Gorilla Playsets 1500CTC Manual Download Page 20

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1: REMOVE THE SAFETY BOARD.

STEP 5: SAFETY BOARD

PLASTIC

PLUG

SAFETY BOARD

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.

2 X 6 X 47-1/2" BOTTOM BOARD

5/16 X 3-1/2"

LAG SCREW

5/16" WASHER

2: PLACE THE SAFETY BOARD YOU JUST REMOVED FLUSH WITH 2 X 6 BOTTOM BOARD. USE TWO 5/16 X 3-1/2"

LAG SCREWS AND TWO 5/16" WASHERS TO ATTACH IT TO CORNER POSTS.

Summary of Contents for 1500CTC

Page 1: ...t Canton GA 30114 www gorillaplaysets com Mountaineer Clubhouse Model 1500CWC BOXES 1501 1503N 1512 1530 1518 Extreme Tube Slide Box and Slide Box Amber Post Option BOXES 1520 2bx 1522 Timber Shield Post Option BOXES W 1 120 51 0033 W 51 0033 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: ...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 ...

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: ...____________ 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: ...FRONT VIEW REAR VIEW ...

Page 10: ...instruction manual 3 DO NOT install the Sandbox Seats in Step 47 Side to Side Roof Step 55 Front to Back Roof or Step 44 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 be leftove...

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: ...LAT 5 4 X 6 X 28 1 4 WINDOW 1 3 1800 WTB 1 BOARD WINDOW TOP 1 X 3 X 18 1 3 2988 OWOS 1 OUTSIDE SUPPORT OPEN WINDOW 1 X 3 X 29 7 8 1 3 3475 WBB 1 BOTTOM BOARD WINDOW 1 X 3 X 34 3 4 1 3 4050 PBB 2 BRACE PANEL BOARD 1 X 3 X 40 1 2 1 4 0900 TBW 3 1 X 4 X 9 31 32 OPEN WINDOW TOP BOARD 3 2 ...

Page 13: ...2775 BWB 5 WINDOW BOARD BOTTOM 1 X 4 X 27 3 4 1 4 2950 OWB 1 BOARD OPEN WINDOW 1 4 5100 WB 6 WALL BOARD 1 X 4 X 51 1 X 4 X 29 1 2 1 6 0843 TBD2 2 DOOR 2 TOP BOARD 1 X 6 X 8 7 16 1 6 1020 TBD1 2 DOOR 1 TOP BOARD 1 X 6 X 10 3 16 1 6 1118 OWTB2 2 1 X 6 X 13 5 8 OPEN WINDOW TOP BOARD 1 2 ...

Page 14: ...00 ATBD 1 BOARD DOOR ARCH 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 ...

Page 15: ... NOT SHOWN WINDOW 1 11 0054 1 07 0013 1518 HARDWARE 1 2 X 6 X 47 1 2 BOTTOM BOARD TUBE SLIDE 2 6 4750 BBTS PICTURE DESCRIPTION QTY ...

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

Page 18: ...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 ANGLE SUPPORT ...

Page 19: ...2 HEX BOLT 3 1 2 LAG SCREWS AND FOUR 5 16 WASHERS TO ATTACH IT TO THE CORNER POSTS 2 PLACE THE BOTTOM BOARD TUDE SLIDE ON THE PLACE END PANEL BOARD USE 5 16 X 4 1 2 HEX BOLTS 5 16 X 2 X 6 X 47 1 2 BOTTOM BOARD TUBE SLIDE A STEP 4 TUBE SLIDE BOARD 1 REMOVE THE END PANEL BOARD ...

Page 20: ...PLUGS AND PLACE THE PLASTIC PLUGS IN THE HOLES LEFT FROM REMOVING THE SAFETY BOARD IN THE CORNER POSTS 2 X 6 X 47 1 2 BOTTOM BOARD 5 16 X 3 1 2 LAG SCREW 5 16 WASHER 2 PLACE THE SAFETY BOARD YOU JUST REMOVED FLUSH WITH 2 X 6 BOTTOM BOARD USE TWO 5 16 X 3 1 2 LAG SCREWS AND TWO 5 16 WASHERS TO ATTACH IT TO CORNER POSTS A ...

Page 21: ...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 3 PLACE THE 2 X 4 X 70 BOTTOM WALL BOARD FLUSH WITH 2 X 6 BOTTOM BOARD USE TWO 5 16 X 3 1 2 LAG SCREWS WITH 5 16 WASHERS TO ATTACH IT TO THE POSTS LAG SCREW 5 16 X 3 1 2 2 X 6 X 70 BOTTOM 2 X 6 X 70 5 16 X 4 1 2 HEX BOLT BOARD 5 16 WASHER 5 16 X 3 1 2 BOTTOM PANEL BOARD DOOR 5 16 WASHER LA...

Page 22: ...E FORT MAKE THE TOP PANEL BOARD FLUSH WITH 2 X 6 X 47 1 2 BOTTOM BOARD TUBE SLIDE 2 USE 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS TO ATTACH THE TOP PANEL BOARD TO THE CORNER POSTS 2 X 6 X 47 1 2 5 16 WASHER BOTTOM BOARD LAG SCREW TUBE SLIDE 5 16 X 3 1 2 2 X 4 X 47 1 2 TOP PANEL BOARD OFFSET DOWN ...

Page 23: ...OARDS AND TWO 1 X 4 X 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 ...

Page 24: ... 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 8 X 1 1 4 WOOD SCREW 1 X 3 X 40 1 2 PANEL BOARD BRACE ...

Page 25: ...CHING THE WINDOWS IN NEXT STEP ARE SHOWN BELOW 2 USE 8 X 1 3 4 WOOD SCREWS LEAVING 1 4 SPACES BETWEEN THE WALL BOARDS TO ATTACH THEM TO THE BOTTOM PANEL BOARD DOOR AND BOTTOM PANEL BOARD 8 X 1 3 4 WOOD SCREW DOOR 1 BOARD THREE BOARDS WALL BOARD TWO TWO BOARDS DOOR2 1 X 6 X 51 BOARD 2 X 4 X 70 BOTTOM PANEL BOARD TOP BOARD 1 X 6 X 8 3 8 TOP 1 X 6 X 10 1 X 4 X 51 WALL BOARD FOUR BOARDS 1 X 4 X 9 TOP ...

Page 26: ...AT THE TOP STEP 11 INSTALL WINDOW 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 ...

Page 27: ... 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 FASTEN WITH 8 X 1 1 4 WOOD SCREWS ...

Page 28: ...1 X 4 X 27 3 4 BOTTOM WINDOW BOARD TWO BOARDS 2 X 6 X 79 1 2 ROPE LADDER RUNNER 8 x 1 3 4 WOOD SCREW STEP 13 RIGHT SIDE WALL BOARDS 1 PLACE WALL BOARDS ON THE RIGHT SIDE OF THE FORT AGAINST THE TOP WALL PANEL BOARD AND ROPE LADDER RUNNER AS SHOWN BELOW THE BOTTOM OF THE WALL BOARDS SHOULD BE 1 1 2 ABOVE THE BOTTOM OF THE ROPE LADDER RUNNER FASTEN WITH 8 X 1 3 4 WOOD SCREWS LEAVING A 1 4 SPACE BETW...

Page 29: ... X 3 X 40 1 2 BOTTOM BOARD OPEN WINDOW STEP 14 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 30: ...OW 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 A 8 X 1 1 4 OPEN WINDOW WOOD SCREW DETAIL A SCALE 2 17 BOTTOM BOARD FLUSH 1 X 3 X 29 7 8 OPEN WINDOW OUTSIDE SUPPORT ...

Page 31: ... 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 FLUSH DETAIL A SCALE 2 17 8 X 1 3 4 BOARD WOOD SCREW 1 X 4 X 29 1 2 OPEN WINDOW PANEL BOARD BRACE ...

Page 32: ...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 5 16 WASHER BOARD LAG SCREW BOTTOM WALL 2 X 4 X 70 2 X 6 X 70 SANDBOX BOARD 30 3 8 ...

Page 33: ...SLAT 3 4 1 8 1 3 1 1 2 STEP 18 PANEL SLATS 1 FIND SEVEN 5 4 X 6 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 ...

Page 34: ...ANGLE SUPPORT STEP 19 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 35: ...LE 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 35 SIDE TO SIDE ROOF OR STEP 44 FRONT TO BACK ROOF FOR DIMENSIONS INSTALL WITH 3 WOOD SCREWS ON THE LEFT SIDE OF THE UNIT AS SHOWN BELOW ...

Page 36: ...e Box 1518 only included with 1500CWC and 1500CWCF Clubhouse models 1525 only included with 1500CWF and 1500CWCF Treehouse models REV 8 11 2017 Amber Post Option BOXES 1520 2bx 1522 Timber Shield Post Option BOXES W 1 120 Model 1500CW shown See cover of manual for the image of your model when it is completed ...

Page 37: ... and Panel Slat Installation Steps 18 19 Swing Beam Assembly Steps 20 27 Roof Assembly Steps 28 31 Hanging Swings and Safety Board Steps 32 33 Picnic Table Assembly and Installation Steps 34 36 Rope Ladder Assembly Installation Step 37 Extreme Tube Slide Slide Panel Slats Right Side Angle Supports Steps 38 39 Slide Rock Wall Rope Safety Handles and Telescope Steps 40 43 Tic Tac Toe Assembly Instal...

Page 38: ... 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 39: ...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 40: ...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 41: ...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 42: ... 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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ...rts components 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 12 16 hours 6 foot unobstructed safety perimeter around playset recommended Trapeze 1 Wave Slide Ladder Swing Belt 2 Rock Wall Rope Ladder Extreme Tube Slide 14 ...

Page 50: ...__ Shovel ___ Marker or Tape Step 37 KIT CONTENTS Swings Slides Accessories ___ Qty Description ___ 2 Swingbelt w Chains ___ 1 Trapeze Swing w Chains ___ 1 Wave Slide ___ 10 Rock Wall Grips 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 ___ 1 Extreme Tube Slid...

Page 51: ... 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 52: ...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 53: ... 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 54: ...E 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 1512 HARDWARE PAGE 1 OF 1 REV A 1 16 2014 J H 5 16 WASHER QTY 28 5 16 X 3 1 2 LAG SCREW QTY 18 8 X 3 WOOD SCREW QTY 3 5 16 X 4 1 2 HEX BOLT QTY 10 19 ...

Page 55: ... FRONT REAR 2 X 4 X 28 9 16 BOARD PICNIC TABLE END PANEL 2 4 1475 PTTS 2 4 2150 EPB STEP 2 4 1800 AS 6 ROPE LADDER 2 X 4 X 14 3 4 5 2 X 4 X 27 1 2 LADDER STEP 2 X 4 X 17 2 4 2750 PTSS 2 2 X 4 X 24 SEAT SUPPORT 2 X 4 X 13 ANGLE SUPPORT 2 4 1300 AS 2 X 4 X 18 ANGLE SUPPORT 4 DESCRIPTION PICTURE QTY 20 ...

Page 56: ...3250 PTL LEG PICNIC TABLE 2 X 4 X 32 1 2 2 4 6600 RWS CENTER 1 HOLE ON ROCK WALL SIDE RIGHT 2 1 LEFT 1 2 4 7000 CDS 2 SUPPORT CENTER DECK 2 X 4 X 70 2 4 6600 LRS 1 2 4 6600 LLS LADDER SIDE 2 X 4 X 66 2 X 4 X 66 2 2 X 4 X 47 1 2 X 4 X 58 2 X 4 X 51 1 8 ROOF SUPPORT 1 HOLE OFFSET 2 4 5113 RSL 2 4 5113 RSR DESCRIPTION PICTURE QTY 21 ...

Page 57: ...HOLES REAR TOP PANEL 2 X 4 X 70 2 6 7000 SB 1 HOLES OFFSET BOARD 4 AND SANDBOX BOTTOM PANEL 2 6 7000 FFB HOLES OFFSET BOARD 4 2 2 FRONT FACE 2 X 6 X 70 2 X 6 X 70 1 2 6 2150 EPB 2 6 4750 ESPB OFFSET 1 BOARD 4 HOLES AND SANDBOX BOTTOM PANEL 2 X 6 X 47 2 X 6 X 21 1 2 X 6 X 70 FRONT TOP PANEL BOARD 4 HOLES OFFSET 1 CENTER 1 DESCRIPTION PICTURE QTY 22 ...

Page 58: ...OUNT SWING BEAM 2 2 6 7950 RLR 1 REAR FACE ON CENTER OFFSET 3 HOLES RUNNER 4 HOLES BOARD ROPE LADDER 2 X 6 X 79 1 2 1 4 X 4 X 47 2 6 7000 RFB 1 5 X 28 X 17 15 1 2 2 4 TIC TAC TOE MOUNT 125 3 1325 PTS 4 SLAT PICNIC TABLE 4 1 5 X 13 8 5 X 2 125 3 1750 TTTM 5 5 4 X 2 5 8 X 28 1 4 PANEL SLAT 125 3 2825 PS DESCRIPTION PICTURE QTY 23 ...

Page 59: ...ER 1 125 4 1450 DS DECK SPACER 2 5 1 X 4 X 14 4 125 4 2250 DS 7 125 3 2387 RWC 8 4 ROCK WALL CAP X 3 X 23 2 1 125 4 4038 DS 2 DECK SPACER 8 5 3 X 4 X 40 4 125 3 1875 LB 1 LADDER BACK 4 5 3 X 3 X 18 5 4 5 4 X 6 X 10 ROOF PEAK SUPPORT 125 6 1000 RPS DESCRIPTION PICTURE QTY 24 ...

Page 60: ...25 6 4737 DB 4 DECK BOARD 4 X 6 X 43 3 8 X 6 X 47 1 6 4750 RP 125 6 2387 RWB 11 BOARD ROCK WALL 8 125 6 2200 SS 2 4 SANDBOX SEAT X 6 X 22 4 5 7 X 6 X 23 ROOF PEAK 1 4 4750 RF 4 5 47 1 2 125 6 4300 PTTS 11 1 TOP AND SEATS PICNIC TABLE 5 5 1 X 4 X 47 1 2 TONGUE ONLY ROOF FINISHER 2 25 ...

Page 61: ...D 2 1 4 4750 RS 1 ROOF STARTER GROOVE ONLY 2 4 2925 SHB 1 BOARD SLIDE HEADER 2 X 4 X 29 1 4 4 4 4000 EWSMP MOUNT POST END WALL SLIDE 4 X 4 X 40 LEG 2 SWING BEAM 4 X 4 X 108 CORNER POST 4 4 X 4 X 96 PLASTIC COATED 1 X 5 X 47 NOTE ANYTHING ON THIS PAGE REFERRED TO AS PLASTIC COATED WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR WOOD OPTION 26 ...

Page 62: ...PICTURE DESCRIPTION QTY SWING W CHAINS 1 03 0013 1 TRAPEZE BAR LADDER ROPE 04 0006 04 0002 ROPES WAVE SLIDE 1 13 3 2 WIKI W CHAINS 10 10 ROCK WALL ROPE 27 ...

Page 63: ...CLIMBING ROCKS 07 0008 11 5002 1 PLATE ROCKS 1 10 EA 1 SWING IS A PACK OF 5 A FRAME SWING LEG BRACKET 11 5010 HARDWARE BOXES 1501 1503N 1512 HARDWARE BOXES DESCRIPTION PICTURE QTY 28 ...

Page 64: ...PICTURE DESCRIPTION QTY 1 1 11 5018 SWING TELESCOPE 07 0001 HANGERS 11 4012 IRON DUCTILE CHANNEL BRACKET 6 29 ...

Page 65: ...DESCRIPTION PICTURE QTY PAIR CLIP 07 0005 SPRING 11 5013 BRACKET GREEN 11 4003 4 6 90 SAFETY HANDLES 1pr 30 ...

Page 66: ...2 2 UNASSEMBLED FLAG KIT 1530 BOX 1 DORMER UNASSEMBLED 1530 BOX CHIMNEY 09 1014 2 PLASTIC DORMER SUNBURST 07 0031 DESCRIPTION PICTURE QTY 31 ...

Page 67: ...ING WHEEL 1 07 0028 G 2 NOT SHOWN SUNBURST LOGO PLATE 1 MANUFACTURER pr 1 1 PLASTIC 1 07 0016 P PAIR STAKE 07 0010 UNASSEMBLED TIC TAC TOE 07 0004 GROUND EXTREME TUBE SLIDE 03 0014 DESCRIPTION PICTURE QTY 32 ...

Page 68: ... THE PLAYSET 4 USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE 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 SHOULD BE FACING THIS DIRECTION HOLES AT THE TOP OF CORNER POSTS 4 X 4 X 96...

Page 69: ...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 3 LAY THE 2 X 6 X 79 1 2 ROPE LADDER SUPPORT ON TOP OF THE RIGHT SIDE CORNER POSTS AND MEASURE 2 FROM THE TOP OF BOTH CORNER POSTS 4 BEFORE INSTALLING LAG SCREWS MEASURE THE DISTANCE ACROSS THE OUTSIDE OF THE BOTTOM OF THE CORNER POSTS AND...

Page 70: ...SET HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN 4 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 5 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 ...

Page 71: ...R 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 3 HAVE AN ASSISTANT HOLD UP THE LEFT OR RIGHT SIDE FRAME WHILE YOU ATTACH THE BOARDS IN STEPS 5 AND 6 SO THAT THE STRUCTURE REMAINS STABLE DURING ASSEMBLY 36 ...

Page 72: ...HE 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 AT THE MIDDLE THE HOLES IN THE FRONT FACE 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 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...

Page 73: ...ORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 PLACE THE 2 X 6 X 70 REAR FACE BOARD ON THE FRONT OF THE CORNER POSTS THE HOLES IN THE FRONT FACE 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 REAR FACE 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 ON THE FRON...

Page 74: ...E 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 LAG SCR...

Page 75: ...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 TOP OF ANGLE SUPPORTS SHOULD BE FLUSH OR LOWER THAN THE DE...

Page 76: ...2 X 4 X 47 1 2 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 OFFSET UP BOTTOM PANEL BOARD 5 16 WASHER 2 X 4 X 47 1 2 5 16 X 3 1 2 LAG SCREW 41 ...

Page 77: ...OSEN 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 REAR FACE 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 RIGHT SIDE BOARDS BOARD ...

Page 78: ...DECK BOARD NEAR THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT LEAVING A 1 4 GAP BETWEEN THE CORNER POSTS AND THE SIDE OF THE DECK BOARD FASTEN THE DECK BOARD TO THE DECK SUPPORTS WITH 2 WOOD SCREWS EACH END BETWEEN THE CORNER POST AND DECK SPACER 5 4 X 4 X 40 3 8 DECK BOARD 5 4 X 6 X 47 3 8 SCREWS 2 WOOD SCREWS 2 WOOD THE SIDE OF THE DECK BOARD LEAVE A 1 4 GAP ON DECK SPACER IS FLUSH TO INSIDE OF...

Page 79: ...D MARK THE MEASUREMENT ON THE INSIDE ALIGN THE TOP AND SIDE OF THE END WALL SLIDE MOUNT POST WITH THE MARKS 3 USE THREE 2 1 2 WOOD SCREWS TO ATTACH THE END WALL SLIDE MOUNT POST TO THE ROPE LADDER SUPPORT FROM THE OUTSIDE OF THE ROPE LADDER SUPPORT 4 THE END WALL SLIDE MOUNT POST CAN HANG FREELY AT THIS TIME SLIDE MOUNT POST FORT FRONT OF 4 X 4 X 40 END WALL ROPE LADDER SUPPORT 2 26 POST FRONT OF ...

Page 80: ...INSIDE ATTACH EACH DECK SUPPORT TO THE POST WITH THREE 2 1 2 WOOD SCREWS 2 DRILL 1 8 PILOTHOLES THROUGH THE DECK BOARD AND DECK SPACER AS SHOWN IN THE TOP VIEW BELOW 3 SECURE 2 WOOD SCREWS THROUGH THE DECK BOARD INTO THE DECK SUPPORTS 4 NOW SECURE THE FAR END OF THE DECK SUPPORTS TO THE DECK SPACER WITH 2 WOOD SCREWS 2 X 4 X 70 DECK SUPPORTS 25 1 21 3 4 4 4 4 3 4 3 4 TOP VIEW HAVE AN ASSISTANT HOL...

Page 81: ...4 X 70 CENTER DECK SUPPORTS TO THE 2 X 6 BOTTOM PANEL BOARD 2 WOOD SCREW 5 4 X 3 3 8 X 14 1 2 DECK SPACER DECK BOARD CENTER DECK SUPPORTS WITH 2 WOOD SCREWS DECK SPACER 5 4 X 3 3 8 X 22 1 2 DECK SPACER 5 4 X 6 X 47 1 2 3 USING TWO 2 1 2 WOOD SCREWS ATTACH THE 5 4 X 3 3 8 X 22 1 2 DECK SPACER 5 4 X 3 3 8 X 14 1 2 2 START WITH A 5 4 X 6 X 47 3 8 DECK BOARD AT ONE END OF THE FORT CENTER THE BOARD BET...

Page 82: ... 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 2 X 4 X 66 ROCK WALL SIDES A T NUT 47 ...

Page 83: ... 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 W...

Page 84: ...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 85: ...N HEAD SCREWS AND WASHERS 2 MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS THREE PAN HEAD SCREWS WITH 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 2 5 8 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 86: ...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 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 WASHER 5 16 X 1 1 2 HEX BOLT INSERT T NUTS IN HOLES ON B...

Page 87: ...INTO THE 5 16 T NUTS LADDER SIDES AND FASTEN WITH 2 WOOD SCREWS 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 LADDER BACK ABOVE THE TOP STEP OF THE LADDER WITH TWO 2 WOOD SCREWS PER SIDE LADDER SIDE 2 X 4 X 66 T NUT SLOTS ON BOTTOM LADDER STEP 2 X 4 X...

Page 88: ...RILL A 3 8 HOLE THROUGH THE REAR ENTRY BOARD 2 FROM THE UNDERSIDE OF THE DECK INSERT A T NUT INTO THE BACKSIDE OF THE 3 8 HOLES ON THE REAR ENTRY BOARD 3 ATTACH THE LADDER WITH 5 16 X 1 1 2 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 3 4 REAR ENTRY BOARD 5 16 WASHER INSERT T NUTS IN HOLES ON BACK S...

Page 89: ...AILINGS 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 A BOTTOM PANEL BOARDS 2 X 4 X 28 9 16 CENTER POSTS RAILINGS DETAIL A SCALE 1 8 8 X 2 1 2 WOOD SCREWS 5 16 WASHER 5 16 T NUT 2 X 4 X 28 9 16 CENTER POST FRONT REA...

Page 90: ... ATTACH THE PANEL SLATS TO THE FORT WITH 2 WOOD SCREWS IN THE PRE DRILLED HOLES STEP 19 PANEL SLATS SWING BEAM PANEL SLAT DIMENSIONS VIEW FROM OUTSIDE THE PLAY SET SCREW PANEL SLAT REAR PANEL 5 4 X 2 5 8 X 28 1 4 2 WOOD SWING BEAM PANEL C FRONT PANEL SLATS ARE INSTALLED FLUSH TO THE NOTCH ON THE FRONT FACE BOARD DETAIL C SCALE 1 8 REAR PANEL SLAT SPACING 2 3 4 2 3 4 9 11 2 1 8 2 16 1 8 17 1 2 55 ...

Page 91: ...LES 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 56 ...

Page 92: ...UCTILE SWING HANGERS WITH THE HOLES IN THE SWINGBEAM IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP THE SWING HANGERS WILL BE ON THE BOTTOM 2 FASTEN THE 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 STEP 21 IRON DUCTILE SWING HANGERS 57 ...

Page 93: ...LUSH TO TOP OF 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 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 STEP 22 ATTACH SWING LEGS TO BRACKET 58 ...

Page 94: ...P 23 REST SWING BEAM ON FORT TWO PEOPLE ARE REQUIRED FOR THIS STEP 1 LAY THE SWING BEAM ACROSS THE 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 59 ...

Page 95: ...DERNEATH THE CHANNEL BRACKET PLACE A BOLT CAP OVER ANY EXPOSED THREADS 4 PREDRILL AN 11 64 HOLE BY 2 1 2 DEEP IN THE CENTER CHANNEL BRACKET HOLE 5 FASTEN A 3 8 X 3 1 2 LAG SCREW WITH 3 8 WASHER TO THE CHANNEL BRACKET IN THE CENTER HOLE STEP 24 MOUNT SWING BEAM TO SWING BEAM LEGS BOLT CAP CHANNEL BRACKET 11 5018 7 CARRIAGE BOLT TORQUE WASHER 3 8 WASHER 3 8 LOCK NUT 3 8 X 3 1 2 LAG SCREW PREDRILL 11...

Page 96: ...F 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 A 3 8 WASHER 5 I...

Page 97: ...EVEL STEP 26 LEVEL SWING BEAM IN 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 OUT 62 ...

Page 98: ...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 27 SWING LEG CROSS MEMBER 63 ...

Page 99: ... 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 100: ...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 65 ...

Page 101: ... 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 102: ...47 1 2 ROOF PEAK 8 X 1 1 4 WOOD SCREW 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 67 ...

Page 103: ...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 104: ...TART 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 32 HANGING THE SWINGS SPRING CLIP SWING CHAIN 69 ...

Page 105: ...OM 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 70 ...

Page 106: ...OULD 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 SUPPORT...

Page 107: ...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 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...

Page 108: ...OP SEAT BOARDS 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 73 ...

Page 109: ...OUGH 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 BE 14 BELOW THE ROPE LADDER SUPPORT 2 1 SLIDE A ROPE LADDER RUNG AGAINST THE THREE KNOTS 5 SLIDE T...

Page 110: ...REME TUBE SLIDE SEE INSTRUCTIONS ENCLOSED IN EXTREME TUBE SLIDE BOX 2 USE STEP 42A TO ATTACH THE SLIDE TO THE PLAY SET PLACE A PLASTIC T SHAPED PLUG IN THE HOLES IN THE CORNER POST HERE BEFORE MOUNTING THE SLIDE TO THE PLAY SET IN THE NEXT STEP 75 ...

Page 111: ...HING THE SLIDE TO THE FORT 1 ATTACH SLIDE ENTRY ASSEMBLY TO THE CORNER POST AND CENTER POST OF THE FORT WITH 3 8 X 3 1 2 LAG SCREWS WITH 3 8 FENDER WASHERS 2 DO NOT ATTACH THE BOTTOM RIGHT HOLE OF THE SLIDE ENTRY PLATE AT THIS TIME LEAVE THIS HOLE EMPTY 76 ...

Page 112: ...THE CORNER POST AND CENTER POST WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS 4 PLACE THE 2 X 4 X 21 1 2 END PANEL BOARD ABOVE THE 2 X 6 X 21 1 2 END PANEL BOARD AND FASTEN TO THE CENTER POST AND CORNER POST WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS 5 FROM THE INSIDE OF THE FORT FASTEN THE 5 4 X 3 X 33 PANEL SLATS WITH 2 WOOD SCREWS 6 TIGHTEN ALL HARDWARE ON THE SLIDE HEX BOLT LAG SCREWS 2 X 6...

Page 113: ...SLIDE AND THE ROPE LADDER SUPPORT ATTACH SLIDE HEADER BOARD TO POSTS WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS STEP 38C ATTACHING SLIDE HEADER BOARD 2 X 4 X 29 1 4 SLIDE HEADER BOARD 5 16 WASHER 5 16 X 3 1 2 LAG SCREW 2 X 6 X 79 1 2 ROPE LADDER SUPPORT 78 ...

Page 114: ...THE RIGHT SIDE TUBE SLIDE SIDE 3 FOR THE 2 X 4 X 18 ANGLE SUPPORTS AT THE RIGHT FRONT USE TWO2 1 2 WOOD SCREWS THROUGH THE DECK AND INTO THE ANGLE SUPPORT USE ONE 2 AND ONE 3 WOOD SCREW TO FASTEN THE RIGHT FRONT ANGLE SUPPORTS TO THE RIGHT FRONT CORNER POST 3 WOOD SCREW 2 WOOD SCREW USE TWO 2 1 2 WOOD SCREWS TO FASTEN THIS ANGLE SUPPORT TO THE DECK SPACER ANGLE SUPPORT AT RIGHT REAR 2 X 4 X 18 USE...

Page 115: ... OF THE FORT LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK 2 THE FLARED END OF THE SLIDE WILL REST ON THE BOTTOM PANEL BOARD 3 ATTACH THE SLIDE TO THE DECK WITH 1 1 4 PAN HEAD SCREWS DO NOT OVERTIGHTEN 14 X 1 1 4 PAN HEAD SCREW DO NOT OVERTIGHTEN 80 ...

Page 116: ...10 ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE FRONT 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 L...

Page 117: ...E 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 CENTER POST OR CORNER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES STEP 42 SAFETY HANDLES 82 ...

Page 118: ...ASTEN 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 83 ...

Page 119: ... 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 TIC TAC TOE MOUNT 5 4 X 3 X 17 1 2 TIC TAC TOE MOUNT 5 4 X 3 X 17 1 2 GREEN BRACKET GREEN BRACKET TIC TAC TOE AFTER ASSEMBLING 84 ...

Page 120: ... 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 45 TIC TAC TOE INSTALLATION SWING BEAM TIC TAC TOE WITH BOARDS ATTACHED 8 X 1 3 4 WOOD SCREWS 4 00 85 ...

Page 121: ...STEP 46 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 DO NOT OVER TIGHTEN FLAG 1 2 PHILLIPS HEAD SCREW 86 ...

Page 122: ...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 STEP 47 SANDBOX SEATS AND NAME PLATE 87 ...

Page 123: ...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 88 ...

Page 124: ...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 89 ...

Page 125: ...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 90 ...

Page 126: ...ur play set that will be leftover when construction is completed 2 pieces 125 3 2825 PS Panel Slats We include these parts in case the customer wishes to fill in the area where the Tic Tac Toe is located Should the Tic Tac Toe become damaged the customer could use these boards to fill in the gap until a replacement Tic Tac Toe is ordered 1 piece 125 4 4038 DS Deck Spacer This part is only used for...

Page 127: ...APPENDIX 92 ...

Page 128: ... 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 129: ...ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY 1 LEFT SIDE CHIMNEY ASSEMBLY 1 CHIMNEY FRONT 1 DESCRIPTION PICTURE QTY ...

Page 130: ...CHIMNEY 2 MOUNTING 1 ASSEMBLY 1 LEFT SIDE DORMER BLOCK 5 4X3X6 3 4 CHIMNEY REAR ASSEMBLY DESCRIPTION PICTURE QTY ...

Page 131: ...DESCRIPTION PICTURE QTY 2 RIGHT SIDE DORMER 07 0031 ASSEMBLY PLASTIC DORMER SUNBURST 2 ...

Page 132: ...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 133: ...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 134: ... 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 135: ...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 136: ... 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 137: ...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...

Page 138: ...TICE 1 Open your Tube Slide box 2 If the model number on the cover of the tube slide manual is 03 0020 then disregard the tube slide mounting steps in this manual and use the mounting steps in APPENDIX A ...

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