Gorilla Playsets 1500AWCR Manual Download Page 35

Page: 35 / 136

Models: 1500AWR

1500AWCR

(BOXES: 1501, 1507, 1518*

1528, 1529 & Slide Box

*1518 only included with

1500AWCR Clubhouse model

REV: 1.13.2016

Amber Post Option

BOXES: 1533-2bx, 1522

Timber Shield Post Option

BOXES: X1, 120

Model 1500AWR shown.

See cover of manual for the

image of your model when it is

completed.

Summary of Contents for 1500AWCR

Page 1: ... Industrial Court Canton GA 30114 www gorillaplaysets com Malibu Clubhouse Model 1500AWCR BOXES 1501 1507 1518 1528 1529 Slide Box Amber Post Option BOXES 1533 2bx 1522 Timber Shield Post Option BOXES X1 120 51 0072 W 51 0072 W playsets playsets playsets playsets ...

Page 2: ...hat 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 INSTRUC TIONS AT www gorillaplaysets com manu...

Page 3: ...nstructions 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...

Page 4: ...ts 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 s...

Page 5: ...__________________ Address __________________________________________________________________________________________________ Comments ________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ___________________________________________________________...

Page 6: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 7: ...ain 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 sm...

Page 8: ... 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 en...

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Page 10: ...instruction manual 3 DO NOT install the Sandbox Seats in Step 45 Side to Side Wood Roof Step 53 Front to Back Wood Roof or Step 43 Tarp Roof of the main instruction manual 4 DO install the Clubhouse Walls after the entire play set structure is completed 5 DO NOT build the picnic table until after the clubhouse walls are installed The 1500 play set series is modular Because of this some parts will ...

Page 11: ...8 9 1 4 3 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 5 16 X 4 1 2 HEX BOLT QTY 4 2 SQUARE DRIVE TIP QTY 1 3 8 x 1 1 8 BLACK PLASTIC PLUG QTY 2 11 0054 1518 HARDWARE PAGE 1 OF 1 REV C 3 24 2014 JH 5 16 x 3 1 2 LAG SCREW QTY 12 ...

Page 12: ...W BRACE 1 X 4 X 9 1 X 3 X 34 3 4 1 4 0900 TBW 3 1 4 0998 OWTB3 TOP BOARD 125 6 2825 PS 7 1 X 3 X 18 PANEL SLAT 5 4 X 6 X 28 1 4 1 3 1800 WTB 1 1 X 3 X 29 7 8 BOARD WINDOW TOP 1 3 2988 OWOS 1 1 1 3 4050 PBB WINDOW BOTTOM BOARD 2 1 X 3 X 40 1 2 1 X 4 X 9 31 32 OPEN WINDOW TOP BOARD 3 2 ...

Page 13: ... 2 OPEN WINDOW 1 6 1360 OWTB1 1 X 4 X 27 3 4 1 4 2950 OWB BOTTOM WINDOW BOARD OPEN WINDOW 1 4 5100 WB BOARD 1 5 1 X 4 X 29 1 2 1 6 0843 TBD2 1 X 4 X 51 WALL BOARD 6 1 X 6 X 8 7 16 1 6 1020 TBD1 TOP BOARD DOOR 2 2 1 X 6 X 10 3 16 1 6 1118 OWTB2 1 X 6 X 13 5 8 OPEN WINDOW TOP BOARD 1 2 ...

Page 14: ...H TOP 1 X 6 X 27 1 6 2775 BBOW 4 OPEN WINDOW BOTTOM BOARD 1 X 6 X 27 3 4 1 6 3400 TBW 1 WINDOW TOP BOARD 1 6 5100 WB 11 WALL BOARD 1 X 6 X 51 1 X 6 X 34 2 4 4750 TPB 1 BOARD TOP PANEL 2 X 4 X 47 1 2 2 4 7000 BWB 2 2 X 6 X 70 BOTTOM PANEL BOARD DOOR 1 DESCRIPTION PICTURE QTY ...

Page 15: ...DESCRIPTION PICTURE QTY 1 1 11 0054 WINDOW 07 0013 1518 HARDWARE NOT SHOWN ...

Page 16: ...SE WALL 2 REMOVE THE SCREWS THAT CONNECT THE PICNIC TABLE SUPPORTS TO THE CORNER POSTS 3 SET THE PICNIC TABLE ASSEMBLY AND SCREWS ASIDE IN CASE YOU WISH TO REINSTALL THE PICNIC TABLE ON THE OTHER SIDE OF THE FORT LATER 4 PLACE CLEAR SILICONE IN THE SCREW HOLES IN THE CORNER POSTS PICNIC TABLE ...

Page 17: ...1 REMOVE THE TWO SANDBOX SEAT BOARDS TO ATTACH THE WALL BOARDS STEP 2 REMOVING SANDBOX SEATS SANDBOX SEAT ...

Page 18: ...O ANGLE SUPPORTS AT THE FRONT 3 AFTER YOU INSTALL ALL THE CLUBHOUSE WALLS PUT THE ANGLE SUPPORTS BACK ON IT IS A GOOD IDEA TO LEAVE SCREWS IN THE ANGLE SUPPORTS AND TO NUMBER THEM AND THEIR LOCATION FOR LATER 4 PLACE CLEAR SILICONE IN THE SCREW HOLES IN THE CORNER POSTS FOR THE ANGLE SUPPORTS AT THE LEFT AND RIGHT SIDES OF THE SET ...

Page 19: ...E TWO 5 16 X 3 1 2 LAG SCREWS AND TWO 5 16 WASHERS TO ATTACH IT TO CORNER POSTS 3 DAB SOME SILICONE ON THE PLASTIC PLUGS AND PLACE THE PLASTIC PLUGS IN THE HOLES LEFT FROM REMOVING THE SAFETY BOARD IN THE CORNER POSTS SAFETY BOARD SAFETY BOARD 5 16 X 3 1 2 5 16 WASHER LAG SCREW 2 X 6 X 47 1 2 BOTTOM BOARD PLASTIC PLUG A ...

Page 20: ...HE POSTS 3 PLACE THE 2 X 4 X 70 BOTTOM WALL BOARD FLUSH WITH 2 X 6 BOTTOM BOARD USE TWO DOOR WITH CUT NOTCH UP USE 5 16 X 4 1 2 HEX BOLTS ON THE TOP HOLES 5 16 X 3 1 2 LAG SCREWS ON BOTTOM HOLES AND 5 16 WASHERS TO ATTACH IT TO THE POSTS 2 X 6 X 70 BOTTOM BOARD 2 X 4 X 70 BOTTOM WALL BOARD 2 X 6 X 70 BOTTOM PANEL BOARD DOOR STEP 5 BACK SANDBOX BOARD AND BOTTOM BOARD 1 REMOVE THE SANDBOX BOARD ON T...

Page 21: ...DER SIDE OF THE FORT MAKE THE TOP PANEL BOARD FLUSH WITH 2 X 6 BOTTOM BOARD 2 USE 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS TO ATTACH THE TOP PANEL BOARD TO THE CORNER POSTS LAG SCREW 5 16 WASHER 5 16 X 3 1 2 2 X 6 X 47 1 2 BOTTOM BOARD 2 X 4 X 47 1 2 TOP PANEL BOARD OFFSET DOWN ...

Page 22: ... 51 WALL BOARDS WITH PRE DRILLED HOLES 2 PLACE WALL BOARDS ON THE SWING BEAM SIDE OF THE FORT AGAINST THE TOP SAFETY BOARD AND SANDBOX BOARD AS SHOWN BELOW THE BOTTOM OF THE WALL BOARDS SHOULD BE 1 1 2 ABOVE THE BOTTOM OF THE SANDBOX BOARD 3 USE 8 X 1 3 4 WOOD SCREWS LEAVING 1 4 SPACES BETWEEN THE WALL BOARDS TO ATTACH THEM TO THE SAFETY BOARD AND SANDBOX BOARD 8 X 1 3 4 WOOD SCREW ...

Page 23: ... BRACE 1 PLACE THE 1 X 3 X 40 1 2 PANEL BOARD BRACE AT THE CENTER OF THE WALL BOARDS YOU ATTACHED TO THE SWING BEAM SIDE FASTEN IT TO THE WALL BOARDS WITH 8 X 1 1 4 WOOD SCREWS BRACE PANEL BOARD 1 X 3 X 40 1 2 8 X 1 1 4 WOOD SCREW ...

Page 24: ...OM PANEL BOARD DOOR 2 14 1 11 1 2 STEP 9 REAR WALL BOARDS 1 PLACE WALL BOARDS ON THE REAR SIDE OF THE FORT AGAINST THE BOTTOM PANEL BOARD DOOR AND BOTTOM PANEL BOARD AS SHOWN BELOW THE BOTTOM OF THE WALL PANEL BOARDS SHOULD BE 1 1 2 ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD DOOR THE OPENING DIMENSIONS FOR ATTACHING THE WINDOWS IN NEXT STEP ARE SHOWN BELOW 2 USE 8 X 1 3 4 WOOD SCREWS LEAVING 1 4 S...

Page 25: ...DOW 1 FIND THE PLASTIC WINDOW PLACE WINDOW AT THE REAR OF THE FORT IN THE OPENING THE 1 WIDE SECTION OF THE WINDOW FRAME SHOULD BE AT THE TOP ATTACH THE WINDOW WITH FOUR 1 1 4 WOOD SCREWS WINDOW 1 WIDE SECTION AT THE TOP ...

Page 26: ...1 PLACE THE 1 X 3 X 34 3 4 BOTTOM BOARD WINDOW FLUSH WITH BOTTOM OF THE WINDOW FASTEN WITH 8 X 1 1 4 WOOD SCREWS 2 PLACE THE 1 X 3 X 18 TOP BOARD WINDOW FLUSH WITH TOP OF THE WINDOW FASTEN WITH 8 X 1 1 4 WOOD SCREWS 3 PLACE THE 1 X 6 X 27 ARCH TOP BOARD DOOR FLUSH WITH THE BOTTOM OF THE TOP DOOR BOARD 2 AND TOP DOOR BOARD 1 FASTEN WITH 8 X 1 1 4 WOOD SCREWS ...

Page 27: ... X 1 3 4 WOOD SCREWS LEAVING A 1 4 SPACE BETWEEN THE BOARDS NOTE SWING BEAM WALL REMOVED FOR CLARITY 8 x 1 3 4 WOOD SCREW OPEN WINDOW TWO BOARDS TOP BOARD 2 1 x 6 x 11 1 8 TWO BOARDS 1 X 6 X 51 WALL BOARD TWO BOARDS TWO BOARDS TOP BOARD 3 OPEN WINDOW 1 x 4 x 10 TOP BOARD 1 OPEN WINDOW 2 X 6 X 79 1 2 ROPE LADDER RUNNER 1 x 6 x 13 5 8 1 X 6 X 27 3 4 BOTTOM BOARD OPEN WINDOW FOUR BOARDS 1 X 4 X 27 3 ...

Page 28: ...ARD OPEN WINDOW OPEN WINDOW TOP BOARDS STEP 13 PANEL BOARD BRACE AND BOARD WINDOW 1 PLACE THE 1 X 3 X 40 1 2 PANEL BOARD BRACE FLUSH WITH BOTTOM BOARD OPEN WINDOWS FASTEN WITH 8 X 1 1 4 WOOD SCREWS 2 PLACE THE 1 X 6 X 34 TOP BOARD WINDOW FLUSH WITH OPEN WINDOW TOP BOARDS FASTEN WITH 8 X 1 1 4 WOOD SCREWS ...

Page 29: ...NDOW 1 X 3 X 29 7 8 BOTTOM BOARD OPEN WINDOW STEP 14 OPEN WINDOW OUTSIDE SUPPORT 1 PLACE THE 1 X 3 X 29 7 8 OPEN WINDOW OUTSIDE SUPPORT ON THE OUTSIDE OF THE RIGHT WALL BOARDS FLUSH THE SUPPORT WITH THE TOP OF THE BOTTOM BOARD OPEN WINDOWS FASTEN WITH 8 X 1 1 4 WOOD SCREWS ...

Page 30: ... WOOD SCREW FLUSH 1 X 4 X 29 1 2 OPEN WINDOW PANEL BOARD BRACE STEP 15 OPEN WINDOW BOARD 1 PLACE THE 1 X 4 X 29 1 2 OPEN WINDOW BOARD ON TOP FLUSH TO INSIDE OF THE PANEL BOARD BRACE FASTEN WITH 8 X 1 3 4 WOOD SCREWS A ...

Page 31: ...F THE 2 X 4 X 70 BOTTOM WALL BOARD SHOULD BE 30 3 8 FROM THE BOTTOM OF THE 2 X 6 X 70 SANDBOX BOARD 2 FASTEN THE 2 X 4 X 70 BOTTOM WALL BOARD TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS 5 16 X 3 1 2 LAG SCREW BOARD 5 16 WASHER BOTTOM WALL 2 X 4 X 70 2 X 6 X 70 SANDBOX BOARD 30 3 8 ...

Page 32: ... X 28 1 4 PANEL SLATS 2 INSTALL THE PANEL SLATS AT EQUAL LENGTHS SEE DETAIL BELOW FOR MEASUREMENTS 3 ATTACH THE PANEL SLATS TO THE FORT WITH 2 WOOD SCREWS IN THE PRE DRILLED HOLES 8 X 2 WOOD SCREW 5 4 X 6 X 28 1 4 PANEL SLAT 8 1 4 1 3 3 1 1 2 ...

Page 33: ...ANGLE SUPPORT STEP 18 ANGLE SUPPORTS 1 REPLACE THE ANGLE SUPPORTS YOU REMOVED IN STEP 3 2 REFER TO STEP 6B IN THE MAIN MANUAL IF YOU DID NOT MARK YOUR ANGLE SUPPORTS IN STEP 3 OF THIS MANUAL ...

Page 34: ...TACH THE PICNIC TABLE SUPPORTS TO THE LEFT CORNER POSTS WITH THE SCREWS REMOVED IN STEP 1 IF THIS IS THE FIRST TIME INSTALLING THE PICNIC TABLE THEN REFER TO THE MAIN PART OF THE MANUAL STEP 34 TARP ROOF OR STEP 39 WOOD ROOF FOR DIMENSIONS INSTALL WITH 3 WOOD SCREWS ON THE LEFT SIDE OF THE UNIT AS SHOWN BELOW ...

Page 35: ...528 1529 Slide Box 1518 only included with 1500AWCR Clubhouse model REV 1 13 2016 Amber Post Option BOXES 1533 2bx 1522 Timber Shield Post Option BOXES X1 120 Model 1500AWR shown See cover of manual for the image of your model when it is completed ...

Page 36: ...at and Roof Support Installation Steps 18 20 Swing Beam Assembly Steps 21 28 Roof Assembly Steps 29 33 Front Gable Assembly Installation Steps 34 35 Front Wall Assembly and Completion of Main Roof Steps 36 40 Hanging Swings and Safety Board Steps 41 42 Picnic Table Assembly and Installation Steps 43 45 Rope Ladder Assembly Installation Step 46 Climbing Rope and Slide Steps 47 48 Tic Tac Toe Assemb...

Page 37: ... 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 ...

Page 38: ...f 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 repa...

Page 39: ...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 9 in depth 12 in depth Double Shredded bark mulch 6 Fall Height 10 Fall Height 11 Fall Height Wood Chips 6 Fall Height 7 Fall Height 12 Fall Height Fine Sand 5 Fall Height 5 Fall Height 9 Fall Height Shredded Tires 1...

Page 40: ...ore 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 s...

Page 41: ... 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 elim...

Page 42: ...ts 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 wil...

Page 43: ...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 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...

Page 44: ...IRST 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 IN...

Page 45: ...art 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 the...

Page 46: ...e 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 Example 3 8 diameter x 5 lag screw This would be like the 4 x 4 board installation shown below Place the LAG SCREW DIAMETER DRILL BIT SIZE 5 16 DIAMETER 9 64 3 8 DIAMETER 11 64 Pre drilling holes for lag s...

Page 47: ...ar 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 SWINGING WEIGHT TRAPEZE BAR REV A 8 29 2012 125 LBS MAX 150 LBS MAX SWINGING WEIGHT 150 LBS MAX SWINGING WEIGHT SWING BELT SWING B...

Page 48: ...ponents and general construction process of your new playset before getting started SITE PLAN Playset height 12 feet 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 Trapeze 1 Wave Slide Ladder Swing Belts 2 Rock Wall Rope Ladder 14 ...

Page 49: ...king Tape or Marker See Step 46 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 Solar Wall Light ___ 1 Front Plastic Arch 07 0027 G ___ 2 Plastic Sunburst 07 0028 G ___ 2 Plastic Dormer Window 07 0029 G ___ 1 Logo Plate ___ 1 Ground...

Page 50: ... WASHER QTY 34 3 8 WASHER QTY 31 5 16 X 1 1 2 HEX BOLT QTY 8 5 16 X 4 1 2 HEX BOLT QTY 14 9 1 4 3 2 5 6 7 8 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 14 X 1 1 4 PAN HEAD SCREW QTY 4 TORQUE WASHER QTY 17 8 X 2 1 2 WOOD SCREW QTY 52 5 16 TEE NUT QTY 22 8 X 2 WOOD SCREW QTY 189 16 ...

Page 51: ...AN BE USED TO MATCH BOLT AND SCREW SIZES 5 16 X 3 1 2 3 8 x 9 CARRIAGE BOLT QTY 1 QTY 12 SCREW HEX LAG QTY 1 DRIVE BIT 2 SQUARE 1501 HARDWARE PAGE 2 OF 2 REV A 9 10 2014 JH 3 8 x 6 1 2 CARRIAGE BOLT QTY 2 3 8 x 3 1 2 CARRIAGE BOLT QTY 2 3 8 X 3 1 2 HEX LAG SCREW QTY 12 PLASTIC BOLT CAP QTY 19 3 8 x 7 CARRIAGE BOLT QTY 14 17 ...

Page 52: ...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 8 X 2 WOOD SCREW QTY 20 5 16 TEE NUT QTY 12 5 16 X 4 1 2 HEX BOLT QTY 12 1507 HARDWARE PAGE 1 OF 1 PRELIMINARY 9 18 2012 J H 5 16 WASHER QTY 25 18 ...

Page 53: ...AGE 1 OF 1 1 16 2015 SO 2 SQUARE DRIVE BIT QTY 1 5 16 X 2 1 2 HEX BOLT QTY 2 8 9 1 4 3 2 5 6 7 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 8 X 2 WOOD SCREW QTY 25 8 X 2 1 2 WOOD SCREW QTY 12 5 16 WASHER QTY 12 8 X 1 1 2 WOOD SCREW QTY 110 19 ...

Page 54: ... STEP 2 4 1700 LS 5 2 X 4 X 27 1 2 PICNIC TABLE SEAT SUPPORT 2 4 2750 PTTS 2 2 X 4 X 24 ROPE LADDER STEP 2 4 2400 RLST 6 2 X 4 X 13 ANGLE SUPPORT 2 4 1300 AS 2 X 4 X 18 ANGLE SUPPORT 2 4 1800 AS 4 4 1 RIGHT 1 LEFT 2 X 4 X 22 75 WALL PANEL SUPPORT 1 HOLES ON CENTER 2 4 2275 WPSL 2 4 2275 WPSR PICTURE DESCRIPTION QTY 20 ...

Page 55: ...50 PTL 2 X 4 X 66 ROCK WALL SIDE 1 HOLE ON CENTER 2 4 6600 RWS 1 LEFT 1 RIGHT 2 2 X 4 X 66 LADDER SIDE 2 4 6600 LLS 2 4 6600 LRS 1 2 X 4 X 58 SWING BEAM CROSS MEMBER 2 HOLES ON CENTER 2 4 5800 CM 2 LEFT 2 RIGHT 2 X 4 X 35 15 ROOF SUPPORT 1 HOLE OFFSET 2 4 3515 RSL 2 4 3515 RSR 2 2 X 4 X 28 9 16 CENTER POST FRONT REAR 2 4 2856 CPFR 21 ...

Page 56: ...X 70 BOTTOM PANEL AND SANDBOX BOARD 4 HOLES OFFSET 2 6 7000 SB 1 2 X 6 X 70 FRONT FACE BOARD 4 HOLES OFFSET 2 6 7000 FFB 1 3 2 X 6 X 47 1 2 BOTTOM PANEL AND SANDBOX BOARD 4 HOLES OFFSET 2 6 4750 ESPB 1 2 X 4 X 70 CENTER DECK SUPPORT 2 4 7000 CDS PICTURE DESCRIPTION QTY 2 X 4 X 69 75 ROOF FINISHER SUPPORT 2 HOLES ON CENTER 2 4 6975 RFS 22 ...

Page 57: ... 6 7950 RLS 1 2 X 6 X 79 1 2 ROPE LADDER RUNNER 4 HOLES OFFSET 3 HOLES ON CENTER 2 6 7950 RLR 1 1 1 2 X 6 X 70 FRONT TOP PANEL BOARD 4 HOLES OFFSET 1 CENTER 2 6 7000 FTPB 5 X 11 X 46 97 ROOF PANEL RIGHT ASSEMBLY 5 11 4697 RPRA 1 2 5 4 X 2 5 8 X 13 1 4 PICNIC TABLE SLAT 125 3 1325 PTS 5 X 11 X 46 97 ROOF PANEL LEFT ASSEMBLY 5 11 4697 RPLA 23 ...

Page 58: ...NT 125 3 1750 TTTM 1 1 5 4 X 5 X 10 81 ROOF PANEL PEAK SUPPORT 125 5 1081 RPPS 5 4 X 3 X 18 3 4 LADDER BACK 125 3 1875 LB 2 5 4 X 6 X 10 ROOF PEAK SUPPORT 125 6 1000 RPS 1 5 4 X 3 X 23 7 8 ROCK WALL CAP 125 3 2387 RWC 2 5 4 X 4 X 40 3 8 DECK SPACER 125 4 4038 DS PICTURE DESCRIPTION QTY 24 ...

Page 59: ... 5 4 X 6 X 23 7 8 ROCK WALL BOARD 125 6 2387 RWB 11 5 4 X 6 X 22 SANDBOX SEAT 125 6 2200 SS 2 4 5 4 X 6 X 43 PICNIC TABLE TOP AND SEATS 125 6 4300 PTTS 11 5 4 X 6 X 47 3 8 DECK BOARD 125 6 4737 DB 1 X 2 X 32 ROOF BATTEN 1 2 3200 RB 2 1 X 4 X 8 3 4 WALL PANEL BOARD 1 4 0875 WPB 2 25 ...

Page 60: ... X 76 7 8 TONGUE ONLY ROOF FINISHER REAR 1 4 7688 RFR 1 1 RIGHT 1 LEFT 1 X 4 X 29 29 TONGUE ONLY ROOF FINISHER FRONT 1 4 2929 RFF 2 2 1 X 4 X 15 3 4 WALL PANEL BOARD 1 4 1575 WPB 1 X 4 X 19 5 16 WALL PANEL BOARD 1 4 1931 WPB 2 1 X 4 X 76 7 8 GROOVE ONLY ROOF STARTER REAR 1 4 7688 RSR 1 PICTURE DESCRIPTION QTY 26 ...

Page 61: ...TED 4 X 4 X 108 CORNER POST 2 PLASTIC COATED 4 X 4 X 108 SWING BEAM LEG SL 1 14 1 X 5 X 76 7 8 TONGUE AND GROOVE ROOF BOARD 1 5 7688 RB 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 27 ...

Page 62: ...1 04 0006 WAVE 03 0013 04 0002 BAR W CHAINS 1 3 SLIDE TRAPEZE SWINGS W CHAINS 2 13 ROPE LADDER ROPES DESCRIPTION PICTURE QTY 28 ...

Page 63: ...DESCRIPTION PICTURE QTY SWING 1 10 11 5002 1 PLATE ROCKS CLIMBING ROCKS 07 0008 EA 1 IS A PACK OF 5 A FRAME SWING LEG BRACKET 11 5010 HARDWARE BOXES HARDWARE BOXES 1501 1507 1528 29 ...

Page 64: ...ROPE DUCTILE SWING TELESCOPE 07 0001 11 4012 HANGERS IRON 10 ROCK WALL 6 DESCRIPTION PICTURE QTY 1 1 30 ...

Page 65: ...DESCRIPTION PICTURE QTY 07 0005 SPRING CLIP 6 11 5013 BRACKET GREEN 11 4003 4 PAIR 90 SAFETY HANDLES 1pr 31 ...

Page 66: ...DESCRIPTION PICTURE QTY 09 2003 2 DORMER WINDOW 07 0028 G 1 SUNBURST PLASTIC 07 0027 G PLASTIC ARCH FRONT 2 07 0029 G PLASTIC SOLAR WALL LIGHT 2 32 ...

Page 67: ...ICTURE QTY PAIR NOT SHOWN 2 LOGO PLATE 1 MANUFACTURER 07 0016 P 1 1 WHEEL 1 STAKE 07 0004 STEERING 1 TIC TAC TOE 07 0010 pr GROUND UNASSEMBLED UNASSEMBLED DORMER 1529 BOX UNASSEMBLED CHIMNEY 1529 BOX OR SLIDE BOX 33 ...

Page 68: ...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 108 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 INT...

Page 69: ... 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 ...

Page 70: ...N 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 COUNTER SUNK HOLES IN THE MIDDLE OF THE SWIN...

Page 71: ...HOLES ON CENTER 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 37 ...

Page 72: ...ARD 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 ...

Page 73: ...UST 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 T...

Page 74: ...D 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 FRAME FRONT OF FORT...

Page 75: ...NDER 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 BOTTOM DETAIL A SCALE 1 9 BOARD PANEL ANGLE 2 X 4 X 13 SUPP...

Page 76: ...SUNK HOLES FRONT OF FORT 1 PLACE THE 2 X 4 X 47 1 2 BOTTOM 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 STEP 7 BOTTOM PANEL BOARDS 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 42 ...

Page 77: ...SEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET REMOVE THE SCREWS ON ONE SIDE OF EACH DECK SPACER 2 ALLOW THE DECK BOARDS TO DROP DOWN IN BETWEEN THE FRONT FACE BOARD AND BOTTOM PANEL BOARD 3 TIGHTEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET 4 RE INSTALL THE SCREWS IN THE DECK SPACERS THEN INSTALL THE DECK BOARDS AS INDICATED IN THE INSTRUCTIONS LEFT SIDE BOARDS RIGHT...

Page 78: ... 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 5 4 X 4 X 40 3 8 DECK SPACER 2 WOOD SCREW 2 X 4 X 14 BOTTOM PANEL BOARDS REMOVED FROM VIEW FOR CLARITY 44 ...

Page 79: ...S USE THE HOLE ON CENTER AS A GUIDE AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE 3 USE 2 WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT 4 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 5 USING TWO 2 1 2 WOOD SCREWS INSTALL THE 2 X 4 X 70 CENTER DECK SUPPORT THROUGH THE...

Page 80: ...OOD SCREWS THROUGH THE DECK BOARD 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 5 4 X 6 X 47 3 8 2 WOOD SCREW 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 46 ...

Page 81: ... NUT 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 47 ...

Page 82: ... 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 HEL...

Page 83: ...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 A 5 16 WASHER GREEN BRACKET 90 5 16 X 1 1 2 HEX BOLT 49 ...

Page 84: ...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 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 ROCK WALL TOP CAP 5 4 X 3 X 23 7 8 2 WOOD ...

Page 85: ...LY 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 ON THE BOTTOM PANEL 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 WASHER 5 16 X 1 1 2 HEX BOLT INSERT T NUT BEH...

Page 86: ...LY TURN THE LADDER OVER AND OTHER AND ARE PARALLEL 5 PLACE THE STEPS INTO THE SLOTS ON THE PUT THE SCREWS INTO THE OTHER SIDE LADDER SIDES AND SET WITH A HAMMER OF THE OUTSIDE 3 INSERT T NUTS INTO THE 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 4 FIND FIVE 2 X 4 X 17 LADDER STEPS 7 INSTALL THE 90 8 INSTALL THE 5 4 X 3 X 18 3 4 LADD...

Page 87: ...ERSIDE 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 THE 2 X 6 ON BOTH SIDES HEX BOLT 5 16 WASHER INSERT A T NUT BEHIND 5 16 X 1 1 2 RIGHT SIDE OF FORT 3 4 53 ...

Page 88: ...INE 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 5 16 T NUT CENTER POST FRONT REAR 5 16 WASHER DETAIL A SCALE 1 8 RAILING 5 16 X 2 1 2 HEX BOLT 8 X 2 ...

Page 89: ...HE PANEL SLATS TO THE FORT WITH 2 WOOD SCREWS IN THE PRE DRILLED HOLES STEP 19 PANEL SLATS 2 PRE DRILL THE SLATS 1 FROM EACH END ON CENTER WITH A 1 8 DRILL BIT PANEL SLAT DIMENSIONS LADDER SIDE PANEL SLAT DIMENSIONS BACK WALL PANEL SLAT DIMENSIONS 2 3 4 2 3 4 5 4 X 2 5 8 X 28 1 4 PANEL SLAT SCREW 2 WOOD SWING BEAM SIDE LADDER SIDE 1 BOTH SIDES 2 3 4 2 5 8 2 16 9 11 17 8 1 2 1 2 1 8 55 ...

Page 90: ...OOF SUPPORT RIGHT SIDE 5 16 X 4 1 2 HEX BOLT STEP 20 ROOF SUPPORTS 1 WITH OFFSET HOLES DOWN ATTACH THE 2 X 4 X 35 15 ROOF SUPPORTS TO THE FORT WITH 5 16 X 4 1 2 HEX BOLTS THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE 2 CONNECT THE ENDS WITH A 2 1 2 WOOD SCREW 56 ...

Page 91: ...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 BOLT 3 8 x 3 1 2 CARRIAGE SWING BEAM PLATE 3 8 NUT 3 8 WASHER BOLT CAP 57 ...

Page 92: ...M 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 BOLT CAPS 7 CARRIAGE BOLT TORQUE WASHER 3 8 WASHER 3 8 LOCK NUT IRON DUCTILE SWING HANGER 58 ...

Page 93: ...LUSH TO TOP OF SWING LEG BRACKET 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 4 X 4 X 108 SWING LEG 59 ...

Page 94: ...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 60 ...

Page 95: ... 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 BOLT CAP 7 CARRIAGE BOLT TORQUE WASHER 3 8 WASHER 3 8 LOCK NUT 3 8 X 3 1 2 LAG SCREW 61 ...

Page 96: ... 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...

Page 97: ...GER 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 OUT 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 63 ...

Page 98: ...SS 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 64 ...

Page 99: ...E THE 5 4 X 6 X 10 ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 2 WOOD SCREWS REPEAT ON OTHER SIDE 2 WOOD SCREW 65 ...

Page 100: ...TER SHOULD 1 PLACE THE 1 X 4 X 76 7 8 ROOF STARTER REAR BOARD AT THE PEAK OF THE ROOF THE HOLES IN THE ROOF THE ROOF STARTER WILL EITHER BE CENTERED ON THE ROOF SUPPORTS OR THEY WILL BE OFFSET EXAMPLE 76 7 8 MINUS 72 75 EQUALS 4 125 THE ROOF NUMBER ON EACH SIDE TO KEEP YOUR ROOF SUPPORTS PARALLEL DIVIDE THIS NUMBER BY 2 THIS WILL GIVE YOU THE OVERHANG FOR EACH SIDE USE THE OVERHANG TOWARDS THE INS...

Page 101: ...R THIS SIDE OF THE ROOF GETS SEVEN ROOF BOARDS 2 FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS 3 PLACE THE 1 X 4 X 76 7 8 ROOF FINISHER AT THE END OF THE ROOF ASSEMBLY AND FASTEN WITH 1 1 2 WOOD SCREWS 4 MOUNT THE 2 X 4 X 69 3 4 ROOF FINISHER SUPPORT UNDERNEATH THE ROOF UP AGAINST THE ROOF FINISHER REAR AND ATTACH TO THE REAR CORNER POST USING 5 16 LAG SCREWS AND 5 16 WASHERS ...

Page 102: ...TEN THE ROOF STARTER FRONT TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS 3 PLACE THE 1 X 5 X 76 7 8 ROOF BOARDS ON TOP OF THE ROOF SUPPORTS FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR THIS SIDE OF THE ROOF GETS SEVEN ROOF BOARDS 4 FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS ROOF BOARD ROOF STARTER FRONT 1 X 4 X 76 7 8 FIRST ONE SEVENTH ONE ROOF BOARD 1 ...

Page 103: ... 1 2 FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE BOTTOM EDGE OF THE DORMER THE DORMER MOUNTING BLOCK SHOULD BE IN BETWEEN THE WALLS OF THE DORMER MAKE SURE THE DORMER IS HORIZONTALLY PARALLEL TO THE ROOF BOARDS AND FULLY RESTING ON TOP OF THE ROOF THE PRE DRILLED HOLES ON EACH SIDE OF THE DORMER SHOULD BE CENTERED WITH THE DORMER MOUNTING BLOCK INSERT ONE 8 X 1 1 2 WOOD SCREW THROUGH EAC...

Page 104: ...P AT THE BOTTOM OF THE SEAM THIS PROVIDES YOU FREEDOM FOR ADJUSTABILITY ASSEMBLY 8 X 1 1 4 WOOD SCREW 2 WOOD SCREW ROOF PANEL BATTENS FASTEN THE ROOF PANEL PEAK FLUSH TO THE SIDES OF THE ROOF BOARD PEAK SUPPORT WOOD SCREWS ON TOP OF THE TWO PANELS AND SUPPORT TO THE ROOF PANELS USING 2 KEEP TIGHT AT THE PEAK FRONT PLASTIC ARCH ROOF BOARD BATTENS FLUSH TO FLUSH AT THE PEAK FASTEN USING 8 X 1 1 4 WO...

Page 105: ...SCREWS IN THE CORRECT LOCATION REMOVE THE ROOF FINISHERS THESE WILL BE USED IN A LATER STEP NOTE CORNER POST REMOVED FOR CLARITY STEP 35 ATTACHING THE FRONT GABLE PULL TOWARDS YOU 1 MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE TOP PANEL BOARD MAKE SURE THE GABLE ASSEMBLY IS FLUSH AGAINST THE FRONT CORNER POSTS THE GABLE ROOF PEAK SHOULD BE RESTING ON TOP OF THE ROOF FRONT SECTION TIP MAKE SURE THE D...

Page 106: ...E GABLE ASSEMBLY THE WALL PANEL SUPPORT TOP EDGE MUST BE PARALLEL AT 21 7 8 TO THE TOP EDGE OF THE TOP PANEL BOARD ATTACH THE WALL PANEL SUPPORT LEFT TO THE GABLE ASSEMBLY WITH ONE 8 X 2 1 2 WOOD SCREW 2 THE COUNTERSUNK HOLE WILL REMAIN EMPTY FOR NOW 3 REPEAT SUB STEPS 1 2 FOR THE OPPOSITE SIDE 2 X 4 X 22 75 SUPPORT RIGHT WALL PANEL SUPPORT LEFT 2 X 4 X 22 75 WALL PANEL TOP PANEL SUPPORT C 7 8 21 ...

Page 107: ...ARE FLUSH ON BOTH SIDES OF THE ROOF AND TIGHT TO THE GABLE ASSEMBLY TIP DO THIS ONLY IF THE ROOF FINISHERS ARE UNEVEN WITH THE OVERHANG REMOVE THE ROOF FINISHERS SO YOU CAN ACCESS THE WOOD SCREWS ATTACHING THE WALL PANEL SUPPORTS ONCE YOU REMOVED THE WALL PANEL SUPPORTS ON BOTH SIDES PROCEED TO LOOSEN UP THE WOOD SCREWS ATTACHING THE GABLE ASSEMBLY FROM UNDERNEATH THE ROOF SLIDE THE GABLE ASSEMBLY...

Page 108: ... BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD MAKE SURE IT IS PARALLEL TO THE ROOF SUPPORTS INSERT 1 1 2 WOOD SCREWS THROUGH THE PRE DRILLED HOLES ALONG THE BATTEN 2 REPEAT THE PREVIOUS SUB STEP FOR THE OTHER SIDE ROOF SUPPORT FLUSH 1 1 2 WOOD SCREW ROOF BATTEN SEVENTH ROOF BOARD ROOF SUPPORT 74 ...

Page 109: ...ARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1 4 FROM THE SIDE EDGE OF THE PREVIOUS WALL PANEL BOARD THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1 FROM THE SIDE EDGE OF THE GABLE ROOF SUPPORT FASTEN THE WALL PANEL BOARD WITH FOUR 1 1 2 WOOD SCREWS 4 MOUNT THE 1 X 4 X 8 75 WALL PANEL BOARD AGAINS...

Page 110: ...OF THE ROOF THE PLASTIC SUNBEAM MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS FASTEN THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS USING TWO 8 X 2 1 2 WOOD SCREWS ON THE TOP AND SIX 8 X 2 WOOD SCREWS ON THE REMAINING HOLES 2 1 2 WOOD SCREW X2 PLASTIC SUNBEAM PLASTIC SUNBEAM ROOF SUPPORT 2 WOOD SCREW X6 76 ...

Page 111: ...ING CLIP SWING CHAIN 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 STEP 41 HANGING THE SWINGS 77 ...

Page 112: ... 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 78 ...

Page 113: ...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...

Page 114: ...HE MARK ON THE RIGHT FRONT CORNER POST ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE 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 LEG ON INSIDE LEFT SIDE ASSEMBLY LEG ON INSIDE RIGHT SIDE ASSEMBLY 8 X 3 WOOD SCREW NOTE ROCK WALL...

Page 115: ...AT 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 STEP 45 PICNIC TABLE 5 4 X 6 X 43 PT TOP SEAT BOARDS 8 X 2 1 2 WOOD SCREWS 81 ...

Page 116: ...AINING 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 6 REPEAT 4 5 FOR REMAINING ROPE LADDER RUNGS STEP 46 ROPE LADDER 1 TIE A KNOT IN EACH ROPE AND THREAD THEM THR...

Page 117: ...ING 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 ...

Page 118: ...G 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 STEP 48 MOUNTING THE SLIDE 84 ...

Page 119: ...AC 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 TIE TAC TOE MOUNT STEP 49 TIC TAC TOE ASSEMBLY 85 ...

Page 120: ...HE 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 STEP 50 TIC TAC TOE INSTALLATION SWING BEAM TIC TAC TOE WITH BOARDS ATTACHED 8 X 1 3 4 WOOD SCREWS 4 00 86 ...

Page 121: ...Y 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 STEP 51 SAFETY HANDLES 14 X 1 1 4 PAN HEAD SCREW 1 4 WASHER SAFETY HANDLES 87 ...

Page 122: ...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 STEP 52 MOUNTING THE TELESCOPE FRONT TOP PANEL BOARD TELESCOPE SLIDE WOOD SCREWS CENTER POST TELESCOPE STAND TELESCOPE BRACKETS 1 1 4 ROCK WALL 88 ...

Page 123: ...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 89 ...

Page 124: ...LLOW 2 PARTIALLY INSERT A 8 X 1 WOOD SCREW INTO THE WALL PANEL BOARD CENTER MARK FROM PREVIOUS SUB STEP MAKE SURE THE HEAD OF THE SCREW IS STICKING OUT ABOUT 3 8 FROM THE OUTSIDE FACE OF THE WALL PANEL BOARD 3 MOUNT THE SOLAR WALL LIGHT ON TO THE WALL USING THE HEAD OF THE WOOD SCREW AS A HANGER IN TO THE SLOT LOCATED IN THE BACK OF THE SOLAR WALL LIGHT THE ON OFF SWITCH IS LOCATED IN THE BOTTOM R...

Page 125: ...AG 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 STEP 55 STEERING WHEEL WASHER STEERING WHEEL STEERING WHEEL CAP 1 BELOW THE T NUT 2 1 2 LAG SCREW STEERING WHEEL INSERT DRILL 3 16 HOLE T NUT 91 ...

Page 126: ...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 STAKE PAN HEAD SCREW 14 x 2 GROUND 1 4 FENDER WASHER 92 ...

Page 127: ...APPENDIX 93 ...

Page 128: ...CTURE VIEWS SHOWN ABOVE ARE 1 1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES QTY 22 8 X 1 1 4 WOOD SCREW 1529 HARDWARE PAGE 1 OF 1 1 16 2015 S O 2 SQUARE DRIVE BIT QTY 1 8 X 1 3 4 WOOD SCREW QTY 8 8 X 2 WOOD SCREW QTY 6 8 X 2 1 2 WOOD SCREW QTY 4 8 X 1 1 2 WOOD SCREW QTY 34 ...

Page 129: ... 10 1355 DS DORMER MOUNT CHIMNEY FRONT 2 10 1500 CRS ASSEMBLY 4 4 DORMER ROOF 2 17 1850 DSRA ASSEMBLY DORMER SUNRAY 2 13 1828 DRPA PANEL ASSEMBLY RIGHT ASSEMBLY ASSEMBLY 2 3 1150 DM DORMER SIDE 2 2 CHIMNEY RIGHT SIDE ASSEMBLY 1 DESCRIPTION PICTURE QTY ...

Page 130: ...2 3 0675 CMB 1 SIDE ASSEMBLY CHIMNEY LEFT 2 8 0700 CRA ASSEMBLY CHIMNEY REAR 2 10 1500 CLS 1 CHIMNEY MOUNTING BLOCK 1 PICTURE DESCRIPTION QTY ...

Page 131: ...IND TWO DORMER SUNRAY ASSEMBLIES 3 PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW 4 ATTACH THE DORMER SIDE ASSEMBLIES TO THE DORMER SUNRAY ASSEMB...

Page 132: ... WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS 2 MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DORMER WINDOW AND FASTEN WITH 8 X 1 1 2 WOOD SCREWS FLUSH FLUSH DORMER SIDE FLUSH DORMER WINDOW DORMER SIDE BATTEN DORMER SUNRAY DORMER SIDE DORMER SIDE 1 1 2 WOOD SCREW ...

Page 133: ...F PANEL ASSEMBLIES 2 PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY ASSEMBLIES THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK MAKE SURE THE PRE DRILLED HOLES ON THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES FASTEN WITH 8 X 1 1 2 WOOD SCREWS 3 REPEAT THE PREVIOUS SUB STEP FOR THE OTHER SIDE ...

Page 134: ...SIDES OF THE CHIMNEY WITH A 2 WOOD SCREW 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 CHIMNEY REAR USE A 2 WOOD SCREW IN THIS LOCATION CHIMNEY RIGHT SIDE CHIMNEY LEFT SIDE USE A 2 WOOD SCREW IN THIS LOCATION CHIMNEY FRONT ...

Page 135: ... 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 ...

Page 136: ...ING BLOCK TO THE ROOF WITH 1 1 2 WOOD SCREWS YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR 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 1 1 2 WOOD SCREW IN...

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