Gorilla Playsets Savannah II 1500FT Manual Download Page 10

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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 16-36

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

Framing Fort……………………………………..…………………………..…....... Steps 2-10

Mounting Deck...............…………………………....……………….…………...….... Step 11

Rock Wall Assembly and Installation…..…………...…..……..……...….…….. Steps 12-16

Angle Support Installation.……………………..……........................................ Steps 17-18

Center Tarp Supports, Panel Slat and Tarp Board Installation....................... Steps 19-21

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

Tarp Installation.……...……………………….……….............................................. Step 30

Hanging Swings, Safety Board…………………………………............…........ Steps 31-32

Picnic Table Assembly and Installation...……………………………......…....... Steps 33-35

Wave Slide…………………………….....……......................................................... Step 36

Tic Tac Toe Assembly and Installation…………………….…….……............... Steps 37-38

Climbing Ropes, Flag Kit, Sandbox Seats/Name Plate, Crown..................... Steps 39-41

Ground Stakes, Steering Wheel …................................................................ Steps 42-43

Center Post and Clatter Bridge Chain Board.................................................. Steps 44-45

PART 2: Clatterbridge Assembly....................................................................... Steps 1-31

PLEASE READ OWNER’S MANUAL CAREFULLY

BEFORE STARTING ASSEMBLY!

TABLE OF CONTENTS

Summary of Contents for Savannah II 1500FT

Page 1: ...ghts Reserved 190 Etowah Industrial Court Canton GA 30114 www gorillaplaysets com Savannah II Model 1500FT BOXES 1501 1502 1509N 1509T 1516 Extreme Tube Slide II Box Slide Box 51 1030 T 51 1030 T Stained Post Option BOXES 1520 2bx 1522 1519 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 ________________________________________________________________________________________________ ____________________________________________________________________________________________________________ ____________________________________________________________________________________________________________ __________________________________________________________...

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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: ...Model 1500FT BOXES 1501 1502 1509N 1509T 1516 Extreme Tube Slide II Box Slide Box REV A 8 30 2018 Stained Post Option BOXES 1520 2bx 1522 1519 ...

Page 10: ...Steps 12 16 Angle Support Installation Steps 17 18 Center Tarp Supports Panel Slat and Tarp Board Installation Steps 19 21 Swing Beam Assembly Steps 22 29 Tarp Installation Step 30 Hanging Swings Safety Board Steps 31 32 Picnic Table Assembly and Installation Steps 33 35 Wave Slide Step 36 Tic Tac Toe Assembly and Installation Steps 37 38 Climbing Ropes Flag Kit Sandbox Seats Name Plate Crown Step...

Page 11: ... children to never run up a slide as this increases their chances of falling The parents should have the children dress appropriately with well fitting shoes Loose clothing such as scarves and ponchos should not be worn Always take off tie up or tuck in cords and drawstrings on children s clothing These things can get caught on playground equipment and strangle a child Teach children not to climb ...

Page 12: ...f excessive wear is found Contact us for warranted replacement parts Swing chains rings ropes etcetera should always be fastened to a rotating swing hanger NEVER attach a chain ring rope etcetera to a stationary hanger such as but not limited to an eye bolt Severe wear could occur leading to an injury For rusted areas on metallic members such as monkey bars hand supports brackets etc sand and repa...

Page 13: ...loose fill surfacing materials are acceptable Surfacing materials are acceptable such as the types and depths shown in the table Fall Heights and Materials Type Of Material 6 in depth 9 in depth 12 in depth Double Shredded bark mulch 6 Fall Height 10 Fall Height 11 Fall Height Wood Chips 6 Fall Height 7 Fall Height 12 Fall Height Fine Sand 5 Fall Height 5 Fall Height 9 Fall Height Shredded Tires 1...

Page 14: ...ore the ground around the outside edges of the sandbox boards on the high side of the fort This is the area that will be dug in Make sure to score deep enough the scored lines will be your digging template Push the frame off and away from the scored area far enough to dig and remove dirt to reach the appropriate depth Dig a channel along the scored line s for the base of the fort corner post and s...

Page 15: ... parts that are structurally defective We use a high quality lumber in our structures however you should inspect each part for splinters or rough spots and sand them smooth to prevent injury After familiarizing yourself with all of the components read all instructions thoroughly Reading instructions after you have studied the parts will help you understand the installation process and help to elim...

Page 16: ...ts EXAMPLE OF OFFSET HOLES UP EXAMPLE OF OFFSET HOLES DOWN Counter sunk holes Many of the parts that will be used have counter sunk holes A counter sunk hole is one that surrounds one side of a through hole but does not extend through the wood it s self When using a counter sunk hole the bolt will be inserted through the through hole and either the head of the bolt and washer or nut and washer wil...

Page 17: ...T nut until the face of the T nut is flush to the wood This picture shows the T nut inserted and installed flush to the wood This picture shows an end view of the T nut installed flush to the wood WARNING DO NOT EMBED THE TOP OF THE T NUT INTO THE FACE OF THE WOOD Cross Section end view you are looking at an X ray view of the post and T nut The barrel of the T nut is in the corner post the line is...

Page 18: ...IRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T NUTS INTO THE CORNER POSTS A T NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT YOU INSERT THE T NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS THE T NUT HAS A BARREL SHAPED END WHICH GOES INTO THE HOLE IN THE CORNER POST THE T NUT ALSO HAS AN FLANGE SHAPED END WITH TEETH THE TEETH PENETRATE IN...

Page 19: ...art to fit into a certain area of the play set B We need the designation to be simple The 3600 is the length of the board It means the board is 36 inches long If the code were 3625 then the board is 36 1 4 in length The BPB abbreviation stands for Bottom Panel Board The wood part bill of materials in the instructions has a description which will match the abbreviation closely In the event that the...

Page 20: ...e 2 x 4 board installation shown below Place the board into position Spot Drill through the holes in the 2 x 4 board into the corner posts with an 11 64 drill bit Remove the 2 x 4 board Continue Example 3 8 diameter x 5 lag screw This would be like the 4 x 4 board installation shown below Place the LAG SCREW DIAMETER DRILL BIT SIZE 5 16 DIAMETER 9 64 3 8 DIAMETER 11 64 Pre drilling holes for lag s...

Page 21: ...ar is 125 lbs Maximum Allowable swinging weight for a three position swing 1 The maximum allowable swinging weight at each Swing Belt position is 150 lbs 2 The maximum allowable swinging weight at the Trapeze position is 125 lbs 3 The MAXIMUM SWING BEAM LOAD IS 425 lbs SWINGING WEIGHT TRAPEZE BAR REV A 8 29 2012 125 LBS MAX 150 LBS MAX SWINGING WEIGHT 150 LBS MAX SWINGING WEIGHT SWING BELT SWING B...

Page 22: ...etting started SITE PLAN Playset height 10 feet 10 3 4 inches Swing Beam height 7 feet 7 1 2 inches Deck height 5 feet Approximate assembly time 16 20 hours 6 foot unobstructed safety perimeter around playset recommended Extreme Tube Slide II Wave Slide Ladder Swing Belts 2 Trapeze 1 Rock Wall Clatter Bridge Rope Ladder 14 ...

Page 23: ... or Tape See Step 26 in Part II Clatterbridge with Tarp ___ Clear Silicone Caulk KIT CONTENTS Swings Slides Accessories ___ Qty Description ___ 2 Swingbelt w Chains ___ 1 Trapeze w Chains ___ 1 Wave Slide ___ 1 Extreme Tube Slide II ___ 10 Rock Wall Grips assorted colors ___ 1 Steering Wheel ___ 1 Tic Tac Toe ___ 2 Safety Handle ___ 2 Flag Kit ___ 2 96 Chain Sections ___ 1 Lower Level Tarp ___ 1 C...

Page 24: ... WASHER QTY 34 3 8 WASHER QTY 31 5 16 X 1 1 2 HEX BOLT QTY 8 5 16 X 4 1 2 HEX BOLT QTY 14 9 1 4 3 2 5 6 7 8 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS PICTURE VIEWS SHOWN ABOVE ARE 1 1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES 14 X 1 1 4 PAN HEAD SCREW QTY 4 TORQUE WASHER QTY 17 8 X 2 1 2 WOOD SCREW QTY 52 5 16 TEE NUT QTY 22 8 X 2 WOOD SCREW QTY 189 16 ...

Page 25: ...AN BE USED TO MATCH BOLT AND SCREW SIZES 5 16 X 3 1 2 3 8 x 9 CARRIAGE BOLT QTY 1 QTY 12 SCREW HEX LAG QTY 1 DRIVE BIT 2 SQUARE 1501 HARDWARE PAGE 2 OF 2 REV A 9 10 2014 JH 3 8 x 6 1 2 CARRIAGE BOLT QTY 2 3 8 x 3 1 2 CARRIAGE BOLT QTY 2 3 8 X 3 1 2 HEX LAG SCREW QTY 12 PLASTIC BOLT CAP QTY 19 3 8 x 7 CARRIAGE BOLT QTY 14 17 ...

Page 26: ...S PICTURE VIEWS SHOWN ABOVE ARE 1 1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES 1 4 WASHER QTY 10 5 16 WASHER QTY 2 1502N HARDWARE PAGE 1 OF 1 REV B 8 18 2015 JH 8 X 1 3 4 WOOD SCREW QTY 4 5 16 X 2 1 2 HEX BOLT QTY 2 5 16 TEE NUT QTY 2 8 X 2 1 2 WOOD SCREW QTY 14 3 8 X 1 1 8 BLACK PLASTIC PLUG QTY 10 18 ...

Page 27: ...5 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 0071 1509N HARDWARE 3 8 X 1 1 8 BLACK PLASTIC PLUG QTY 4 8 X 2 1 2 WOOD SCREW QTY 18 5 16 X 3 1 2 HEX LAG SCREW QTY 26 QUICK LINK QTY 2 5 16 X 1 3 4 HEX BOLT QTY 30 19 ...

Page 28: ...BOLTS AND SCREWS PICTURE VIEWS SHOWN ABOVE ARE 1 1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES QTY 29 5 16 WASHER LAG SCREW QTY 15 1516 HARDWARE PAGE 1 OF 1 PRELIMINARY 9 19 2012 J H 5 16 X 3 1 2 3 8 WASHER QTY 4 8 X 2 WOOD SCREW QTY 16 3 8 x 5 LAG SCREW QTY 4 5 16 TEE NUT QTY 14 20 ...

Page 29: ... PTSS 2 4 1300 AS 4 2 5 4 6 2 2 SEAT SUPPORT PICNIC TABLE 2 X 4 X 27 1 2 2 X 4 X 13 ANGLE SUPPORT PICNIC TABLE TOP SUPPORT 2 4 1475 PTTS 1501 2 X 4 X 14 3 4 2 X 4 X 17 LADDER STEP 2 4 1700 LS 2 X 4 X 18 ANGLE SUPPORT 2 4 1800 AS 2 X 4 X 32 1 2 PICNIC TABLE LEG 2 4 3250 PTL 21 ...

Page 30: ... SBEP 2 1 1 1 2 2 1 2 X 4 X 58 SWING BEAM CROSS MEMBER 2 4 5800 CM 2 X 4 X 66 LADDER LEFT SIDE 2 4 6600 LLS 2 X 4 X 66 LADDER RIGHT SIDE 2 4 6600 LRS 2 X 4 X 66 ROCK WALL SIDE 2 4 6600 RWS 2 X 4 X 70 DECK SUPPORT 2 4 7000 DS 2 X 4 X 70 CENTER DECK SUPPORT 2 4 7000 CDS 22 ...

Page 31: ... 6 4750 ESPB 2 X 6 X 70 FRONT FACE BOARD 2 6 7000 FFB 2 X 6 X 70 SANDBOX BOARD 2 6 7000 SB 4 X 4 X 47 1 2 SWING BEAM MOUNT 4 4 4750 SBM 5 4 X 3 X 13 1 4 PICNIC TABLE SLAT 125 3 1325 PTS 5 4 X 3 X 17 1 2 TIC TAC TOE MOUNT 125 3 1750 TTTM 1 2 1 1 1 2 2 PICTURE DESCRIPTION QTY 23 ...

Page 32: ... LB 5 4 X 3 X 23 7 8 ROCK WALL CAP 125 3 2387 RWC 5 4 X 3 X 28 1 4 PANEL SLATS 125 3 2825 PS 5 4 X 4 X 40 3 8 DECK SPACER 125 4 4038 DS 5 4 X 6 X 22 SANDBOX SEAT 125 6 2200 SS 5 4 X 6 X 23 7 8 BOTTOM ROCK WALL BOARD 125 6 2387 BRW 5 4 X 6 X 23 7 8 ROCK WALL BOARD 125 6 2387 RWB 24 ...

Page 33: ... PICNIC TABLE TOP SEAT BOARD 125 6 4300 PTTS 4 11 3 2 5 4 X 6 X 47 3 8 DECK BOARD 125 6 4737 DB 1502 2 X 4 X 47 3 8 TARP BOARD 2 4 4738 TB 2 X 4 X 71 7 8 CENTER TARP SUPPORT 2 4 7188 CTS PICTURE DESCRIPTION QTY 25 ...

Page 34: ... 2 4 2900 BD 2 X 4 X 33 VERTICAL TARP SUPPORT 2 4 3300 VTS 2 X 4 X 36 3 4 SAFETY BOARD WITH CHAIN HOLES 2 4 3675 SBH 2 X 4 X 36 3 4 SAFETY BOARD 2 4 3675 SB 2 X 4 X 36 3 4 TARP BOARD 2 4 3675 TB 2 X 4 X 66 RAIL 2 4 6600 R 2 X 6 X 36 3 4 BOTTOM PANEL BOARD 2 6 3675 BPB 26 ...

Page 35: ...POST 4 4 2900 CP 1 20 2 7 5 4 X 3 X 16 RAIL SLAT 125 3 1600 RS 5 4 X 4 X 29 3 8 DECK SPACER 125 4 2937 DS 5 4 X 4 X 36 1 2 DECK BOARD 125 4 3650 DB 5 4 X 3 X 28 1 2 PANEL SLAT 125 3 2850 PS 11 PICTURE DESCRIPTION QTY 27 ...

Page 36: ... BPB 2 X 6 X 47 1 2 PANEL BOARD 2 6 4750 PB 5 4 X 3 X 28 1 4 PANEL SLATS 125 3 2825 PS 2 X 4 X 47 1 2 CLATTERBRIDGE CHAIN BOARD 2 4 4750 CCB 2 X 4 X 47 1 2 SAFETY BOARD 2 4 4750 SBEP 2 X 6 X 47 1 2 PANEL BOARD CLATTERBRIDGE 2 6 4750 PBC 2 X 6 X 67 ROPE LADDER RUNNER 2 6 6700 RLR 28 ...

Page 37: ...ROPE LADDER SUPPORT 2 6 6700 RLS 2 X 6 X 70 FRONT TOP PANEL BOARD 2 6 7000 FTPB 2 X 6 X 70 SANDBOX BOARD 2 6 7000 SB 4 X 4 X 32 RAD 5 POST 4 4 3200 R5P 1 1 2 X 4 X 18 ANGLE SUPPORT 2 4 1800 AS PICTURE DESCRIPTION QTY 29 ...

Page 38: ...4 X 4 X 96 CORNER POST 4 X 4 X 96 CORNER POST 4 X 6 X 120 SWING BEAM 4 X 4 X 108 SWING LEG PICTURE DESCRIPTION QTY 4 4 1 2 30 ...

Page 39: ...10 ROCK WALL ROPE 10 1007 1 03 0017 2 W CHAINS 3 ROPES 04 0006 LADDER 04 0002 BAR 1 10 1008 10 WAVE SLIDE ROPE 13 TRAPEZE SWING W CHAINS 1 PICTURE DESCRIPTION QTY 31 ...

Page 40: ...DWARE BOXES 1501 1502 1509N 1516 HARDWARE BOXES INSTRUCTIONS 5 ROCKS ARE IN ONE 11 5002 1 PLATE ROCKS 1 10 EA 1 SWING BAG 07 0008 CLIMBING ROCK A FRAME SWING LEG BRACKET 11 5010 DESCRIPTION PICTURE QTY 32 ...

Page 41: ...DESCRIPTION PICTURE QTY 6 BRACKET 4 11 4003 GREEN 11 5013 90 SPRING CLIP 6 IRON DUCTILE SWING HANGER 11 4012 33 ...

Page 42: ...DESCRIPTION PICTURE QTY CHAIN 1 96 1 08 1006 TARP 57 1 2 X 34 05 1012 1 4 09 1014 2 2 FLAG KIT CLATTER BRIDGE CLATTER BRIDGE TARP 100 x 47 3 8 05 0010 34 ...

Page 43: ...Note Actual product may vary DESCRIPTION PICTURE QTY 07 0004 NOT SHOWN UNASSEMBLED LOGO PLATE 1 MANUFACTURER PR 1 1 07 0010 STAKES 07 0016 P PAIR GROUND TIC TAC TOE STEERING WHEEL 1 35 ...

Page 44: ... NOT SHOWN 1 1 CHANNEL 11 5018 BRACKET 06 2004 1PR CLATTERBRIDGE MESH NOT SHOWN SAFETY WARNING PLATE 11 5023 1 DESCRIPTION PICTURE QTY 5 EXTREME TUBE SLIDE II 03 0020 36 ...

Page 45: ...IRECTION 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 7 PLACE A PLASTIC PLUG INTO ALL THE CORNER POST TOP HOLES USE A DAB OF CLEAR SILICONE ON THE PLUGS TO SEAL THE HOLES CORNER POST T NUT NO T NUT IN THE...

Page 46: ... BOARD CLATTERBRIDGE 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 PANEL BOARD CLATTERBRIDGE TO THE T NUTS INSTALLED ON THE CORNER POSTS THE TOP HOLES WILL BE USED LATER 5 LAY THE 2 X 4 X 47 1 2 TOP PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS THE HOLES IN THE TOP PANEL BOARD MUST BE OFFSET DOWN 6 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS...

Page 47: ...STS THE TOP HOLES WILL BE USED LATER 6 LAY THE 4 X 4 X 47 1 2 SWING BEAM MOUNT ON TOP OF THE RIGHT SIDE CORNER POSTS THE THREE COUNTERSUNK HOLES IN THE MIDDLE OF THE SWING BEAM MOUNT MUST FACE DOWNWARD 7 FIND TWO TORQUE WASHERS PLACE A 6 1 2 CARRIAGE BOLT THROUGH THE TORQUE WASHER MAKING SURE THAT THE TEETH ARE FACING IN THE SAME DIRECTION AS THE THREADS OF THE CARRIAGE BOLT PLACE THE TORQUE WASHE...

Page 48: ...HE 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 5 16 X 4 1 2 HEX BOLT WASHER REAR OF FORT 5 16 2 X 4 X 70 DECK SUPPORT COUNTER SUNK HOLES ON CENTER RIGHT SIDE OF FORT 40 ...

Page 49: ... 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 FRONT TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS THE HOLES IN THE FRONT TOP PANEL BOARD SHOULD BE OFFSET UP 6 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH THE TOP HOLES OF THE FRONT TOP P...

Page 50: ...S INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 PLACE THE 2 X 6 X 70 BOTTOM PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS THE 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 BOTTOM PANEL BOARD TO THE T NUTS INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 5 PLACE THE 2 X 4 X 7...

Page 51: ... 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 RIGHT SIDE OF FORT 5...

Page 52: ...TH 5 16 WASHERS OFFSET HOLES UP END PANEL BOARD LAG SCREW 5 16 WASHER 5 16 X 3 1 2 2 X 4 X 47 1 2 FRONT OF FORT ON CENTER 5 16 WASHER COUNTER SUNK HOLES FORT FRONT OF 2 X 4 X 14 BOTTOM PANEL BOARD 5 16 X 3 1 2 LAG SCREW 2 PLACE THE 2 X 4 X 14 BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD CLATTER BRIDGE AND FASTEN TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREW WITH 5 16 WASHER 44 ...

Page 53: ...47 1 2 END PANEL BOARDS REMOVED FOR CLARITY STEP 9 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 3 8 DECK SPACERS TO PREVENT INSTALLATION DAMAGE PRE DRILL BOTH ENDS WITH A1 8 DRILL BIT AT THE DIMENSIONS SHOWN BELOW THE HOLE AT 20 3 16 IS THE CENTER OF THE BOARD AND ONLY NEEDS TO BE DRILLED ONCE THIS HOLE IS TO ATTACH ...

Page 54: ...E DECK SPACERS TO THE CENTER DECK SUPPORT 4 CENTER THE 2 X 4 X 70 CENTER DECK SUPPORT ON THESE MARKS AND PUSH THE CENTER DECK SUPPORT FLUSH TO THE BOTTOM SIDE OF THE DECK BOARDS 5 USING TWO 2 1 2 WOOD SCREWS INSTALL THE 2 X 4 X 70 CENTER DECK SUPPORT THROUGH THE OUTSIDE OF THE 2 X 6 AND INTO THE END OF THE CENTER DECK SUPPORT REPEAT THIS STEP ON THE OPPOSITE END OF THE FORT USE 2 1 2 WOOD SCREWS I...

Page 55: ... 8 FRONT OF FORT 2 START WITH A 5 4 X 6 X 47 3 8 DECK BOARD AT ONE END OF THE FORT CENTER THE BOARD BETWEEN THE FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2 WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW LEAVE A UNIFORM APPROX 1 4 SPACE BETWEEN THE DECK BOARDS NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK BOARDS LAY ALL DECK...

Page 56: ...TEP 12 ROCK WALL 1 FIND TWO 2 X 4 X 66 ROCK WALL SIDES 2 POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY 3 INSERT T NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER T NUT 48 ...

Page 57: ...STENING EACH BOARD WITH TWO 2 WOOD SCREWS ON EACH END 4 THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE ATTACH WITH TWO 2 WOOD SCREWS PER SIDE 5 IN SOME CASES THERE WILL BE EXCESS LENGTH ON THE ROCK WALL SIDES THIS IS DUE TO MILLING VARIATIONS AND IS ALSO USED TO HELP LEVEL THE ROCK WALL SIDES ON UNEVEN GROUND 6 ROCK WALL SIDES MAY NOT BE EVEN WITH THE BOTTOM ROCK WALL BOARD DUE T...

Page 58: ...L 1 FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5 16 X 1 1 2 HEX BOLTS AND 5 16 WASHERS 2 DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T NUTS AT THIS TIME 5 16 WASHER GREEN BRACKET 90 5 16 X 1 1 2 HEX BOLT 50 ...

Page 59: ...4 PAN HEAD SCREWS WITH WASHERS 2 MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL NOTE THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL YOUR ACTUAL 3 PLACE THE 5 4 X 3 X 23 7 8 ROCK WALL TOP CAP ON TOP OF THE ROCK WALL SIDES FASTEN THE ROCK WALL TOP CAP TO THE ROCK WALL SIDES WITH 2 WOOD SCREWS...

Page 60: ...THROUGH THE FRONT FACE BOARD 2 FROM THE UNDERSIDE OF THE DECK INSERT A T NUT INTO THE BACK SIDE 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 WASHER 5 16 X 1 1 2 HEX BOLT INSERT T NUTS IN HOLES ON BACK SIDE O...

Page 61: ...THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT 4 AT THE TOP USE 2 1 2 WOOD SCREWS THROUGH THE ANGLE SUPPORT INTO THE BOTTOM PANEL BOARD AT THE BOTTOM USE ONE 2 WOOD SCREW AND ONE 3 WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST SCALE 2 15 SHOULD BE FLUSH OR LOWER 2 X 4 X 13 ANGLE THAN THE DECK SUPPORT S...

Page 62: ... 2 PANEL BOARD CLATTER BRIDGE THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT 4 AT THE TOP USE 2 1 2 WOOD SCREWS THROUGH THE ANGLE SUPPORT INTO THE 2 X 6 X 47 1 2 PANEL BOARD CLATTER BRIDGE AT THE BOTTOM USE ONE 2 AND ONE 3 WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST 18 18 A SUPPORT DECK SUPPORT ANGLE 2 X 4 X 18 2 X 4 X 18 ANGLE CLATTER BRiDGE S...

Page 63: ... INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET LINE UP THE HOLES IN THE CENTER TARP SUPPORTS WITH THE HOLES IN THE RAILINGS 3 FASTEN THE CENTER TARP SUPPORTS TO THE RAILINGS WITH 5 16 X 2 1 2 HEX BOLTS AND 5 16 WASHERS AT THE TOP 4 SQUARE EACH CENTER TARP SUPPORT TO THE DECK AND SECURE THE BOTTOM OF THE CENTER TARP SUPPORT TO THE BOTTOM PANEL BOARDS WITH 8 X 2 1 2 WOOD SCREWS CENTER TAR...

Page 64: ...EFT SIDE 5 4 X 2 5 8 X 28 1 4 16 PANEL SLATS ON REAR AND SWING BEAM PANEL SIDE DETAIL A REAR PANEL SLAT SPACING 2 7 16 STEP 20 PANEL SLATS CLATTER BRIDGE SIDE PANEL 1 FIND SIXTEEN 5 4 X 2 5 8 X 28 1 4 PANEL SLATS AND THREE 5 4 X 2 5 8 X 28 1 2 PANEL SLATS 2 PRE DRILL THE SLATS 1 FROM EACH END ON CENTER WITH A 1 8 DRILL BIT 3 INSTALL THE PANEL SLATS AT EQUAL LENGTHS SEE DETAIL BELOW FOR MEASUREMENT...

Page 65: ...RP BOARDS 1 LOCATE THREE 2 X 4 X 47 3 8 TARP BOARDS 2 ATTACH EACH TARP BOARD TO THE TOP OF THE CENTER TARP SUPPORT OR THE CORNER POSTS WITH 8 X 2 1 2 WOOD SCREWS 8 X 2 1 2 WOOD SCREW 2 X 4 X 47 3 8 TARP BOARD 57 ...

Page 66: ...UP THE PILOT HOLES 2 FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3 1 2 CARRIAGE BOLTS ON TOP AND 3 8 LOCK NUTS WITH 3 8 WASHERS FROM UNDERNEATH IN THE COUNTER SUNK HOLES OF THE SWING BEAM MOUNT 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 58 ...

Page 67: ...IDE UP THE SWING HANGERS WILL BE ON THE BOTTOM 2 FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7 CARRIAGE BOLTS WITH TORQUE WASHERS AND 3 8 WASHERS WITH 3 8 LOCK NUTS 3 PLACE BOLT CAPS OVER EXPOSED THREADS STEP 23 IRON DUCTILE SWING HANGERS 7 CARRIAGE BOLT 3 8 LOCK NUT TORQUE WASHER 3 8 WASHER BOLT CAPS IRON DUCTILE SWING HANGER 59 ...

Page 68: ...CH SWING LEGS TO BRACKET 2 FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3 8 X 3 1 2 LAG SCREWS AND 3 8 WASHERS 1 PLACE THE 4 X 4 X 108 SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET 4 X 4 X 108 SWING LEG SWING LEGS FLUSH TO TOP OF SWING LEG BRACKET 60 ...

Page 69: ...P 25 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 61 ...

Page 70: ...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 26 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 71: ...GS 2 LINE UP THE PILOT HOLE AT 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 THE SWING BEAM MOUNT USING A 9 CARRIAGE BOLT WITH A TORQUE WASHER AND A 3 8 LOCK NUT WITH A 3 8 WASHER ON THE BOTTOM PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING 4 FASTEN THE SWING BEAM TO THE SWING BEAM PLATE FROM UNDERNEATH WITH A ...

Page 72: ...EVEL STEP 28 LEVEL SWING BEAM IMPORTANT NOTE THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND DOWN SLOPE THE LEGS ARE LONGER THAN REQUIRED IF YOUR GROUND IS RELATIVELY LEVEL YOU MAY EITHER A DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR B BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE IN OUT 64 ...

Page 73: ...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 29 SWING LEG CROSS MEMBER 65 ...

Page 74: ...B STEP 30 TARP 1 PLACE THE TARP ACROSS THE TARP BOARDS WITH THE HEMS ON THE INSIDE 2 FASTEN THE OUTSIDE CORNERS OF THE TARP TO THE SIDE OF THE TARP BOARD FIRST ATTACH THE GROMMETS IN THE TARP TO THE TARP BOARD WITH 14 X 1 1 4 PAN HEAD SCREWS WITH 1 4 WASHERS REPEAT FOR OTHER SIDE NOTE IF YOU WISH YOU MAY PREDRILL HOLES FOR THE PAN HEAD SCREW WITH A 1 8 DRILL BIT 3 NOW FOLD THE FLAP UNDER THE TARP ...

Page 75: ...ING CLIP SWING CHAIN STEP 31 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 67 ...

Page 76: ...M THE BOTTOM OF THE CORNER POSTS ON THE RIGHT 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 TO 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 68 ...

Page 77: ...ER PLACE A 2 X 4 X 32 1 2 PT LEG ON TOP AT THE 7 1 2 DIMENSION THE TOP OF THE PT LEG SHOULD BE FLUSH TO THE TOP OF THE PT TOP SUPPORT ATTACH THE PT LEG TO THE SUPPORTS WITH 8 X 2 1 2 WOOD SCREWS 4 PLACE THE PICNIC TABLE SLAT NEXT TO THE PICNIC TABLE LEG FOR EACH ASSEMBLY BELOW LEAVE A 3 16 GAP BETWEEN THE TOP OF THE SLAT AND THE LEG USE THE 6 15 16 DIMENSION TO LOCATE THE BOTTOM END OF THE SLAT FA...

Page 78: ...AYSET MAKE MARKS ON 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 LEFT REAR 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 LEFT FRONT CORNER POST ATTACH THE LEFT SIDE ASSEMBLY TO THE INSIDE OF THE ...

Page 79: ...AT BOARDS 2 CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS 3 FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH 8 X 2 1 2 WOOD SCREWS STEP 35 PICNIC TABLE 5 4 X 6 X 43 PT TOP SEAT BOARDS 8 X 2 1 2 WOOD SCREWS 71 ...

Page 80: ...ITH THE LIP EXTENDING ONTO THE DECK 2 PREDRILL 1 8 HOLES INTO THE DECK BOARDS AT THE DIMPLE LOCATIONS SHOWN 3 ATTACH THE SLIDE TO THE DECK BOARDS WITH 14 X 1 1 4 TRUSS HEAD SCREWS INCLUDED WITH THE SLIDE DO NOT OVERTIGHTEN NOTE THE DIMPLE LOCATIONS SHOWN ARE RECOMMENDED OTHER DIMPLES MAY BE USED IF ONE OF THE RECOMMENDED LOCATIONS LANDS OVER A GAP OR IF IT IS TOO CLOSE TO THE EDGE OF A DECK BOARD ...

Page 81: ... 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 73 ...

Page 82: ...HE PANEL SLATS AT THE RIGHT SIDE OF THE PLAY SET ON THE INSIDE THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4 OFF THE DECK 2 ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH 8 X 1 3 4 WOOD SCREWS 8 X 1 3 4 WOOD SCREWS TIC TAC TOE WITH BOARDS ATTACHED SWING BEAM 74 ...

Page 83: ...UGH 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 STEP 39 I...

Page 84: ...FLAG 1 2 PHILLIPS HEAD SCREW STEP 40 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 76 ...

Page 85: ...W 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 A ATTACH NAME PLATE ON FRONT WITH 8 X 1 WOOD SCREWS SANDBOX SEAT 5 4 X 6 X 22 WOOD SCREW 8 X 2 DETAIL A 5 4 X 6 X 22 SANDBOX SEAT 77 ...

Page 86: ...HE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY 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 STEP 42 GROUND STAKES 78 ...

Page 87: ...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 STEERING WHEEL CAP 1 BELOW THE T NUT STEERING WHEEL STEERING WHEEL INSERT WASHER 2 1 2 LAG SCREW DRILL 3 16 HOLE T NUT 79 ...

Page 88: ... POST TO 2 X 4 X 14 BOTTOM PANEL BOARD FASTEN THE CENTER POST TO THE PANEL BOARDS WITH FOUR 8 X 3 WOOD SCREWS ON THE TOP BOARD AND BOTTOM BOARD ATTACH THE CENTER POST TO THE DECK WITH THREE 8 X 3 WOOD SCREWS CENTER POST 4 X 4 X 29 BOTTOM PANEL BOARD 2 X 4 X 14 8 X 3 WOOD SCREW 8 X 3 WOOD SCREW 8 X 3 WOOD SCREW 2 X 4 X 47 1 2 TOP PANEL BOARD 80 ...

Page 89: ...ATTER BRIDGE ANGLE SUPPORT CHAIN BOARD 2 X 4 X 70 DECK SUPPORTS STEP 45 CLATTER BRIDGE CHAIN BOARD 1 LOCATE A 2 X 4 X 47 1 2 CLATTER BRIDGE CHAIN BOARD 2 ATTACH IT UNDER THE DECK SUPPORTS AND TO THE LEFT CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS 81 ...

Page 90: ...PART II CLATTER BRIDGE WITH TARP 82 ...

Page 91: ...N 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 POSTS SHOULD FACE NOTE LETTERS A B C AND D ARE FOR REFERENCE ONLY YOUR POSTS ARE B A TO THE CORNER POSTS 1 THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY IF ANY MISTAKES ARE MADE HERE YOU WILL NEED TO DIS ASSEMBLE AND THEN RE ASSEMBLE TO MAKE Y...

Page 92: ...THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET 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 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 BOLT...

Page 93: ...DLE 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 BOTTOM PANEL BOARD TO THE T NUTS INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 5 LAY THE 2 X 4 X 36 3 4 TOP PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS 6 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH ...

Page 94: ... WITH HOLES C STEP 4 DECK SUPPORTS WASHERS FROM THE INSIDE OF THE CORNER POST B A D 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 1 WITH HELP STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES YOU WILL NEED AN EXTRA PERSON FOR THIS STEP NOTE 2 X 6 BOTTOM PANEL BOARD REMOVED FOR CLARITY 86 ...

Page 95: ...R TO THE T NUTS INSTALLED ON THE CORNER POSTS THE BOTTOM HOLES WILL BE USED LATER 3 PLACE THE 2 X 6 X 67 ROPE LADDER SUPPORT ON THE FRONT OF THE CORNER POSTS 4 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER SUPPORT TO THE T NUTS INSTALLED ON THE CORNER POSTS 5 DO NOT INSTALL LAG SCREWS AT THIS TIME HEX BOLT 5 16 X 4 1 2 5 16 WASHER FRONT OF TOWER 2 X 6 X 67 ...

Page 96: ...THE CORNER POSTS THE HOLES IN 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 USED LATER 3 PLACE THE 2 X 4 X 36 3 4 TOP PANEL BOARD ON THE REAR OF THE CORNER POSTS 4 USE 5 16 X 4 1 2 HEX BOLTS AND 5 16 WASHERS TO ATTACH THE HOLES OF THE TOP PANEL B...

Page 97: ... DECK 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 BRIDGE RAIL THEN MAKE THE DECKS LEVEL TO ONE ANOTHER D 59 5 16 X 3 1 2 LAG SCREW 5 16 WASHER FRONT OF TOWER PUT 5 16 X 3 1 2 LAG SCREWS IN THE BOTTOM HOLES OF THESE BOARDS ONCE YOU LEVEL AND SQUARE T...

Page 98: ...LOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD STEP 8 DECK BOARDS INSTALLATION DAMAGE PRE DRILL BOTH ENDS WITH A 1 8 DRILL BIT USING THE DIMENSIONS SHOWN BELOW 2 PLACE THE 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 ATTACH EACH DECK SPACER TO THE DECK SUPPORTS WIT...

Page 99: ...TEP 9 FRONT FACE BOARD 1 PLACE THE 5 4 X 4 X 36 1 2 DECK BOARDS ON TOP OF THE DECK SUPPORTS DO NOT FASTEN THE DECK BOARDS AT THIS TIME 2 PLACE THE 2 X 4 X 36 3 4 BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS THE TOP OF THE BOTTOM PANEL BOARD SHOULD BE FLUSH WITH DECK BOARD 3 FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS WITH 5 16 WASHERS 91 ...

Page 100: ...ARD FRONT OF TOWER 2 WOOD SCREWS C B DECK BOARDS ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH 2 WOOD SCREWS STEP 10 DECK A 1 INSTALL THE 5 4 X 4 X 36 1 2 DECK BOARDS LEAVE A UNIFORM APPROXIMATELY 1 4 SPACE BETWEEN THE D 92 ...

Page 101: ...WITH HOLES AGAINST THE REAR CORNER POSTS AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS 2 FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5 16 X 3 1 2 LAG SCREWS WITH 5 16 D WITH HOLES LAG SCREW 5 16 X 3 1 2 5 16 WASHER PANEL BOARD 2 X 4 X 36 3 4 BOTTOM REAR OF TOWER 93 ...

Page 102: ...NTER WITH A 1 8 DRILL BIT SEE TOP LEFT PICTURE BELOW 3 ON THE LEFT SIDE OF THE TOWER INSTALL THE FIRST PANEL SLAT 2 5 8 FROM THE CORNER POST THEN INSTALL THE REMAINING FOUR PANEL SLATS 2 7 8 APART AS SHOWN IN THE PICTURE AT THE MIDDLE LEFT BELOW ATTACH 2 X 6 FRONT OF 2 WOOD SCREW RIGHT SIDE 2 X 4 OF TOWER TOWER LEFT SIDE OF TOWER 2 X 6 2 8 7 8 7 2 2 5 8 2 7 8 5 4 X 3 X 28 1 2 PANEL SLAT 16 5 5 1 1...

Page 103: ...DGE 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 EACH LOWER 2 X 4 X 66 BRIDGE RAIL ON THE MARK ON THE CORNER POST D HOLES FACE COUNTERSUNK THE INSIDE LAG SCREW TOP PANEL BOARD OF BRIDGE RAIL 2 X 4 X 66 COUNTERSUNK HOLES EACH END FACE THE INSIDE IN T...

Page 104: ...E THE BRIDGE RAILS AGAINST THE CORNER POST AND 4 X 4 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 EACH LOWER BRIDGE RAIL TO THE CORNER POSTS USING THE 16 DIMENSION AT THE LEFT SIDE AS SHOWN ON STEP 13 AND BELOW ATTACH EACH LOWER BRIDGE RAIL WITH 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS 96 ...

Page 105: ...H A 1 8 DRILL BIT SEE TOP IMAGE BELOW 2 PLACE THE BRIDGE 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 THE SLATS SLAT 5 4 X 3 X 16 BRIDGE RAIL 2 WOOD SCREW 5 4 X 3 X 16 BRIDGE RAIL SLAT 3 4 1 16 5 5 16 4 1 1 3 1 2X 1 8 97 ...

Page 106: ...AND INSERT T NUTS INTO THE PRE DRILLED HOLES USE A 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 STEP 16 BRIDGE DECK AND CHAIN ASSEMBLY T NUT BOARD BRIDGE DECK 2 X 4 X 29 T NUT FLANGE 98 ...

Page 107: ...THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW 3 LINE UP THE 18TH LINK IN THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES STEP 17 BRIDGE DECK AND CHAIN ASSEMBLY 96 CHAIN SECTIONS B DETAIL B SCALE 1 6 18TH CHAIN LINK LINE UP OVER HOLE IN FIRST BRIDGE DECK BOARD FIRST BRIDGE DECK BOARD 99 ...

Page 108: ...ARE 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 TIGHTEN THE BOLT BUT NOT SO TIGHT THAT YOU CRACK THE WOOD 5 REPEAT SUBSTEPS 3 4 UNTIL YOU HAVE SECURED THE CHAIN TO THE BRIDGE DECK BOARDS ALONG ONE SIDE THEN START OVER WITH THE OTHER CHAIN AND REPEAT ...

Page 109: ...DERNEATH THE TOWER DECK AND USE A QUICK STEP 19 BRIDGE DECK CHAIN INSTALLATION 1 LAY THE BRIDGE DECK CHAINS ASSEMBLY BETWEEN THE PLAY SET AND THE TOWER WITH THE CHAINS FACING THE GROUND THREAD THE CHAIN ENDS IN THE BRIDGE DECK ASSEMBLY THROUGH THE HOLES IN THE BOTTOM PANEL BOARD AND DECK SUPPORT BOARD ON THE TOWER 3 REPEAT THIS PROCESS AT THE PLAY SET TO ATTACH THE CHAINS AT THE PLAY SET EACH CHAI...

Page 110: ...X 33 VERTICAL TARP SUPPORTS ON THE INSIDE OF THE TOP PANEL BOARDS THE END OF SCREWS 2 ATTACH THE VERTICAL TARP SUPPORTS TO THE ROPE LADDER SUPPORT BOARDS WITH 2 1 2 WOOD STEP 20 VERTICAL TARP SUPPORTS EACH VERTICAL TARP SUPPORT WITH THE CENTER OF THE TOP PANEL BOARD SQUARE EACH VERTICAL TARP SUPPORT TO THE TOP PANEL BOARD 2 X 4 X 33 VERTICAL TARP SUPPORT 102 ...

Page 111: ...PPORTS 3 ATTACH THE TARP BOARD TO THE VERTICAL TARP SUPPORTS WITH 2 1 2 WOOD SCREWS 4 PLACE ONE TARP BOARD ON TOP OF THE CORNER POSTS THE TARP BOARD SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST 5 ATTACH THE TARP BOARD TO THE TOP OF THE CORNER POSTS WITH 2 1 2 WOOD SCREWS 6 REPEAT SUBSTEPS 4 AND 5 TO INSTALL THE LAST TARP BOARD 2 1 2 WOOD SCREWS 2 X 4 X 36 3 4 TARP BOARDS VERTICAL TARP SUPPORT...

Page 112: ...4 X 57 1 2 CLATTER BRIDGE TARP 2 PLACE THE TARP OVER THE TOP OF THE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS THE HEMS SHOULD FACE THE INSIDE 3 THE TARP WILL OVERLAP THE SIDE OF THE TARP BOARDS ON TOP OF THE CORNER POSTS 4 ATTACH THE TARP THROUGH THE GROMMETS TO THE TARP BOARDS WITH 14 X 1 1 4 PAN HEAD SCREWS AND 1 4 FLAT WASHERS 104 ...

Page 113: ...P STEP 23 LAG POSTS C 3 ATTACH EACH LAG POST TO THE CORNER POST WITH 3 8 X 5 LAG SCREWS AND 3 8 WASHERS 1 LOCATE TWO 4 X 4 X 32 LAG POSTS 2 PLACE THE LAG POSTS ON THE INSIDE OF CORNER POSTS C AND D AS SHOWN THE COUNTERSUNK HOLE THAT IS 4 FROM THE END SHOULD BE AT THE TOP D 105 ...

Page 114: ... 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 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 INST...

Page 115: ...EVEL USING THE LADDER BRACKETS AS A TEMPLATE DRILL A 3 8 HOLE THROUGH THE BOTTOM PANEL BOARD 4 INSERT T NUTS IN THE BACK OF THE HOLES 5 ATTACH THE BRACKET TO THE BOTTOM PANEL BOARD WITH 1 1 2 HEX BOLTS WITH 5 16 WASHERS STEP 25 ATTACHING THE LADDER FRONT SIDE A 5 16 X 1 1 2 HEX BOLT 5 16 WASHER GREEN BRACKET DETAIL A 90 2 X 4 X 36 3 4 BOTTOM PANEL BOARD 3 4 107 ...

Page 116: ...DE 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 SUPPORT SLIDE EACH ROPE THROUGH THE HOLES IN ONE ROPE LADDER RUNG SLIDE THE RUNG UP AGAINST THE BOTTOM OF THE KNOTS 3 TIE THREE KNOTS BELOW THE ROPE LADDER RUNG 4 MEASURE DOWN FROM THE BOTTOM OF THE ROP...

Page 117: ...ILL REMOVE THE T NUTS THAT SECURED THE TOP PANEL BOARD TO THE CORNER POSTS SCREW THE 5 16 X 4 1 2 HEX BOLTS INTO THE T NUTS PARTIALLY AND THEN HIT THE HEAD OF THE HEX BOLT TO DRIVE THE T NUT OUT OF THE POST UNSCREW THE HEX BOLT FROM THE T NUT AND REMOVE THE T NUT 2 x 4 x 36 3 4 TOP PANEL BOARD SEE SUBSTEP 2 ABOVE ABOUT REMOVING T NUTS 109 ...

Page 118: ...PED PLUG IN THE TOP AND BOTTOM HOLES IN THE CORNER POSTS YOU WILL NEED 8 PLUGS TO SEAL THE FOUR HOLES IN THE POSTS STEP 28 EXTREME TUBE SLIDE 1 ASSEMBLE THE EXTREME TUBE SLIDE SEE INSTRUCTIONS ENCLOSED IN THE EXTREME TUBE SLIDE BOX 2 USE STEP 29 TO ATTACH THE SLIDE TO THE PLAY SET 110 ...

Page 119: ...H THE MARKS AT 87 LOOK TO SEE IF THE FOOTER IS FLAT UPON THE GROUND ADJUST THE SLIDE UP OR DOWN SLIGHTLY UNTIL THE FOOT RESTS FLAT UPON THE GROUND 3 FASTEN THE LOWEST HOLES AS SHOWN BELOW WITH A 2 LAG SCREW AND A 1 1 4 FENDER WASHER 4 WORK YOUR WAY UP THE SIDES INSTALLING MORE 2 LAG SCREWSWITH 1 1 4 FENDER WASHERS 5 NOW GO ALL AROUND THE SLIDE AND TIGHTEN UP ALL OF THE BOLTS IF YOU HAVE NOT DONE S...

Page 120: ...X 3 1 2 LAG SCREWS AND 5 16 WASHERS TO ATTACH IT TO THE CORNER POSTS 2 PLACE A SECOND 2 X 4 X 36 3 4 TOP PANEL BOARD ABOVE THE OTHER ONE CENTERING IT VERTICALLY IN THE OPENING USE 5 16 X 3 1 2 LAG SCREWS AND 5 16 WASHERS TO ATTACH IT TO THE CORNER POSTS 3 PLACE THE 2 X 6 X 36 3 4 BOTTOM PANEL BOARD BELOW THE SLIDE MAKE SURE YOU FLUSH THE BOTTOM PANEL BOARD WITH THE BOTTOM OF THE SLIDE USE 5 16 X 3...

Page 121: ... STEP 31 SAFETY HANDLES 1 MOUNT THE GREEN PLASTIC SAFETY HANDLES ABOVE THE LADDER ON THE CORNER POSTS 2 ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD 3 ATTACH THE SAFETY HANDLES WITH THE PAN HEAD SCREWS AND WASHERS PROVIDED IN THE BAG WITH THE SAFETY HANDLES 113 ...

Page 122: ...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 FOR RESIDENTIAL USE ONLY NOTE THE GROMMETS HAVE A RECESSED PART ON ONE SIDE AN IT SHOULD FACE YOU YOU MAY PRE DRILL 1 8 X 1 DEEP HOLES AT EACH GROMMET LOCATION ALONG THE TOP PRIOR TO INSTALLING THE PAN ...

Page 123: ...gn 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 fasteners procedure Then BOARDS THAT ARE FASTENED TO THE CHAINS WITH THE END OF THE 2 X 4 BRIDGE DECK MARK THROUGH THE CENTER OF THE CENTER GROMMET ONTO THE MIDDLE DECK BOARD DRILL A 1 8 X 1 DEEP HOLE AT THE...

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