Gorilla Playsets Blue Ridge Mountaineer 2009 Assembly Manual Download Page 12

Page: 12 / 92

Please familiarize yourself with the manual, parts/components and general construction process of your new playset
before getting started.

SITE PLAN:

Playset height: 12’
Approximate assembly time:
12-16 Hours
{ 6 foot unobstructed safety perimeter around playset recommended }

RAD RIDE

10’ WAVE

SLIDE

ROCK WALL

SWING BELTS (2)
TRAPEZE ARM (1)

ROPE LADDER

23’

LADDER

13’

Summary of Contents for Blue Ridge Mountaineer 2009

Page 1: ...Blue Ridge Mountaineer 2009 ASSEMBLY MANUAL Copyright 2009 Gorilla Playsets All Rights Reserved Gorilla Playsets 190 Etowah Industrial Court Canton GA 30114 800 882 0272 5 MAY 2009 Version 1 4 2 ...

Page 2: ... TO THE RETAILER OR CONTACT THE RETAILER DIRECT THE RETAILER DOES NOT STOCK COMPONENTS PLEASE RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE KEEP THEM IN A SAFE PLACE WHERE YOU CAN REFER TO THEM AS NEEDED CONTACT INFO Gorilla Playsets 190 Etowah Industrial Court Canton GA 30114 Tel 678 880 3328 Fax 678 880 3329 custsrv gorillaplaysets com Check for revised instructions at www gorillaplaysets com s...

Page 3: ...stalling panel slats and Tic Tac Toe Panel step 20 Assembling Swing steps 21 28 Assembling roof and sunburst steps 29 36 Hanging swings step 37 Securing supports then adding picnic table and benches steps 38 41 Rope Ladder Installation steps 42 43 Rad Ride Assembly steps 44 52 Installing dormers and chimney steps 53 58 Installing angle supports step 59 Installing slide step 60 Installing climbing ...

Page 4: ...ess to minimize shrinkage warping and cupping Because our pine has been pre shrunk the hardware used to assemble your playset will hold tight Our preserved pine is clean odorless non staining and non irritating to humans animals or plants Gorilla s Preserved Pine uses one of the only exterior wood preservation systems that is EPA approved Our pine lumber is preserved with a preservative system con...

Page 5: ...sequent to the original purchaser gorilla playsets disclaims all other representations and warranties of any kind express implied statutory or otherwise including the implied warranties of merchantability and fitness for a particular purpose gorilla playsets will not be liable for any incidental or consequential damages Some states do not allow limitations on implied warranties or exclusion of inc...

Page 6: ...WING 50 LBS TODDLER BUCKET SWING 50 LBS INFANT SWING 35 LBS TIRE SWING 125 LBS TOTAL WEIGHT ROPE LADDER 75 LBS ROCK WALL 150 LBS ALL SLIDES 125 LBS Gorilla Playsets recommends that the weight limits for all components must not be exceeded Failure to adhere to these and other safety guidelines could result in damage to the playset and injury to the users ...

Page 7: ...lides feet first Never slide headfirst Teach children to look before they slide to make sure no one is at the bottom Teach children to never run up a slide as this increases their chances of falling The parents should have the children dress appropriately with well fitting shoes Loose clothing such as scarves and ponchos should not be worn Always take off tie up or tuck in cords and drawstrings on...

Page 8: ...ic seats or has exposed metal in the edges of the swing seat If there are already exposed metal inserts on the edge of the seat immediately remove the seats and chains to prevent serious injury Ropes cables and chains should be removed and replaced if excessive wear is found Contact Gorilla Playsets for warranted replacement parts For rusted areas on metallic members such as monkey bars hand suppo...

Page 9: ...ne Sand 5 1 52m 5 1 52m 9 2 74m 5 1 52m Coarse Sand 5 1 52m 5 1 52m 6 1 83m 4 1 22m Fine Gravel 5 1 52m 7 2 13m 10 3 05m 6 1 83m Medium Gravel 5 1 52m 5 1 52m 6 1 83m 5 1 52m Shredded Tires 10 12 3 0 3 6m N A N A N A This data is from tests conducted by independent testing laboratories on a 6 inch depth of uncompressed shredded tire samples produced by four manufacturers The tests reported critica...

Page 10: ...ppropriate depth Dig a channel along the scored line s for the base of the fort corner post and sandbox boards to rest into Dig the channel s to the same level depth The bottom of the channel s should be level to each other so your frame doesn t teeter or rock because the channel s are uneven Once you have removed enough grass and dirt slide push the frame into the channel s Place a level on the v...

Page 11: ..._ Safety Handles Pair 1 __________ Tic Tac Toe Panel 1 __________ Description Fort Hardware see following pages Description Swing Beam Hardware see following pages Description Wood Components see following pages REQUIRED TOOL LIST Standard or Cordless Drill w Phillips Bit 2 square bit provided Extension Cord if using standard drill Locking Pliers Vise Grips For Carriage Bolts 1 8 Drill Bit 3 8 Dri...

Page 12: ...truction process of your new playset before getting started SITE PLAN 12 Playset height 12 Approximate assembly time 12 16 Hours 6 foot unobstructed safety perimeter around playset recommended RAD RIDE 10 WAVE SLIDE ROCK WALL SWING BELTS 2 TRAPEZE ARM 1 ROPE LADDER 23 LADDER 13 ...

Page 13: ...ury After familiarizing yourself with all of the components read all instructions thoroughly Reading instructions after you have studied the parts will help you understand more clearly the installation process and help to eliminate unnecessary mistakes Pay close attention to the diameter and length of each bolt and screw Never tighten hardware completely at first It helps to have some adjustment f...

Page 14: ... there will not be any reference to how to offset these parts EXAMPLE OF OFFSET HOLES UP 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 thru hole but does not extend through the wood it s self When using a counter sunk hole the bolt will be inserted through the thru hole and either the head of the bolt and wash...

Page 15: ...r drive the T nut until the face of the T nut is flush to the wood This picture shows the T nut insert and installed flush to the wood This picture shows an end view of the T nut insert and installed flush to the wood WARNING DO NOT EMBED THE TOP OF THE T NUT INTO THE FACE OF THE WOOD Cross Section end views you are looking at an X ray view of the post and T nut The barrel of the T nut is in the c...

Page 16: ...ES 5 16 X 4 1 2 HEX BOLT QTY 27 5 16 X 1 1 2 HEX BOLT QTY 8 5 16 X 3 4 HEX BOLT QTY 82 5 16 WASHER QTY 231 3 8 LOCK NUT QTY 19 QTY 31 3 8 WASHER 5 16 LOCK NUT QTY 82 1 2 WASHER QTY 2 TORQUE WASHER QTY 17 14 X 1 1 4 PAN HEAD SCREW QTY 24 8 X 1 1 2 WOOD SCREW QTY 140 8 X 2 WOOD SCREW QTY 196 8 X 2 1 2 WOOD SCREW QTY 135 8 X 3 WOOD SCREW QTY 8 5 16 TEE NUT QTY 35 ...

Page 17: ...ABOVE ARE 1 1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES 3 8 x 9 CARIAGE BOLT QTY 1 3 8 x 7 CARIAGE BOLT QTY 16 QTY 2 CARIAGE BOLT 3 8 x 3 1 2 EYEBOLT LAG QTY 3 5 16 X 4 2 SQUARE DRILL BIT QTY 1 5 16 X 3 1 2 HEX LAG SCREW QTY 34 3 8 X 3 1 2 HEX LAG SCREW QTY 12 GREEN PLASTIC BOLT CAP QTY 19 ...

Page 18: ...2 BOARD LEFT SAFETY BOARD BOARD 1 BOTTOM PANEL SUPPORT 2 PICNIC TABLE 2 X 4 X 15 BENCH SUPPORT 2 PICNIC TABLE 2 X 4 X 23 VERT SUPPORT 2 PICNIC TABLE 3 2 X 4 X 30 2 1 2 X 4 X 21 BOARD 2 X 4 X 47 1 2 2 X 4 X 51 ROOF SUPPORT 2 DESCRIPTION PICTURE QTY ...

Page 19: ... 70 2 X 6 X 16 CROSS MEMBER 1 SWING BEAM ROCK WALL SIDE 2 2 X 4 X 66 2 X 4 X 58 SUPPORT 2 CENTER DECK DECK SUPPORT 2 2 X 4 X 70 2 X 4 X 70 PANEL BOARD 1 REAR TOP SUN 2 2 X 4 X 78 ROPE LADDER 1 DESCRIPTION PICTURE QTY ...

Page 20: ...M PANEL 2 X 6 X 472 12 SANDBOX BOARD 2 2 X 6 X 70 END PANEL BOARD 1 2 X 6 X 70 FRONT FACE LARGE RAY SANDBOX BOARD RUNNER SWING BEAM 4 1 2 1 X 2 X 10 3 2 X 6 X 78 4 X 4 X 47 1 5 4 X 2 X 16 1 2 X 6 X 70 REAR ENTRY BOARD DESCRIPTION PICTURE QTY ...

Page 21: ...2 4 5 5 X 3 X 28 4 DECK SPACER 1 5 4 1 X 4 X 40 4 CAP 11 ROCK WALL 8 5 7 X 3 X 23 4 BOARD 1 ROCK WALL 8 5 7 X 6 X 23 4 WALL BOARD 1 4 BOTTOM ROCK 8 7 X 6 X 23 DECK BOARD 9 3 8 PANEL SLAT 2 X 3 X 33 4 5 5 X 6 X 47 4 DECK SPACER 5 5 4 X 4 X 14 1 2 1 DESCRIPTION PICTURE QTY ...

Page 22: ...ROOF PEAK X 10 4 SEAT AND TOP 3 PICNIC TABLE X 6 X 51 4 5 ROOF FINISHER 2 TONGUE ONLY 1 X 4 X 47 2 1 ROOF STARTER 2 GROOVE ONLY 1 X 4 X 47 2 1 ROOF BOARD 18 TONGUE GROOVE 1 X 6 X 47 1 47 1 4 X 4 X 40 END WALL SLIDE 1 DESCRIPTION PICTURE QTY ...

Page 23: ...CK 1 2 X 4 X 66 SWING BEAM 2 PLASTIC COATED 4 X 6 X 120 SWING LEG 4 PLASTIC COATED 4 X 4 X 96 CORNER POST PLASTIC COATED 2 X 6 X 21 4 X 4 X 96 LADDER SIDE 1 RIGHT BOARD 1 END PANEL LADDER STEP 1 2 X 4 X 17 1 1 LEFT 2 5 4 X 3 X 18 3 4 1 ...

Page 24: ...DESCRIPTION PICTURE QTY W CHAINS RAD RIDE 5 1 BAR 1 ASSEMBLY 1 LADDER ROPE W CHAINS TRAPEZE SWINGS 2 ...

Page 25: ...PICTURE DESCRIPTION QTY SWING PLATE 1 10 1 1 EA CLIMBING ROCKS NOT SHOWN HARDWARE BOX INSTRUCTIONS A FRAME SWING LEG BRACKET ...

Page 26: ...PICTURE DESCRIPTION QTY IRON DUCTILE SWING HANGERS TIC TAC TOE ASSEMBLY 10 ROPE 6 1 1 ...

Page 27: ...1 1 2 X 1 1 2 GREEN BRACKET SPRING CLAMP 4 6 SAFETY HANDLE PAIR 1 PICTURE DESCRIPTION QTY ...

Page 28: ...PICTURE DESCRIPTION QTY 10 RADICAL WAVE SLIDE 1 1 TELESCOPE UNASSEMBLED CHIMNEY 1 UNASSEMBLED DORMER 2 ...

Page 29: ... PLAYSET 4 USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE 5 USE A HAMMER TO SEAT THE T NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW 6 THE BARREL OF THE T NUT SHOULD GO IN THE HOLE FIRST HAMMER THE T NUT UNTIL IT IS FLUSH ALMOST FLUSH TO THE CORNER POSTS HOLES AT THE TOP OF CORNER POSTS NOT USED CORNER POST SHOULD BE FACIN...

Page 30: ... 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 4 X 78 ROPE LADDER SUPPORT ON TOP OF THE RIGHT SIDE CORNER POSTS AND MEASURE 4 FROM THE TOP 4 USE 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS TO ATTACH THE HOLES OF THE ROPE LADDER SUPPORT TO THE CORNER POSTS ROPE LADDER FRONT OF FORT HEX BOLT RUNNER 5 16 WASHER SUPPORT 5 16 ...

Page 31: ...E MIDDLE OF THE CORNER POSTS THE OFFSET HOLES IN THE BOTTOM PANEL BOARD MUST FACE DOWNWARD 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 SWI...

Page 32: ...RT 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 ...

Page 33: ... THE OFFSET HOLES IN THE FRONT FACE BOARD SHOULD FACE 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 4 X 70 TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS THE OFFSET HOLES IN THE TOP PANEL BOARD SHOULD FACE UP 6 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASH...

Page 34: ...HE CORNER POSTS THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE UP 2 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T NUTS INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 PLACE THE 2 X 6 X 70 REAR ENTRY BOARD ON THE FRONT OF THE CORNER POSTS THE OFFSET HOLES IN THE FRONT FACE BOARD MUST FACE UP 4 USE 5 16 X 4 1 2 HEX BOLTS AND 5 ...

Page 35: ...CE THE 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 2 X 4 X 47 1 2 5 16 WASHER BOTTOM PANEL BOARD 5 16 X 3 1 2 LAG SCREW ...

Page 36: ...TOP OF THE DECK SPACER 8 15 8 5 1 21 3 4 16 7 16 2 1 11 16 DECK SPACER 5 4 X 3 3 8 X 40 1 2 2 WOOD SCREW STEP 8 DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1 PRE DRILL THE ENDS OF THE 5 4 X 4 X 40 1 2 DECK SPACER TO PREVENT INSTALLATION DAMAGE PRE DRILL BOTH ENDS WITH A 1 8 DRILL BIT AT THE DIMENSIONS SHOWN BELOW THE HOLE AT 21 5 8 ONLY NEEDS TO BE DRILLED...

Page 37: ...CORNER POST AND MARK THE MEASUREMENT ON THE INSIDE OF THE 2 X 4 X 78 ROPE LADDER SUPPORT 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 4 X 4 X 40 END WALL SLIDE MOUNT POST 26 ...

Page 38: ...HE DECK BOARDS THAT WERE PREVIOUSLY INSTALLED PLACE THE CENTER DECK SUPPORTS ON THE SIDES OF THE END WALL SLIDE MOUNT AND FASTEN WITH THREE 2 1 2 WOOD SCREWS USE THE PRE DRILLED HOLES IN THE DECK BOARDS AS A GUIDE AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE FOR EACH CENTER DECK SUPPORT 5 CENTER THE 2 X 4 X 70 CENTER DECK SUPPORTS ON THESE MARKS AND PUSH THE CENTER DECK SU...

Page 39: ...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 2 X 4 X 66 ROCK WALL SIDES A T NUT ...

Page 40: ...K 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 ...

Page 41: ...EEN BRACKET 90 5 16 X 1 1 2 HEX BOLT STEP 13 ROCK WALL 1 FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5 16 X 1 1 2 HEX BOLTS AND 5 16 WASHERS 2 DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T NUTS AT THIS TIME ...

Page 42: ...EN ROCKS AND TWENTY 1 1 4 PAN HEAD SCREWS 2 MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS TWO PAN HEAD SCREWS 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 1 ...

Page 43: ...A TEMPLATE DRILL A 3 8 HOLE THROUGH THE BOTTOM PANEL BOARD 2 FROM THE UNDERSIDE OF THE DECK INSERT A T NUT INTO THE BACKSIDE OF THE 3 8 HOLES ON THE BOTTOM PANEL BOARD 3 ATTACH THE 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 BOLTSON THE ROCK WALL SIDES ...

Page 44: ...S 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 ANGLE BRACKETS TO THE INSIDE OF THE LADDER RAILS WITH 5 16 X 1 1 2 BOLTS 5 16 WASHERS INTO THE 5 16 T NUTS 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 STEP LADDER 2 X 4 X 17 2 ...

Page 45: ... 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 ...

Page 46: ...COLLARS AND SLIDE THEM OVER THE DOWELS 4 LOCATE ONE OF THE GREEN BRACKETS AND PLACE THE DOWELS IN AS SHOWN 2 SCREW THE STUDS INTO THE INSERTS UNTIL TIGHT 1 LOCATE THE GREEN DOWELS AND MATCH THEM AS FOLLOWS ONE THREADED STUD END AND ONE THREADED INSERT STEP 18 TIC TAC TOE ...

Page 47: ...9 TIC TAC TOE COLLARS AND TUMBLERS ON THE DOWELS UNTIL NONE REMAIN ABOVE THE COLLARS 1 LOCATE THE TIC TAC TOE TUMBLERS AND PLACE 3 LOCATE THE GREEN BRACKET AND PLACE ON TOP OF ASSEMBLY LINE UP THE HOLES IN THE BRACKET WITH THE DOWELS ON THE UNIT ...

Page 48: ...TS ON THE BACK WALL 4 FROM THE DECK AND ATTACH WITH 2 WOOD SCREWS 6 PLACE THE TIC TAC TOE PANEL ON THE PREVIOUSLY INSTALLED BOARD AND THEN PLACE THE OTHER 1 3 4 X 1 1 2 X 10 3 4 BLOCK AT THE TOP OF THE TIC TAC TOE PANEL 7 WITH A PENCIL MAKE A MARK AT THE TOP OF THE BOARD AND SET THE ASSEMBLY ASIDE 8 PLACE THE TIC TAC TOE PANEL BLOCK BACK AT THE MARK THAT WAS PREVIOUSLY MADE AND ATTACH IT WITH 2 WO...

Page 49: ... CARRIAGE BOLTS WITH 1 2 WASHERS 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 USE LOCKING PLIERS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING 1 2 WASHER BOLT 3 1 2 CARRIAGE SWING BEAM PLATE 3 8 NUT 3 8 WASHER BOLT CAP ...

Page 50: ...BEAM 2 FASTEN THE SWING HANGER TO THE SWING BEAM USING 6 1 2 OR 7 CARRIAGE BOLTS SIZE MAY VARY FROM UNIT TO UNIT WITH TORQUE WASHERS AND 3 8 WASHERS WITH 3 8 LOCK NUTS 3 PLACE BOLT CAPS OVER EXPOSED THREADS 3 8 LOCK NUT 3 8 WASHER BOLT CAPS IRON DUCTILE 6 1 2 OR 7 CARRIAGE BOLT TORQUE WASHER ...

Page 51: ...SWING LEGS TO BRACKET 4 X 4 X 96 SWING LEG 1 PLACE THE 4 X 4 X 96 SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET 2 FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3 8 X 3 1 2 LAG SCREWS AND 3 8 WASHERS SWING LEG BRACKET 3 8 X 3 1 2 LAG SCREW 3 8 WASHER ...

Page 52: ...FOR THIS STEP 1 LAY THE SWING BEAM ACROSS THE FORT AND POSITION THE LEGS UNDERNEATH THE END OF THE BEAM 2 LINE UP THE PRE DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND SWING LEGS MAKE SURE THE IRON DUCTILES ARE FACING DOWN ...

Page 53: ...BEAM LEGS 1 FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 6 1 2 OR 7 CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM AND 3 8 LOCK NUTS WITH 3 8 WASHERS FROM UNDERNEATH 2 USE A 3 8 X 3 1 2 LAG SCREW WITH 3 8 WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET 3 PLACE A BOLT CAP OVER ANY EXPOSED THREADS ...

Page 54: ... LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE 3 FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM SUPPORT USING A 9 CARRIAGE BOLT WITH A TORQUE WASHER ON TOP AND A 3 8 LOCK NUT AND WASHER ON THE BOTTOM PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING 4 FASTEN THE SWING BEAM TO THE SWING BEAM PLATE FROM UNDERNEATH WITH A 3 8 X ...

Page 55: ...F YOUR GROUND IS RELATIVELY LEVEL YOU MAY NEED TO EITHER A SHORTEN THE END OF THE LEGS B DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR C BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE 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 ...

Page 56: ...ER 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 CROSS MEMBER 2 X 4 X 58 3 8 WASHER 3 8 X 3 1 2 LAG SCREW ...

Page 57: ... X 51 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 ROOF SUPPORT SCREW IN THIS 2 X 4 X 51 2 X 4 X 51 LOCATION ROOF SUPPORT LEFT SIDE 5 16 WASHER RIGHT SIDE USE A 2 WOOD 5 16 X 4 1 2 HEX BOLT ...

Page 58: ...S IN THE 5 4 X 10 ROOF PEAK SUPPORT TO THE PATTERN SHOWN BELOW 2 PLACE THE 5 4 X 10 ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS FLUSH TO THE SIDES FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS 5 4 X 10 ROOF PEAK SUPPORT ...

Page 59: ...TS AND THE SMOOTH ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING 2 FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS NOTE MAKE SURE THE FORT IS SQUARE BEFORE INSTALLING ROOF BOARDS THIS WILL ALLOW THE ROOF TO BE SQUARE ALONG THE EDGES 1 X 4 X 47 1 2 ROOF STARTER 1 1 2 WOOD SCREW ...

Page 60: ...STEP 32 ROOF 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 1 1 2 WOOD SCREWS 47 1 2 ROOF PEAK ...

Page 61: ... THE ROOF STARTERS EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS 2 FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS 3 PLACE A 1 X 4 X 47 1 2 ROOF FINISHER ON EACH END OF THE ROOF AND FASTEN WITH 1 1 2 WOOD SCREWS STEP 33 ROOF 1 X 6 X 47 1 2 ROOF BOARD 1 1 2 WOOD SCREW 1 X 4 X 47 1 2 ROOF FINISHER ...

Page 62: ...ATTERN SHOWN BELOW 2 PLACE THE 2 X 6 X 16 SUN CENTERED AGAINST THE 5 4 X 2 5 8 X 42 SUN SUPPORT FASTEN THE SUN TO THE SUN SUPPORT WITH 2 WOOD SCREWS STEP 34 SUNBURST 5 4 X 2 5 8 X 42 SUN SUPPORT FASTEN 2 WOOD SCREWS FROM THIS SIDE 2 X 6 X 16 SUN 4 4 ...

Page 63: ... SUPPORT FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS MAKE SURE THAT THE BOARD IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP 2 FASTEN THE SUN ASSEMBLY TO THE FORT WITH 2 WOOD SCREWS FROM THE OUTSIDE INTO THE ROOF SUPPORTS STEP 35 SUNBURST FASTEN WITH 2 WOOD SCREWS FROM THIS SIDE OF THE ROOF SUPPORT BOARDS ...

Page 64: ...H TWO 1 1 2 SCREWS 3 EQUALLY SPACE THE SMALL RAYS ABOUT THE HALF SUN THREE ON EACH SIDE OF LARGE RAY AND MARK THE POSITION OF THE SMALL SUNRAYS WITH A PENCIL 4 SECURE THE SMALL SUNRAYS ONE AT A TIME TO THE HALF SUN AND THE ROOF SUPPORT BEAMS AND LINE THEM UP WITH THE MARK DRAWN FASTEN THE SMALL SUNRAYS WITH TWO 1 1 2 WOOD SCREWS EACH REPEAT ON OTHER SIDE OF FORT NOTE ROOF BOARDS REMOVED FROM VIEW ...

Page 65: ...RING CLIP SWING CHAIN STEP 37 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 ...

Page 66: ...N 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 HOLES ON CENTER TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS SAFETY BOARD 2 X 4 X 47 1 2 LAG SCREW 5 16 X 3 1 2 5 16 WASHER ...

Page 67: ...PORT WITH THREE 2 1 2 WOOD SCREWS IN THE PATTERN SHOWN BELOW MAKE SURE TO ASSEMBLE THE THE PICNIC TABLE SUPPORT AND THE PICNIC TABLE VERTICAL SUPPORT TO ACCOMODATE OPPOSITE SIDES OF THE PICNIC TABLE MAKE SURE THE ASSEMBLY IS SQUARE BEFORE PROCEEDING TO THE NEXT STEP 3 MEASURE OUT 15 ON THE SANDBOX BOARDS FROM THE OUTSIDE OF THE CORNER POSTS TO ENSURE THAT THE ASSEMBLY IS SQUARE 4 FASTEN THE ASSEMB...

Page 68: ...E CORNER POST SO THAT THE TOP IS AT 18 FROM THE GROUND ATTACH IT WITH THREE 2 1 2 WOOD SCREWS IN EACH END THEN LEVEL SEAT SUPPORT AND ATTACH IT TO THE VERTICAL SUPPORT ON EACH SIDE 3 REPEAT THESE STEPS FOR THE OPPOSITE SIDE OF THE PLAYSET BENCH SUPPORT 2 X 4 X 23 PICNIC TABLE 2 1 2 WOOD SCREW ROCK WALL REMOVED FOR ASSEMBLY CLARIFICATION ...

Page 69: ...CREW ROCK WALL REMOVED FOR ASSEMBLY CLARIFICATION STEP 41 PICNIC TABLE 1 ATTACH THE PICNIC TABLE SEAT ON THE SEAT SUPPORTS WITH TWO 2 WOOD SCREWS IN EACH END 2 ATTACH THE PICNIC TABLE TOPS TO THE TABLE SUPPORTS WITH TWO 2 WOOD SCREWS IN EACH END ...

Page 70: ...EP 42 ROPE LADDER ASSEMBLY 1 DRILL THREE 1 8 PILOT HOLES 2 DEEP INTO THE BOTTOM OF THE ROPE LADDER SUPPORT SEE DIMENSIONS BELOW 2 PLACE THE EYEBOLT LAGS INTO THE HOLES AT THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIGHTEN ...

Page 71: ...E LADDER ASSEMBLY 1 PLACE THE HOOKS ON THE END OF THE ROPE LADDER ASSEMBLY THROUGH THE EYE OF THE EYBOLT LAG 2 THREAD THE BOTTOM OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE A SECURE KNOT ...

Page 72: ...E THE LEFT AND RIGHT ENTRANCE SECTION 2 FASTEN THE LEFT AND RIGHT SECTIONS TOGETHER ALONG THE RIBS OF THE SLIDE SECTION WITH 5 16 X 3 4 HEX BOLTS 5 16 WASHERS AND 5 16 LOCK NUTS 3 DO NOT FULLY TIGHTEN BOLTS UNTIL THE ENTIRE UNIT HAS BEEN FULLY ASSEMBLED THIS WILL ALLOW FOR NECESSARY FLEX OF THE SLIDE BODY WHILE ASSEMBLING ...

Page 73: ...NUTS SEE BELOW FOR ATTACHMENT LOCATIONS 3 LIKE THE PREVIOUS STEP DO NOT FULLY TIGHTEN THE HARDWARE UNTIL THE SLIDE IS FULLY ASSEMBLED AND ATTACHED TO THE FORT SLIDE ENTRY PANEL 5 16 WASHER NUT 5 16 LOCK SLIDE ENTRY ASSEMBLY ATTACH SLIDE ENTRANCE SECTION ASSEMBLY TO THESE HOLES THESE HOLES WILL BE USED TO ATTACH THE SLIDE TO THE FORT THIS APPLIES TO THE HOLES ON THE OPPOSITE OF THE SLIDE ENTRY PANE...

Page 74: ...0 SLIDE SECTION AND THE 90 EXIT SECTION YOU WILL ASSEMBLE THE SLIDE EXIT THE SLIDE EXIT IS ASSEMBLED THE SAME WAY THAT THE OTHER 90 SECTION WAS ASSEMBLED 3 DO NOT FULLY TIGHTEN HARDWARE UNTIL ENTIRE SLIDE HAS BEEN ASSEMBLED STEP 46 ASSEMBLING THE SLIDE SECTIONS 5 16 WASHER 5 16 WASHER 5 16 X 3 4 HEX BOLT 5 16 LOCK NUT 90 SLIDE SECTION 90 SLIDE EXIT SECTION ...

Page 75: ...IBS SO THAT IT LOOKS LIKE THE ONE SHOWN BELOW 2 ATTACH THE SLIDE SECTIONS WITH 5 16 X 3 4 HEX BOLTS 5 16 WASHERS AND 5 16 LOCK NUTS 3 DO NOT FULLY TIGHTEN HARDWARE UNTIL SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT 5 16 WASHER HEX BOLT 5 16 X 3 4 5 16 LOCK NUT 5 16 WASHER LINE UP THE RIBS OF THE SLIDE SECTIONS ...

Page 76: ...ECTION TO THE FOOT STAND AND FOOTER SUPPORT WITH 5 16 X 3 4 HEX BOLTS 5 16 WASHERS AND 5 16 LOCK NUTS 3 DO NOT FULLY TIGHTEN THE HARDWARE UNTIL THE SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT 5 16 LOCK NUT 5 16 WASHER START HERE AND WORK CLOCKWISE 5 16 X 3 4 FOOTER SUPPORT FOOT STAND 5 16 WASHER HEX BOLT THE TOP HOLE OF THE EXIT SECTION WILL BE EXPOSED ...

Page 77: ... THE FOOT STAND AND THE OTHER END INSIDE THE FOOTER SUPPORT 2 ATTACH USING 5 16 X 3 4 HEX BOLTS 5 16 WASHERS AND 5 16 LOCK NUTS 3 DO NOT FULLY TIGHTEN HARDWARE UNTIL SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT 5 16 WASHER 5 16 LOCK NUT 5 16 WASHER HEX BOLT 5 16 X 3 4 FOOTER STRAP ...

Page 78: ...BS OF THE SLIDE ENTRY AND SLIDE SECTIONS 1 ATTACH THE SLIDE ASSEMBLY TO THE SLIDE ENTRY ASSEMBLY WITH 5 16 X 3 4 HEX BOLTS 5 16 WASHERS AND 5 16 LOCK NUTS 2 DO NOT FULLY TIGHTEN HARDWARE UNTIL SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT STEP 50 ATTACHING THE SLIDE BODY TO THE SLIDE ENTRY ...

Page 79: ...H SLIDE ENTRY ASSEMBLY TO THE CORNER POST AND CENTER POST OF THE FORT WITH 5 16 X 3 1 2 LAG SCREWS WITH 5 16 WASHERS 2 DO NOT ATTACH THE BOTTOM RIGHT HOLE OF THE SLIDE ENTRY PLATE AT THIS TIME LEAVE THIS HOLE EMPTY 5 16 WASHER 5 16 X 3 1 2 LAG SCREW ...

Page 80: ...POST WITH OFFSET HOLES DOWN AND MOUNT THE BOTTOM RIGHT HOLE WITH A 5 16 X 4 1 2 HEX BOLT AND 5 16 WASHER INTO THE HOLE OF THE CORNER POST AND INTO THE T NUT 3 FASTEN THE REMAINING HOLES OF THE 2 X 6 X 21 1 2 END PANEL BOARD TO THE CORNER AND CENTER POSTS WITH 5 16 X 3 1 2 LAG SCREWS 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 AND COR...

Page 81: ...BLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW 4 ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1 1 4 WOOD SCREWS FROM THE ROOF BOARDS OF THE ROOF ASSEMBLIES STEP 53 DORMER USE 1 1 4 WOOD SCREWS IN THESE LOCATIONS EACH SIDE DORMER ROOF RIGHT SIDE ASSEMBLY ASSEMBLY DORMER ROOF LEFT SIDE DORMER SUNRAY ASSEMBLY ...

Page 82: ...DORMER ROOF PEAK 1 FIND THE DORMER ROOF PEAK ASSEMBLY 2 PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1 1 2 WOOD SCREWS STEP 54 DORMER ...

Page 83: ...USE 2 WOOD SCREWS IN THESE LOCATIONS EACH SIDE 1 CENTER THE DORMER ASSEMBLIES ON THE ROOF 2 USE 2 WOOD SCREWS TO FASTEN THE DORMERS TO THE ROOF STEP 55 DORMER ...

Page 84: ...EFT SIDE OF THE CHIMNEY 2 ATTACH THE FRONT AND LEFT 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 STEP 56 CHIMNEY USE A 2 WOOD SCREW IN THIS LOCATION CHIMNEY REAR CHIMNEY RIGHT SIDE ...

Page 85: ...TACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2 AND 1 1 4 WOOD SCREWS STEP 57 CHIMNEY USE A 2 WOOD SCREW IN THIS LOCATION EACH SIDE USE 1 1 4 WOOD SCREWS IN THIS LOCATION EACH SIDE ...

Page 86: ... 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 4 WOOD SCREW IN EACH SIDE STEP 58 CHIMNEY 1 1 2 WOOD SCREW CHIMNEY MOUNTING BLOCK 5 4 X 3 X 6 3 4 1 1 4 WOOD SCREW ...

Page 87: ...OD SCREWS ON TOP OF THE BRACE AND ONE 2 AND ONE 3 WOOD SCREW TO FASTEN THE ANGLE SUPPORTS TO THE CORNER POSTS 5 MOUNT THE ANGLE SUPPORT THAT WILL GO UNDERNEATH THE RAD RIDE IN THE SAME MANNER THAT THE 13 ANGLE SUPPORTS WERE MOUNTED WITH TWO 2 1 2 WOOD SCREWS THROUGH THE DECK AND INTO THE ANGLE SUPPORT 1 THE FOUR 2 X 4 X 13 ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT AND BACK OF THE FORT...

Page 88: ...G AT THE FRONT 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 STEP 60 WAVE SLIDE ...

Page 89: ...H THE HOLE IN THE END PANEL BOARD 2 THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND HINT TO REDUCE THE AMOUNT OF SLACK IN THE ROPE LIFT THE ROCK WALL ASSEMBLY SLIGHTLY WHEN TYING THE KNOT IN THE BOTTOM ROCK WALL BOARD WHEN YOU LOWER THE ASSEMBLY THE ROPE WILL TIGHTEN ...

Page 90: ...STEP 62 SAFETY HANDLES 1 PLACE THE SAFETY HANDLES ON THE UNIT AS SHOWN BELOW AND ATTACH WITH THE PROVIDED HARDWARE ...

Page 91: ...OUNT BETWEEN THE SWING BEAM AND THE CORNER 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 STEP 63 TELESCOPE 1 1 4 WOOD SCREW TELESCOPE TELESCOPE BRACKET ...

Page 92: ...he quality of our product Excellent Above average Average Below average Poor Would you recommend this product Yes No Comments _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ __________________________________________________________...

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