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KidKraft BEAR CAVE LODGE, Installation And Operating Instructions Manual, Page: 117 / 153

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KidKraft BEAR CAVE LODGE Installation And Operating Instructions Manual Download Page 117

 117 

Hardware

Step 63:  Build Tunnel Assembly 

Part 2

E:

  Attach the tops of each Tunnel Side together using 2 (MB1) #12 x ½” Pan Bolts (with #12 Lock Nut) per side. 

(fig. 63.4 and 63.5)

12 x 

#12 x 1/2” Pan Bolt (with #12 lock nut)

MB1

Fig. 63.4

Fig. 63.5

#12 Lock 

Nut

MB1

Summary of Contents for BEAR CAVE LODGE

Page 1: ...076DE Amsterdam The Netherlands europecustomerservice kidkraft com 31 20 305 8620 M F from 09 00 to 17 30 GMT 1 For online parts replacement visit https parts kidkraft eu 18 24 Hrs Two person assembly...

Page 2: ...nd loose ll surfacing materials washing away during heavy rains DO NOT allow children to play on the play set until the assembly is complete and the unit is properly anchored Never add extra length to...

Page 3: ...pth on the play equipment support posts will help you to see when the material has settled and needs to be raked and or replenished Be sure to rake and evenly redistribute the surfacing in heavily use...

Page 4: ...constructed of quality materials with your child s safety in mind As with all outdoor products used by children it will weather and wear To maximize the enjoyment safety and life of your Play Set it...

Page 5: ...ete and mail registration card to receive important product notifications and assure prompt warranty service 5 Year Limited Warranty KidKraft warrants that this product is free from defect in material...

Page 6: ...f installation liquid soap can be used on all lag type screws For bolts tap T Nut into hole with hammer Insert the hex bolt through lock washer first then flat washer then hole Because the assemblies...

Page 7: ...le HARDWARE LENGTH CHART inches vs millimetres 6 152 5 140 5 127 4 114 4 102 3 89 3 76 2 64 2 51 1 38 1 32 1 1 8 29 1 25 4 7 8 22 3 4 19 1 2 12 7 1 4 6mm Flat Washer 1 4 6mm Lock Washer 1 4 0 25 6mm H...

Page 8: ...3 8 85 7 60 3 2 3 8 15 9 5 8 1505mm KIDKRAFT DESIGN WOOD PROFILES LENGTH CONVERSION For example 1 inch 25 4mm BOARD LENGTH 59 59 25 inches 59 25 inches x 25 4mm Dimensions in brackets mm represent mi...

Page 9: ...Flat Panel Bracket 4 Pk 1x 3200640 3200641 1x Narrow Angle 1x ADD ON C Bracket Set 3204910 2pc 2677 Narrow Panel 1 x 22 x 87 37632677 1pc 2671 Back Small Roof 1 x 22 9 16 x 33 3 8 37632671 1pc 2672 F...

Page 10: ...2 9264504 2pc TN1 1 4 T Nut 54503200 2pc LW1 1 4 Lock Washer 51303200 22pc S8 Pan Screw 12 x 3 4 52433603 3pc S7 Pan Screw 12 x 2 52433620 45pc S11 Wood Screw 8 x 2 52043520 65pc S2 Wood Screw 8 x 1...

Page 11: ...1x Magnetic Catch 1x Catch Plate Door Handle 9207713 Door Hinge 2x 9201713 Door Catch 2x 9207711 1x Door Hardware 3201710 1 Jamb Mount 2 PK 3206301 4pc S18 Wood Screw 6 x 1 52013910 16pc S13 Pan Scre...

Page 12: ...ormer Lt 1 x 14 6 x 22 37632689 1pc 2688 Dormer Cleat 1 x 3 x 12 3632688 ADD ON C Parts Reduced Part Size 1pc 2608 1 1 4 x 3 x 40 3 4 Floor Joist 3632608 1pc 2672 Front Small Roof 1 x 22 9 16 x 33 5 8...

Page 13: ...0 Truss Screw 8 x 7 8 52933505 2pc TN1 1 4 T Nut 54503200 2pc LW1 1 4 Lock Washer 51303200 2pc FW1 1 4 Flat Washer 51103200 8pc S5 Pan Screw 8 x 1 2 52433502 30pc S11 Wood Screw 8 x 2 52043520 20pc TS...

Page 14: ...1 1 2 x 1 1 2 1 x 4 5 8 x 3 3 8 1 x 6 5 8 x 5 3 8 1 1 4 x 2 1 4 1 1 4 x 2 1 4 1 1 4 x 3 1 1 4 x 3 4 x 4 3 x 3 4 x 6 3 x 5 1 4 Box 1 2 of 6 1x 2x 2616 2611 1x 1x 1x 1x 1x 1x KidKraft 9320374 1x 1x 1x 1...

Page 15: ...8 Part Identification Reduced Part Size Lower Window Insert 1 27 x 18 8 x 35 86 1 27 x 18 8 x 41 91 2pc Upper Window Insert Box 2 37632649 2655 Box 2 37632655 1pc 2649 1pc MOD 3 Pane Transom 2Pk Box 1...

Page 16: ...c S6 Pan Screw 12 x 1 52433610 Hardware Identification Actual Size 5pc FW0 3 16 Flat Washer 51103100 5pc S10 Pan Screw 8 x 1 52433510 10pc TN1 1 4 T Nut 54503200 66pc FW2 5 16 Flat Washer 51103300 15p...

Page 17: ...4 53703340 14pc G7 Hex Bolt 5 16 x 5 1 2 53703352 4pc H1 Hex Bolt 1 4 x 1 1 2 53703212 2pc H10 Hex Bolt 1 4 x 2 1 4 53703221 4pc H11 Hex Bolt 1 4 x 2 3 4 53703223 2pc G25 Hex Bolt 5 16 x 7 1 4 537033...

Page 18: ...6 2 x 430 2mm Tunnel Spacer Box 1 3636014 2pc 6001 31 8 x 82 6 x 406 4mm Gusset Box 1 3636001 2pc 6006 31 8 x 82 6 x 396 9mm Back Gusset Box 1 3636006 1pc 0600 15 9 X 101 6 X 596 9mm Bottom Trim Box 1...

Page 19: ...pc 6010 15 9 x 133 4 x 596 9mm Rock Board A Box 1 3636010 5pc 6009 15 9 x 133 4 x 596 9mm Rock Board B Box 1 3636009 1pc 6029 23 8 x 82 6 x 784 2mm Side Top Box 1 3636029 1pc 6030 23 8 x 82 6 x 784 2m...

Page 20: ...Box 1 3636007 4pc 6031 15 9 x 72 6 x 996 9mm Window Brace Box 1 3636031 2x Steel Hand Grip 9200311 Red 1x Telescope w Mount 3320161 1x Flag and Pole 2 Pk 3320632 1x Tower Canopy 3754810 1x Corner Brac...

Page 21: ...t Washer 51103100 12pc FW3 8 Flat Washer 51003500 9pc PB2 Pan Bolt 1 4 x 1 1 4 53433212 30pc S11 Wood Screw 8 x 2 52043520 5pc LS2 Lag Screw 1 4 x 2 1 2 52213222 3pc LS3 Lag Screw 1 4 x 3 52213230 13p...

Page 22: ...3202 2pc 8935 32 2 x 206 4 x 668 3 mm Lower SL Insert Box 1 7608935 10x TNR 4 Clamp Ring 9300130 Green 10pcs number 3300130 1x Quadrex Driver 9200015 8pc FW6 12 Screw Bezel 9299500 1pc LW1 1 4 Lock Wa...

Page 23: ...3639087 14pc 9092 15 9 x 114 3 x 428 6mm Floor Board Box 1 3639092 1pc 6039 32 3 x 203 2 x 477 5mm Lower Tunnel Insert Box 1 37636039 1pc 6038 32 3 x 362 x 477 4mm Upper Tunnel Insert Box 1 37636038 1...

Page 24: ...51103300 8pc FW1 1 4 Flat Washer 51103200 24pc MB1 Pan Bolt 12 x 1 2 53433602 75pc S2 Wood Screw 8 x 1 1 2 52043512 4pc G1 Hex Bolt 5 16 x 1 1 2 53703312 24pc LN4 12 Lock Nut 54303600 40pc S10 Pan Sc...

Page 25: ...Brkt 2 Pk 3200636 1x Tire 3320702 2x MOD Tunnel Set 4Pk 3330101 1x Swing Brkt Set 4 Pk 3201532 1x Tire Rope Chain 4 Pk 3533870 1x Swing Brkt Set 2 Pk 3201533 Part Identification Reduced Part Size 6 T...

Page 26: ...mation if you contact the Consumer Relations Department Please refer to Page 6 for proper hardware assembly Each step indicates which bolts and or screws you will need for assembly as well as any flat...

Page 27: ...ll Panel and 2627 SW Wall Panel to the back 2677 Narrow Panel with 4 WL5 1 4 x 2 1 2 Wafer Lags per side fig 2 1 2 2 and 2 3 2 x Narrow Panel 1 1 4 x 22 x 87 1 x SW Wall Panel 1 1 4 x 42 x 87 2677 262...

Page 28: ...8 x 1 4 x 2 1 2 Wafer Lag WL5 Left Side Step 2 Frame Assembly Part 2 B Place 2622 End Panel Assembly between 2 2677 Narrow Panels noticing the panel orientations The tops and bottoms of the panels sh...

Page 29: ...om of the panels attach 1 2792 Ground Brace to each 2677 Narrow Panel with 2 S11 8 x 2 Wood Screws per board fig 3 1 and 3 2 2 x Ground Brace 1 1 4 x 3 x 43 3 4 Wood Parts Hardware 2792 4 x 8 x2 Wood...

Page 30: ...m of the panels attach 1 2608 Floor Joist to each 2677 Narrow Panel with 2 S11 8 x 2 Wood Screws per board fig 3 3 and 3 4 2 x Floor Joist 1 1 4 x 3 x 40 3 4 Wood Parts Hardware 4 x 8 x2 Wood Screw Ti...

Page 31: ...row Panels on the outside of the 2792 Ground Braces and 2608 Floor Joists on the front and back walls then from the inside of the assembly attach 2792 Ground Braces and 2608 Floor Joists to each 2618...

Page 32: ...ut Bolts are installed from inside the assembly Make sure 2794 Joist is level and flush to the top of 2610 Side Joist then attach with 5 S3 8 x 2 1 2 Wood Screws fig 3 6 and 3 7 G Repeat E and F for t...

Page 33: ...t to each side of 2622 End Panel Assembly and each side of 2627 SW Wall Panel then attach each to 2677 Narrow Panels and 2618 Front Back Panels on both the front and back walls with 4 S11 8 x 2 Wood S...

Page 34: ...the front and back walls using 4 Flat Panel Brackets per wall in the places shown with 4 S8 12 x 3 4 Pan Screws per bracket fig 3 9 and 3 10 32 x 12 x 3 4 Pan Screw Hardware S8 Other Parts 8 x Flat P...

Page 35: ...the top of boards then attach 2795 Long Floor Joist to each panel with 2 S4 8 x 3 Wood Screws per end fig 4 1 4 2 and 4 3 Step 4 Floor Assembly Part 1 1 x Long Joist 1 1 4 x 3 x 84 3 4 2795 Fig 4 2 Wo...

Page 36: ...each 2610 Side Joist and 2794 Joist with 5 S2 8 x 1 1 2 Wood Screws per board fig 4 4 and 4 5 Step 4 Floor Assembly Part 2 1 x Floor Board 1 x 4 x 40 5 8 18 x Floor Board 1 x 5 x 40 5 8 2648 Wood Part...

Page 37: ...s to be flush to the bottom of 2627 SW Wall Panel fig 5 1 and 5 2 B Pre drill pilot hole with a 3 16 drill bit then attach each 2607 Diagonal to 2627 SW Wall Panel with 1 LS3 1 4 x 3 Lag Screw with fl...

Page 38: ...ACHED IT WILL MINIMIZE CHECKING OF WOOD D Attach KidKraft Plaque to centre of 2614 Engineered Beam over top of t nut using 4 S18 6 x 1 Wood Screws fig 6 4 12 x 5 16 x 5 1 2 Hex Bolt 5 16 flat washer x...

Page 39: ...ut Tighten all bolts fig 7 1 C Install 2 WB7 5 16 x 3 Wafer Bolts with flat washer and t nut in the top bolt holes in 2615 SW Upright as shown in fig 7 1 IT IS IMPORTANT THAT THESE BOLTS ARE ATTACHED...

Page 40: ...left and right side and attach with 5 G21 5 16 x 3 3 4 Hex Bolts with 2 flat washers and 1 lock nut fig 8 1 and 8 2 Hardware 5 x 5 16 x 3 3 4 Hex Bolt 5 16 flat washer x 2 5 16 lock nut Other Parts 2...

Page 41: ...e assembly is level then attach from inside the fort assembly into each L Beam Bracket with 4 G8 5 16 x 2 Hex Bolts with 2 flat washers and 1 lock nut fig 9 1 5 16 Flat Washer 4 x 5 16 x 2 Hex Bolt 5...

Page 42: ...hammering stakes into the ground as this could cause the washer to break off B Attach ground stakes using 1 S7 12 x 2 Pan Screw per ground stake fig 10 2 and 10 3 C After driving stakes into the grou...

Page 43: ...nts using 4 S0 8 x 7 8 Truss Screws per mount fig 11 2 11 3 11 4 and 11 5 Step 11 Install Upper and Lower Jambs 17 17 Do not cover holes with Jamb Mount 2601 Jamb Mount S0 x 4 per Jamb Mount Jamb Moun...

Page 44: ...s Screws per insert fig 12 1 and 12 2 B On the Front of the assembly in the openings of the 2618 Front Back Panel install 2 649A Short Half Walls in the lower openings and 2 MOD 3 Pane Transoms in the...

Page 45: ...7 D In the upper left opening of 2622 End Panel Assembly install 1 649A Short Half Wall with 4 S0 8 x 7 8 Truss Screws fig 12 5 12 6 and 12 8 20 x 8 x 7 8 Truss Screw 2 x Lower Window Insert 1 27 x 1...

Page 46: ...618 Front Back Panel using 4 S0 8 x 7 8 Truss Screws per insert fig 12 9 12 10 and 12 11 F Install 3 2655 Upper Window Inserts in the upper openings of 2618 Front Back Panel and the Left Side 2677 Nar...

Page 47: ...the Clock Screw fig 13 1 B On the Front of the Assembly place Clock Assembly centred under window of the Slide Side 2655 Upper Window Insert then with a helper attach through insert and into each 271...

Page 48: ...1 1 2 Wood Screws per board Placing them as shown in fig 14 1 this will prevent rocks from forming a straight line Make sure the boards are evenly spaced and do not exceed 2 3 8 between boards E Place...

Page 49: ...Board Use 8 x 2 Wood Screws to attach Rock Rail to fort flush to top edge Re attach top Access Board to Rock Rails Hardware Wood Parts Step 15 Attach Rock Wall Assembly to Fort Part 1 A Place Rock Wa...

Page 50: ...Stake Other Parts Rebar Ground Stake 0349 S7 S7 13 In Ground C Drive 1 Rebar Ground Stake 13 into the ground against outside 0349 Rock Rail then attach with 1 S7 12 x 2 Pan Screw Be careful not to hi...

Page 51: ...as shown in fig 16 1 B Place Table Top Assembly tight in the opening of the back 2618 Front Back Panel on top of 2665 Half Wall Insert as shown in Fort Guide at the end of the instructions then attach...

Page 52: ...1 1 2 down from the first screw then attach a second screw and washer Follow measurements as shown in fig 17 2 for remaining screws and washers Measurements must be exact C Hold the Cafe Canopy Frame...

Page 53: ...attach with 4 S10 8 x 1 Pan Screws from the inside and 1 S10 8 x 1 Pan Screw from the outside fig 18 1 18 2 18 3 and 18 4 Step 18 Attach Sky Chalk Wall to Fort Fig 18 2 Fig 18 1 Fig 18 4 Fig 18 3 Outs...

Page 54: ...ntre of each opening of 2618 Front Back Panel pre drill with a 1 8 drill bit then attach both slides to fort through the panel using 3 S7 12 x 2 Pan Screws per slide fig 19 1 19 2 and 19 3 Hardware Ot...

Page 55: ...er Back fig 20 1 B Place the remaining 2 5736 Counter Joists centred over the pilot holes in the middle of 2687 Counter Back and flush to the top of the board then attach in the top holes with 1 S2 8...

Page 56: ...Wall Panel place Counter Assembly so the top of 2687 Counter Back is flush to the top of the opening then attach with 5 S2 8 x 1 1 2 Wood Screws fig 20 2 and 20 3 Step 20 Counter Assembly Part 2 Hardw...

Page 57: ...he front and outside edge of each outer 5736 Counter Joist and tight to 2627 SW Wall Panel then attach with 2 S3 8 x 2 1 2 Wood Screws per brace fig 20 4 and 20 5 Step 20 Counter Assembly Part 3 Wood...

Page 58: ...over the pilot holes Measure 5 8 down from the top of 2686 Counter Front on both ends and attach to the 5736 Counter Joists with 4 S2 8 X 1 1 2 Wood Screws fig 20 6 Step 20 Counter Assembly Part 4 Wo...

Page 59: ...H Tight to 2685 Counter Top and centred over the middle 2 5736 Counter Joists with ends flush to the outside edges attach 2 2716 Counter Mid Tops with 4 TS 6 x 30 mm Trim Screws per board fig 20 7 I A...

Page 60: ...d 2 Sink Knobs in opening of Sink and attach Sink Knobs with included hardware fig 20 9 Important Use a hand held screw driver and DO NOT over tighten Other Parts Faucet Sink Knob Sink Knob 1 x Sink 2...

Page 61: ...bottom of the Sink and Stove to secure in place fig 20 10 and 20 11 Important Use a hand held screw driver and DO NOT over tighten Note To remove the Sink or Stove loosen screw 1 4 turn then twist Mo...

Page 62: ...627 SW Wall Panel above the counter attach Utensil Shelf with 2 S5 8 x 1 2 Pan Screws as shown in fig 21 1 and 21 2 B Attach Pot Pan and Spatula to the Utensil Shelf fig 21 2 and 21 3 Hardware Other P...

Page 63: ...crews fig 22 1 B On the inside of 2709 Door Window Panel measure 22 up from the bottom and attach 1 Door Handle using 2 S13 6 x 5 8 Pan Screws fig 22 1 Fig 22 1 Step 22 Attach Door Components Part 1 H...

Page 64: ...22 2 D On the opposite side of the Door Handle measure 5 8 from the top and bottom of 2709 Door Window Panel attach 2 Door Hinges on the outside using 3 S13 6 x 5 8 Pan Screws per Hinge fig 22 2 and 2...

Page 65: ...ure 5 8 up from the bottom of the opening and maximum 5 8 from 2677 Narrow Panel and attach the remaining side of the hinges to 2677 Narrow Panel using 3 S13 6 x 5 8 Pan Screws per hinge fig 23 1 and...

Page 66: ...B On the inside of the assembly attach 2715 Door Stop to the panel with 3 S11 8 x 2 Wood Screws making sure 2715 Door Stop overhangs the panel by 1 1 4 and is in position to receive the Catch Plate fi...

Page 67: ...o a second 2617 Roof Support at peak using 1 S4 8 x 3 Wood Screw Repeat this step so there are 2 Roof Support Assemblies fig 25 1 B Attach 1 2680 Roof Support to a second 2680 Roof Support at peak usi...

Page 68: ...Truss Screws per bracket fig 26 1 and 26 2 B Attach the third Narrow Angle Bracket centred on the middle slat with 2 S0 8 x 7 8 Truss Screws fig 26 1 and 26 3 Step 26 Large Roof Assembly Part 1 Other...

Page 69: ...ends of the roof panels Attach with 6 S11 8 x 2 Wood Screws fig 26 4 D Attach the second Roof Support Assembly on the opposite side peaks to meet and ends are flush with 6 S11 8 x 2 Wood Screws fig 26...

Page 70: ...tach Sky Gable A On each side of the Large Roof Assembly attach 2 Sky Gables to the inside of the 2617 Roof Supports with 4 S5 8 x 1 2 Pan Screws per gable fig 27 1 and 27 2 Other Parts 2 x Sky Gable...

Page 71: ...the peaks meet and the ends of the roof supports are flush with the ends of the roof panels Attach with 6 S11 8 x 2 Wood Screws fig 28 1 C Attach 1 Sky Gable to the inside of the 2680 Roof Supports w...

Page 72: ...able Dormer LT with 1 Narrow Angle Bracket using 2 S5 8 x 1 2 Pan Screws fig 29 1 and 29 2 6 x 8 x 1 2 Pan Screw S5 Other Parts Sky Gable Hardware Fig 29 1 S5 2689 2699 1 x Gable Dormer LT 1 1 4 x 14...

Page 73: ...e middle inside slat then attach with 2 S11 8 x 2 Wood Screws Make sure the screws go into the siding and the slats fig 30 1 B Place completed Gable Dormer Assembly over 2688 Dormer Cleat and attach w...

Page 74: ...hand side measure overhang so it is 2 5 8 then attach with 3 S11 8 x 2 Wood Screws per board fig 31 1 31 2 and 31 3 B Repeat Step A for 2 2647 Roof End Lefts fig 31 1 31 2 and 31 3 Step 31 Attach Roo...

Page 75: ...h 2677 Narrow Panel centred over the pilot holes then measure 1 1 4 down from the top of the panel and attach from the inside with 1 S4 8 x 3 Wood Screw and from the outside with 1 S3 8 x 2 1 2 Wood S...

Page 76: ...83 Wall Tie place 1 2802 Transom Window on each panel and attach with 1 S11 8 x 2 Wood Screw from the inside and 2 S11 8 x 2 Wood Screws from the outside per 2802 Transom Window fig 32 1 32 3 and 32 4...

Page 77: ...x 8 x 3 Wood Screw Step 33 Mid Roof Support Assemblies A Attach 1 2788 Mid Roof Support to a second 2788 Mid Roof Support at peak using 1 S4 8 x 3 Wood Screw Repeat this step so there are 2 Mid Roof...

Page 78: ...Roof End then attach to 2802 Transom Window using 2 S3 8 x 2 1 2 Wood Screws per 2788 Mid Roof Support and to each 2684 Mid Roof End with 1 S4 8 x 3 Wood Screw per side fig 34 1 and 34 2 Hardware 4 x...

Page 79: ...upports with 1 S3 8 x 2 1 2 Wood Screws and 1 S4 8 x 3 Wood Screw per support and to each side of the 2802 Transom Windows using 2 S3 8 x 2 1 2 Wood Screws per side fig 35 1 and 35 2 Fig 35 1 4 x Long...

Page 80: ...o the bottom of 2788 Mid Roof Support attach 1 2791 Transom Board B to 2788 Mid Roof Support and 2793 Long Roof End with 4 S2 8 x 1 1 2 Wood Screws fig 36 1 and 36 2 C Repeat Steps A and B for all 4 c...

Page 81: ...all Roof Assembly The front of the Small Roof Assembly should be flush to the front of each 2646 Roof End and 2647 Roof End Left fig 37 1 and 37 2 B Attach Small Roof Assembly to Mid Roof Support Asse...

Page 82: ...oof Ends and 2647 Roof End Lefts with 1 S3 8 x 2 1 2 Wood Screw per support fig 37 3 and 37 4 Hardware 4 x 8 x 2 1 2 Wood Screw 2647 S3 2646 2647 Fig 37 3 Fig 37 4 S3 Step 37 Attach Roof Assemblies to...

Page 83: ...e Roof Assembly onto the fort so all four 2617 Roof Supports sit flush to the front and outside edges of each 2793 Long Roof End fig 37 5 and 37 6 F Attach 2617 Roof Supports to each 2793 Long Roof En...

Page 84: ...bly with 1 Spiral Wave Bracket and 3 S8 12 x 3 4 Pan Screws per side fig 37 7 and 37 8 Step 37 Attach Roof Assemblies to Fort Part 4 Fig 37 7 Fig 37 8 Inside View Hardware 6 x 12 x 3 4 Pan Screw 2 x S...

Page 85: ...s 2 x Flag Hardware 4 x 8 x 1 Pan Screw Flag x 2 per Flag A Place 1 Flag at the peak of each Small Roof Assembly and attach to 2680 Roof Supports with 2 S10 8 x 1 Pan Screws per flag fig 38 1 Fig 38 1...

Page 86: ...sembly place 1 6012 Short Post and 1 6000 Upper Post side by side with the 6012 Short Post on the right side notched side facing out and the 6000 Upper Post on the left side Place 6023 Roof Side at th...

Page 87: ...oor Support making sure the pre drilled holes match what is shown on fig Fig 40 2 Attach using 2 H3 x 2 1 2 Hex Bolts with lock washer flat washer and t nuts Fig 40 1 Fig 40 2 1 x Long Post 31 8 x 82...

Page 88: ...ail Attach 6018 Long Ground using 2 H2 x2 Hex Bolts with lock washer flat washer and t nuts Fig 40 3 F On the underside of the 6018 Long Ground place 1 0369 Lower Diagonal tight and flush to the 6002...

Page 89: ...042 Narrow Floor Board as a guide place 0600 Bottom trim flush to the top of the front 6042 Narrow Floor Board and attach to the Rock Rails using 2 S7 12 x 2 Pan Screws with 3 16 flat washer and 2 S20...

Page 90: ...ttom Trim The angle cut should be flush with the 0600 Bottom trim Fig 42 1 and 42 2 and 42 3 Attach using 2 S11 8 x 2 Wood Screws per side Fig 42 1 and 42 2 and 42 3 B Evenly Space the remaining 6013...

Page 91: ...hown in fig 43 1 Attach using 4 S20 8 x 1 3 8 Wood Screws per board Fig 43 1 43 2 Note Board orientation must be followed closely Hardware Step 43 Climbing Wall Assembly 6009 6009 6009 6009 6009 6010...

Page 92: ...l with a 1 8 3 2mm drill bit and install 1 LS3 1 4 x 3 Lag Bolt with flat washer Install 1 H3 1 4 x 2 1 2 Hex Bolt with flat washer lock washer and t nut in the 6000 Upper Post fig 44 1 44 2 flat wash...

Page 93: ...Wall Top Right Wall Top Before proceeding to the next step ensure that unit is completely square and all hardware is tightened flat washer LS3 H3 flat washer lock washer 1 4 t nut 6026 6000 flat washe...

Page 94: ...ost ost ole unit up at this time H8 H8 1 4 lock washer 1 4 lock washer 1 4 flat washer 1 4 t nut 1 4 flat washer S7 S7 S20 S20 6023 6018 6020 Wood Parts 6028 1 x Top Back 23 8 x 82 6 x 644 5mm H8 2 x...

Page 95: ...he outside attach the 6006 Back Gussets at the top using 2 S15 8 x 1 3 4 Wood Screws Attach the 6006 Back Gussets to the 6002 Long Posts using 1 S4 8 x 3 Wood Screw per side in the upper hole and 1 S1...

Page 96: ...set previously installed Install 6001 Gussets using 6 S11 8 x 2 Wood Screws and 2 S4 8 x 3 Wood Screws Fig 46 3 46 4 Step 46 Install Gussets Part 2 view from underneath Hardware 2 x 8 x 3 Wood Screw 6...

Page 97: ...3 8 Wood Screws per side B On each inside corner attach a Corner Bracket to the 6024 Tarp Ends and 6023 Roof Sides using 3 S37 7 x 5 8 Pan Screws per bracket Fig 47 1 47 2 S37 S20 Fig 47 1 Fig 47 2 Ha...

Page 98: ...6025 Tarp Support with 2 S4 8 x 3 Wood Screws Fig 47 3 47 4 Step 47 Attach Tarp Frame Part 2 Fig 47 4 S15 S4 Roof Side 15 9 x 82 6 x 1019 2mm Tarp Support 38 1 x 38 1 x 901 7mm Tarp Upright 38 1 x 38...

Page 99: ...arp End using 5 S37 7 x 5 8 Pan Screws with 8 flat washer Fig 48 1 D Attach Tower Canopy to each end of the 6025 Tarp Support using 2 S37 7 x 5 8 Pan Screws with 8 flat washer Fig 48 1 Step 48 Attach...

Page 100: ...Screws per side Fig 49 1 49 2 Step 49 Install Flags Hardware 4 x 8 x 1 Pan Screws S10 center in end of Tarp Support 8 x 1 Pan Screw X4 center in end of Tarp Support 8 x 1 Pan Screw X4 center in end o...

Page 101: ...ing sure that it s flush with the top of 6030 Tunnel Side Top and both 0601 Side Trims attach 1 0603 Top trim to the 6000 Upper Posts using 4 S20 8 x 1 3 8 Wood Screws Fig 50 1 50 2 Hardware 1 x Top T...

Page 102: ...to install a second Hand Grip on the other side Step 51 Attach Hand Grips centred on face and flush to edge of Side Trim both sides 1 4 flat washer 1 4 flat washer Steel Hand Grip per side Fig 51 1 Sh...

Page 103: ...032 TNR Wall so it s pressed against the inside of the 6005 Slide Block 6026 Rock Rail and 6002 Long Post Ensure that the bottom of the 6032 TNR Wall is flush with the bottom of the 6005 Slide Block a...

Page 104: ...ure to ensure that there is a 17 432mm space between the 2 6007 Wall Supports and attach 1 6014 Tunnel Spacer flush to the top of the floor boards with 5 S11 8 x 2 Wood Screws Fig 53 1 53 2 Step 53 At...

Page 105: ...lours and shapes attach 1 rock to each rock board using 1 PB2 x 1 1 4 Pan Bolt with lock washer 3 16 flat washer and barrel nut and 1 S10 8 x 1 Pan Screw per rock Fig 54 1 54 2 54 3 The Pan Screw is p...

Page 106: ...Parts approximately 67 apart with the openings lining up Step 55 Attach Telescope A On the Back Wall center the Telescope and attach to 6028 Top Back with 2 S20 8 x 1 3 8 Wood Screws fig 55 1 55 2 Mov...

Page 107: ...gers to Tire Joist 6 Tunnel Tire Swing Assembly A Position 1 6036 Tire Joist so that the counter sunk holes are at the top Attach the Swing Hangers from underneath 2 flat washer and 1 lock nut per swi...

Page 108: ...ly Part 1 Wood Parts Hardware 4 x 5 16 T nut Fig 57 2 A Place 2 6035 Tunnel Side Joists side by side making sure that the pre drilled holes for the t nuts are at the top Install 1 5 16 T Nut on the in...

Page 109: ...s so that the 6036 Tire Joist fits into the cut outs fig 57 3 Attach 6040 Tunnel Ends to 6036 Tire Joist using 3 S4 8 x 3 Wood Screws per end and then attach 6035 Tunnel Side Joists to 6040 Tunnel End...

Page 110: ...el frame ensuring that it s flush with the ends and the sides of the 6035 Tunnel Side Joists and attach using 5 S2 8 x 1 1 2 Wood Screws fig 58 1 and 58 2 D Evenly space the remaining 9092 Floor Board...

Page 111: ...Joists and attach 4 Swing Brackets using 1 G1 5 16 x 1 1 2 Hex Bolt with flat washer and lock washer per bracket fig 59 1 and 59 2 Hardware 5 16 x 1 1 2 Hex Bolt X4 washer loc washer leave 1 1 4 to en...

Page 112: ...Attach to the Wall Supports with 4 S0 8 x 7 8 Truss Screws fig 60 2 and 60 3 Hardware 4 x 8 x 7 8 Truss Screw Fig 60 1 Outside View Fig 60 2 Inside View Fig 60 3 outside view Lower Tunnel Insert in ma...

Page 113: ...t as shown in fig 61 1 B From inside the Adventure Tower attach the 6035 Tunnel Side Joists to the Wall Supports using 4 S4 8 x 3 Wood Screws fig 61 1 and 61 2 C Repeat Step B for the fort side D From...

Page 114: ...Step 61 Attach Tunnel Assembly Frame to Fort Part 2 E From underneath the tunnel place 1 Swing Bracket on each end of the 6036 Tire Joist Pre drill holes using a 1 8 drill bit and connect to the stru...

Page 115: ...rom the top of the Wall Support as shown in fig 46 2 and place the 6038 Upper Tunnel Insert into the opening Attach to the Wall Supports using 4 S0 8 x 7 8 Truss Screws fig 62 1 and 62 2 Fig 62 1 Fig...

Page 116: ...on the other until you hear the connector tabs click together and the bottom edges are flush You may have to knock panels on a hard surface to align properly Do this so there are 4 MOD Tunnel Panels...

Page 117: ...ild Tunnel Assembly Part 2 E Attach the tops of each Tunnel Side together using 2 MB1 12 x Pan Bolts with 12 Lock Nut per side fig 63 4 and 63 5 12 x 12 x 1 2 Pan Bolt with 12 lock nut MB1 Fig 63 4 Fi...

Page 118: ...nnel Assembly Part 3 F Join the 2 Tunnel Sides together so the tops are tight together and attach with 12 MB1 12 x Pan Bolts with 12 Lock Nut fig 63 6 and 63 7 Fig 63 7 12 Lock Nut x 12 x 12 MB1 12 x...

Page 119: ...t the bottom edge rests on the swing brackets and attach to the 6035 Tunnel Side Joists using 24 S10 8 x 1 Pan Screws fig 64 1 64 2 and 64 3 24 x 8 x 1 Pan Screw Hardware S10 Step 64 Attach MOD Tunnel...

Page 120: ...Panel Bracket 8 x 8 x 7 8 Truss Screw 6037 Fig 64 4 Fig 64 5 S0 B From inside the fort attach 1 6037 Tunnel Top to the Wall Support using 2 Flat Panel Brackets and 8 S0 8 x 7 8 Truss Screws fig 64 4 a...

Page 121: ...S10 8 x 1 Pan Screws per side fig 65 1 and 65 2 B From outside the assembly attach Tunnel to the 6037 Tunnel Top on one side and to the 6038 Upper Tunnel Insert on the other using 4 S0 8 x 7 8 Truss...

Page 122: ...Rope and Chain Tire Rope and Chain Eyebolt Included Lock Nut Flat Washer Tire Rope and Chain A Insert the eyebolts on the Tire Rope and Chains into the tire as shown in fig 66 1 Attach using 1 flat w...

Page 123: ...123 B Attach Tire Rope and Chain to the swing hangers as shown in fig 66 3 66 4 and 66 5 Step 66 Attach Tire Swing Part 2 Swing Hanger Fig 66 3 Fig 66 4 Fig 66 5 Tire Rope and Chain...

Page 124: ...n Screw per ground stake as shown in fig 67 1 67 2 C After driving stakes into the ground check for sharp edges caused by the impact of the hammer Smooth any sharp edges from impact area and touch up...

Page 125: ...he outside Fig 68 3 Attach with 2 H1 x 1 1 2 Hex Bolts with flat washer lock washer and t nut 2 S15 8 x 1 3 4 Wood Screws and 2 S4 8 x 3 Wood Screws as shown in Fig 68 1 68 2 Step 68 Sand and Water Ta...

Page 126: ...6001 Gusset per side so that the short angle is flush to the 6015 Box Legs and the long angles are flush to the 6011 Box Sides Attach using 1 S15 8 x 1 3 4 Wood Screw and 1 S4 8 x 3 Wood Screw per si...

Page 127: ...nd and attach the 6027 Sand and Water Supports to the 6002 Long Posts using 4 S7 12 x 2 Pan Screws with 3 16 washers Fig 68 5 68 6 68 7 Step 68 Sand and Water Table Assembly Part 3 right side view Fig...

Page 128: ...using 8 S37 7 x 5 8 Pan Screws as shown in Fig 68 8 68 9 68 10 J Insert plugs into the drain holes and put the shovel into the Sand and water Insert Place the seat over the Sand and Water Insert fig 6...

Page 129: ...ide of the Back Wall making sure that there is a 9 1 2 241 3mm opening in the center Attach 6031 Window Braces using 4 S20 8 x 1 3 8 Wood Screws per board Fig 69 1 69 2 S20 Fig 69 1 Fig 69 2 Back Wall...

Page 130: ...dware 10 x 7 x 5 8 Pan Screw S37 Step 70 Install MOD Side Lite A From inside the assembly place the MOD Side Lite into the opening and attach to the 6031 Window Braces using 10 S37 7 x 5 8 Pan Screws...

Page 131: ...that the narrow board is at the bottom Make sure that it s flush with 6029 Side Top and attach using 4 S0 8 x 7 8 Truss Screws Fig 71 1 71 2 4 x 8 x 7 8 Truss Screws S0 S0 6029 8935 Flush Fig 71 1 Fig...

Page 132: ...in Fig 72 1 72 2 Attach 6033 Post Supports to 6012 Short Posts and 6002 Long Posts using 7 S15 8 x 1 3 4 Wood Screws Fig 72 1 72 2 6033 6012 6002 x 7 6031 S15 Lower SL Insert Hardware 14 x 8 x 1 3 4...

Page 133: ...ch bolts as indicated B Repeat Step A 3 more times to create 4 Elbow Sections in total C Attach TNR3 Extend Flange RT and TNR3 Extend Flange LT together using 9 PB1 1 4 x 3 4 Pan Bolts with lock nut a...

Page 134: ...Attach TNR2 Slide Exit Top and the remaining TNR2 Slide Elbow together using 8 PB1 1 4 x 3 4 Pan Bolts with lock nut as shown in Fig 73 4 It is very important to attach bolts as indicated This creates...

Page 135: ...e a minimum of 1 25 4mm deep Fig 74 1 C Attach the Flange Assembly flush to Lower SL Insert using 4 S6 12 x 1 Pan Screws with 12 Screw Bezel in the pre drilled holes as shown in Fig 74 1 and to both l...

Page 136: ...l pilot hole with a 3 16 4 8mm drill bit then attach 8934 SL Gusset to 6005 Slide Block with 1 WL5 1 4 x 2 1 2 Wafer Lag with flat washer Fig 74 3 74 4 Hardware Wood Parts 2 x 12 x 1 Pan Screws 1 x 1...

Page 137: ...e up the arrows on each assembly Attach using 6 x 12 7mm Pan Bolts with Square Lock Nut Repeat this instruction to make 2 more Fig 75 2 75 3 Use Quadrex Driver as a guide pin for each hole before inse...

Page 138: ...s with lock nuts starting with the bottom middle hole and working up each side fig 76 2 76 3 C At this point make sure all the slide bolts are tight Use a 7 16 open end wrench to hold nut and then tig...

Page 139: ...quare Lock Nut A Fit the Exit End Assembly to the last Elbow Assembly by lining up the arrows on each assembly Notice the elbow orientation fig 77 1 Attach with 6 PB7 x 12 7mm Pan Bolts and Square Loc...

Page 140: ...mp Rings in 2 spots using 1 PB6 x 1 Pan Bolt with lock nut per side fig 78 3 Note When installing Pan Bolts make sure to look at holes so bolts go through the side with the round recess and the lock n...

Page 141: ...hole Make sure both boards are square then attach with 1 S11 8 x 2 Wood Screw Fig 79 1 1 x 8 x 2 Wood Screw 1 x 1 4 x 4 1 4 Hex Bolt 1 4 lock washer 1 4 flat washer 1 4 t nut Hardware Wood Parts 1 x...

Page 142: ...olt with flat washer and the previously removed lock nut fig 80 1 C Rotate TNR3 Tube Support and attach to 6002 Long Post using 1 S6 12 x 1 Pan Screw as shown in fig 80 1 D Fully tighten screw and bol...

Page 143: ...an Head Bolt and Square Lock Nut fig 81 2 D Attach TNR4 Post Mount Base to 8965 TNR Upright pre drill with a 1 8 3 2mm drill bit then attach with 2 S6 12 x 1 Pan Screws fig 81 2 E Attach the Post Moun...

Page 144: ...lines A In the spot shown in Fig 82 1 drive 1 Rebar Ground Stake 13 330mm into the ground against the 8965 TNR Upright Be careful not to hit the washer while hammering stake into the ground as this co...

Page 145: ...re assembly is level then secure with 2 H1 1 4 x 1 1 2 Hex Bolts with lock washer flat washer and t nut per side fig 83 4 C Tighten the top screws in all 4 Bench Legs fig 83 4 4 x 1 4 x 1 1 2 Hex Bolt...

Page 146: ...Handle to the Space Glider Body using 1 G25 5 16 x 7 1 4 Hex Bolt with 2 flat washers and 1 lock nut Repeat for the second Space Glider Handle fig 84 1 B Install 2 Glider Rope with Chains into each Sp...

Page 147: ...adjustable wrench fig 85 1 and 85 2 Warning Check entire play centre for bolts protruding beyond t nuts Use extra washers to eliminate this condition Step 85 Attach Belt Swings and Glider Other Parts...

Page 148: ...t that is easily seen and read by a supervising adult using 4 S5 8 x 1 2 Pan Screws as shown below ATTACH THIS WARNING I D PLAQUE TO THIS LOCATION ON YOUR PLAY EQUIPMENT This provides warnings concern...

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Page 153: ...e of assembly Excellent Very Good Average Below Average Poor How would you rate our instructions Excellent Very Good Average Below Average Poor How would you rate the quality of packaging Excellent Ve...

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