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Gorilla Playsets Malibu Pioneer Peak 1500DWR, Manual, Page: 10 / 171

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Gorilla Playsets Malibu Pioneer Peak 1500DWR Manual Download Page 10

Safety Guidelines………………………………………...............................……...Pages 3-6

Leveling Fort, General Information and Definitions……………………...............Pages 6-8

How to Install T-Nuts, Board Identification, Predrill Lag Screw Directions and

 

Swing Beam Loading........................................................................................Pages 9-13 

Site Plan, Required Tool List and Kit Contents...............................................Pages 14-15

Hardware, Lumber and Accessory Checklist......……………………………....Pages 16-42

Adding T-Nuts to Corner Posts...…………………………………..………...…........... Step 1

Framing Fort……………………………………..…………………………..……..... Steps 2-9

Mounting Deck...............…………………………....……………….…………...….... Step 10

Rock Wall Assembly and Installation…..…………...…..……..……...….…….. Steps 11-15

Ramp Assembly and Installation.……………………..……............................. Steps 16-19

Center Post and Panel Slat Installation.......................................................... Steps 20-21

Swing Beam Assembly……….……………………..……..............................… Steps 22-29

Roof Assembly.……...……………………….………........................................ Steps 30-35

Front Gable Assembly/Installation.................................................................. Steps 36-37

Front Wall Assembly and Completion of Main Roof....................................... Steps 38-42

Hanging Swings, Safety Board…………………………………............…........ Steps 43-44

Picnic Table Assembly and Installation...……………………………......…....... Steps 45-47

Tire Swing Assembly and Installation…………………………….....……......... Steps 48-55

Rope Ladder Assembly and Installation…………………….…….……................... Step 56

Telescope and Safety Handles………………………..……............................. Steps 57-58

Climbing Ropes, Sandbox Seats/Name Plate, Steering Wheel..................... Steps 59-61

Solar Wall Light, Ground Stakes.................................................................... Steps 62-63

PART 2: Clatterbridge Assembly....................................................................... Steps 1-34

Appendix: Chimney and Dormer Instructions, Bridge Mesh Instructions............Page 152

PLEASE READ OWNER’S MANUAL CAREFULLY 

BEFORE STARTING ASSEMBLY!

TABLE OF CONTENTS

2

Summary of Contents for Malibu Pioneer Peak 1500DWR

Page 1: ...urt Canton GA 30114 www gorillaplaysets com Malibu Pioneer Peak Model 1500DWR BOXES 1501 1509N 1509W 1510 1511 1523 1528 1529 Tire Swing Slide Box Amber Post Option BOXES 1519 1533 2bx 1522 1524 Timbe...

Page 2: ...at 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 N...

Page 3: ...ardware 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...

Page 4: ...s 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 frequent...

Page 5: ...____________ Comments ________________________________________________________________________________________________ _________________________________________________________________________________...

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

Page 7: ...in 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 askin...

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 likeli...

Page 9: ...Model 1500DWR BOXES 1501 1509N 1509W 1510 1511 1523 1528 1529 Tire Swing Slide Box REV A 6 15 2017 Amber Post Option BOXES 1519 1533 2bx 1522 1524 Timber Shield Post Option BOXES CB X1 TSB 120...

Page 10: ...ion Steps 20 21 Swing Beam Assembly Steps 22 29 Roof Assembly Steps 30 35 Front Gable Assembly Installation Steps 36 37 Front Wall Assembly and Completion of Main Roof Steps 38 42 Hanging Swings Safet...

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...

Page 12: ...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...

Page 13: ...oose 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...

Page 14: ...re 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 temp...

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 fami...

Page 16: ...s 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...

Page 17: ...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 WARN...

Page 18: ...RST 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 NUT...

Page 19: ...rt 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...

Page 20: ...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 Exampl...

Page 21: ...r 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...

Page 22: ...rize yourself with the manual parts components and general construction process of your new playset before getting started SITE PLAN Playset height 12 feet Swing Beam height 7 feet 7 1 2 inches Deck h...

Page 23: ...Slides Accessories ___ Qty Description ___ 2 Swingbelt w Chains ___ 1 Trapeze Swing w Chains ___ 1 Wave Slide ___ 10 Rock Wall Grip assorted colors ___ 1 Telescope ___ 2 Safety Handles pair ___ 2 Plas...

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...

Page 25: ...N 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 QT...

Page 26: ...16 X 4 1 2 HEX BOLT QTY 25 5 16 TEE NUT QTY 55 8 X 2 WOOD SCREW QTY 94 PAGE 1 OF 1 QTY 6 PAN HEAD SCREW REV A 9 19 2014 JH QTY 111 1 4 WASHER 8 X 3 WOOD SCREW QTY 5 QTY 6 5 16 WASHER 14 x 1 1 4 11 00...

Page 27: ...x 3 1 2 8 X 2 5 16 WASHER QTY 4 8 X 1 1 2 WOOD SCREW QTY 60 1509W HARDWARE PAGE 1 OF 1 9 11 2014 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 A...

Page 28: ...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...

Page 29: ...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...

Page 30: ...X 2 1 2 LAG SCREW QTY 4 8 X 1 1 4 PAN HEAD SCREW EYE BOLT QTY 2 3 8 WASHER QTY 2 3 8 16 X 3 4 DIA I D X 5 16 X 1 1 2 HEX BOLT QTY 4 8 X 2 1 2 WOOD SCREW QTY 127 11 0065 1523 Hardware 9 17 2014 JH 8 9...

Page 31: ...GE 1 OF 1 1 16 2015 SO 2 SQUARE DRIVE BIT QTY 1 5 16 X 2 1 2 HEX BOLT QTY 2 8 9 1 4 3 2 5 6 7 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS PICTURE VIEWS SHOWN ABOVE ARE 1 1 SCALE AND CA...

Page 32: ...TTS 2 2 X 4 X 17 LADDER STEP 2 4 1700 LS 5 2 X 4 X 27 1 2 PICNIC TABLE SEAT SUPPORT 2 4 2750 PTTS 2 2 X 4 X 24 ROPE LADDER STEP 2 4 2400 RLST 6 2 X 4 X 13 ANGLE SUPPORT 2 4 1300 AS 2 X 4 X 18 ANGLE SU...

Page 33: ...LL SIDE 1 HOLE ON CENTER 2 4 6600 RWS 1 LEFT 1 RIGHT 2 2 X 4 X 66 LADDER SIDE 2 4 6600 LLS 2 4 6600 LRS 1 2 X 4 X 58 SWING BEAM CROSS MEMBER 2 HOLES ON CENTER 2 4 5800 CM 2 LEFT 2 RIGHT 2 X 4 X 35 15...

Page 34: ...7000 DS 2 X 4 X 70 REAR TOP PANEL BOARD 2 HOLES OFFSET 1 CENTERED 2 4 7000 RTPB 1 2 2 X 6 X 70 BOTTOM PANEL AND SANDBOX BOARD 4 HOLES OFFSET 2 6 7000 SB 1 2 X 6 X 70 FRONT FACE BOARD 4 HOLES OFFSET 2...

Page 35: ...PE LADDER RUNNER FRONT RIGHT 2 6 10200 RLRFR 1 1 1 2 X 6 X 102 ROPE LADDER SUPPORT FRONT RIGHT 2 6 10200 RLSFR 5 X 11 X 46 97 ROOF PANEL RIGHT ASSEMBLY 5 11 4697 RPRA 1 2 5 4 X 2 5 8 X 13 1 4 PICNIC T...

Page 36: ...17 1 2 TIC TAC TOE MOUNT 125 3 1750 TTTM 1 1 5 4 X 5 X 10 81 ROOF PANEL PEAK SUPPORT 125 5 1081 RPPS 5 4 X 3 X 18 3 4 LADDER BACK 125 3 1875 LB 2 5 4 X 6 X 10 ROOF PEAK SUPPORT 125 6 1000 RPS 1 5 4 X...

Page 37: ...LL BOARD 125 6 2387 RWB 11 5 4 X 6 X 22 SANDBOX SEAT 125 6 2200 SS 2 4 5 4 X 6 X 43 PICNIC TABLE TOP AND SEATS 125 6 4300 PTTS 11 5 4 X 6 X 47 3 8 DECK BOARD 125 6 4737 DB 1 X 2 X 32 ROOF BATTEN 1 2 3...

Page 38: ...RONT 1 4 7688 RSF 1 X 4 X 76 7 8 TONGUE ONLY ROOF FINISHER REAR 1 4 7688 RFR 1 1 RIGHT 1 LEFT 1 X 4 X 29 29 TONGUE ONLY ROOF FINISHER FRONT 1 4 2929 RFF 2 2 1 X 4 X 15 3 4 WALL PANEL BOARD 1 4 1575 WP...

Page 39: ...14 1 X 5 X 76 7 8 TONGUE AND GROOVE ROOF BOARD 1 5 7688 RB 4 X 4 X 72 TIRE SWING LEG 4 4 7200 AFL 2 X 4 X 47 1 2 TIRE SWING CROSS MEMBER 2 4 4750 CM 2 1 PICTURE DESCRIPTION QTY 31...

Page 40: ...E SOLID CEDAR WOOD OPTION PICTURE DESCRIPTION QTY 1 PLASTIC COATED 4 X 6 X 120 SWING BEAM SB 3 0 4 PLASTIC COATED 4 X 4 X 108 CORNER POST 2 PLASTIC COATED 4 X 4 X 108 SWING BEAM LEG SL 1 PLASTIC COATE...

Page 41: ...OARD 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...

Page 42: ...X 4 X 36 3 4 1 3 3675 RPB2 ROOF STARTER 1 1 X 3 X 36 3 4 2 ROOF BOARD 1 X 4 X 36 3 4 1 X 5 X 36 3 4 1 4 3675 RS 2 2 BOARD 2 FINISHER 1 4 3675 RF 2 1 1 4 3675 RPB1 1 X 4 X 36 3 4 2 1 5 3675 RB ROOF PEA...

Page 43: ...H CHAIN SAFETY BOARD RAILING DECK TIRE SWING CROSS MEMBER 15 2 4 6600 R 6 BRIDGE RAIL 2 X 4 X 66 2 X 4 X 36 3 4 2 6 3675 BPB 1 PANEL BOARD BOTTOM 4 4 2900 CP 1 CENTER POST 2 X 6 X 36 3 4 4 X 4 X 29 2...

Page 44: ...CK SPACER 7 125 4 2937 DS 11 5 4 X 4 X 29 3 8 5 4 X 3 X 28 1 2 PANEL SLAT 125 4 3650 DB 5 4 X 4 X 36 1 2 20 DECK BOARD 125 3 2850 PS 5 4 X 3 X 16 BRIDGE RAIL SLAT 125 3 1600 RS DESCRIPTION PICTURE QTY...

Page 45: ...PICTURE DESCRIPTION QTY ROPE 13 2 LADDER 03 0013 ROPE 3 W CHAINS ROPES ROPES WAVE SLIDE 1 12 or 13 04 0006 RAMP HANDRAIL BAR 04 0002 W CHAINS 1 1 TRAPEZE SWINGS 10 ROCK WALL 2 37...

Page 46: ...CTURE DESCRIPTION QTY HARDWARE BOXES 1501 1509N 1509W 1510 1511 1523 1528 HARDWARE BOXES SWING PLATE 11 5002 1 10 ROCKS 2 1 EA CLIMBING ROCKS 07 0008 IS A PACK OF 5 A FRAME SWING LEG BRACKET 11 5010 3...

Page 47: ...PICTURE DESCRIPTION QTY IRON DUCTILE SWING HANGERS 11 4012 TELESCOPE 07 0001 6 BRACKET 28 0001 2 TIRE SWING SWIVEL 11 4010 TIRE SWING W CHAINS 04 0014 1 1 1 39...

Page 48: ...2 DORMER SUNBURST PLASTIC 07 0031 CLATTER BRIDGE MESH PANELS 06 2004 1pr NOT SHOWN PICTURE DESCRIPTION QTY 90 GREEN BRACKET 11 5013 SPRING CLIP 11 4003 6 9 SAFETY HANDLES PAIR 07 0005 2pr 40...

Page 49: ...PICTURE DESCRIPTION QTY 2 PLASTIC SUNBURST 07 0028 G 1 FRONT PLASTIC ARCH 07 0027 G PLASTIC DORMER WINDOW 07 0029 G 2 SOLAR WALL LIGHT 09 2003 2 41...

Page 50: ...UFACTURER LOGO PLATE 1 1pr 1 GROUND STAKE PAIR 07 0016 P TIC TAC TOE UNASSEMBLED 07 0010 STEERING WHEEL 07 0004 1 2 UNASSEMBLED DORMER 1529 BOX 1 UNASSEMBLED CHIMNEY 1529 BOX OR SLIDE BOX PICTURE DESC...

Page 51: ...DING THE FORT SIDE OF THE PLAYSET 4 USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE 5 USE A HAMMER TO SEAT THE T NUTS AFTER INSERTING THEM INTO THE...

Page 52: ...M HOLES WILL BE USED LATER 3 LAY THE 2 X 6 X 47 1 2 BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN 4...

Page 53: ...E BOTTOM OF THE CORNER POSTS THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN 3 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T NUTS INSTALLED ON TH...

Page 54: ...X 6 X 70 FRONT FACE BOARD STEP 3A DRILL HOLES FOR BRIDGE CHAINS 1 LOCATE ONE 2 X 4 X 70 DECK SUPPORT AND ONE 2 X 6 X 70 FRONT FACE BOARD 2 MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD 3 PLACE...

Page 55: ...E ASSEMBLIES 2 FASTEN THE 2 X 4 X 70 DECK SUPPORTS TO THE HOLES AT 54 3 4 WITH 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS FROM THE INSIDE OF THE FORT 5 16 WASHER 5 16 X 4 1 2 HEX BOLT LEFT SIDE OF PLAY S...

Page 56: ...S INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 PLACE THE 2 X 6 X 70 FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS THE HOLES IN THE FRONT FACE BOARD SHOULD BE OF...

Page 57: ...ST 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...

Page 58: ...ALL 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...

Page 59: ...SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS 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 DECK SUPPOR...

Page 60: ...OFFSET HOLES UP AND 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 OFFSET HOLES UP LAG SCREW 5...

Page 61: ...EN 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 BO...

Page 62: ...Y CORNER POSTS AND ATTACH IT WITH 2 WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER 1 PLACE THE 5 4...

Page 63: ...USE THE HOLE ON CENTER AS A GUIDE AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE 3 USE 2 WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT 4 CENTER THE 2 X 4 X...

Page 64: ...HE DECK BOARDS DECK BOARD FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2 WOOD SCREWS THROUGH THE 1 START WITH A 5 4 X 6 X 47 3 8 DECK BOARD AT ONE END OF THE FORT CENTER THE BOA...

Page 65: ...NUT STEP 11 ROCK WALL 1 FIND TWO 2 X 4 X 66 ROCK WALL SIDES 2 POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY 3 INSERT T NUTS INTO THE INSIDE OF THE ROCK WALL...

Page 66: ...AND ATTACH WITH TWO 2 WOOD SCREWS IN EACH SIDE 3 CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS FASTENING EACH BOARD WITH TWO 2 WOOD SCREWS ON EACH END 4 THE FINAL BOARD WILL BE THE B...

Page 67: ...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...

Page 68: ...OCKS 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 YOU...

Page 69: ...OF THE FRONT FACE BOARD USING THE 90 GREEN BRACKETS AS A TEMPLATE DRILL A 3 8 HOLE THROUGH THE BOTTOM PANEL BOARD 2 GO UNDERNEATH THE DECK TO INSERT A T NUT INTO THE BACKSIDE OF THE 3 8 HOLES IN THE F...

Page 70: ...UPPORT 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 PLA...

Page 71: ...IDE 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 INSI...

Page 72: ...AGAINST EACH OF THE RAMP SIDE BOARDS FASTEN THE FLOOR BOARDS TO THE RAMP SUPPORT BOARDS WITH TWO 2 1 2 WOOD SCREWS PER SUPPORT THE BOARDS SHOULD BE FLUSH AT THE SQUARE END OF THE RAMP SIDES 2 PLACE T...

Page 73: ...LIMBING RAMP 1 HAMMER A 3 8 T NUT INTO THE INSIDE OF EACH POST NOTE THIS IS THE SIDE OF THE POST THAT DOES NOT HAVE THE COUNTERBORED HOLE 2 SCREW A 3 8 EYE BOLT WITH A WASHER INTO THE T NUT SO IT LOOK...

Page 74: ...BELOW 2 PLACE T NUTS ON THE INSIDE OF THE HOLES IN THE RAMP SIDE BOARDS SET THE T NUTS WITH A HAMMER FLUSH NEAR FLUSH WITH THE RAMP SIDES 3 FASTEN THE 90 GREEN BRACKET TO THE RAMP SIDES WITH 5 16 X 1...

Page 75: ...POST EYE BOLTS ON OUTSIDE OF RAMP POSTS RAMP SIDE A STEP 18A CLIMBING RAMP 1 ATTACH A RAMP POST TO EACH RAMP SIDE WITH 5 16 X 2 1 2 HEX BOLTS AND 5 16 WASHERS THE EYE BOLTS SHOULD BE ON THE OUTSIDE OF...

Page 76: ...RE 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...

Page 77: ...T 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...

Page 78: ...1 1 2 ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD USING THE BRACKETS AS A TEMPLATE DRILL A 3 8 HOLE THROUGH THE BOTTOM PANEL BOARD 2 FROM THE UNDERSIDE OF THE DECK INSERT A T NUT INTO THE BACKSIDE OF...

Page 79: ...OLES AS A GUIDE THEN ATTACH 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 CAREFU...

Page 80: ...SIDE NOW THREAD IT THROUGH THE EYE BOLT NOW THREAD IT THROUGH THE HOLE IN THE ROPE MOUNT ON THE ROPE LADDER SUPPORT REPEAT THIS PROCESS FOR THE OTHER ROPE ON THE OTHER SIDE OF THE RAMP 3 TO MAKE THE R...

Page 81: ...UT INTO THE CENTER POST HOLE YOU JUST DRILLED FASTEN THE CENTER POST TO THE RAILING WITH A 5 16 X 4 1 2 HEX BOLT AND 5 16 WASHER AT THE TOP SQUARE THE CENTER POST TO THE DECK AND SECURE THE BOTTOM OF...

Page 82: ...THIS ARE INSTALLED FLUSH SWING BEAM REAR PANEL SWING BEAM BOARD LEAVE THIS SLAT OFF UNTIL AFTER THE CLATTER BRIDGE IS INSTALLED FRONT PANEL SLAT IS INSTALLED FLUSH TO THE NOTCH ON THE SIDE PANEL ROCK...

Page 83: ...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...

Page 84: ...DE 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...

Page 85: ...H 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...

Page 86: ...F 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...

Page 87: ...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...

Page 88: ...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 EXPO...

Page 89: ...TO MAKE THE SWING BEAM LEVEL 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...

Page 90: ...S MEMBER 1 POSITION THE 2 X 4 X 58 SWING LEG CROSS MEMBER AGAINST THE SWING BEAM LEGS 2 LEVEL CROSS MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS MEMBER HOLES 3 USE 3 8 X 3 1 2 L...

Page 91: ...35 15 ROOF SUPPORTS TO THE FORT WITH 5 16 X 4 1 2 HEX BOLTS THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE 2 CONNECT THE ENDS WITH A 2 1 2 WOOD SCREW ROOF SUPPORT LEFT SIDE 2 X 4 X...

Page 92: ...THE 5 4 X 6 X 10 ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 2 WOOD SCREWS REPE...

Page 93: ...ER SHOULD 1 PLACE THE 1 X 4 X 76 7 8 ROOF STARTER REAR BOARD AT THE PEAK OF THE ROOF THE HOLES IN THE ROOF THE ROOF STARTER WILL EITHER BE CENTERED ON THE ROOF SUPPORTS OR THEY WILL BE OFFSET EXAMPLE...

Page 94: ...THIS SIDE OF THE ROOF GETS SEVEN ROOF BOARDS 2 FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS 3 PLACE THE 1 X 4 X 76 7 8 ROOF FINISHER AT THE END OF THE ROOF ASSEMBLY AND FASTEN W...

Page 95: ...THE FLAT TOP END OF THE ROOF STARTER FRONT SHOULD BE PLACED FLUSH TO THE TOP EDGE OF THE ROOF STARTER REAR 2 FASTEN THE ROOF STARTER FRONT TO THE ROOF SUPPORTS WITH 1 1 2 WOOD SCREWS 3 PLACE THE 1 X 5...

Page 96: ...MOUNTING BLOCK INSERT TWO 8 X 2 WOOD SCREWS THROUGH THE MOUNTING BLOCK INTO THE ROOF BOARD 2 MOUNT THE DORMER ON TOP OF THE ROOF 4 1 2 FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE BOTTOM EDG...

Page 97: ...AT THE BOTTOM OF THE SEAM THIS PROVIDES YOU FREEDOM FOR ADJUSTABILITY ASSEMBLY 8 X 1 1 4 WOOD SCREW 2 WOOD SCREW ROOF PANEL BATTENS FASTEN THE ROOF PANEL PEAK FLUSH TO THE SIDES OF THE ROOF BOARD PEA...

Page 98: ...E THE GABLE ASSEMBLY LEFT OR RIGHT UNTIL FINAL POSITION IS PULL TOWARDS YOU FINISHER LEFT SLIDE LEFT OR RIGHT FINISHER RIGHT ROPE LADDER SUPPORT EMPTY TEST FIT ONLY ROOF OVERHANG GABLE ASSEMBLY 1 X 4...

Page 99: ...THE GABLE ASSEMBLY LEFT SIDE AND THE OPPOSITE END WITH THE COUNTERSUNK HOLE FLUSH AGAINST THE LEFT FRONT CORNER POST MAKE SURE THE ANGLED END OF THE WALL PANEL SUPPORT IS FLUSH TO THE INSIDE OF THE G...

Page 100: ...INISHERS SO YOU CAN ACCESS THE WOOD SCREWS ATTACHING THE WALL PANEL SUPPORTS ONCE YOU REMOVED THE WALL PANEL SUPPORTS ON BOTH SIDES PROCEED TO LOOSEN UP THE WOOD SCREWS ATTACHING THE GABLE ASSEMBLY FR...

Page 101: ...THE ROOF PANEL CENTERED BETWEEN THE ROOF SUPPORTS FLUSH THE BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD MAKE SURE IT IS PARALLEL TO THE ROOF SUPPORTS INSERT 1 1 2 WOOD...

Page 102: ...RD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1 4 FROM THE SIDE EDGE OF THE PREVIOUS WALL PANEL BOARD THE WALL PANEL...

Page 103: ...RST 1 MOUNT THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF THE PLASTIC SUNBEAM MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS FASTEN THE PLASTIC SUNBEAM TO THE ROOF SU...

Page 104: ...ART 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 43 HANGING THE SWINGS SPRING CLIP SWING CHAI...

Page 105: ...K 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 CA...

Page 106: ...R 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 PLAC...

Page 107: ...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 REA...

Page 108: ...WOOD SCREWS 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...

Page 109: ...SCREW SWING LEG BRACKET 3 8 X 3 1 2 4 X 4 X 72 TIRE SWING LEG 1 PLACE THE 4 X 4 X 72 TIRE SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET 2 FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WI...

Page 110: ...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 49 TIRE SWING BOLT CAP...

Page 111: ...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...

Page 112: ...IGHTLY TO MATCH YOUR 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 G...

Page 113: ...EAM 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...

Page 114: ...LEVEL STEP 53 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...

Page 115: ...NG 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 SCREW...

Page 116: ...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 STEP 55 HANGING THE TIRE SWING SPRING CLIP TIRE SWING CH...

Page 117: ...E OF THE ROPE LADDER SUPPORT PULL EACH ROPE TAUGHT 2 MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 6 INCHES AND TIE A KNOT THE BOTTOM OF THE KNOT SHOULD BE 6 INCHES BELOW THE ROPE LADDER SUP...

Page 118: ...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 FAS...

Page 119: ...R 1 LOCATE THE SAFETY HANDLE BAG 2 ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD 3 ATTACH EACH SAFETY HANDLE TO THE PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED...

Page 120: ...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 S...

Page 121: ...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 SE...

Page 122: ...ILOT 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 REA...

Page 123: ...E THE HEAD OF THE SCREW IS STICKING OUT ABOUT 3 8 FROM THE OUTSIDE FACE OF THE WALL PANEL BOARD 3 MOUNT THE SOLAR WALL LIGHT ON TO THE WALL USING THE HEAD OF THE WOOD SCREW AS A HANGER IN TO THE SLOT...

Page 124: ...GAINST 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 AT...

Page 125: ...PART 2 CLATTER BRIDGE ASSEMBLY 117...

Page 126: ...IS 3 LAY OUT EACH OF THE 4 X 4 X 96 CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE TOWER OF THE CLATTER BRIDGE 4 USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE...

Page 127: ...THE SANDBOX BOARD TO THE T NUTS INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 LAY THE 2 X 4 X 36 3 4 TOP PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS 4 USE 5 16 X 4 1 2 HEX...

Page 128: ...SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS THE COUNTERSUNK HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET UP 4 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH THE TOP HOLES OF THE BOTTO...

Page 129: ...ASSEMBLIES 2 FASTEN THE 2 X 4 X 36 3 4 DECK SUPPORTS TO THE HOLES AT 54 1 2 WITH 5 16 X 4 1 2 HEX BOLTS AND 5 16 D STEP 4 DECK SUPPORTS LEFT SIDE DECK SUPPORT HEX BOLT 5 16 X 4 1 2 FRONT OF TOWER FRA...

Page 130: ...DBOX BOARD TO THE T NUTS INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 PLACE THE 2 X 4 X 36 3 4 TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS 4 USE 5 16 X 4 1 2 HEX BOLTS AND...

Page 131: ...THE SANDBOX BOARD SHOULD BE OFFSET DOWN 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...

Page 132: ...ECK OF THE TOWER TO THE DECK OF THE FORT PLACE A DECK BOARD ACROSS THE 2 X 4 S THEN PLACE A 2 X 4 X 66 BRIDGE RAIL ON TOP OF THE DECK BOARD AND ON TOP OF THE FORT DECK PLACE A LEVEL ON TOP OF THE 66 B...

Page 133: ...5 4 X 4 X 29 3 8 DECK SPACERS BETWEEN THE CORNER POSTS MAKE EACH DECK SPACER FLUSH TO THE INSIDE SURFACE OF THE 2 X 6 OR THE OUTSIDE SURFACE OF THE CORNER POSTS DO NOT ATTACH THE DECK SPACERS YET 5 4...

Page 134: ...OTTOM PANEL BOARD SHOULD FLUSH TO THE TOP OF THE DECK 3 FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS WITH 5 16 WASHERS LEAVE THE LAG SCREWS LOOSE UNTIL THE NEXT STEP...

Page 135: ...4 TIGHTEN THE FASTENERS IN THE 2 X 6 AT THE FRONT OF THE TOWER AND IN THE BOTTOM PANEL BOARD WITH HOLES 5 TIGHTEN THE FASTENERS IN THE 2 X 6 ON THE LEFT SIDE OF THE TOWER 6 PLACE THE 2 X 4 X 36 3 4 B...

Page 136: ...ECK BOARDS TO THE DECK SUPPORTS WITH 2 WOOD SCREWS B C STEP 11 DECK 1 INSTALL THE 5 4 X 6 X 36 1 2 DECK BOARDS LEAVE A UNIFORM APPROXIMATELY 1 4 SPACE BETWEEN THE D 5 4 X 6 X 36 1 2 FRONT OF TOWER DEC...

Page 137: ...EL SLATS 2 IF THE SLATS ARE NOT ALREADY PRE DRILLED THEN PRE DRILL THE PANEL SLATS 1 FROM EACH END ON CENTER WITH A 1 8 DRILL BIT SEE TOP LEFT PICTURE BELOW 3 ON THE LEFT SIDE OF THE TOWER INSTALL TWO...

Page 138: ...TIC TAC TOE MOUNTS 4 USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIE TAC TOE MOUNT STEP 13 TIC T...

Page 139: ...THE LEFT SIDE OF THE TOWER ON THE INSIDE THE TIC TAC TOE SHOULD BE APPROXIMATELY 3 OFF THE DECK 2 ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH 8 X 1 3 4 WOOD SCREWS 8 X 1 3 4 WOOD SCREWS PAN...

Page 140: ...E RAIL TO THE CORNER POST WITH 5 16 X 3 1 2 LAG SCREWS WITH 5 16 WASHERS 2 MEASURE 16 FROM THE TOP OF EACH BRIDGE RAIL AND MAKE A PENCIL MARK ON THE INSIDE OF THE CORNER POSTS 3 PLACE THE BOTTOM OF EA...

Page 141: ...THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER POST ON THE PLAY SET 2 LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS 3 ATTACH...

Page 142: ...RAIL SLATS 3 FROM THE FACE OF THE CORNER POSTS AND ATTACH WITH 2 WOOD SCREWS THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS 3 ATTACH THE REMAINING SLATS TO THE UNIT WITH 3 SPACING BETWEEN TH...

Page 143: ...USE A HAMMER TO SEAT THE T NUTS INTO THE BOARDS 2 FLIP ALL 15 BRIDGE DECK BOARDS OVER SO THAT THE FLANGE OF THE T NUT IS FACING DOWN LAY THE BRIDGE DECK BOARDS OUT ON A FLAT SURFACE AS SHOWN BELOW ST...

Page 144: ...DECK BOARD 96 CHAIN SECTIONS B 1 LOCATE TWO 96 CHAIN SECTIONS THAT SHIPPED WITH THE CLATTER BRIDGE 2 PLACE THE CHAINS OVER THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW 3 LINE UP THE 18TH LINK IN...

Page 145: ...BETWEEN THE BOLTS 4 PLACE A 5 16 X 1 3 4 HEX BOLT WITH 5 16 WASHER THROUGH THE CHAIN LINK THEN THROUGH THE 5 16 WASHER THEN THROUGH THE HOLE IN THE BRIDGE DECK BOARD AND SCREW IT INTO THE T NUT TIGHT...

Page 146: ...CORRECT GAP GO UNDERNEATH THE TOWER DECK AND USE A QUICK PANEL BOARD ON THE TOWER THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS STEP 21 BRIDGE DECK CHAIN INSTALLATION LINK TO ATTACH...

Page 147: ...OF SUPPORTS FLUSH WITH ONE ANOTHER PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW 3 USE FOUR 8 X 2 WOOD SCREWS TO ATTACH THE ROOF PEAK SUPPO...

Page 148: ...E AS SHOWN BELOW AND MAKE MARKS ON THE CORNER POSTS ON THE INSIDE 3 DRILL A 9 64 HOLE BY 2 1 2 DEEP AT EACH MARK 4 REPEAT SUBSTEPS 2 3 ON THE INSIDE OF THE OTHER POSTS AS POINTED OUT BELOW REPEAT THE...

Page 149: ...N INSIDE STEP 24 INSTALL ROOF SUPPORT ASSEMBLIES 1 PLACE TWO ROOF SUPPORT ASSEMBLIES ON THE CLATTER BRIDGE TOWER DECK 2 THE TRIANGLE ROOF PEAK SUPPORT SHOULD FACE THE INSIDE 3 ATTACH EACH ROOF SUPPORT...

Page 150: ...OVERHANG 8 X 1 1 2 WOOD SCREW 1 X 4 X 36 3 4 ROOF STARTER STEP 25 ROOF STARTERS 1 PLACE THE 1 X 4 X 36 3 4 GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE ROOF REFER TO THE DIAGRAM BELOW AND MAKE THE OV...

Page 151: ...K BOARD 1 TO ROOF PEAK BOARD 2 WITH FOUR 8 X 1 1 2 WOOD STEP 26 ROOF PEAK ASSEMBLY TO THE ROOF STARTERS WITH EIGHT 8 X 1 1 4 WOOD SCREWS 2 PLACE THE ROOF PEAK ASSEMBLY ON TOP OF THE ROOF STARTERS FAST...

Page 152: ...O THE ROOF SUPPORTS WITH FOUR 8 X 1 1 2 WOOD SCREWS 3 REPEAT SUBSTEP 2 FOR THE NEXT 3 ROOF BOARDS 4 LOCATE A 1 X 4 X 36 3 4 ROOF FINISHER TONGUE ONLY INSERT THE TONGUE OF THE ROOF FINISHER INTO THE GR...

Page 153: ...AND 5 PLACE THE STEPS INTO THE SLOTS ON THE PUT THE SCREWS INTO THE OTHER SIDE 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 LADDER SIDES A...

Page 154: ...STEP 29 MOUNTING THE LADDER 1 PLACE THE TOP OF THE BRACKETS 1 1 2 DOWN FROM THE TOP OF THE 2 X 6 2 CENTER THE LADDER SIDE TO SIDE 3 MARK THROUGH EACH BRACKET ONTO THE 2 X 6 4 DRILL 3 8 HOLES AT EACH...

Page 155: ...SAFETY HANDLES 1 PLACE A PLASTIC SAFETY HANDLE ON EACH CORNER POST ABOVE THE LADDER 2 ADJUST THE SAFETY HANDLE UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD 3 FASTEN EACH SAFETY HANDLE WITH THE 1 4 FLAT...

Page 156: ...SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK SPACER 2 PREDRILL 1 8 HOLES INTO THE DECK SPACER AT THE SCREW LOCATIONS 3 ATTACH THE SLIDE TO THE DECK SPACER WITH 1 1 4 PAN HEAD SCREWS DO NOT...

Page 157: ...RIDGE RAILS STEP 32 PANEL SLAT 1 PLACE THE 5 4 X 3 X 28 1 4 PANEL SLAT FLUSH TO THE SIDE OF THE BRIDGE RAILS AS SHOWN BELOW 2 ATTACH THE PANEL SLAT TO THE ROPE LADDER SUPPORT AND FRONT FACE BOARD ON T...

Page 158: ...UGS AND TAP THEM INTO EACH END OF THESE HOLES 1 LOCATE FOUR PLASTIC PLUGS 2 APPLY A DAB OF CLEAR SILICONE ONTO EACH PLUG AND TAP THEM INTO THE FRONT AND BACK SIDE OF THE HOLES SHOWN BELOW STEP 33 PLAS...

Page 159: ...2 PAN HEAD SCREWS IN EACH HOLE TO FASTEN THE PLASTIC SUNBURST TO THE ROOF SIDES REPEAT SUBSTEPS 2 THROUGH 4 FOR THE PLASTIC SUNBURST ON THE OTHER SIDE OF THE ROOF PLASTIC DORMER SUNBURST PIECES A CLA...

Page 160: ...APPENDIX 152...

Page 161: ...TURE VIEWS SHOWN ABOVE ARE 1 1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES QTY 22 8 X 1 1 4 WOOD SCREW 1529 HARDWARE PAGE 1 OF 1 1 16 2015 S O 2 SQUARE DRIVE BIT QTY 1 8 X 1 3 4 WOOD SCREW QTY...

Page 162: ...10 1355 DS DORMER MOUNT CHIMNEY FRONT 2 10 1500 CRS ASSEMBLY 4 4 DORMER ROOF 2 17 1850 DSRA ASSEMBLY DORMER SUNRAY 2 13 1828 DRPA PANEL ASSEMBLY RIGHT ASSEMBLY ASSEMBLY 2 3 1150 DM DORMER SIDE 2 2 CHI...

Page 163: ...2 3 0675 CMB 1 SIDE ASSEMBLY CHIMNEY LEFT 2 8 0700 CRA ASSEMBLY CHIMNEY REAR 2 10 1500 CLS 1 CHIMNEY MOUNTING BLOCK 1 PICTURE DESCRIPTION QTY...

Page 164: ...ND TWO DORMER SUNRAY ASSEMBLIES 3 PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF...

Page 165: ...WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS 2 MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DO...

Page 166: ...PANEL ASSEMBLIES 2 PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY ASSEMBLIES THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK MAKE SURE THE PRE DRILLED HOLES ON TH...

Page 167: ...IDES 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 LOCAT...

Page 168: ...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...

Page 169: ...NG BLOCK TO THE ROOF WITH 1 1 2 WOOD SCREWS YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY 2 AFTER INSTALLING THE...

Page 170: ...4 Repeat substeps 1 through 3 for the mesh panel on the lower bridge rail on the opposite side 2 The recessed area in the grommet will receive the washer Place a pan head screw through a washer TWO F...

Page 171: ...ign the edge of the mesh border with the end of the go from the center grommet to the other side and do the same from the center grommet to one end of the mesh and repeat the mark drill install fasten...

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