS
Swings, Slides, Accessories: ___ (Qty ) Description ___ (2) Swingbelt w/ Chains ___ (1) Trapeze Swing w/Chains ___ (1) Wave Slide ___ (10) Rock Wall Grip (assorted colors) ___ (1) Telescope ___ (1) Safety Handles (pair) ___ (2) Flag Kit ___ (2) Plastic Sunburst 07-0028-G ___ (1) Logo Plate ___ (1) Ground Stakes (pair) ___ (1) Tic Tac Toe ___ (1) Steering Wheel ___ (2) Plastic Dormer Sunburst 07-0031
Fort Hardware: see following pages
Swing Beam Hardware: see following pages
Wood Components: see following pages
15
#8 X 1" WOOD SCREW
QTY: 2
#14 X 1-1/4" PAN HEAD SCREW
QTY: 4
#8 X 1-3/4" WOOD SCREW
QTY: 4 #8 X 2" WOOD SCREW QTY: 189
3/8" X 1-1/8" BLACK PLASTIC
PLUG QTY: 6
#8 X 2-1/2" WOOD SCREW
QTY: 52 #8 X 3" WOOD SCREW QTY: 20
1501 HARDWARE
PAGE: 1 OF 2
REV A: 9/10/2014 JH
9
8
7
6
5/16" TEE NUT QTY: 22
TORQUE WASHER QTY: 17
5
4
3/8" LOCK NUT QTY: 19
3
3/8" WASHER
2
QTY: 31
1
5/16 X 4-1/2" HEX BOLT QTY: 14
5/16 X 1-1/2" HEX BOLT QTY: 8
5/16" WASHER QTY: 34
USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
16
1501 HARDWARE PAGE: 2 OF 2 REV A: 9/10/2014 JH
5/1HQS6EC"TXYXR:LE3AW1-G12/2" HE3X/QL8ATXGY:3S-11C2/R2"EW
9
8
7
6
5
4
3
#2 SQUARE DRIVE BIT QTY: 1
2
1
3/8 x 9" CARRIAGE BOLT
QTY: 1
3/8 x 7" CARRIAGE BOLT
QTY: 14
3/8 x 6-1/2" CARRIAGE BOLT
QTY: 2
3/8 x 3-1/2" CARRIAGE BOLT
QTY: 2
PLASTIC BOLT CAP QTY: 19
USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
17
#8 X 1-1/4" WOOD SCREW
QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 104
#8 X 2" WOOD SCREW
QTY: 30 #8 X 2-1/2" WOOD SCREW
QTY: 8
1503N HARDWARE
PAGE: 1 OF 1
REV C: 8/10/2015 JH
9
8
7
6
5
3/8" X 1-1/8" BLACK PLASTIC
PLUG QTY: 4
4
3
5/16" TEE NUT QTY: 6
2
1
5/16 X 4-1/2" HEX BOLT QTY: 4
5/16 X 2-1/2" HEX BOLT QTY: 2
5/16" WASHER QTY: 6
USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
18
1507 HARDWARE PAGE: 1 OF 1 REV A: 9/10/2014 JH
9
8
#8 X 2" WOOD SCREW
7
QTY: 20
6
5
5/16" TEE NUT QTY: 12
4
3
2
5/16" WASHER QTY: 25
1
5/16 X 4-1/2" HEX BOLT QTY: 12
5/16" X 3-1/2" LAG SCREW
QTY: 14
USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
19
PICTURE
COUNT AND ORGANIZE YOUR LUMBER INTO LIKE STACKS (2 X 4, 2 X 6, 4 X 4, 4 X 6, ETC.). THIS WILL HELP IN IDENTIFYING COMPONENTS AND REDUCE YOUR BUILDING TIME
DESCRIPTION
2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-AS
QTY.
4 4
2 X 4 X 14" BOTTOM PANEL
2
BOARD
2-4-1400-BPB
2 X 4 X 14-3/4" PICNIC TABLE TOP SUPPORT
2
2-4-1475-PTTS
2 X 4 X 17" LADDER STEP
5
2-4-1700-LS
2 X 4 X 24"
ROPE LADDER STEP
6
2-4-2400-RLST
2 X 4 X 27-1/2" PICNIC TABLE
2
SEAT SUPPORT
2-4-2750-PTSS
2 X 4 X 28-9/16" CENTER POST FRONT/REAR 2-4-2856-CPFR
2
20
PICTURE
DESCRIPTION QTY.
2 X 4 X 32-1/2"
PICNIC TABLE LEG
2
2-4-3250-PTL
2 X 4 X 4721" END PANEL/
2
SAFETY BOARD
(2 HOLES OFFSET)
2-4-4750-SBEP
2 X 4 X 51-1/8" ROOF SUPPORT (1 HOLE OFFSET) 2-4-5113-RSL 2-4-5113-RSR
2 LEFT 2 RIGHT
2 X 4 X 58"
SWING BEAM CROSS MEMBER
1
(2 HOLES ON
CENTER)
2-4-5800-CM
2 X 4 X 66" LADDER SIDE 2-4-6600-LLS 2-4-6600-LRS
1 LEFT 1 RIGHT
2 X 4 X 66"
ROCK WALL SIDE (1 HOLE ON
2
CENTER)
2-4-6600-RWS
2 X 4 X 70" CENTER DECK SUPPORT 2-4-7000-CDS
1
21
PICTURE
DESCRIPTION QTY.
2 X 4 X 70"
DECK SUPPORT (2 HOLES ON
2
CENTER)
2-4-7000-DS
2 X 4 X 70"
REAR TOP PANEL
BOARD (2 HOLES OFFSET/ 1
1
CENTERED)
2-4-7000-RTPB
2 X 6 X 4712"
BOTTOM PANEL AND SANDBOX
3
BOARD (4 HOLES
OFFSET)
2-6-4750-ESPB
2 X 6 X 70"
FRONT FACE BOARD (4
1
HOLES OFFSET)
2-6-7000-FFB
2 X 6 X 70"
BOTTOM PANEL AND SANDBOX
3
BOARD (4
HOLES OFFSET)
2-6-7000-SB
2 X 6 X 70"
FRONT TOP
PANEL BOARD (4 HOLES OFFSET,
1
1 CENTER)
2-6-7000-FTPB
2 X 6 X 79-1/2" ROPE LADDER SUPPORT (4 HOLES OFFSET, 3 HOLES ON CENTER) 2-6-7950-RLS
1
22
PICTURE
DESCRIPTION
2 X 6 X 79-1/2" ROPE LADDER RUNNER(4 HOLES OFFSET, 3 HOLES ON CENTER) 2-6-7950-RLR
QTY.
1
4 X 4 X SWING
4B7E12A" M
1
MOUNT
4-4-4750-SBM
5 4
X
258
X
1314"
PICNIC TABLE
2
SLAT
125-3-1325-PTS
5 4
X
258
X
1712"
TIC TAC TOE
2
MOUNT
125-3-1750-TTTM
5 4
X
258
X
2814"
PANEL SLAT
24
125-3-2825-PS
5 4
X
4
X
4038"
DECK SPACER
2
125-4-4038-DS
L54 AXD3DXER18B34A" CK 125-3-1875-LB
1
23
PICTURE
DESCRIPTION QTY.
54ROX C3 KX W23A78"LL CAP
1
125-3-2387-RWC
5 4
X
6
X
10"
ROOF PEAK
2
SUPPORT
125-6-1000-RPS
5 4
X
6
X
22"
SANDBOX SEAT
2
125-6-2200-SS
5 4
X
6
X
2378"
BOTTOM ROCK
1
WALL BOARD
125-6-2387-BRW
54ROX C6 KX W23A78"LL BOARD
11
125-6-2387-RWB
54PIXC6NXIC4T3A" BLE
4
TOP AND SEATS
125-6-4300-PTTS
5 4
X
6
X
4738"
DECK BOARD
125-6-4737-DB
11
24
PICTURE
DESCRIPTION QTY.
4712" ROOF PEAK
1
1-6-4750-RP
1 X 4 X 4712"
TONGUE-ONLY ROOF FINISHER
2
1-4-4750-RF
1 X 4 X 4712"
GROOVE-ONLY ROOF STARTER
2
1-4-4750-RS
1 X 5 X 4712"
22 TONGUE-AND-
GROOVE ROOF BOARD 1-5-4750-RB
NOTE: ANYTHING ON THIS PAGE REFERRED
TO AS "PLASTIC COATED" WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR
PLASTIC COATED
WOOD OPTION.
4 X 4 X 108" SWING BEAM
2
LEG
PLASTIC COATED
4 X 4 X 96" CORNER POST
4
PLASTIC COATED 4 X 6 X 120"
1
SWING BEAM
25
PICTURE
DESCRIPTION QTY.
10' WIKI
1
WAVE
SLIDE
ROPE LADDER
3
ROPES
(13' ROPE)
SWING W/CHAINS
2
04-0002
TRAPEZE BAR
W/CHAINS 04-0006
1
26
PICTURE
DESCRIPTION QTY.
SWING PLATE
1
11-5002
CLIMBING ROCKS (07-0008
IS A PACK OF 5)
10
ROCKS
A-FRAME SWING LEG
1
BRACKET
11-5010
HARDWARE BOXES: 1501, 1503N, 1507
1 HARDWARE BOXES
EA. INSTRUCTIONS 27
PICTURE
DESCRIPTION QTY.
IRON DUCTILE SWING
6
HANGERS
11-4012
1 TELESCOPE 07-0001
ROCK
1
WALL
(10' ROPE)
28
PICTURE
DESCRIPTION QTY.
4 90 GREEN
BRACKET 11-5013
SPRING CLIP
6
11-4003
SAFETY HANDLES
(PAIR) 07-0005
1PR
29
PICTURE
DESCRIPTION QTY.
1 UNASSEMBLED CHIMNEY (1530 BOX)
2 UNASSEMBLED DORMER (1530 BOX)
FLAG KIT 09-1014
2
30
PICTURE
(NOT SHOWN)
DESCRIPTION QTY.
PLASTIC SUNBURST
2
07-0028-G
MANUFACTURER LOGO PLATE
1
GROUND STAKE (PAIR) 07-0016-P
1PR
TIC TAC TOE (UNASSEMBLED)
1
07-0010
STEERING WHEEL 07-0004
1
PLASTIC DORMER SUNBURST 07-0031
2
31
STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS
1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE. 5: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 6: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
HOLES AT THE TOP OF CORNER POSTS SHOULD BE FACING THIS DIRECTION
NO T-NUT IN THESE HOLES (FOR SWING BEAM MOUNT
USING CARRIAGE
BOLTS)
T-NUT 4 X 4 X 96" CORNER POST
LEFT (SWING BEAM) SIDE OF FORT
FRONT OF FORT
32
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME
1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 79-1/2" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER RUNNER TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 4: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN. 5: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM HOLES OF THE BOTTOM PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE TOP HOLES WILL BE USED LATER. 6: LAY THE 2 X 6 X 79-1/2" ROPE LADDER SUPPORT ON TOP OF THE RIGHT SIDE CORNER POSTS. THE HOLES IN THE ROPE LADDER SUPPORT MUST BE OFFSET DOWN. 7: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER SUPPORT TO THE T-NUTS INSTALLED ON THE CORNER POSTS. 8: DO NOT INSTALL ANY LAG SCREWS AT THIS TIME.
5/16" WASHER 5/16" X 4-1/2"
HEX BOLT
2 X 6 X 79-1/2" ROPE LADDER SUPPORT (OFFSET HOLES DOWN) 2 X 6 X 47-1/2" BOTTOM PANEL BOARD (OFFSET HOLES DOWN)
FRONT OF FORT
5/16" WASHER 5/16" X 4-1/2" HEX BOLT
2 X 6 X 79-1/2" ROPE LADDER RUNNER (OFFSET HOLES DOWN)
5/16" WASHER 5/16" X 4-1/2" HEX BOLT
33
STEP 3: ASSEMBLING THE LEFT SIDE FRAME
1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION.
2: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN.
3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
4: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN.
5: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM HOLES OF THE BOTTOM PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE TOP HOLES WILL BE USED LATER.
6: LAY THE 4 X 4 X 47-1/2" SWING BEAM SUPPORT ON TOP OF THE LEFT SIDE CORNER POSTS. THE THREE COUNTERSUNK HOLES IN THE MIDDLE OF THE SWING BEAM SUPPORT MUST FACE DOWNWARD.
7: FIND TWO TORQUE WASHERS. PLACE A 6-1/2" CARRIAGE BOLT THROUGH THE TORQUE WASHER, MAKING SURE THAT THE TEETH ARE FACING IN THE SAME DIRECTION AS THE THREADS OF THE CARRIAGE BOLT. PLACE THE TORQUE WASHER/CARRIAGE BOLT ASSEMBLY INTO THE CORNER POST HOLES SO THAT THE HEAD OF THE CARRIAGE BOLT FACES WHAT WILL BE THE INSIDE OF THE FORT. USE A HAMMER TO SET THE TORQUE WASHER INTO THE CORNER POST.
8: ATTACH THE SWING BEAM SUPPORT AS SHOWN IN DETAIL A.
A
4 X 4 X 47-1/2"
SWING BEAM SUPPORT
DETAIL A
6-1/2" CARRIAGE BOLT
TORQUE WASHER
2 X 6 X 47-1/2" BOTTOM PANEL BOARD (OFFSET HOLES DOWN)
3/8" WASHER 3/8" NUT BOLT CAP
THE THREE COUNTERSUNK HOLES ON THE SWING BEAM SUPPORT WILL FACE DOWN WHEN PROPERLY INSTALLED.
5/16 X 4-1/2" HEX BOLT 5/16" WASHER
2 X 6 X 47-1/2" SANDBOX BOARD (OFFSET HOLES DOWN)
FRONT OF
FORT
34
STEP 4: DECK SUPPORTS
YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT
5/16" WASHER 5/16 X 4-1/2" HEX BOLT
2 X 4 X 70" DECK SUPPORT COUNTER-SUNK HOLES
ON CENTER
35
STEP 5: FRONT FRAME ASSEMBLY
1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD SHOULD BE OFFSET UP. 4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE FRONT FACE BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 5: PLACE THE 2 X 6 X 70" TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE TOP PANEL BOARD SHOULD BE OFFSET UP. 6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE TOP PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
2 X 6 X 70" TOP PANEL BOARD OFFSET HOLES UP 2 X 6 X 70" FRONT FACE BOARD OFFSET HOLES UP
5/16" WASHER 5/16 X 4-1/2" HEX BOLT
2 X 6 X 70" SANDBOX BOARD OFFSET HOLES UP
FRONT OF FORT
36
STEP 6: REAR FRAME ASSEMBLY
1: PLACE THE 2 X 6 X 70" SANDBOX BOARD AT THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" BOTTOM PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET UP. 4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE BOTTOM PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 5: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD NEAR THE TOP OF THE REAR CORNER POSTS. THE HOLES IN THE TOP PANEL BOARD MUST BE OFFSET UP. 6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE HOLES OF THE TOP PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
2 X 4 X 70" REAR TOP PANEL BOARD OFFSET HOLES UP
2 X 6 X 70" BOTTOM PANEL BOARD OFFSET HOLES UP
5/16" WASHER 5/16 X 4-1/2" HEX BOLT
2 X 6 X 70" SANDBOX BOARD OFFSET HOLES UP
REAR OF FORT
37
STEP 6A: LEVELING THE PLAY SET AND LAGS
1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS.
2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE FRAME HAS BEEN LEVELED AND SQUARED.
3: ONCE THE FRAME IS LEVEL, SQUARE AND SET INTO POSITION; GO BACK AND INSERT THE 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS IN ALL THE REMAINING HOLES OF THE 2 X 6 PARTS ON THE FRONT, SIDES AND REAR OF THE PLAY SET. NOTE: THERE WILL NOT BE ANY PREDRILLED HOLES IN THE CORNER POSTS FOR THE LAG SCREWS.
***IMPORTANT*** SQUARE BOARDS TO POSTS; THEN INSTALL LAG SCREWS AND WASHERS ONLY IN THESE FOUR 2 X 6 BOARDS FIRST. THEN LEVEL/SQUARE THE FRAME. FINALLY, INSTALL LAG SCREWS IN THE REMAINING 2 X 6 BOARDS.
LEFT SIDE FRAME
FRONT OF FORT
5/16" X 3-1/2" LAG SCREW 5/16" WASHER
RIGHT SIDE FRAME
38
STEP 6B: ANGLE SUPPORTS
1: FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE ANGLE SUPPORT INTO THE BOTTOM PANEL BOARD. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
3: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT AND REAR OF THE PLAY SET TO THE 2 X 4 DECK SUPPORTS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
4: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE ANGLE SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
DECK SUPPORT
2 X 4 X 13" ANGLE SUPPORT 3" WOOD SCREW
2" WOOD SCREW
2-1/2" WOOD SCREW
2 X 6 BOTTOM PANEL BOARD
2 X 4 X 18" ANGLE SUPPORT
DECK SUPPORT
TOP OF ANGLE SUPPORTS SHOULD BE FLUSH OR LOWER THAN THE DECK SUPPORT
2 X 6 BOTTOM PANEL BOARD
3" WOOD SCREW 2" WOOD SCREW
2 X 4 X 13" ANGLE SUPPORT
2 X 4 X 18" ANGLE SUPPORT
DETAIL A SCALE 1 : 9
A
39
STEP 7: BOTTOM PANEL BOARDS
1: PLACE THE 2 X 4 X 47-1/2" END PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
5/16" WASHER
2 X 4 X 47-1/2" END PANEL BOARD OFFSET HOLES UP
5/16 X 3-1/2" LAG SCREW
FRONT OF FORT
2: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD, AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
FRONT OF FORT
5/16" WASHER 5/16 X 3-1/2" LAG SCREW
2 X 4 X 14" BOTTOM PANEL BOARD COUNTER-SUNK HOLES ON CENTER
40
STEP 8: DECK SPACERS
THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD
1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER.
20
3 16
"
2
3 8
"
11 16
"
5/4 X 4 X 40-3/8" DECK SPACER
1"
1 8
"
THIS IS THE CENTER OF THE BOARD, THIS HOLE ONLY
NEEDS TO BE DRILLED ONCE
1
11 16
"
2: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE CORNER POSTS AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER.
2" WOOD SCREW 5/4 X 4 X 40-3/8"
DECK SPACER
2 X 4 X 14" BOTTOM PANEL BOARDS REMOVED FROM VIEW FOR CLARITY
41
STEP 9: CENTER DECK SUPPORT
1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. 3: CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT ON THESE MARKS AND PUSH THE CENTER DECK SUPPORT FLUSH TO THE BOTTOM SIDE OF THE DECK BOARDS. 4: USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT. 5: USING TWO 2-1/2" WOOD SCREWS, INSTALL THE 2 X 4 X 70" CENTER DECK SUPPORT THROUGH THE OUTSIDE OF THE 2 X 6, AND INTO THE END OF THE CENTER DECK SUPPORT. REPEAT THIS STEP ON THE OPPOSITE END OF THE FORT.
2" WOOD SCREW 2 X 4 X 70" CENTER DECK SUPPORT
USE 2-1/2" WOOD SCREWS IN THESE LOCATIONS ON EACH SIDE.
42
STEP 10: DECK BOARDS
THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD
1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW.
1
3 8
"
4
1 8
"
5/4 X 6 X 47-3/8" DECK BOARD
1 8
"
2
3 4
"
1
3 8
"
4
1 8
"
4
1 8
"
23
11 16
"
4
1 8
"
2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW. LEAVE A UNIFORM (APPROX. 1/4") SPACE BETWEEN THE DECK BOARDS. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK BOARDS.
LAY ALL DECK BOARDS ACROSS THE DECK SUPPORTS BEFORE SECURING THEM TO THE FORT. THIS WILL ENSURE THAT YOU HAVE EQUAL SPACING ACROSS THE DECK.
2" WOOD SCREW
5/4 X 6 X 47-3/8" DECK BOARD
43
STEP 11: ROCK WALL
1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER.
T-NUT
A
2 X 4 X 66" ROCK WALL
SIDES
44
STEP 12: ROCK WALL
1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2" WOOD SCREWS IN EACH SIDE. 3: CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS, FASTENING EACH BOARD WITH TWO 2" WOOD SCREWS ON EACH END. 4: THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE. ATTACH WITH TWO 2" WOOD SCREWS PER SIDE. 5: IN SOME CASES, THERE WILL BE EXCESS LENGTH ON THE ROCK WALL SIDES. THIS IS DUE TO MILLING VARIATIONS, AND IS ALSO USED TO HELP LEVEL THE ROCK WALL SIDES ON UNEVEN GROUND. 6: ROCK WALL SIDES MAY NOT BE EVEN WITH THE BOTTOM ROCK WALL BOARD DUE TO MILLING VARIATIONS AND WOOD SHRINKAGE.
5/4 X 6 X 23-7/8" ROCK WALL BOARD
2" WOOD SCREW
TOP IS FLUSH TO ENDS OF SIDES.
5/4 X 6 X 23-7/8" BOTTOM ROCK
WALL BOARD
45
STEP 13: ROCK WALL
1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
90 GREEN BRACKET 5/16" WASHER
5/16" X 1-1/2" HEX BOLT
A
46
STEP 14: ROCK WALL
1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT. BE CREATIVE!
1-1/4" PAN HEAD SCREW WASHER
CLIMBING ROCKS
3: PLACE THE 5/4 X 3 X 23-7/8" ROCK WALL TOP CAP ON TOP OF THE ROCK WALL SIDES. FASTEN THE ROCK WALL TOP CAP TO THE ROCK WALL SIDES WITH 2" WOOD SCREWS.
5/4 X 3 X 23-7/8" ROCK WALL TOP CAP
2" WOOD SCREW
47
STEP 15: ATTACHING THE ROCK WALL
1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8" HOLE THROUGH THE FRONT FACE BOARD. THE BOTTOM OF THE GREEN BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8" HOLES IN THE FRONT FACE BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2" BOLTS AND 5/16" WASHERS. 4: WHEN THE BRACKETS ARE SECURE, AND THE ROCK WALL IS IN ITS FINAL POSITION; TIGHTEN THE 5/16 X 1-1/2" BOLTS ON THE ROCK WALL SIDES.
5/16 X 1-1/2" HEX BOLT
5/16" X WASHER
3/4" INSERT T-NUT BEHIND THE 2 X 6 ON BOTH SIDES
48
STEP 16: LADDER
1: FIND TWO 2 X 4 X 66" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
T-NUT
2 X 4 X 66" LADDER SIDE
2" WOOD SCREW
2 X 4 X 17" LADDER STEP
4: FIND FIVE 2 X 4 X 17" LADDER STEPS. 5: PLACE THE STEPS INTO THE SLOTS ON THE LADDER SIDES, AND FASTEN WITH 2" WOOD SCREWS. 6: CAREFULLY TURN THE LADDER OVER AND PUT THE SCREWS INTO THE OTHER SIDE.
5/16 X 1-1/2" HEX BOLT 5/16" WASHER
90 ANGLE BRACKET
7: INSTALL THE 90 ANGLE BRACKETS TO THE INSIDE OF THE LADDER RAILS WITH 5/16 X 1-1/2" BOLTS, 5/16 WASHERS, INTO THE 5/16" T-NUTS.
2" WOOD SCREW
5/4 X 3 X 18-3/4" LADDER BACK
8: INSTALL THE 5/4 X 3 X 18-3/4" LADDER BACK ABOVE THE TOP STEP OF THE LADDER WITH TWO 2" WOOD SCREWS PER SIDE.
49
STEP 17: LADDER TO FORT
1: PLACE THE LADDER INTO POSITION ON THE RIGHT SIDE OF THE FORT AS SHOWN BELOW. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8" HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8" HOLES ON THE BOTTOM PANEL BOARD. 3: ATTACH THE LADDER WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 4: WHEN THE BRACKETS ARE SECURE, AND THE LADDER IS IN ITS FINAL POSITION; TIGHTEN THE 5/16 X 1-1/2" BOLTS ON THE LADDER SIDES.
5/16" WASHER 5/16" X 1-1/2" HEX BOLT
3/4"
RIGHT SIDE OF FORT
INSERT A T-NUT BEHIND THE 2 X 6 ON BOTH SIDES.
50
STEP 18: CENTER POST FRONT/REAR
1: HAMMER A T-NUT INTO THE HOLE OF EACH 2 X 4 X 28-9/16" CENTER POST FRONT/REAR.
2: PLACE THE CENTER POSTS INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET. LINE UP THE HOLES IN THE CENTER POSTS WITH THE HOLES IN THE RAILINGS.
3: FASTEN THE CENTER POSTS TO THE RAILINGS WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS AT THE TOP.
4: SQUARE EACH CENTER POST TO THE DECK AND SECURE THE BOTTOM OF THE CENTER POST TO THE BOTTOM PANEL BOARDS WITH #8 X 2-1/2" WOOD SCREWS.
RAILINGS
2 X 4 X 28-9/16" CENTER POSTS
A
BOTTOM PANEL BOARDS
5/16" X 2-1/2" HEX BOLT 5/16" WASHER RAILING
5/16" T-NUT
2 X 4 X 28-9/16" CENTER POST FRONT/REAR
BOTTOM PANEL BOARD
DETAIL A SCALE 1 : 8
#8 X 2-1/2" WOOD SCREWS
51
STEP 19: PANEL SLATS
1: FIND TWENTY-TWO 5/4 X 2-5/8 X 28-1/4" PANEL SLATS.
2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT.
3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS.
4: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES.
2
3 4
"
2
3 4
"
2
3 4
"
2
5 8
"
BACK WALL PANEL SLAT DIMENSIONS
2" WOOD SCREW
5/4 X 2-5/8 X 28-1/4" PANEL SLAT
SWING BEAM SIDE
LADDER SIDE PANEL SLAT DIMENSIONS
LADDER SIDE
1" BOTH SIDES
17
1 2
"
SWING BEAM SIDE PANEL SLAT DIMENSIONS
2
1 8
"
(VIEW FROM OUTSIDE
THE PLAY SET)
11
9 16
"
2
1 8
"
52
STEP 20: ROOF SUPPORT ASSEMBLIES
1: LOCATE TWO 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW. 3: USE FOUR #8 X 2" WOOD SCREWS TO ATTACH THE ROOF PEAK SUPPORT TO THE ROOF SUPPORTS AS SHOWN BELOW. 4: MAKE ONE MORE ROOF SUPPORT ASSEMBLY BY REPEATING 2 AND 3.
COUNTERSUNK HOLE FACES UP
2 X 4 X 51-1/8" ROOF SUPPORT - RIGHT
2 X 4 X 51-1/8" ROOF SUPPORT - LEFT
FLUSH
DETAIL A
#8 X 2" WOOD SCREW FLUSH
5/4 X 6 X 10" ROOF PEAK SUPPORT
A
USE A CARPENTERS SQUARE TO MAKE THESE PARTS SQUARE TO ONE ANOTHER.
53
STEP 20A: INSTALLING ROOF SUPPORT ASSEMBLIES
1: PLACE THE ROOF SUPPORT ASSEMBLIES ON TOP OF THE DECK OF THE PLAY SET. CLIMB ONTO THE DECK TO INSTALL THE ROOF SUPPORT ASSEMBLIES. 2: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
ROOF SUPPORT ASSEMBLIES
5/16" FLAT WASHER 5/16" X 4-1/2" HEX BOLT
54
STEP 21: SWING BEAM PLATE
1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH, IN THE COUNTER-SUNK HOLES OF THE SWING BEAM SUPPORT. USE BOLT CAPS TO COVER ANY EXPOSED THREADS. 3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER. 4: IF NECESSARY USE LOCKING PLIERS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.
3/8" x 3-1/2" CARRIAGE BOLT
SWING BEAM PLATE
3/8" WASHER 3/8" NUT BOLT CAP
55
STEP 22: IRON DUCTILE SWING HANGERS
1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
L
7" CARRIAGE BOLT TORQUE WASHER
IRON DUCTILE SWING HANGER
3/8" WASHER 3/8" LOCK NUT BOLT CAPS
56
STEP 23: ATTACH SWING LEGS TO BRACKET
1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
SWING LEGS FLUSH TO TOP OF SWING
LEG BRACKET
3/8 X 3-1/2" LAG SCREW
3/8" WASHER
SWING LEG BRACKET
4 X 4 X 108" SWING LEG
57
STEP 24: REST SWING BEAM ON FORT
AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: REST THE SWING BEAM ON TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM.
THESE TWO HOLE LOCATIONS WILL BE EMPTY ON YOUR SWING BEAM. LINE THEM UP WITH THE HOLES IN THE SWING LEG BRACKET UNDER THE SWING BEAM.
58
STEP 25: MOUNT SWING BEAM TO SWING BEAM LEGS
1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET. 3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.
7" CARRIAGE BOLT
3/8" WASHER
3/8" LOCK NUT BOLT CAP
TORQUE WASHER
3/8 X 3-1/2" LAG SCREW
59
STEP 26: MOUNT SWING BEAM ON FORT
AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT WITH A TORQUE WASHER ON TOP AND A 3/8" LOCK NUT AND WASHER ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING. 4: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE FROM UNDERNEATH WITH A 3/8 X 3-1/2" LAG SCREW AND 3/8" WASHER. 5: IF NECESSARY USE VISE GRIPS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.
TORQUE WASHER
9" CARRIAGE BOLT
3/8" WASHER 3/8" NUT
BOLT CAP
3/8" WASHER 3/8 X 3-1/2" LAG SCREW
60
STEP 27: LEVEL SWING BEAM
1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THE LEGS ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY EITHER: A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
IN OUT
61
STEP 28: SWING LEG CROSS-MEMBER
1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS.
3/8 X 3-1/2" LAG SCREW 3/8" WASHER
2 X 4 X 58" CROSS-MEMBER
62
STEP 29: ROOF STARTERS
1: PLACE THE 1 X 4 X 47-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE APPROXIMATELY CENTERED (SEE BELOW) ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS. WHEN ATTACHING THE ROOF STARTERS DIM B AT THE ROOF PEAK SHOULD MATCH DIM A. THIS WILL MAKE THE ROOF SUPPORTS PARALLEL TO EACH OTHER. DUE TO WOOD MILLING VARIATIONS YOUR HOLES IN THE ROOF STARTERS WILL EITHER BE CENTERED ON THE ROOF SUPPORTS OR THEY WILL BE OFFSET TOWARDS THE INSIDE OF THE ROOF SUPPORTS SLIGHTLY. SUBTRACT DIM A FROM 47-1/2" AND THEN DIVIDE THIS NUMBER BY 2. THIS WILL GIVE YOU THE OVERHANG FOR EACH SIDE. USE THE OVERHANG NUMBER ON EACH SIDE TO KEEP YOUR ROOF SUPPORTS PARALLEL.
OVERHANG ROOF SUPPORT
DIM B
TOP OF ROOF SUPPORT AT THE PEAK OF THE ROOF.
47
1 2
"
ROOF
STARTER
LENGTH
EXAMPLE: 47-1/2" MINUS 40-5/8" EQUALS 6-7/8". 6-7/8" DIVIDED BY 2 EQUALS 3-7/16" OVERHANG PER SIDE.
ROOF STARTER OVERHANG ROOF SUPPORT
40
5 8
"
EXAMPLE
DIMENSION
DIM A
BOTTOM OF ROOF SUPPORT ATTACHED TO THE CORNER POST.
#8 X 1-1/2" WOOD SCREW
1 X 4 X 47-1/2" ROOF STARTER
PLACE AS CLOSE TOGETHER AS POSSIBLE WITHOUT THE STARTERS OVERLAPPING.
ROOF SUPPORT ROOF SUPPORT
63
STEP 30: ROOF PEAK
1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS.
2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS.
47-1/2" ROOF PEAK
#8 X 1-1/4" WOOD SCREW
64
STEP 31: ROOF
NOTE: THE SMALL PICTURE BELOW IS A GENERIC VIEW OF A PLAY SET IN OUR 1500 MODEL LINE. TYPICALLY THE ROCK WALL AND/OR SLIDE IS LOCATED ON THE FRONT OF THE 1500 SERIES PLAY SETS. THE BIG PICTURE BELOW SHOWS THE RIGHT SIDE ROOF WITH THE DORMER AND CHIMNEY. THE LEFT SIDE ROOF ONLY GETS A DORMER. INSTRUCTIONS TO BUILD THE CHIMNEY AND DORMERS ARE IN THE APPENDIX AT THE BACK OF THIS MANUAL. PLEASE NOTE THAT EACH SIDE OF THE ROOF WILL HAVE 11 ROOF BOARDS AND 1 ROOF FINISHER. 1: PLACE THE 1 X 5 X 47-1/2" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS 11 ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS 3: FIT THE TONGUE END OF THE 1 X 4 X 47-1/2" ROOF FINISHER INTO THE GROOVE END OF THE LAST ROOF BOARD. FASTEN IT TO THE ROOF SUPPORT WITH FOUR 1-1/2" WOOD SCREWS. TIP: INSTALL FOUR ROOF BOARDS AND THEN INSTALL THE CHIMNEY ACCORDING TO THE CHIMNEY INSTRUCTIONS. AFTER INSTALLING THE EIGHTH ROOF BOARD INSTALL THE DORMER ACCORDING TO THE DORMER INSTRUCTIONS. THEN FINISH INSTALLING THE REMAINING ROOF BOARDS AND ROOF FINISHER.
DORMERS (2)
CHIMNEY (1)
RIGHT ROOF SIDE
RIGHT SIDE OF PLAY SET
FRONT OF PLAY SET (ROCK WALL AND/OR SLIDE WILL BE ON THIS SIDE.)
1 X 5 X 47-1/2" ROOF BOARD (FIRST ONE)
1 X 5 X 47-1/2" ROOF BOARD (FOURTH ONE)
1 X 5 X 47-1/2" ROOF BOARD (EIGHTH ONE)
RIGHT ROOF SIDE CHIMNEY DORMER (ONE ON EACH SIDE OF THE ROOF)
1 X 4 X 47-1/2" ROOF FINISHER
65
STEP 32: HANGING THE SWINGS
1: START BY ATTACHING ONE SPRING CLIP TO EACH IRON DUCTILE ON THE SWING BEAM. 2: ATTACH ONE CHAIN PER ACCESSORY TO EACH SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED.
SPRING CLIP SWING CHAIN
66
STEP 33: SAFETY BOARD
1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS. NOTE: THE OFFSET HOLES CAN BE PLACED UP OR DOWN IN THIS STEP.
2 X 4 X 47-1/2" SAFETY BOARD
5/16" WASHER 5/16 X 3-1/2" LAG SCREW
24"
67
STEP 34: PICNIC TABLE
1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS. 2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4" PT TOP SUPPORT AND A 2 X 4 X 27-1/2" PT SEAT SUPPORT PARALLEL TO ONE ANOTHER. PLACE A 2 X 4 X 32-1/2" PT LEG ON TOP AT THE 7-1/2" DIMENSION. THE TOP OF THE PT LEG SHOULD BE FLUSH TO THE TOP OF THE PT TOP SUPPORT. ATTACH THE PT LEG TO THE SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS. 3: FOR THE RIGHT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4" PT TOP SUPPORT AND A 2 X 4 X 27-1/2" PT SEAT SUPPORT PARALLEL TO ONE ANOTHER. PLACE A 2 X 4 X 32-1/2" PT LEG ON TOP AT THE 7-1/2" DIMENSION. THE TOP OF THE PT LEG SHOULD BE FLUSH TO THE TOP OF THE PT TOP SUPPORT. ATTACH THE PT LEG TO THE SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS. 4: PLACE THE PICNIC TABLE SLAT NEXT TO THE PICNIC TABLE LEG FOR EACH ASSEMBLY BELOW. LEAVE A 3/16" GAP BETWEEN THE TOP OF THE SLAT AND THE LEG. USE THE 6-15/16" DIMENSION TO LOCATE THE BOTTOM END OF THE SLAT. FASTEN THE PICNIC TABLE SLAT TO THE SUPPORTS WITH TWO #8 X 2" WOOD SCREWS.
TOP OF PIECES SHOULD BE FLUSH HERE 2 X 4 X 14-3/4" PT TOP SUPPORT
7
1 2
"
3 16
"
2 X 4 X 27-1/2" PT SEAT SUPPORT
10"
#8 X 2-1/2" WOOD SCREW 2 X 4 X 32-1/2" PT LEG
LEFT SIDE ASSEMBLY
6
15 16
"
#8 X 2" WOOD SCREW
5/4 X 3 X 13-1/4" PICNIC TABLE SLAT
7
1 2
"
3 16
"
10"
TOP OF PIECES SHOULD BE FLUSH HERE 2 X 4 X 14-3/4" PT TOP SUPPORT 2 X 4 X 27-1/2" PT SEAT SUPPORT
RIGHT SIDE ASSEMBLY
6
15 16
"
#8 X 2" WOOD SCREW
#8 X 2-1/2" WOOD SCREW
5/4 X 3 X 13-1/4" PICNIC TABLE SLAT
2 X 4 X 32-1/2" PT LEG
68
STEP 35: PICNIC TABLE
1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS. 3: PLACE THE TOP OF THE LEFT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT REAR CORNER POST. ATTACH THE LEFT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS.
RIGHT SIDE ASSEMBLY (LEG ON INSIDE) NOTE: ROCK WALL AND LADDER REMOVED FOR CLARITY.
#8 X 3" WOOD SCREW LEFT SIDE ASSEMBLY (LEG ON INSIDE) 26-3/8"
69
STEP 36: PICNIC TABLE
1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS. 2: CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS. 3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS.
5/4 X 6 X 43" PT TOP/SEAT BOARDS. #8 X 2-1/2" WOOD SCREWS
70
STEP 37: ROPE LADDER
1: FIND THREE ROPE LADDER ROPES. MAKE A KNOT IN THE END OF EACH ROPE AND THREAD THE FREE END THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT. PULL EACH ROPE TAUGHT.
2: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 6 INCHES AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 6 INCHES BELOW THE ROPE LADDER SUPPORT. SLIDE EACH ROPE THROUGH THE HOLES IN ONE ROPE LADDER RUNG. SLIDE THE RUNG UP AGAINST THE BOTTOM OF THE KNOTS.
3: TIE THREE KNOTS BELOW THE ROPE LADDER RUNG.
4: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER RUNG 10-5/8 INCHES AND MAKE A MARK ON THE ROPE WITH A PIECE OF TAPE OR A MARKER. THREAD ANOTHER ROPE LADDER RUNG ONTO THE ROPES.
5: WITH THE TOP OF THE RUNG EVEN WITH THE 10-5/8 INCH MARK TIE THREE KNOTS BELOW THE SECOND ROPE LADDER RUNG.
6: REPEAT SUBSTEPS 4-5 FOR THE REMAINING ROPE LADDER RUNGS.
7: THREAD THE BOTTOM END OF EACH ROPE THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE THEM OFF. GRAB EACH EACH ROPE AND ATTEMPT TO WRAP IT AROUND YOUR HAND. IF THE ROPE WRAPS AROUND YOUR HAND IT IS TOO LOOSE. IF THE ROPE IS TOO LOOSE UNTIE THE KNOT BEHIND THE ROPE LADDER RUNNER AND RETIE IT UNTIL YOU CAN NO LONGER WRAP THE ROPE AROUND YOUR HAND.
ROPE LADDER SUPPORT
1) TIE A KNOT IN EACH ROPE AND THREAD THEM THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT.
2) MEASURE DOWN 6" BELOW THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIE 3 KNOTS. THE BOTTOM OF EACH KNOT SHOULD BE 6" BELOW THE ROPE LADDER SUPPORT 6"
10
5 8
"
2.1) SLIDE A ROPE LADDER RUNG AGAINST THE THREE KNOTS.
3) TIE THESE THREE KNOTS BELOW THE ROPE LADDER RUNG. 4) MEASURE DOWN 10-5/8" BELOW THE ROPE LADDER RUNG AND PLACE TAPE ON THE ROPE OR MARK WITH A PEN. 5) SLIDE THE NEXT ROPE LADDER RUNG UP TO THE MARKS OR TAPE. TIE THREE KNOTS UNDER THE ROPE LADDER RUNG. 6) REPEAT 4 & 5 FOR REMAINING ROPE LADDER RUNGS.
7) TIE KNOTS ON BACK SIDE OF ROPE LADDER RUNNER
ROPE LADDER RUNNER
THIS IS THE VIEW AS IF YOU WERE STANDING AT
THE RIGHT SIDE OF THE FORT LOOKING AT IT.
71
STEP 38: MOUNTING THE SLIDE
1: PLACE THE SLIDE IN THE OPENING AT THE FRONT-LEFT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH 1-1/4" PAN HEAD SCREWS. **DO NOT OVERTIGHTEN**
1**-D1/O4"NPOATNOHVEEARDTIGSCHRTEEWN**
72
STEP 39: MOUNTING THE TELESCOPE
1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE FRONT TOP PANEL BOARD ON THE SLIDE SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH THE 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE.
TELESCOPE
TELESCOPE STAND
FRONT TOP PANEL BOARD
TELESCOPE BRACKETS
1-1/4" WOOD SCREWS
SLIDE
CENTER POST ROCK WALL
73
STEP 40: INSTALLING CLIMBING ROPE
1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE TOP PANEL BOARD. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND. HINT: TO REDUCE THE AMOUNT OF SLACK IN THE ROPE, LIFT THE ROCK WALL ASSEMBLY SLIGHTLY WHEN TYING THE KNOT IN THE BOTTOM ROCK WALL BOARD. WHEN YOU LOWER THE ASSEMBLY, THE ROPE WILL TIGHTEN. 3: YOU CAN TIE A FEW (NO MORE THAN THREE) KNOTS IN THE ROPE TO AID IN CLIMBING APPROXIMATELY 18" APART BEFORE TYING THE KNOT BEHIND THE BOTTOM ROCK WALL BOARD.
YOU MAY TIE KNOTS HERE TO AID IN CLIMBING
74
STEP 41: TIC TAC TOE ASSEMBLY
1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 3: LOCATE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS. EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIC TAC TOE MOUNT.
GREEN BRACKET 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT
TIC TAC TOE AFTER ASSEMBLING.
GREEN BRACKET
5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT
75
STEP 42: TIC TAC TOE INSTALLATION
1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE PLAY SET ON THE INSIDE. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS.
SWING BEAM
TIC TAC TOE WITH BOARDS ATTACHED.
#8 X 1-3/4" WOOD SCREWS 4.00
76
STEP 43: SAFETY HANDLES
1: LOCATE THE SAFETY HANDLE BAG.
2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD.
3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
#14 X 1-1/4" PAN HEAD SCREW
1/4" WASHER
SAFETY HANDLES
77
STEP 44: FLAG KIT
1: PLACE A FLAG ON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED.
FLAG 1/2" PHILLIPS HEAD SCREW
78
STEP 45: SANDBOX SEATS AND NAME PLATE
1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET. ATTACH THE NAME PLATE TO THE FRONT OF THE SWING BEAM WITH #8 X 1" WOOD SCREWS.
PLACE NAME PLATE HERE AND ATTACH WITH #8 X 1" WOOD SCREWS
A
5/4 X 6 X 22" SANDBOX SEAT
5/4 X 6 X 22" SANDBOX SEAT
#8 X 2" WOOD SCREW
79
STEP 46: PLASTIC SUNBURST
1: LOCATE TWO PLASTIC SUNBURST PIECES. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2" WOOD SCREWS. 4: REPEAT SUBTEPS 2 AND 3 ON THE OTHER SIDE OF THE PLAY SET.
#8 X 2" WOOD SCREWS (6 IN THE SIDES)
#8 X 2-1/2" WOOD SCREWS (2 IN TRIANGLE PORTION)
PLASTIC SUNBURST
PLASTIC SUNBURST ROOF SUPPORTS
80
STEP 47: GROUND STAKES
1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE AGAINST THE SWING LEG. FINALLY INSTALL THE SCREW AND WASHER. 2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #14 X 2" PAN HEAD SCREW AND A 1/4" FENDER WASHER PROVIDED WITH THE GROUND STAKE.
DETAIL A SCALE 1 : 6
1/4" FENDER WASHER #14 x 2" PAN HEAD SCREW GROUND STAKE
A 81
STEP 48: STEERING WHEEL
1: GO TO THE REAR CENTER POST ON THE DECK.
2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP.
3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL.
4: USE THE 2-1/2" LAG SCREW AND WASHER TO FASTEN THE STEERING WHEEL TO THE REAR CENTER POST. DO NOT OVER-TIGHTEN THE LAG SCREW OR THE STEERING WHEEL WILL NOT TURN.
5: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL AND SNAP IT INTO THE STEERING WHEEL INSERT.
STEERING WHEEL INSERT
WASHER
STEERING WHEEL
2-1/2" LAG SCREW
DRILL 3/16" HOLE 1" BELOW THE T-NUT.
T-NUT
STEERING WHEEL CAP
82
APPENDIX
83
Chimney and Dormers
Hardware Kit
8/10/2015 JH
9
#8 X 2-1/2"
WOOD SCREW QTY: 2
8
#8 X 2"
WOOD SCREW QTY: 4
7
#8 X 1-1/2"
WOOD SCREW
QTY: 14
6
#8 X 1-1/4
WOOD SCREW
QTY: 6
5
4
3 #2 SQUARE
DRIVE BIT QTY: 1 2
1
USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
PICTURE
DESCRIPTION QTY.
CHIMNEY LEFT SIDE
1
ASSEMBLY
CHIMNEY RIGHT SIDE
1
ASSEMBLY
CHIMNEY FRONT
ASSEMBLY
1
PICTURE
DESCRIPTION QTY.
CHIMNEY REAR
1
ASSEMBLY
5/4X3X6-3/4" CHIMNEY MOUNTING
1
BLOCK
DORMER LEFT SIDE ASSEMBLY
2
PICTURE
DESCRIPTION QTY.
PLASTIC DORMER
2
SUNBURST
(07-0031)
DORMER RIGHT SIDE
2
ASSEMBLY
STEP 1: DORMER
1: OVERLAP THE LEFT DORMER SIDE ONTO THE PEAK SUPPORT OF THE RIGHT DORMER SIDE. 2: MAKE SURE THE FRONT ROOF EDGES ARE FLUSH TO ONE ANOTHER 3: FASTEN THE LEFT DORMER SIDE TO THE PEAK SUPPORT WITH #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1-3 TO CONSTRUCT ANOTHER ROOF ASSEMBLY.
#8 X 1-1/2" WOOD SCREW
DORMER ROOF (LEFT SIDE)
DORMER ROOF (RIGHT SIDE)
COMPLETED ROOF
ASSEMBLY FRONT ROOF EDGES FLUSH TO ONE ANOTHER HERE. (FRONT FACE SUPPORTS) THE BACK OF THE PLASTIC DORMER SUNBURST WILL SIT AGAINST THESE IN THE NEXT STEP.
BOTTOM VIEW
STEP 2: DORMER
1: PLACE THE PLASTIC DORMER SUNBURST AGAINST THE FRONT FACE SUPPORT ON THE LEFT AND RIGHT ROOF SIDES. 2: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION. 3: INSTALL #8 X 1/2" PAN HEAD SCREWS TO FASTEN THE SUNBURST TO THE ROOF SIDES. REPEAT SUBSTEPS 1 THROUGH 3 TO CONSTRUCT THE SECOND DORMER.
PREDRILL 7/64" HOLES X 1/2" DEEP AT EACH HOLE LOCATION ON BOTH SIDES OF THE PLASTIC SUNBURST. INSTALL A #8 X 1/2" PAN HEAD SCREW AT EACH HOLE LOCATION.
DETAIL A SCALE 1 : 3
#8 X 1/2" PAN HEAD SCREW (6 REQUIRED PER PLASTIC SUNBURST) PLASTIC DORMER SUNBURST
A
STEP 3: DORMER
1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: FOR 1500 SERIES UNITS LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 8TH ROOF BOARD. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF. 4: ATTACH THE DORMER TO THE ROOF WITH ONE #8 X 2-1/2" WOOD SCREW AT THE REAR PEAK OF THE ROOF. ATTACH THE DORMER SUNBURST TO THE ROOF WITH TWO #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1 THROUGH 4 FOR THE DORMER ON THE OTHER SIDE OF THE ROOF.
DORMER
#8 x 2-1/2" WOOD SCREW
DORMER
#8 x 1-1/2" WOOD SCREWS
THE UNIT SHOWN ABOVE MAY NOT BE YOUR EXACT PLAY SET. SHOWN FOR ILLUSTRATION PURPOSES ONLY.
STEP 4: CHIMNEY
1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW.
USE A 2" WOOD SCREW IN THIS LOCATION
CHIMNEY LEFT SIDE
CHIMNEY FRONT
1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY. 2: ATTACH THE REAR AND RIGHT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW.
USE A 2" WOOD SCREW IN THIS LOCATION
CHIMNEY REAR CHIMNEY RIGHT SIDE
STEP 5: CHIMNEY
1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS.
USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE)
USE 1-1/4" WOOD SCREWS IN THIS LOCATION (EACH SIDE)
STEP 6: CHIMNEY
1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH #8 X 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE FOR A SUGGESTED PLACE TO MOUNT THE CHIMNEY. 2: AFTER INSTALLING THE CHIMNEY MOUNTING BLOCK PLACE THE CHIMNEY ASSEMBLY ON THE ROOF SO THAT THE INSIDE OF THE BACK WALL RESTS AGAINST THE BLOCK. 3: FASTEN THE CHIMNEY TO THE CHIMNEY MOUNTING BLOCK WITH A #8 X 1-1/2" WOOD SCREW IN EACH SIDE.
CHIMNEY #8 X 1-1/2" WOOD SCREWS
BACK WALL OF CHIMNEY #8 X 1-1/2" WOOD SCREW (1 ON EACH SIDE)
CHIMNEY MOUNTING BLOCK 5/4 X 3 X 6-3/4"
THE ABOVE UNIT MAY NOT BE YOUR EXACT PLAY SET. SHOWN FOR ILLUSTRATION PURPOSES ONLY.
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