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Gorilla Playsets 1500BW Manual Download Page 72

SCREW

2" WOOD

2" WOOD

SCREW

3" WOOD

SCREW

3" WOOD

SCREW

2 X 6 

BOTTOM

PANEL

BOARD

2-1/2" WOOD

SCREW

DECK SUPPORT

PANEL

BOARD

BOTTOM

ANGLE

DETAIL A 

2 X 4 X 13"
SUPPORT

SCALE 1 : 8

2 X 6 

2 X 4 X 18"

ANGLE

SUPPORT

DECK SUPPORT

TOP OF ANGLE SUPPORTS

SHOULD BE FLUSH OR LOWER

THAN THE DECK SUPPORT

A

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" WOOD SCREW 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 ANGLE SUPPORT INTO THE BOTTOM PANEL BOARD. AT THE 

BOTTOM USE ONE 2" WOOD SCREW AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER 

POST.

STEP 20: ANGLE SUPPORTS

64

Summary of Contents for 1500BW

Page 1: ...0 Etowah Industrial Court Canton GA 30114 www gorillaplaysets com Frontier Model 1500BW BOXES 1501 1503N 1510 1511 1530 1523 Tire Swing Box Slide Box Amber Post Option BOXES 1520 2bx 1522 1524 Timber Shield Post Option BOXES W 1 TSB 120 51 0004 W 51 0004 W 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...

Page 9: ...0 Tire Swing Box Slide Box 1525 only included with 1500BWF Treehouse model REV 9 17 2015 Amber Post Option BOXES 1520 2bx 1522 1524 Timber Shield Post Option BOXES W 1 TSB 120 Model 1500BW shown See cover of manual for the image of your model when it is completed ...

Page 10: ... 16 19 Angle Supports Center Post and Panel Slat Installation Steps 20 22 Swing Beam Assembly Steps 23 30 Roof Assembly Steps 31 34 Hanging Swings Safety Board Steps 35 36 Picnic Table Assembly and Installation Steps 37 39 Tire Swing Assembly and Installation Steps 40 47 Rope Ladder Assembly and Installation Step 48 Slide Telescope Steps 49 50 Tic Tac Toe Assembly and Installation Steps 51 52 Safe...

Page 11: ... 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 12: ...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 13: ...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 14: ...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 15: ... 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 16: ...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 17: ...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 18: ...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 19: ...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 20: ...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 21: ...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 22: ...onents and general construction process of your new playset before getting started SITE PLAN Playset height 11 feet 2 inches Swing Beam height 7 feet 7 1 2 inches Deck height 5 feet Approximate assembly time 8 10 hours 6 foot unobstructed safety perimeter around playset recommended Trapeze Arm 1 Wave Slide Ramp Swing Belts 2 Rock Wall Rope Ladder Tire Swing 14 ...

Page 23: ...se Grips ___ Shovel ___ Tape or Marker See step 48 KIT CONTENTS Swings Slides Accessories ___ Qty Description ___ 2 Swingbelts w Chains ___ 1 Trapeze Swing w Chains ___ 1 Wave Slide ___ 10 Rock Wall Grips assorted colors ___ 1 Telescope ___ 4 Safety Handles ___ 2 Flag Kit ___ 2 Plastic Sunburst 07 0028 G ___ 1 Logo Plate ___ 1 Ground Stakes pair ___ 1 Tic Tac Toe ___ 1 Steering Wheel ___ 1 Tire Sw...

Page 24: ... 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 25: ...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 26: ... 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 QTY 6 WOOD SCREW 8 X 1 1 4 5 16 WASHER QTY 6 1503N HARDWARE PAGE 1 OF 1 REV C 8 10 2015 JH 8 X 1 1 2 WOOD SCREW QTY 104 5 16 X 2 1 2 HEX BOLT QTY 2 5 16 TEE NUT QTY 6 18 ...

Page 27: ... CAN BE USED TO MATCH BOLT AND SCREW SIZES 3 8 LOCK NUT QTY 4 1 2 WASHER QTY 2 3 8 WASHER QTY 17 TORQUE WASHER QTY 4 1510 HARDWARE PAGE 1 OF 1 REV B 8 19 2014 JH 5 16 PLASTIC BOLT CAP QTY 2 3 8 PLASTIC BOLT CAP QTY 4 3 8 x 7 CARRIAGE BOLT QTY 4 3 8 X 3 1 2 HEX LAG SCREW QTY 11 5 16 TEE NUT QTY 2 5 16 X 7 HEX BOLT QTY 2 19 ...

Page 28: ...3 J H 5 16 WASHER QTY 26 8 X 2 WOOD SCREW QTY 20 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 5 16 X 3 1 2 HEX LAG SCREW QTY 14 5 16 TEE NUT QTY 10 20 ...

Page 29: ...5 16 X 2 1 2 QTY 6 QTY 10 5 16 18 x 5 8 L T NUT 8 X 3 1 2 QTY 4 WOOD SCREW HEX BOLT QTY 2 3 8 16 x 5 8 L T NUT QTY 4 LAG SCREW 5 16 X 2 1 2 2 1 2 L QTY 16 SQUARE DRIVE PAN HEAD SCREW 8 X 1 1 4 QTY 2 EYE BOLT QTY 2 3 8 WASHER QTY 10 5 16 WASHER 3 8 16 X 3 4 DIA I D X 5 16 X 1 1 2 HEX BOLT QTY 4 1523 HARDWARE PAGE 1 OF 1 9 10 2014 JH 8 X 2 1 2 WOOD SCREW QTY 124 21 ...

Page 30: ...00 AS 2 X 4 X 18 ANGLE SUPPORT 2 4 1800 AS 2 X 4 X 14 BOTTOM PANEL BOARD 2 4 1400 BPB 2 X 4 X 14 3 4 PICNIC TABLE TOP SUPPORT 2 4 1475 PTTS 2 X 4 X 27 1 2 PICNIC TABLE SEAT SUPPORT 2 4 2750 PTSS 2 X 4 X 24 ROPE LADDER 2 4 2400 RLST 4 2 2 6 2 2 4 2856 CPFR STEP CENTER POST NOTE THIS ITEM WILL NOT BE USED FOR THIS PLAY SET 22 ...

Page 31: ...ON CENTER 2 4 6600 RWS 2 1 LEFT 1 RIGHT 2 X 4 X 66 LADDER SIDE 2 4 6600 LLS 2 4 6600 LRS 2 X 4 X 58 SWING BEAM CROSS MEMBER 2 HOLES ON CENTER 2 4 5800 CM 1 2 X 4 X 47 1 2 SAFETY BOARD END PANEL BOARD 2 4 4750 SBEP 2 2 X 4 X 51 1 8 ROOF SUPPORT 1 HOLE OFFSET 2 4 5113 RSL 2 4 5113 RSR 2 LEFT 2 RIGHT NOTE THIS ITEM WILL NOT BE USED FOR THIS PLAY SET 23 ...

Page 32: ... 2 X 6 X 70 BOTTOM PANEL SANDBOX BOARD 4 HOLES OFFSET 2 6 7000 SB 2 2 X 6 X 70 FRONT FACE BOARD 4 HOLES OFFSET 2 6 7000 FFB 1 1 2 X 6 X 47 1 2 TOP PANEL BOARD 2 6 4750 TPB 2 X 4 X 70 REAR TOP PANEL BOARD 2 HOLES OFFSET 1 CENTERED 2 4 7000 RTPB 1 1 2 X 6 X 102 ROPE LADDER SUPPORT FRONT RIGHT 2 6 10200 RLSFR PICTURE DESCRIPTION QTY 24 ...

Page 33: ...4 4750 SBM 1 2 5 4 X 2 5 8 X 13 1 4 PICNIC TABLE SLAT 125 3 1325 PTS 5 4 X 2 5 8 X 17 1 2 TIC TAC TOE MOUNT 125 3 1750 TTTM 2 5 4 X 3 X 23 7 8 ROCK WALL CAP 125 3 2387 RWC 1 5 4 X 2 5 8 X 28 1 4 PANEL SLAT 125 3 2825 PS 24 1 5 4 X 3 X 18 3 4 LADDER BACK 125 3 1875 LB NOTE THIS ITEM WILL NOT BE USED FOR THIS PLAY SET 25 ...

Page 34: ...OOF PEAK SUPPORT 125 6 1000 RPS 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 23 7 8 ROCK WALL BOARD 125 6 2387 RWB 1 5 4 X 6 X 23 7 8 BOTTOM ROCK WALL BOARD 125 6 2387 BRW 5 4 X 6 X 47 3 8 DECK BOARD 125 6 4737 DB 11 26 ...

Page 35: ...LY ROOF STARTER 1 4 4750 RS 2 1 X 4 X 47 1 2 TONGUE ONLY ROOF FINISHER 1 4 4750 RF 1 X 5 X 47 1 2 TONGUE GROOVE ROOF BOARD 1 5 4750 RB 22 1 2 X 4 X 47 1 2 TIRE SWING CROSS MEMBER 2 4 4750 CM 4 X 4 X 72 TIRE SWING LEG 4 4 7200 AFL 2 PICTURE DESCRIPTION QTY 27 ...

Page 36: ...EFERRED TO AS PLASTIC COATED WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR WOOD OPTION 4 X 6 X 108 PLASTIC COATED TIRE SWING BEAM 1 4 X 4 X 96 PLASTIC COATED CORNER POST 4 4 X 4 X 108 PLASTIC COATED SWING LEG 2 4 X 6 X 120 PLASTIC COATED SWING BEAM 1 28 ...

Page 37: ...BOARD ROPE MOUNT 2 4 4 0800 RM 2 4 X 4 X 8 7 3 2 4 3300 RP 2 2 1600 FS 2 4 1800 RPB 4 2 X 4 X 18 3 4 RAMP SUPPORT RAMP POST BRACE 2 2 4 1875 RS 2 X 4 X 18 2 4 9550 MFB 2 X 2 X 16 RAMP FLOOR SUPPORT 2 X 4 X 95 1 2 2 X 4 X 96 SIDE BOARD 2 4 9600 SB DESCRIPTION QTY PICTURE 1523 29 ...

Page 38: ...2 04 0006 1 1 SLIDE W CHAINS 04 0002 BAR 13 3 ROPE LADDER ROPE WIKI WAVE 1 10 ROCK WALL ROPE 12 or 13 RAMP HANDRAIL ROPES TRAPEZE SWING W CHAINS 2 PICTURE DESCRIPTION QTY 30 ...

Page 39: ...IPTION PICTURE QTY ROCK 5 ROCKS ARE IN ONE 11 5002 1 PLATE rocks 2 10 EA 1 SWING BAG 07 0008 CLIMBING A FRAME SWING LEG BRACKET 11 5010 HARDWARE BOXES 1501 1503N 1523 1510 1511 HARDWARE BOXES INSTRUCTIONS 31 ...

Page 40: ...MANUFACTURER 2 NOT SHOWN LOGO PLATE TELESCOPE 11 4012 HANGER 07 0001 6 1 IRON DUCTILE SWING BRACKET 28 0001 DESCRIPTION PICTURE QTY 1 32 ...

Page 41: ...DESCRIPTION PICTURE QTY PAIR CLIP 07 0005 SPRING 11 5013 BRACKET GREEN 11 4003 4 9 90 SAFETY HANDLE 2pr 33 ...

Page 42: ...09 1014 2 CHIMNEY 1530 BOX 1530 BOX 1 DORMER UNASSEMBLED UNASSEMBLED FLAG KIT 2 DESCRIPTION PICTURE QTY 34 ...

Page 43: ...7 0028 G STAKE 04 0014 PLASTIC SUNBURST 1 TIC TAC TOE TIRE SWING SWIVEL 11 4010 07 0010 UNASSEMBLED 07 0004 1 1 STEERING WHEEL GROUND TIRE SWING W CHAINS 1 2 PLASTIC DORMER SUNBURST 07 0031 1PR PICTURE DESCRIPTION QTY 35 ...

Page 44: ...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...

Page 45: ...RS 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 5 LAY THE 2 X 6 X 47 1 2 TOP PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS THE HOLES IN THE TOP PANEL BOARD MUST BE OFFSET DOWN 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 POST...

Page 46: ...ST 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 SWING BEAM SUPPORT MUST FACE DOWNWARD 7 FIND TWO TORQUE WASHERS PLACE A 6 1...

Page 47: ...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 39 ...

Page 48: ...OLES 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 102 ROPE LADDER SUPPORT ON THE FRONT OF THE CORNER POSTS THE HOLES IN THE ROPE LADDER SUPPORT SHOULD BE OFFSET UP 6 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHE...

Page 49: ...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 50: ...TALL 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 YOUR 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...

Page 51: ... 2 LAG SCREW 5 16 WASHER 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 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 43 ...

Page 52: ...EEN THE FRONT FACE BOARD AND BOTTOM PANEL BOARD DO THE FOLLOWING 1 LOOSEN 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 T...

Page 53: ...CK SPACERS BOARD AND ONLY NEEDS TO BE DRILLED ONCE THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER 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 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 A...

Page 54: ...ER 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 OUTSIDE OF THE 2 X 6 AND INTO THE END OF THE CENTER DECK SUPPORT REPEAT THIS STEP ON THE OPPOSITE...

Page 55: ...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 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 DR...

Page 56: ...TEP 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 48 ...

Page 57: ...STENING 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 T...

Page 58: ...L 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 5 16 WASHER GREEN BRACKET 90 5 16 X 1 1 2 HEX BOLT 50 ...

Page 59: ...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 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...

Page 60: ...ARD 2 GO UNDERNEATH THE DECK TO INSERT A T NUT INTO THE BACKSIDE OF THE 3 8 HOLES IN 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 1 1 2 5 16 WASHER HEX BOLTS INSERT T NUT BEHIND THE 2 X 6 ON BOTH SIDES RIGHT SIDE OF FORT 52...

Page 61: ...SUPPORT BOARD AT THE SQUARE END OF THE 2 X 4 X 96 RAMP SIDE BOARDS OFFSET THE BOARD 1 FROM THE END FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS WITH TWO 2 1 2 WOOD SCREWS PER SIDE 3 SECOND PLACE ONE 2 X 4 X 18 3 4 RAMP SUPPORT BOARD AT THE ROUND END OF THE 2 X 4 X 96 RAMP SIDE BOARDS OFFSET THE BOARD 4 FROM THE ROUND END FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS WITH TWO 2 1 2...

Page 62: ...SIDE ON A FIRM SURFACE THEN HAMMER IN THE 5 16 T NUTS REPEAT FOR THE OTHER 5 16 T NUT STEP 16A CLIMBING RAMP 1 PLACE THE RAMP SIDE ON A FIRM LEVEL SURFACE HAMMER A 5 16 T NUT INTO EACH HOLE ON THE INSIDE OF THE RAMP SIDE 2 REPEAT FOR THE OTHER RAMP SIDE 54 ...

Page 63: ... 2 1 2 WOOD SCREWS PER RAMP SUPPORT 3 ABOVE EACH OF THE RAMP SUPPORTS PLACE ONE 2 1 2 WOOD SCREW THROUGH THE RAMP SIDE BOARDS INTO THE 2 X 6 FLOOR BOARDS BETWEEN EACH RAMP SUPPORT INSTALL TWO MORE 2 1 2 WOOD SCREWS THROUGH THE RAMP SIDE INTO THE FLOOR BOARD 2 1 2 WOOD SCREW PLACE ONE 2 1 2 WOOD SCREW ABOVE EACH OF THE THREE RAMP SUPPORTS INTO THE 2 X 6 FLOOR BOARDS NOW GO BACK AND ADD 2 1 2 SCREWS...

Page 64: ...THAT DOES NOT HAVE THE COUNTERBORED HOLE 2 SCREW A 3 8 EYE BOLT WITH A WASHER INTO THE T NUT SO IT LOOKS LIKE THE BOTTOM PICTURE DO NOT TIGHTEN THE EYE BOLT SO TIGHTLY THAT IT CRACKS THE WOOD JUST SNUG IT UP 3 8 T NUT 3 8 EYE BOLT RAMP POST 3 8 WASHER 2 X 4 X 33 COUNTERBORED HOLE OUTSIDE FACE INSIDE FACE 56 ...

Page 65: ...ND OF THE FLOOR SUPPORT BOARDS STEP 18 CLIMBING RAMP 1 ATTACH THE 2 X 2 X 16 FLOOR SUPPORT BOARDS TO THE FLOOR BOARDS WITH 2 1 2 WOOD SCREWS SEE DETAIL VIEW BELOW 2 FASTEN THE 90 GREEN BRACKET TO THE RAMP SIDES WITH 5 16 X 1 1 2 HEX BOLTS AND 5 16 WASHERS FLOOR SUPPORT BOARD 2 X 2 X 16 2 1 2 WOOD SCREW A 57 ...

Page 66: ...S THE EYE BOLTS SHOULD BE ON THE OUTSIDE OF THE RAMP POSTS 2 SQUARE THE RAMP POST TO THE RAMP SIDE AND DRIVE IN TWO 2 1 2 WOOD SCREWS TO SECURE IT RAMP POST EYE BOLTS ON OUTSIDE OF RAMP POSTS RAMP SIDE A 5 16 X 2 1 2 5 16 WASHER SCALE 1 4 DETAIL A HEX BOLT 8 X 2 1 2 WOOD SCREWS RAMP POST RAMP SIDE 90 00 58 ...

Page 67: ...AN HEAD SQUARE DRIVE SCREWS STEP 18B CLIMBING RAMP 1 FASTEN A BRACKET AS SHOWN UNDERNEATH THE RAMP TO THE RAMP POST AND THE RAMP SUPPORT 2 USE 8 X 1 1 4 PAN HEAD SQUARE DRIVE SCREWS TO ATTACH THE BRACKET 3 REPEAT FOR THE RAMP POST ON THE OTHER SIDE 59 ...

Page 68: ...ST 4 ATTACH THE TOP OF THE RAMP POST SUPPORT TO THE RAMP POST WITH ONE 8 X 2 1 2 WOOD SCREW AND ONE 8 X 3 1 2 WOOD SCREW 5 ATTACH THE BOTTOM OF THE RAMP POST SUPPORT TO THE RAMP SIDE WITH FOUR 8 X 2 1 2 WOOD SCREWS 6 REPEAT SUBSTEPS 2 TO 5 FOR THE REMAINING RAMP POST SUPPORTS RAMP POST RAMP SIDE RAMP POST SUPPORT SUPPORT RAMP POST SUPPORT RAMP POST SUPPORT RAMP POST RAMP POST A 8 X 2 1 2 WOOD SCRE...

Page 69: ...A T NUT INTO THE BACKSIDE OF THE 3 8 HOLES IN THE FRONT FACE BOARD 3 ATTACH THE CLIMBING RAMP WITH 5 16 X 1 1 2 HEX BOLTS AND 5 16 WASHERS 4 WHEN THE 90 BRACKETS ARE SECURE AND THE RAMP IS IN ITS FINAL POSITION TIGHTEN THE 5 16 X 1 1 2 BOLTS ON THE RAMP SIDES THE BACK SIDE OF HEX BOLT CENTER RAMP IN FRONT 5 16 WASHER IN THE HOLES ON RIGHT OPENING 5 16 X 1 1 2 THE FRONT FACE BOARD PLACE A T NUT ROC...

Page 70: ...TTACH THE MOUNTS WITH 5 16 X 2 1 2 LAG SCREWS WITH WASHERS DO NOT OVER TIGHTEN 2 USE THE HOLES AS A GUIDE TO DRILL 3 8 DIAMETER HOLES THROUGH THE ROPE LADDER SUPPORT DRILL CAREFULLY SO YOU DO NOT SPLINTER THE WOOD AS THE DRILL BIT EXITS THE OTHER SIDE YOU MAY PLACE A SCRAP BLOCK OF WOOD ON THE BACK SIDE OF WHERE YOU ARE DRILLING TO PREVENT SPLINTERING BUT DO NOT PLACE YOUR HAND NEAR THE DRILLING A...

Page 71: ...D BE ON THE GROUND IF THE RAMP IS ELEVATED OFF THE GROUND THEN YOU SHOULD PUT A SMALLER BLOCK UNDER THE END OF THE RAMP AND THEN RETIE THE ENDS NEAR THE ROPE MOUNTS 4 IF THERE IS ANY EXTRA LENGTH OF ROPE AT THE ROPE MOUNTS THEN TIE AN ADDITIONAL KNOT IN THE EXTRA LENGTH IF POSSIBLE SAFETY CHECK STAND ON THE END OF THE RAMP AT GROUND LEVEL WITH YOUR WEIGHT ON THE RAMP GRAB EACH ROPE AND ATTEMPT TO ...

Page 72: ...H 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 WOOD SCREW 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 ...

Page 73: ...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 ...

Page 74: ...PRE DRILL THE SLATS 1 FROM EACH END ON CENTER WITH A 1 8 DRILL BIT 1 FIND TWENTY TWO 5 4 X 2 5 8 X 28 1 4 PANEL SLATS 3 INSTALL THE PANEL SLATS AT EQUAL LENGTHS SEE DETAIL BELOW FOR MEASUREMENTS ROCK WALL SIDE PANEL 4 ATTACH THE PANEL SLATS TO THE FORT WITH 2 WOOD SCREWS IN THE PRE DRILLED HOLES STEP 22 PANEL SLATS SWING BEAM PANEL SLAT DIMENSIONS VIEW FROM OUTSIDE THE PLAY SET 8 2 2 1 16 9 11 17 ...

Page 75: ... 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 HOLESOF 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 HOLE CARRIAGE BOLTS IN PLACE WHEN INSTALLING 67 ...

Page 76: ...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 BOLT CAPS 7 CARRIAGE BOLT TORQUE WASHER 3 8 WASHER 3 8 LOCK NUT IRON DUCTILE SWING HANGER 68 ...

Page 77: ...CH SWING LEGS TO BRACKET 2 FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3 8 X 3 1 2 LAG SCREWS AND 3 8 WASHERS 1 PLACE THE 4 X 4 X 108 SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET 4 X 4 X 108 SWING LEG SWING LEGS FLUSH TO TOP OF SWING LEG BRACKET 69 ...

Page 78: ...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 70 ...

Page 79: ... 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 STEP 27 MOUNT SWING BEAM TO SWING BEAM LEGS TORQUE WASHER 3 8 WASHER 3 8 LOCK NUT BOLT CAP 7 CARRIAGE BOLT 3 8 X 3 1 2 LAG SCREW 71 ...

Page 80: ... FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND THE SWING BEAM SUPPORT USING A 9 CARRIAGE BOLT WITH A TORQUE WASHER AND A 3 8 LOCK NUT WITH A 3 8 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 WH...

Page 81: ...EVEL STEP 29 LEVEL SWING BEAM 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 73 ...

Page 82: ...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 STEP 30 SWING LEG CROSS MEMBER 74 ...

Page 83: ... 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 ATTAC...

Page 84: ...A 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 76 ...

Page 85: ... 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...

Page 86: ...47 1 2 ROOF PEAK 8 X 1 1 4 WOOD SCREW STEP 33 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 78 ...

Page 87: ...OF 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 ...

Page 88: ...ING CLIP SWING CHAIN STEP 35 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 80 ...

Page 89: ...M 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 81 ...

Page 90: ...ER 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 FA...

Page 91: ...E 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 NOTE RAMP AND ROCK WALL REMOVED FOR CLARITY 26 3 8 LEFT SIDE ASSEMBLY LEG ON INSIDE RIGHT SIDE ASSE...

Page 92: ... 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 8 X 2 1 2 WOOD SCREWS 5 4 X 6 X 43 PT TOP SEAT BOARDS 84 ...

Page 93: ... TO THE TOP OF THE SWING LEG BRACKET 2 FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WITH 3 8 X 3 1 2 LAG SCREWS AND 3 8 WASHERS 3 8 WASHER LAG SCREW SWING LEG BRACKET 3 8 X 3 1 2 4 X 4 X 72 TIRE SWING LEG TIRE SWING LEGS FLUSH TO TOP OF SWING LEG BRACKET 85 ...

Page 94: ...E BOLT 1 LINE UP THE HOLES OF THE TIRE SWIVEL WITH THE HOLES IN THE TIRE SWING BEAM 2 FASTEN THE TIRE SWIVEL TO THE TIRE SWING BEAM USING 3 8 X 7 CARRIAGE BOLTS WITH TORQUE WASHERS AND 3 8 WASHERS WITH 3 8 LOCK NUTS 3 PLACE BOLT CAPS OVER EXPOSED THREADS STEP 41 TIRE SWING 86 ...

Page 95: ...WASHERS ON TOP OF THE TIRE SWING BEAM AND 3 8 LOCK NUTS WITH 3 8 WASHERS FROM UNDERNEATH PLACE A BOLT CAP OVER ANY EXPOSED THREADS 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 8 LOCK NUT BOLT CAP 7 CARRIAGE BOLT TORQUE WASHER 3 8 WASHER 3 8 X 3 1 2 LAG SCREW 87 ...

Page 96: ...UR GRADE ALSO SEE STEP 48 AN EXTRA PERSON IS NEEDED FOR THIS STEP 1 SIT THE SWING BEAM LEGS UPRIGHT 2 TAKE THE ASSEMBLED TIRE SWING BEAM AND LEGS AND INSERT THE SWING BEAM INTO THE GAP BETWEEN THE BACK RIGHT CORNER POST AND THE PANEL SLAT PLACE A SMALL LEVEL ON TOP OF THE BEAM IN ORDER TO LEVEL CORRECTLY 3 WITH A 3 8 DRILL BIT USE THE PRE DRILLED HOLES IN THE END OF THE TIRE SWING BEAM AS A TEMPLA...

Page 97: ...BEAM TO THE CORNER POST USING 5 16 X 7 HEX BOLTS WITH 5 16 AND 1 2 WASHERS THROUGH THE TIRE SWING BEAM AND CORNER POST INTO THE T NUTS 4 AFTER THE TIRE SWING BEAM HAS BEEN SECURED INSTALL THE 5 4 X 3 X 28 1 4 PANEL SLAT FLUSH TO THE SIDE OF THE TIRE SWING BEAM WITH 2 WOOD SCREWS 5 THE END OF THE 7 HEX BOLTS SHOULD NOT EXTEND PAST THE FLANGED SIDE OF THE T NUT IF IT DOES THEN PUT 5 16 BOLT CAPS OVE...

Page 98: ...AM LEVEL STEP 45 LEVEL TIRE SWING BEAM IMPORTANT NOTE THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND DOWN SLOPE THEY ARE LONGER THAN REQUIRED IF YOUR GROUND IS RELATIVELY LEVEL YOU MAY NEED TO EITHER A DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR B BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE 90 ...

Page 99: ...TION THE 2 X 4 X 47 1 2 TIRE SWING LEG CROSS MEMBER AGAINST THE SWING LEGS 2 LEVEL THE TIRE SWING CROSS MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS MEMBER HOLES ONTO THE SWING LEGS 3 USE 3 8 X 3 1 2 LAG SCREWS WITH 3 8 WASHERS TO SECURE THE TIRE SWING CROSS MEMBER TO THE SWING BEAM LEGS 91 ...

Page 100: ...7 HANGING THE TIRE SWING 1 START BY ATTACHING THREE SPRING CLIPS TO THE TIRE SWIVEL ON THE SWING BEAM 2 ATTACH ONE CHAIN AT A TIME TO ONE SPRING CLIP 3 ADJUST HEIGHT AS NEEDED SPRING CLIP TIRE SWING CHAIN 92 ...

Page 101: ...OPE THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE THEM OFF GRAB 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 RUNNER LADDER SUPPORT AND TIE 3 KNOTS THE BOTTOM OF EACH 2 MEASURE DOWN 6 BELOW...

Page 102: ...ACE 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 94 ...

Page 103: ... 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 1 1 4 WOOD SCREWS PROVIDED WITH THE TELESCOPE 95 ...

Page 104: ... 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 TIC TAC TOE MOUNT GREEN BRACKET GREEN BRACKET 5 4 X 3 X 17 1 2 TIC TAC TOE MOUNT 5 4 X 3 X 17 1 2 TIC TAC TOE AFTER ASSEMBLING 96 ...

Page 105: ... ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH 8 X 1 3 4 WOOD SCREWS 1 PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE PLAY SET ON THE STEP 52 TIC TAC TOE INSTALLATION SWING BEAM TIC TAC TOE WITH BOARDS ATTACHED 8 X 1 3 4 WOOD SCREWS 4 00 97 ...

Page 106: ... 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 SAFETY HANDLES 1 4 WASHER 98 ...

Page 107: ...FETY HANDLES RAMP 1 LOCATE THE SECOND 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 CENTER POST AND PANEL SLAT WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES 99 ...

Page 108: ...PE 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 IF THERE IS A LARGE AMOUNT OF EXCESS ROPE ON ROCK WALL YOU CAN TIE THREE KNOTS APPROXIMATELY 18 APART ON THE ROCK WALL TO AID YOUR CHILD IN CLIMBING STEP 55 INSTALLING C...

Page 109: ...STEP 56 FLAG KIT 1 PLACE A FLAGON THE CORNER POSTS AT THE FRONT OF THE FORT 2 ATTACH THE BASE OF THE FLAG WITH THE 1 2 PHILLIPS HEAD SCREWS PROVIDED DO NOT OVER TIGHTEN FLAG 1 2 PHILLIPS HEAD SCREW 101 ...

Page 110: ...STEP 57 SANDBOX SEATS AND NAMEPLATE 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 102 ...

Page 111: ...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 PLASTIC SUNBURST 8 X 2 1 2 WOOD SCREWS 8 X 2 WOOD SCREWS 6 IN THE SIDES 2 IN TRIANGLE PORTION PLASTIC SUNBURST ROOF SUPPORTS 103 ...

Page 112: ...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 104...

Page 113: ...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 105...

Page 114: ...APPENDIX 106 ...

Page 115: ... SCREW QTY 2 8 X 2 WOOD SCREW QTY 4 2 SQUARE DRIVE BIT QTY 1 Chimney and Dormers Hardware Kit 8 10 2015 JH 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 ...

Page 116: ...ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY 1 LEFT SIDE CHIMNEY ASSEMBLY 1 CHIMNEY FRONT 1 DESCRIPTION PICTURE QTY ...

Page 117: ...CHIMNEY 2 MOUNTING 1 ASSEMBLY 1 LEFT SIDE DORMER BLOCK 5 4X3X6 3 4 CHIMNEY REAR ASSEMBLY DESCRIPTION PICTURE QTY ...

Page 118: ...DESCRIPTION PICTURE QTY 2 RIGHT SIDE DORMER 07 0031 ASSEMBLY PLASTIC DORMER SUNBURST 2 ...

Page 119: ...KE 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 BOTTOM VIEW 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 COMPLETED ROOF ASSEMBLY ...

Page 120: ...T INSTALL A 8 X 1 2 PAN HEAD SCREW AT EACH HOLE LOCATION 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 A ...

Page 121: ... 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 8 x 2 1 2 WOOD SCREW DORMER 8 x 1 1 2 WOOD SCREWS DORMER THE UNIT SHOWN ABOVE MAY NOT BE YOUR EXACT PLAY SET SHOWN FOR ILLUSTRATION PURPOS...

Page 122: ...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 123: ... 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 124: ...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 1 ON EACH SIDE WOOD SCREWS BACK WALL OF CHIMNEY CHIMNEY MOUNTING BLOCK 5 4 X 3 X 6...

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