™ playsets ™ playsets Empire Extreme Timber Shield Post Option BOXES: X3, 120 Model: 1500MW (BOXES: 1501, 1504, 1506, 1509N, 1509W, 1514, 1528, 1529, 1535, 1535F, 1537, Rad Ride 7 Box, 14’ Scoop Slide (bagged) & Slide Box) *51-0090-W* 51-0090-W Copyright © 2017 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.
Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that 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.
GORILLA PLAYSETS WARRANTY – 2017 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set. As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury.
Product registration - emPire extreme Gorilla Playsets ™ manufactures 3 Easy Ways To REgisTER the finest quality products that are designed for outstanding strength and durability. We back Complete the online registration form at: oPtion 1 http://www.gorillaplaysets.com/register our products with unparalleled warranties.
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IMPORTANT – PLEASE READ Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years. As your swing set acclimates to its new environment, natural characteristics of the wood can show in the form of checks, or “cracks” in the lumber.
IMPORTANT DOCUMENTS CUSTOMER MUST READ AND RETAIN Please go to the following links and read important SAFETY information prior to using your new play structure. http://www.gorillaplaysets.com/Swing-Set-Safety-s/85.htm https://www.gorillaplaysets.com/Maintenance-s/129.htm http://www.gorillaplaysets.com/manuals.html (Click on your specific model) http://www.gorillaplaysets.com/Warranty-s/82.htm NOTE: Your children’s safety is our #1 concern.
Timber Shield Post Option BOXES: X3, 120 Model: 1500MW (BOXES: 1501, 1504, 1506, 1509N, 1509W, 1514, 1528, 1529, 1535, 1535F, 1537, Rad Ride 7 Box, 14’ Scoop Slide (bagged) & Slide Box) REV: 4.17.
TABLE OF CONTENTS Safety Guidelines……………………………………….......……...........................Pages 4-7 Leveling Fort, General Information and Definitions............................................Pages 7-9 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading......................................................................................Pages 10-14 Site Plan, Required Tool List and Kit Contents ……………………….............
TABLE OF CONTENTS Upper Level Wood Roof Assembly.……………………….......……................. Steps 66-70 Middle Level Wood Roof Assembly................................................................ Steps 71-76 Lower Level Wood Roof Assembly................................................................. Steps 77-84 Wall Panel Boards................................................................................................. Step 85 Plastic Sunburst...........................................................
Safety and Maintenance Tips for Your New Play Set: NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with your children.
Safety and Maintenance Tips for Your New Play Set: (continued) Playgrounds should be inspected on a regular basis. If any of the following conditions are noted, they should be removed, corrected, or repaired immediately to prevent injuries. • Hardware that is loose, worn or that has protrusions or projections. • Exposed equipment footings. • Scattered debris, litter, rocks, or tree roots. • Splinters, large cracks, and decayed wood components.
Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/PageFiles/122149/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6’ in all directions from the perimeter of the equipment. Swings should have a fall zone extending a minimum of 6’ from the outer edge of the support structure on each side.
General Info to Review Before Installation • Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly. • Identify all of the parts for your play set. Empty each box and lay out boards so you can see each part. Your instruction book will have detailed drawings that will make it easy for you to recognize individual parts.
This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board.
Common Installation Practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut This picture shows the T-nut inserted and installed flush to the wood. Flush (Correct) Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood. This picture shows an end view of the T-nut installed flush to the wood.
HOW A T-NUT WORKS THE FIRST 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.
BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" • The 2 is the thickness of the board. "Nominal Lumber" at a home center will measure 11/2" for the thickness. We "remill" that lumber to 1-3/8" thick.
PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole. Pay attention to the DIAMETER of the lag screw you are installing. Your playset may come with two different diameter lag screws.
SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar 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.
Everest Extreme / Empire Extreme Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started.
REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” and a 1” Paddle style bit.
1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" PAN HEAD SCREW QTY: 4 #8 X 1-3/4" WOOD SCREW QTY: 4 9 8 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 6 7 #8 X 3" WOOD SCREW QTY: 20 6 5 5/16" TEE NUT QTY: 22 4 3/8" LOCK NUT QTY: 19 3 TORQUE WASHER QTY: 17 3/8" WASHER QTY: 31 2 1 5/16 X 4-1/2" HEX BOLT QTY: 14 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 34 USE THE RULER TO THE RIGHT TO MEASURE YOUR B
1501 HARDWARE 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 9 PAGE: 2 OF 2 REV A: 9/10/2014 JH 8 7 6 5 4 3 #2 SQUARE DRIVE BIT QTY: 1 2 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8 x 7" CARRIAGE BOLT QTY: 14 3/8 x 6-1/2" CARRIAGE BOLT QTY: 2 3/8 x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 19 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.
1504 HARDWARE PAGE: 1 OF 1 PRELIMINARY 9/18/2012 J.H. 9 #8 X 2" WOOD SCREW QTY: 71 8 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3" WOOD SCREW QTY: 5 #14 x 3" PAN HEAD SCREW QTY: 3 7 #10 x 3-1/2" WOOD SCREW QTY: 2 6 5 4 5/16" TEE NUT QTY: 18 3 3/8" WASHER QTY: 4 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 31 5/16 X 4-1/2" HEX BOLT QTY: 18 3/8 X 5" HEX LAG SCREW QTY: 4 5/16" WASHER QTY: 49 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
1506N HARDWARE #8 X 1-1/4" WOOD SCREW QTY: 6 PAGE: 1 OF 1 REV B: 8/18/2015 J.H. #8 X 1-1/2" WOOD SCREW QTY: 104 #8 X 2" WOOD SCREW QTY: 28 9 8 #8 X 2-1/2" WOOD SCREW QTY: 10 7 #8 X 3" WOOD SCREW QTY: 2 6 5 4 5/16" TEE NUT QTY: 6 3 5/16" WASHER QTY: 6 2 1 5/16 X 4-1/2" HEX BOLT QTY: 5 5/16 X 2-1/2" HEX BOLT QTY: 1 3/8" X 5" LAG SCREW QTY: 9 3/8" WASHER QTY: 9 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
11-0071 1509N HARDWARE PAGE: 1 OF 1 REV A: 9/19/2014 JH 9 #8 X 2" WOOD SCREW QTY: 94 #14 x 1-1/4" PAN HEAD SCREW QTY: 6 8 #8 X 2-1/2" WOOD SCREW QTY: 18 #8 X 3" WOOD SCREW QTY: 5 7 6 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 4 5/16" TEE NUT QTY: 55 1/4" WASHER QTY: 6 QUICK LINK QTY: 2 5 4 3 5/16" WASHER QTY: 111 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 26 5/16 X 1-3/4" HEX BOLT QTY: 30 5/16 X 4-1/2" HEX BOLT QTY: 25 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
1509W HARDWARE #8 X 1-1/4" WOOD SCREW QTY: 8 PAGE 1 OF 1 9/11/2014 JH #8 X 1-1/2" WOOD SCREW QTY: 60 #8 X 2" WOOD SCREW QTY: 8 9 8 7 5/16" x 3-1/2" HEX LAG SCREW QTY: 4 6 5 5/16" WASHER QTY: 4 4 3 2 1 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.
1514 HARDWARE PAGE: 1 OF 1 PRELIMINARY 9/19/2012 J.H. END OF SCREW LOOKS SPLIT SIMILAR TO A DRILL BIT. #10 X 2" SELF DRILLING SCREW QTY: 18 9 8 #14 x 1-1/4" PAN HEAD SCREW QTY: 4 7 5/16" TEE NUT QTY: 8 6 5 3/8" WASHER QTY: 4 4 3 5/16" WASHER QTY: 8 2 5/16" x 3-1/2" HEX BOLT QTY: 8 1/4" WASHER QTY: 4 3/8" X 5" HEX LAG SCREW QTY: 2 1 3/8" x 5-1/2" HEX LAG SCREW QTY: 2 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
1528 HARDWARE PAGE 1 OF 1 1/16/2015 SO. #8 X 1" WOOD SCREW QTY: 2 9 #8 X 1-1/4" WOOD SCREW QTY: 25 #8 X 1-1/2" WOOD SCREW QTY: 110 8 #8 X 2" WOOD SCREW QTY: 25 7 #8 X 2-1/2" WOOD SCREW QTY: 12 6 5 #2 SQUARE DRIVE BIT QTY:1 4 3 5/16" WASHER QTY: 12 2 5/16" X 4-1/2" HEX BOLT QTY: 4 5/16" X 2-1/2" HEX BOLT QTY: 2 5/16" x 3-1/2" LAG SCREW QTY: 6 5/16" TEE NUT QTY: 6 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
1529 HARDWARE PAGE 1 OF 1 1/16/2015 S.O. #8 X 1-1/4" WOOD SCREW QTY: 22 9 #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 7 6 5 #2 SQUARE DRIVE BIT QTY:1 4 3 2 1 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.
11-0087 1535 Hardware PAGE 1 OF 1 REV: C 4/12/2017 S.O.
11-2027 SUB BRACKET HARDWARE 12/09/2015 JH 3/8" X 2-1/2" LAG SCREW QTY: 4 3/8" WASHER QTY: 4 9 8 7 6 5 4 3 2 1 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.
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PICTURE DESCRIPTION 5/4 X 3 X 28-1/2" PANEL SLAT 125-3-2850-PS QTY.
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PICTURE DESCRIPTION QTY. 1 X 4 X 29.29" ROOF FINISHER FRONT 1-4-2929-RFFL 1-4-2929-RFFR 1 LEFT 1528 1 RIGHT 1 X 4 X 76-7/8" ROOF STARTER REAR 1-4-7688-RSR 1 1 X 4 X 76-7/8" ROOF STARTER FRONT 1-4-7688-RSF 1 1 X 4 X 76-7/8" ROOF FINISHER REAR 1-4-7688-RFR 1 3 NOT USED 1 X 5 X 76-7/8" ROOF BOARD 1-5-7688-RB 14 1 GETS CUT DURING ASSEMBLY 1 X 2 X 32.
PICTURE DESCRIPTION QTY. 1 X 4 X 12-1/4" WALL PANEL BOARD 1-4-1225-WPB 2 1 X 4 X 15-3/4" WALL PANEL BOARD 1-4-1575-WPB 2 1 X 4 X 19-5/16" WALL PANEL BOARD 1-4-1931-WPB 2 5/4 X 5 X 10.
PICTURE DESCRIPTION 2 X 4 X 22.75" WALL PANEL SUPPORT (1 HOLE ON ON CENTER) 2-4-2275-WPSL 2-4-2275-WPSR 2 X 4 X 35.15" ROOF SUPPORT (1 HOLE OFFSET) 2-4-3515-RSL 2-4-3515-RSR NOT USED 2 X 4 X 69.75" ROOF FINISHER SUPPORT (2 HOLES ON CENTER) 2-4-6975-RFS QTY. 1 LEFT 1 RIGHT 2 LEFT 2 RIGHT 1 NOT USED 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY 5-11-4697-RPRA 1 NOT USED 5 X 11 X 46.
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PICTURE DESCRIPTION 8' WIKI WAVE SLIDE 03-0015-G QTY.
PICTURE DESCRIPTION 10' ROCK WALL ROPE SWING W/CHAINS 04-0002 QTY.
PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCK (5 ROCKS ARE IN ONE BAG) 07-0008 10 A-FRAME SWING LEG BRACKET 11-5010 HARDWARE BOXES: 1501,1504, 1506, 1509N, 1509W, 1514, 1528, 1535, 1535F, 11-2027 1 1 INSTRUCTIONSEA.
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PICTURE (NOT SHOWN) DESCRIPTION QTY. CROWN 07-0019 2 PLASTIC WINDOW 07-0013-G 2 8-5/8"W X 6-1/2"H MONKEY BAR PLATE 11-5014 2 1-5/16" DIA.
STEP 1: ATTACHING T-NUTS 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 YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 108" CORNER POSTS AND 4 X 4 X 120" MIDDLE CORNER POST IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET.
STEP 2: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT USING 3/8" X 3-1/2" CARRIAGE BOLTS ON TOP AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 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.
STEP 3: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" SIDE SANDBOX BOARD- RIGHT ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SIDE SANDBOX BOARD - RIGHT 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 THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 4: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" SIDE SANDBOX BOARD - LEFT ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SIDE SANDBOX BOARD - LEFT 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 SIDE SANDBOX BOARD - LEFT TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 5: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT.
STEP 6: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD 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 IN THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: MEASURE UP 29-5/8" FROM THE TOP OF THE FRONT DECK SUPPORT AND MAKE A MARK ON THE BACK OF EACH FRONT CORNER POSTS. 4: PLACE THE 2 X 4 X 70" TOP PANEL BOARD ON THE MARKS.
STEP 7: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE 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 IN THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" BACK PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE BACK PANEL BOARD MUST BE OFFSET DOWN.
STEP 8: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID 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 SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED.
STEP 9: BOTTOM PANEL BOARDS 1: 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. 2 X 4 X 14" BOTTOM PANEL BOARD COUNTER-SUNK HOLES ON CENTER 5/16" WASHER 5/16" X 3-1/2" LAG SCREW NT FRO F OF OR T 2: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD (HOLES OFFSET UP) ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP10: ANGLE SUPPORTS 1: TWO 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE RIGHT SIDE OF 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. 2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE ANGLE SUPPORT INTO THE BOTTOM PANEL BOARD. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 11: DECK SPACERS 1: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE CORNER POSTS AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORT BELOW. NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER.
STEP 12: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND DRAW A LINE ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. 3: CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT ON THE LINE AND PUSH THE CENTER DECK SUPPORT FLUSH TO THE BOTTOM SIDE OF THE DECK SPACERS.
STEP 13: DECK BOARDS 1: 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 SUPPORTS 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 BOARDS ACROSS THE DECK SUPPORTS BEFORE SECURING THEM TO THE FORT.
STEP 14: CONNECTOR POSTS 1: TWO 4 X 4 x 28.5" CONNECTOR POSTS WILL BE USED TO EXTEND THE FRONT CORNER POSTS TO ACCEPT THE LOWER LEVEL PLATFORM. 2: MAKE SURE TO INSTALL THE T-NUTS INTO THE CONNECTOR POSTS SIDE HOLES AS SHOWN IN THE DRAWING BELOW BEFORE MOUNTING IT TO THE FRONT POSTS. 3: USE 5/16" X 6" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP COUNTERBORE HOLE OF EACH CONNECTOR POST TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
STEP 15: LOWER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE LOWER LEVEL PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 87-1/2" LOWER LEVEL CORNER POSTS AT THE FRONT OF THE PLAYSET. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 16: LOWER LEVEL PANEL BOARDS 1: PLACE THE 2 X 4 X 35.5" TOP PANEL BOARD FLUSH TO THE CONNECTOR POST. ATTACH THE COUNTERSUNK HOLE OF THE TOP PANEL BOARD TO THE T-NUT INSTALLED IN THE CONNECTOR POST USING ONE 5/16" X 4-1/2" HEX BOLT AND ONE 5/16" WASHER. ATTACH THE OPPOSITE COUNTERSUNK HOLE OF THE TOP PANEL BOARD TO THE T-NUT INSTALLED IN THE LOWER LEVEL CORNER POST USING ONE 5/16" X 4-1/2" HEX BOLT AND ONE 5/16" WASHER. 2: PLACE A LEVEL ON TOP OF THE TOP PANEL BOARD TO ADJUST IT UP OR DOWN.
STEP 16A: DRILL HOLES FOR BRIDGE CHAINS 1: LOCATE ONE 4 X 4 X 70" LOWER LEVEL UNDER 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 A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES WITH A SPADE BIT. TIP: IF USING A 1" PADDLE STYLE BIT, DRILL THROUGH THE BOARD UNTIL YOU CAN JUST SEE THE TIP OF THE BIT EMERGE FROM THE OTHER SIDE. STOP. THEN GO TO THE OTHER SIDE OF THE BOARD AND PLACE THE TIP WHERE IT EMERGED.
STEP 17: LOWER LEVEL FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" FRONT TOP PANEL BOARD ON THE FRONT OF THE LOWER LEVEL CORNER POSTS. THE HOLES IN THE FRONT TOP PANEL BOARD SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE FRONT TOP PANEL BOARD TO THE T-NUTS INSTALLED IN THE LOWER LEVEL 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 LOWER LEVEL CORNER POSTS.
STEP 18: LEVELING THE LOWER LEVEL FRAME 1: INSTALL LAG SCREWS ONLY IN THE THREE 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE THREE BOARDS TO THE LOWER LEVEL CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS. 2: FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE FRAME HAS BEEN LEVELED AND SQUARED.
STEP 19: LOWER LEVEL DECK SUPPORTS 1: FASTEN THE 2 X 4 X 39" PANEL AND DECK SUPPORTS TO THE HOLES AT 45" WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT.
STEP 20: LOWER LEVEL UNDER DECK SUPPORTS 1: PLACE THE 4 X 4 X 70" LOWER LEVEL UNDER DECK SUPPORT DIRECTLY UNDERNEATH THE LOWER LEVEL DECK SUPPORTS. MAKE SURE THE CHAIN HOLES ARE OFFSET TO THE RIGHT SIDE OF THE PLAY SET. ATTACH THE UNDER DECK SUPPORT TO THE LOWER LEVEL CORNER POSTS WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS. 2: PLACE THE 2 X 4 X 70" TRANSITION STEP / UNDER DECK SUPPORT DIRECTLY UNDERNEATH THE LOWER LEVEL DECK SUPPORTS.
STEP 21: LOWER LEVEL DECK SPACER AND DECK BOARD 1: PLACE THE 5/4 X 4 X 63" DECK SPACER AT THE FRONT OF THE LOWER LEVEL FORT. CENTER THE BOARD BETWEEN THE LOWER LEVEL CORNER POSTS AND FLUSH TO THE FRONT FACE BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE LOWER LEVEL DECK SUPPORT BELOW. NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER.
STEP 22: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 35.5" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACER AND DECK BOARD THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACER AND DECK BOARD (USE THE HOLE ON CENTER AS A GUIDE) CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT ON THE HOLES AND PUSH THE CENTER DECK SUPPORT FLUSH TO THE BOTTOM SIDE OF THE DECK SPACER AND DECK BOARD.
STEP 23: LOWER LEVEL DECK BOARDS 1: START WITH A 5/4 X 6 X 69.875" DECK BOARD AT THE BACK OF THE LOWER LEVEL FORT. CENTER THE BOARD BETWEEN THE BOTTOM PANEL BOARDS AND ATTACH IT WITH #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES AND INTO THE DECK SUPPORTS 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 BOARDS ACROSS THE DECK SUPPORTS BEFORE SECURING THEM TO THE FORT.
STEP 24: PANEL SUPPORTS 2: PLACE THE 2 X 4 X 39" PANEL AND DECK SUPPORT ON TOP OF THE 2 X 6 BOTTOM PANEL BOARD WITH OFFSET HOLES DOWN AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 25: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57” LADDER SIDE ON A FLAT SURFACE WITH CHANNELS FACING DOWN. PLACE THE BARREL OF A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE, AND SECURE WITH A HAMMER. REPEAT THIS STEP FOR THE OTHER LADDER SIDE. 2: FLIP THE LADDER SIDE OVER SO THAT THE CHANNELS ARE FACING UP. 3: PLACE THE LADDER STEPS INTO THE CHANNELS, AND THEN PLACE THE SECOND LADDER SIDE ON TOP, WITH THE CHANNELS FACING DOWN. 4: NOW PLACE TWO 2” WOOD SCREWS IN EACH STEP.
STEP 26: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE FRONT SIDE OF THE LOWER LEVEL FORT AS SHOWN BELOW.CENTER THE LADDER HORIZONTALLY ON THE 2 X 6. CENTER THE 90 BRACKETS VERTICALLY ON THE 2 X 6. USE THE HOLES IN THE LADDER BRACKETS AS A TEMPLATE TO DRILL 3/8" HOLES THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACK SIDE OF THE 3/8" HOLES ON THE BOTTOM PANEL BOARD. 3: ATTACH THE LADDER WITH 5/16" X 1-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 27: LOWER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" LOWER LEVEL STEP FLUSH WITH THE TOP OF THE MAIN LEVEL DECK BOARDS. LOWER LEVEL STEPS HAVE TWO HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH TWO 5/16" X 3-1/2" LAG SCREWS AND TWO 5/16" WASHERS. 3: PLACE THE BOTTOM OF ONE 2 X 4 X 70" LOWER LEVEL STEP FLUSH WITH THE TOP OF THE LOWER LEVEL DECK BOARDS. LOWER LEVEL STEPS HAVE TWO HOLES THAT ARE CENTERED.
STEP 28: MAIN LEVEL CENTER POST 1: LOCATE THE 4 X 4 X 32" CENTER POST AND PLACE IT CENTERED BEHIND THE HOLE IN THE TOP PANEL BOARD. 2: HAMMER A T-NUT INTO THE HOLE IN THE BACK SIDE OF THE CENTER POST. FASTEN THE CENTER POST TO THE TOP PANEL BOARD WITH A 5/16" X 4-1/2" HEX BOLT AND A 5/16" WASHER. 3: SQUARE THE CENTER POST TO THE DECK. ATTACH THE CENTER POST TO THE DECK WITH THREE #8 X 3" WOOD SCREWS FROM THE UNDERNEATH THE DECK..
STEP 29: 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.
STEP 30: ROCK WALL 1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, 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 BOTTOM ROCK WALL BOARD WITH ONE HOLE.
STEP 31: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
STEP 32: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT.
STEP 33: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE LEFT SIDE OF THE MAIN LEVEL FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 2-1/4" ABOVE THE BOTTOM OF THE BOTTOM PANEL 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 BOTTOM PANEL BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
STEP 33A: ANGLE SUPPORTS 1: TWO 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE ROCK WALL SIDE OF 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. 2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE ANGLE SUPPORT INTO THE BOTTOM PANEL BOARD. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 34: UPPER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE UPPER LEVEL PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT POSTS PROPERLY. 4: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW.
STEP 35: LAG POSTS 1: TWO 4 X 4 60-1/4" LAG POSTS WILL BE USED TO EXTEND THE MIDDLE CORNER POSTS TO ACCEPT THE UPPER LEVEL ROOF. 2: MAKE SURE TO INSTALL THE T-NUTS INTO THE LAG POSTS TOP HOLES AS SHOWN IN THE DRAWING BELOW BEFORE MOUNTING IT TO THE MIDDLE POSTS. 3: REST THE BOTTOM OF EACH LAG POST ON TOP OF THE 2 X 6 X 70 BACK PANEL BOARD. 4: CENTER EACH LAG POST DIRECTLY OVER THE CENTER OF THE MIDDLE CORNER POSTS. 5: ATTACH EACH LAG POST TO THE MIDDLE CORNER POST WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS.
STEP 36: REAR CORNER POSTS & DECK SUPPORTS & SIDE TOP PANEL BOARDS TIP: BEFORE YOU INSTALL THESE BOARDS LEAVE THEM ALL A LITTLE LOOSE. WHEN YOU HAVE FASTENERS IN ALL THE BOARDS GO BACK AND TIGHTEN THEM ALL UP. 1: ATTACH THE BOTTOM OF THE REAR CORNER POSTS TO THE SIDE SANDBOX BOARDS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 2: PLACE THE 2 X 4 X 30-7/16" SIDE TOP PANEL BOARDS (OFFSET DOWN) AT THE TOP OF THE CORNER POSTS ON THE SIDES OF THE FORT.
STEP 37: UPPER LEVEL - RAILING & UNDER DECK SUPPORT 1: PLACE THE 2 X 4 X 70" UPPER LEVEL STEPS/RAILING BOARD (3 HOLES ON CENTER) AT THE TOP OF THE REAR CORNER POSTS. THIS BOARD WILL GET ATTACHED TO THE 2ND HOLE DOWN FROM THE TOP OF THE POSTS. THE T-NUT FOR THIS BOARD SHOULD BE ON THE INSIDE OF EACH POST ALREADY. FASTEN THE UPPER LEVEL RAILING BOARD TO THE REAR CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 38: LOWER LEVEL REAR CENTER POST 1: HAMMER A T-NUT INTO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST HOLE. 2: ATTACH THE LOWER LEVEL CENTER POST TO THE MIDDLE HOLE OF THE 2 X 6 X 70" BACK PANEL BOARD. USE A 5/16" X 4-1/2" HEX BOLT AND A 5/16" WASHER TO ATTACH THE BOARDS TOGETHER.
STEP 39: CENTER DECK SUPPORT ASSEMBLY NOTE: IT IS BEST TO PLACE THESE BOARDS UPON A FLAT SURFACE BEFORE ATTACHING THEM TOGETHER. 1: PLACE ONE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET UP) ON THE RIGHT SIDE OF THE 4 X 4 X 30-1/2" UPPER LEVEL CENTER BLOCK SUPPORT. PLACE ONE MORE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET DOWN) ON THE LEFT SIDE OF THE 4 X 4 X 30-1/2" UPPER LEVEL CENTER BLOCK SUPPORT. 2: MAKE SURE THE ENDS AND BOTTOMS OF THE BOARDS ARE FLUSH TO ONE ANOTHER.
STEP 40: CENTER DECK SUPPORT ASSEMBLY INSTALLATION AND LAGS 1: PLACE THE CENTER DECK SUPPORT ASSEMBLY ON TOP OF THE 4 X 4 X 70" UPPER LEVEL UNDER DECK SUPPORT. THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST SHOULD FIT INSIDE THE CENTER DECK SUPPORT ASSEMBLY. 2: MAKE THE CENTER DECK SUPPORT ASSEMBLY LEVEL WITH THE CENTER DECK SUPPORTS. THE END OF THE CENTER DECK SUPPORT ASSEMBLY SHOULD BE FLUSH TO THE SIDE OF THE LOWER LEVEL CENTER POST.
STEP 41: SLIDE BLOCK 1: PLACE THE 4 X 4 X 23-1/2" SLIDE BLOCK AGAINST THE UPPER DECK SUPPORT ON THE LEFT SIDE (LADDER SIDE) OF THE PLAY SET. THE TOP OF THE BLOCK SHOULD BE FLUSH TO THE TOP OF THE DECK SUPPORT. THE BLOCK FITS BETWEEN THE LAG POST AND THE REAR CORNER POST. 2: HAVE AN ASSISTANT HOLD THE BOARD IN POSITION OR USE A CLAMP TO HOLD THE BOARD FIRMLY TO THE DECK SUPPORT. USE THE HOLES IN THE SLIDE BLOCK AS A TEMPLATE TO DRILL 3/8" HOLES THROUGH THE DECK SUPPORT.
STEP 42: ANGLE SUPPORT - UPPER LEVER REAR 1: PLACE A 2 X 4 X 18" ANGLE SUPPORT -UPPER LEVEL REAR AGAINST THE 4 X 4 X 70 UPPER LEVEL UNDER DECK SUPPORT ON EACH SIDE AT THE REAR OF THE PLAY SET. 2: THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH TO THE TOP OF THE UNDER DECK SUPPORT. FASTEN THE TOP OF THE ANGLE SUPPORT TO THE UNDER DECK SUPPORT WITH FOUR #8 X 2-1/2" WOOD SCREWS. 3: FASTEN THE BOTTOM OF THE ANGLE SUPPORT TO THE REAR CORNER POST WITH ONE #8 X 2" WOOD SCREW AND ONE #8 X 3" WOOD SCREW.
STEP 43: SIDE REAR ANGLE SUPPORTS 1: (SEE DETAIL A) PLACE THE 2 X 4 X 18" ANGLE SUPPORT UPPER LEVEL RAD RIDE SIDE UNDER THE 4 X 4 X 23-1/2" SLIDE BLOCK ON THE LEFT SIDE OF THE FORT. THE ANGLE SUPPORT SHOULD BE FLUSH TO THE LEFT SIDE OF THE LEFT REAR CORNER POST. ATTACH THE ANGLE SUPPORT AT THE TOP AND AT THE BOTTOM WITH ONE #8 X 2" WOOD SCREW AND ONE #8 X 3" WOOD SCREW.
STEP 44: UPPER LEVEL DECK SPACERS 1: MAKE SURE THE LOWER LEVEL CENTER POST HAS AN EQUAL OPENING ON EACH SIDE. 2: PLACE THE 5/4 X 4 X 29-1/2" UPPER DECK SPACERS BETWEEN THE LOWER LEVEL CENTER POST AND THE MIDDLE CORNER POSTS. ATTACH EACH UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2" WOOD SCREWS. 3: PLACE THE 5/4 X 4 X 63" UPPER DECK SPACER BETWEEN THE UPPER LEVEL LAG POSTS. ATTACH THE UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2" WOOD SCREWS.
STEP 45: SLIDE POST ASSEMBLY 1: PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH IN THE 4 X 4 X 43-1/2" RAD RIDE CENTER POST. 2: PLACE ONE END OF THE 5/4 X 4 X 25" RAD RIDE DECK SPACER INTO THE NOTCH IN THE RAD RIDE CENTER POST. THE END WITHOUT ANY PREDRILLED HOLES GOES INTO THE NOTCH. 3: FASTEN THE RAD RIDE DECK SPACER TO THE RAD RIDE CENTER POST WITH TWO #10 X 3-1/2" WOOD SCREWS. 4 X 4 X 43-1/2" RAD RIDE CENTER POST WHEN YOU RECEIVE THIS BOARD IT WILL HAVE TWO HOLES PREDRILLED IN THIS END.
STEP 46: SLIDE POST INSTALLATION 1: PLACE THE END OF THE DECK SPACER AGAINST THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. FASTEN THE DECK SPACER TO THE DECK SUPPORT WITH #8 X 2" WOOD SCREWS. 2: MAKE THE DECK SPACER LEVEL WITH THE DECK BOARD BEHIND IT. DRIVE A 3/8" X 5" LAG SCREW WITH 3/8" WASHER THROUGH THE RAD RIDE CENTER POST INTO THE 4 X 4 X 70" UNDER DECK SUPPORT. 3: MEASURE THE BOTTOM OPENING AND RECORD THIS MEASUREMENT.
STEP 47: UPPER LEVEL REAR DECK SPACER 1: PLACE THE 5/4 X 4 X 35-1/2" REAR DECK SPACER ON TOP OF THE DECK SUPPORTS. THE END SHOULD BE FLUSH TO THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST/CENTER POST. 2: FASTEN THE REAR DECK SPACER TO THE DECK SUPPORTS WITH FOUR #8 X 2" WOOD SCREWS.
STEP 48: UPPER LEVEL DECK BOARDS 1: PLACE FOUR 5/4 X 6 X 69-7/8" UPPER DECK BOARDS ACROSS THE DECK SUPPORTS AS SHOWN. EQUALLY SPACE THE DECK BOARDS 5/16" FROM ONE ANOTHER AND FROM THE DECK SPACER. 2: SECURE EACH UPPER DECK BOARD TO THE DECK SUPPORTS WITH FIVE #8 X 2" WOOD SCREWS.
STEP 49: UPPER LEVEL CENTER POST 1: PLACE THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST AGAINST THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST. FLUSH THE TOPS AND SIDES OF THE POSTS TOGETHER. 2: ATTACH THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST TO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS.
STEP 50: RAILING 1: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD (RAILING) AGAINST THE MIDDLE POSTS, FLUSH WITH THE TOP END OF THE CENTER POST. 2: THE TOP OF THE RAILING SHOULD BE 33" ABOVE THE DECK BOARDS. 3: ATTACH THE RAILING TO THE LAG POSTS AND UPPER LEVEL CENTER POST WITH 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 51: RADICAL RIDE TUBE SLIDE 1: ASSEMBLE THE RADICAL RIDE TUBE SLIDE ACCORDING TO THE DIRECTIONS INCLUDED WITH THE SLIDE. 2: PLACE THE SLIDE FACEPLATE AT THE OPENING AT THE REAR OF THE PLAY SET. THE SIDE OF THE FACE PLATE SHOULD BE 3/4" AWAY FROM THE CORNER POST SIDE. 3: THE BOTTOM OF THE SLIDE OPENING SHOULD BE FLUSH WITH THE UPPER LEVEL DECK. 4: ATTACH THE SLIDE FACE PLATE TO THE CORNER POST AND RAD RIDE CENTER POST WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 52: UPPER LEVEL BOTTOM PANEL BOARDS 1: PLACE THE 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD (OFFSET UP) ON THE SWING BEAM SIDE (RIGHT SIDE) OF THE PLAYSET. ATTACH THE TOP HOLES OF THE BOARD TO THE POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. ATTACH THE BOTTOM HOLES WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2: PLACE THE 2 X 6 X 42-1/2" REAR BOTTOM PANEL BOARD (OFFSET DOWN) ON THE BACK SIDE OF THE UPPER LEVEL.
STEP 53: UPPER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" UPPER LEVEL STEP FLUSH WITH THE TOP OF THE UPPER LEVEL DECK SPACERS. UPPER LEVEL STEPS HAVE THREE HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16" WASHERS. 3: LEAVE A 3-3/8" GAP BETWEEN THE UPPER LEVEL STEP YOU JUST INSTALLED AND THE NEXT UPPER LEVEL STEP. ATTACH THE NEXT UPPER LEVEL STEP WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16" WASHERS.
STEP 54: UPPER LEVEL REAR CENTER POST 1: PLACE THE 2 X 4 X 35-5/8" UPPER LEVEL REAR CENTER POST AGAINST THE REAR RAILING ON THE UPPER LEVEL. HAMMER A T-NUT INTO THE TOP HOLE IN THE UPPER LEVEL REAR CENTER POST. LINE UP THE HOLE IN THE UPPER LEVEL REAR CENTER POST WITH THE HOLE IN THE REAR RAILING. 2: ATTACH THE UPPER LEVEL CENTER POST TO THE RAILING AT THE TOP WITH A 5/16" X 2-1/2" HEX BOLT WITH A 5/16" WASHER.
STEP 55: UPPER LEVEL PANEL SLATS 1: 5/4 X 3 X 34-1/2" PANEL SLATS WILL BE INSTALLED ON THE RIGHT AND REAR-RIGHT SIDES OF THE PLAY SET. THE PANEL SLATS WILL BE INSTALLED ON THE INSIDE OF THE BOTTOM PANEL BOARDS AND RAILINGS. 2: SPACE THE PANEL SLATS IN THE OPENINGS AS SHOWN BELOW. ATTACH EACH PANEL SLAT WITH TWO #8 X 2" WOOD SCREWS.
STEP 56: MAIN LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FOUR SLATS ON THE LEFT SIDE, SIX SLATS ON THE RIGHT SIDE OF THE MAIN LEVEL. 2: PLACE EACH SLAT AS SHOWN BELOW ON THE INSIDE OF THE PANEL BOARDS AND ATTACH EACH PANEL SLAT TO THE FORT WITH TWO #8 X 2" WOOD SCREWS.
STEP 57: LOWER LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FIVE SLATS ON THE LEFT SIDE, FIVE SLATS ON THE RIGHT SIDE AND TWO SLATS ON THE FRONT OF THE LOWER LEVEL. 2: PLACE EACH SLAT AS SHOWN BELOW ON THE INSIDE OF THE PANEL BOARDS AND ATTACH EACH PANEL SLAT TO THE FORT WITH TWO #8 X 2" WOOD SCREWS.
STEP 58: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE 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 59: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 60: REST SWING BEAM ON FORT 1: REST THE SWING BEAM ASSEMBLY ON TOP OF THE UPPER RAILING BOARDS OF THE FORT. 2: THE END OF THE SWING BEAM WITH 2 HOLES SHOULD OVERHANG THE SWING BEAM SIDE OF THE FORT. IN THE NEXT STEP YOU WILL ATTACH THE SWING BEAM LEGS ONTO THIS END OF THE SWING BEAM.
STEP 61: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH ONE TORQUE WASHER AND THE SUB BRACKET ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: PREDRILL AN 11/64" HOLE THROUGH THE CENTER HOLE IN THE SWING LEG BRACKET. USE A 3/8 X 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET. 3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.
STEP 62: MOUNT SWING BEAM TO FORT 1: PLACE A 3/8" X 9" CARRIAGE BOLT THROUGH A TORQUE WASHER. INSERT THE CARRIAGE BOLT INTO THE HOLE AT THE END OF THE SWING BEAM OVER THE SWING BEAM MOUNT. ALIGN THE SQUARE SHANK OF THE CARRIAGE BOLT WITH THE SQUARE HOLE IN THE TORQUE WASHER. HAMMER THE CARRIAGE BOLT TO SET THE TORQUE WASHER INTO THE SWING BEAM. 2: ON THE BOTTOM SIDE OF THE SWING BEAM MOUNT ATTACH A 3/8" FLAT WASHER AND A 3/8" LOCK NUT ONTO THE END OF THE CARRIAGE BOLT.
STEP 63: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. 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.
STEP : SWING LEG CROSS-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" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS. 4: CHOOSE TWO HOLES IN THE SUB BRACKET THAT DO NOT INTERFERE WITH THE OTHER LAG SCREWS IN THE SWING LEG. DRILL 11/64" HOLES BY 2-1/2" DEEP INTO 2 HOLES IN THE SUB BRACKET.
STEP 65: 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.
STEP 66: ROOF SUPPORT ASSEMBLY 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.
STEP 66A: UPPER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE UPPER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LAG POSTS OR REAR CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS WITH 5/16" WASHERS.
STEP 67: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE UPPER LEVEL ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH TOP SIDE OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS.
STEP 68: UPPER LEVEL ROOF 1: PLACE THE 1 X 6 X 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH FOUR #8 X 1-1/4" WOOD SCREWS.
STEP 69: UPPER LEVEL ROOF 1: PLACE THE TONGUE OF A 1 X 5 X 30-1/2" ROOF BOARD INTO THE SLOT OF THE ROOF STARTER. ALIGN THE ENDS OF THE BOARDS. FASTEN THE ROOF BOARD TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREW. REPEAT THIS PROCESS FOR TEN MORE ROOF BOARDS. 2: PLACE A 1 X 4 X 30-1/2" ROOF FINISHER AT THE END OF THE ROOF. PLACE THE TONGUE OF THE ROOF FINISHER INTO THE GROOVE OF THE LAST ROOF BOARD, THEN ALIGN THE ENDS OF THE BOARDS.
STEP 70: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBURST TO THE ROOF SUPPORTS ON THE FRONT AND REAR OF THE ROOF. THE PLASTIC SUNBURST MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBURST TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS ON THE TOP AND SIX #8 X 2" WOOD SCREWS IN THE REMAINING HOLES.
STEP 71: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 35.15" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35.15" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN.
STEP 72: ROOF SUPPORTS (MAIN LEVEL) 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE MAIN LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE MAIN LEVEL CORNER POSTS WITH 5/16 X 4-1/2" HEX BOLTS WITH 5/16" WASHERS.
STEP 73: ROOF STARTER REAR 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER BOARD AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER SHOULD BE PLACED FLUSH TO THE PEAK OF THE ROOF SUPPORTS. 2: FASTEN THE ROOF STARTER REAR TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS. WHEN ATTACHING THE ROOF STARTER DIM B AT THE ROOF PEAK SHOULD MATCH DIM A.
STEP 74: ROOF REAR SECTION 1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR. THIS SIDE OF THE ROOF GETS FOUR 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 WITH 1-1/2" WOOD SCREWS.
STEP 75: ROOF FRONT SECTION 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPPING THE ROOF STARTER REAR. THE HOLES IN THE ROOF STARTER FRONT SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND 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.
STEP 76: DORMERS 1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE DORMERS. AFTER INSTALLING THE SEVENTH ROOF BOARD, INSTALL THE DORMER MOUNTING BLOCK 9-3/4" FROM THE SIDE EDGE OF THE ROOF TO THE SIDE EDGE OF THE DORMER MOUNTING BLOCK, AND 15" FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE TOP EDGE OF THE DORMER MOUNTING BLOCK. INSERT TWO #8 X 2" WOOD SCREWS THROUGH THE MOUNTING BLOCK INTO THE ROOF BOARD.
STEP 77: LOWER LEVEL FRONT ROOF SUPPORT ASSEMBLY 1: LOCATE ONE 2 X 4 X 47.88" FRONT ROOF SUPPORT (LEFT), ONE 2 X 4 X 47.88" FRONT ROOF SUPPORT (RIGHT) AND ONE 5/4 X 6 X 12.81" ROOF PEAK SUPPORT. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS THE.
STEP 78: LOWER LEVEL REAR ROOF SUPPORT ASSEMBLY 1: LOCATE ONE 2 X 4 X 47.35" REAR ROOF SUPPORT (LEFT), ONE 2 X 4 X 47.35" REAR ROOF SUPPORT (RIGHT) AND ONE 5/4 X 6 X 10.81" ROOF PEAK SUPPORT. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.
STEP 79: MOUNTING LOWER LEVEL ROOF SUPPORTS 1: PLACE THE REAR ROOF SUPPORT ASSEMBLY AGAINST THE MAIN LEVEL FRONT CORNER POST AND REST ON TOP OF THE LOWER LEVEL CONNECTOR POSTS. THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE BACK TOWARDS THE MAIN LEVEL ROOF. 2: MAKE SURE THE BOTTOM ENDS OF THE REAR ROOF SUPPORT ASSEMBLY ARE FLUSH TO THE MAIN LEVEL CORNER POSTS SIDE FACES. FASTEN USING 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 3: PLACE THE FRONT ROOF SUPPORT ASSEMBLY ON THE LOWER LEVEL CORNER POSTS.
STEP 80: ROOF PANEL ASSEMBLIES TO FORT 1: MOUNT THE ROOF PANEL ASSEMBLY (LEFT) AND ROOF PANEL ASSEMBLY (RIGHT) ON TOP OF THE LOWER LEVEL ROOF SUPPORTS ASSEMBLIES (FRONT & REAR). MAKE SURE EACH ROOF PANEL ASSEMBLY BEVEL END IS FLUSH TO THE MAIN LEVEL ROOF. 2: UNDERNEATH THE ROOF PANEL ASSEMBLIES, THE FRONT AND REAR BATTEN SHOULD BE FLUSH BETWEEN THE ROOF SUPPORT ASSEMBLIES (FRONT AND REAR). 3: MAKE SURE THE PEAK IS FLUSH AND THE OVERHANG IS UNIFORM AT THE FRONT.
STEP 81: ROOF 1: PLACE THE 1 X 5 X 38.875" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF PANEL ASSEMBLY. EACH SIDE OF THE ROOF GETS 7 ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: FIT THE TONGUE END OF THE 1 X 5 X 38.875" ROOF FINISHER INTO THE GROOVE END OF THE LAST ROOF BOARD. FASTEN IT TO THE ROOF SUPPORT WITH FOUR 1-1/2" WOOD SCREWS.
STEP 82: WALL PANEL SUPPORTS 1: PLACE THE 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT ANGLED END ON TOP OF 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 ROOF PANEL. THE WALL PANEL SUPPORT TOP EDGE MUST BE PARALLEL AT 21-7/8" TO THE TOP EDGE OF THE CONNECTOR POST. ATTACH THE WALL PANEL SUPPORT LEFT TO THE ROOF PANEL WITH ONE #8 X 2-1/2" WOOD SCREW.
STEP 83: ROOF FINISHERS 1: PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT LEFT ANGLED END ON TOP OF THE ROOF PANEL ASSEMBLY LEFT SIDE. PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT ANGLED END ON TOP OF THE ROOF PANEL ASSEMBLY RIGHT SIDE. FIT THE TONGUE END INTO THE GROOVE OF THE ROOF BOARD ABOVE THEM. 2: MAKE SURE THAT BOTH ROOF FINISHERS ENDS ARE FLUSH ON BOTH SIDES OF THE ROOF AND TIGHT TO THE ROOF PANEL ASSEMBLY.
STEP 84: ROOF BATTEN 1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE FRONT 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 IS PARALLEL TO THE ROOF SUPPORTS. INSERT 1-1/4" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ALONG THE BATTEN. 2: THE REMAINING 1 X 2 X 32" ROOF BATTEN WILL BE CUT TO FIT THE REAR ROOF PANEL SECTION. MEASURE FROM THE BOTTOM END 22-1/2" TO THE TOP, MAKE A MARK WITH A PENCIL.
STEP 85: WALL PANEL BOARDS 1: START MOUNTING THE 1 X 4 X 19.31" WALL PANEL BOARD AGAINST THE LEFT SIDE OF THE LOWER LEVEL ROOF SUPPORT ASSEMBLY REAR 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 FRONT LEFT CORNER POST. THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1" TO THE SIDE EDGE OF THE ROOF SUPPORT. FASTEN THE WALL PANEL BOARD WITH FOUR 1-1/2" WOOD SCREWS. 2: MOUNT THE 1 X 4 X 15.
STEP 86: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBURST TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF, THE PLASTIC SUNBURST MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBURST TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS AT THE TOP AND SIX #8 X 2" WOOD SCREWS IN THE REMAINING HOLES.
STEP 87: SANDBOX SEATS AND NAME PLATE 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET. ATTACH THE NAME PLATE TO THE FRONT OF THE SWING BEAM WITH #8 X 1" WOOD SCREWS. PLACE NAME PLATE HERE AND ATTACH WITH #8 X 1" WOOD SCREWS.
STEP 88: PICNIC TABLE 1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS. 2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4" PT TOP SUPPORT AND A 2 X 4 X 27-1/2" PT SEAT SUPPORT PARALLEL TO ONE ANOTHER. PLACE A 2 X 4 X 32-1/2" PT LEG ON TOP AT THE 7-1/2" DIMENSION. THE TOP OF THE PT LEG SHOULD BE FLUSH TO THE TOP OF THE PT TOP SUPPORT. ATTACH THE PT LEG TO THE SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS.
STEP 88A: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE PLAYSET. 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-MIDDLE 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.
STEP 88B: PICNIC TABLE 1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS. 2: CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS. 3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS.
STEP 89: SAFETY BOARDS 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE MAIN FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS. 2: PLACE THE 2 X 4 X 34" SAFETY BOARD (UPPER LEVEL) ON TOP OF THE 2 X 4 X 47-1/2" SAFETY BOARD (MAIN LEVEL). ATTACH IT WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 90: ASSEMBLING THE MONKEY BAR LADDER 1: SEE FRONT SIDE BELOW. START WITH 4 X 4 X 86-1/2"L LADDER SIDES. WITH THE LARGE HOLES FACING YOU INSTALL A TEE NUT INTO THE TWO SMALL HOLES AT THE END OF EACH SIDE. 2: SEE FRONT SIDE BELOW. LOCATE FOUR 1-5/16" DIAMETER X 19.75" LONG CYLINDRICAL MONKEY BAR RUNGS. LAY ONE LADDER SIDE ON THE GROUND WITH THE LARGE HOLES FACING UP. INSERT A RUNG INTO EACH LARGE HOLE WITH THE WELD SEAM INSIDE THE RUNG FACING THE END OF THE LADDER SIDE.
STEP 91: ASSEMBLING THE MONKEY BAR ASSEMBLY 1: PLEASE NOTE: THERE IS A LEFT AND RIGHT MONKEY BAR RUNNER (SEE BOTTOM LEFT PICTURES BELOW). 2: START WITH THE 4 X 4 X 70" MONKEY BAR RUNNERS. WITH THE FIVE LARGE HOLES FACING YOU INSTALL A 5/16" T NUT INTO THE TWO SMALL HOLES AT THE ANGLED END OF EACH MONKEY BAR RUNNER. 3: SEE TOP BELOW. LOCATE FIVE 1-5/16" DIAMETER X 19.75" LONG CYLINDRICAL MONKEY BAR RUNGS. LAY THE LEFT MONKEY BAR RUNNER ON THE GROUND WITH THE LARGE HOLES FACING UP.
STEP 92: ATTACHING THE LADDER TO THE MONKEY BAR ASSEMBLY 1: LOCATE TWO 8-5/8" W X 6-1/2"H MONKEY BAR PLATES, EIGHT 5/16" X 3-1/2"L HEX BOLTS AND EIGHT 5/16" FLAT WASHER. LOOSELY ATTACH THE LADDER ASSEMBLY TO THE MONKEY BAR ASSEMBLY WITH THE MONKEY BAR PLATES. USE 5/16" X 3-1/2"L HEX BOLTS WITH 5/16" FLAT WASHERS TO ATTACH THE MONKEY BAR PLATES TO THE T-NUTS PREVIOUSLY INSTALLED. 2: ONCE ALL THE HEX BOLTS ARE STARTED IN THE T-NUTS TIGHTEN THEM DOWN.
STEP 93: MONKEY BAR MOUNT 1: CENTER THE MONKEY BAR ASSEMBLY ON TOP OF THE 4 X 4 X 35.5" MONKEY BAR MOUNT. THE COUNTERSUNK HOLES IN THE MONKEY BAR ASSEMBLY SHOULD FACE UP. 2: THE END OF THE MONKEY BAR ASSEMBLY SHOULD BE FLUSH AGAINST THE INSIDE FACE OF THE MONKEY BAR MOUNT. 3: ATTACH THE MONKEY BAR ASSEMBLY TO THE MONKEY BAR MOUNT WITH TWO 3/8" X 5-1/2" LAG SCREWS AND TWO 3/8" WASHERS. 3/8" X 5-1/2" LAG SCREW MONKEY BAR ASSEMBLY 3/8" WASHER 4 X 4 X 35.
STEP 94: ATTACHING THE MONKEY BAR FILLER BOARD 1: FIND ONE 2 X 4 X 28" MONKEY BAR FILLER BOARD AND ATTACH IT TO THE MONKEY BAR ASSEMBLY USING 5/16" X 2-1/2" LAG SCREWS AND 5/16" WASHERS THROUGH THE FILLER BOARD COUNTERSUNK HOLES INTO THE MONKEY BAR RUNNERS (LEFT & RIGHT). SEE BELOW FOR MORE DETAILS.
STEP 95: MOUNTING THE MONKEY BARS TO THE FORT 1: CENTER THE MONKEY BAR ASSEMBLY MONKEY BAR MOUNT BETWEEN THE LOWER LEVEL CORNER POST AND THE CONNECTOR POST. 2: LEVEL THE MONKEY BAR ASSEMBLY TO THE FORT AND VERIFY THE THE MONKEY BAR MOUNT IS PARALLEL TO THE TOP PANEL BOARD FROM UNDERNEATH.
STEP 95A: MONKEY BAR FILLER BOARD 1: MEASURE THE GAP BETWEEN THE MONKEY BAR MOUNT AND THE TOP PANEL BOARD (RAILING). IF THE DISTANCE IS 3-1/2" OR MORE THEN USE THE 2 X 4 X 35.5" TOP PANEL BOARD (FILLER BOARD) TO CLOSE UP THE OPENING. ATTACH IT TO THE LOWER LEVEL CORNER POST AND CONNECTOR POST WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2: IF THE GAP BETWEEN THE MONKEY BAR MOUNT AND THE TOP PANEL BOARD (RAILING) IS LESS THAN 3-1/2" THEN LEAVE THAT AREA OPEN.
STEP 96: ATTACHING THE SAFETY HANDLES 1: LOCATE THE TWO GREEN SAFETY HANDLES, FOUR #14 X 1-1/4" PAN HEAD SCREWS AND FOUR 1/4" FLAT WASHERS. 2: ATTACHING EACH SAFETY HANDLE TO THE LADDER SIDE WITH TWO #14 X 1-1/4" PAN HEAD SCREWS AND TWO 1/4" FLAT WASHERS PER HANDLE. ADJUST THE HANDLES UP AND DOWN VERTICALLY TO SUIT YOUR CHILD'S REACH.
STEP 97: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE 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.
STEP 98: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 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. GREEN BRACKET 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT TIC TAC TOE AFTER ASSEMBLING.
STEP 99: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAYSET (SWING BEAM SIDE) ON THE INSIDE OF MAIN LEVEL. 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 SWING BEAM TIC TAC TOE WITH BOARDS ATTACHED 4" NOTE: 2 X 6 X 70" FRONT TOP PANEL BOARD REMOVED FOR CLARITY.
STEP 100: INSTALLING THE ROCK WALL ROPE 1: USE A 1" PADDLE BIT TO DRILL A HOLE IN THE CENTER OF THE TOP PANEL BOARD. THIS IS THE ONLY TIME YOU WILL NEED THIS DRILL BIT IN THE ASSEMBLY. YOU MAY PUT IT AWAY AFTER DRILLING THE HOLE. TIP: IF USING A 1" PADDLE STYLE BIT, DRILL THROUGH THE BOARD UNTIL YOU CAN JUST SEE THE TIP OF THE BIT EMERGE FROM THE OTHER SIDE. STOP. THEN GO TO THE OTHER SIDE OF THE BOARD AND PLACE THE TIP WHERE IT EMERGED. COMPLETE DRILLING THE HOLE.
STEP 101: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE TOP PANEL BOARD ON THE ROCK WALL SIDE OF THE MAIN LEVEL. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE.
STEP 102: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK (UPPER LEVEL). 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2" LAG SCREW AND WASHER TO FASTEN THE STEERING WHEEL TO THE REAR CENTER POST. DO NOT OVER-TIGHTEN THE LAG SCREW OR THE STEERING WHEEL WILL NOT TURN. 5: PLACE THE STEERING WHEEL CAP OVER THE STEERING WHEEL AND SNAP IT INTO THE STEERING WHEEL INSERT.
STEP 103: ATTACHING SUPER SCOOP SLIDE 1: PLACE THE SUPER SCOOP SLIDE IN THE OPENING AT THE LEFT SIDE OF UPPER LEVEL OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH #14 X 3" PAN HEAD SCREWS.
STEP 104: LOWER LEVEL FRONT CENTER POST 1: LOCATE THE 4 X 4 X 29" CENTER POST. PLACE THE 4 X 4 X 29" CENTER POST CENTERED BEHIND THE HOLE IN THE FRONT TOP PANEL BOARD. CAREFULLY DRILL A 3/8" HOLE THROUGH THE CENTER POST USING THE HOLE IN THE ROPE LADDER SUPPORT AS A GUIDE. 2: HAMMER A T-NUT INTO THE HOLE IN THE BACK SIDE OF THE CENTER POST. FASTEN THE CENTER POST TO THE FRONT TOP PANEL BOARD WITH A 5/16" X 4-1/2" HEX BOLT AND A 5/16" WASHER. 3: SQUARE THE CENTER POST TO THE DECK.
STEP 105: SAFETY HANDLES(UPPER/MAIN/LOWER) LEVEL 1: LOCATE THE SAFETY HANDLE BAGS. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLAT, CENTER POSTS AND CORNER POSTS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES. SEE DIAGRAM BELOW FOR DETAILS.
STEP 106: SUN SUPPORT 1: PLACE THE 2 X 4 X 29.5" SUN SUPPORT UNDERNEATH THE LOWER LEVEL FRONT ROOF SUPPORTS. MAKE SURE THE SUN SUPPORT IS LEVEL. ATTACH THE SUN SUPPORT THROUGH THE PRE-DRILLED HOLES IN THE BOTTOM TO THE ROOF SUPPORTS WITH 2-1/2" WOOD SCREWS. 2 X 4 X 29.
STEP 107: WALL PANEL BOARDS 1: MOUNT THE 1 X 4 X 26" WINDOW PANEL BOARD ABOVE THE LOWER LEVEL CENTER POST. THE END WITH TWO PREDRILLED HOLES SHOULD BE OFFSET TO THE TOP. MAKE SURE IT IS STRAIGHT VERTICALLY AND FASTEN IT TO THE SUN SUPPORT USING TWO #8 X 1-1/2" WOOD SCREWS. 2: MOUNT ONE 1 X 4 X 28" WINDOW PANEL BOARD ON EACH SIDE OF THE CENTER BOARD PREVIOUSLY INSTALLED. THE TOP END MUST BE IN LINE WITH THE WINDOW PANEL BOARD PREVIOUSLY INSTALLED.
STEP 108: WINDOW AND CROWNS 1: PLACE EACH PLASTIC WINDOW INTO THE FRONT OPENINGS, WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS. 2: CENTER THE WINDOW CROWN OVER THE TOP OF THE PLASTIC WINDOW AND ATTACH THE CROWN TO THE TOP WINDOW PANEL BOARDS WITH #8 X 1" WOOD SCREWS.
STEP 109: WALL PANEL BOARDS 1: MOUNT THE 1 X 4 X 24" WINDOW PANEL BOARD NEXT TO THE 1 X 4 X 27" WINDOW PANEL BOARD INSTALLED ON PREVIOUS STEPS. LEAVE A 1/4" GAP BETWEEN THEM. THE ANGLED END MUST BE OFFSET UP AND PARALLEL TO THE ROOF SUPPORT.FASTEN IT USING FOUR #8 X 1-1/2" WOOD SCREWS. 2: MOUNT THE 1 X 4 X 21" WINDOW PANEL BOARD NEXT TO THE 1 X 4 X 24" WINDOW PANEL BOARD PREVIOUSLY INSTALLED. LEAVE A 1/4" GAP BETWEEN THEM. THE ANGLED END MUST BE OFFSET UP AND PARALLEL TO THE ROOF SUPPORT.
STEP 110: SOLAR WALL LIGHTS 1: WITH A PENCIL MAKE A CENTER MARK ON THE OUTSIDE FACE OF THE 1 X 4 X 21" WINDOW PANEL BOARD, MEASURE 8-5/8" HORIZONTALLY FROM THE OUTSIDE EDGE OF THE CORNER POST TOWARDS THE CENTER OF THE WALL PANEL BOARD AND 10" FROM THE TOP EDGE OF THE FRONT TOP PANEL BOARD UP TOWARDS THE CENTER OF THE WALL PANEL BOARD AS SHOWN IN THE DIAGRAM BELOW.
PART 2 CLATTER BRIDGE ASSEMBLY 178
STEP 1: ATTACHING T-NUTS 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 YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 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.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF 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 6 X 36-3/4" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS.
STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE LEFT 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 TNUTS 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 LEFT SIDE CORNER POSTS.
STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 36-3/4" DECK SUPPORTS TO THE HOLES AT 45-5/16" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE FRONT OF 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 FRONT OF THE CORNER POSTS.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE REAR OF 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.
STEP 7: LAG SCREWS 1: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. TO SQUARE AND LEVEL THE 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.
STEP 8: DECK BOARDS 1: 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 X 36-3/4" BOTTOM PANEL BOARD OR THE OUTSIDE SURFACE OF THE CORNER POSTS. ATTACH EACH DECK SPACER TO THE DECK SUPPORTS WITH TWO 2" WOOD SCREWS. NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH WITH THE TOP OF THE DECK SPACER.
STEP 9: REAR BOTTOM PANEL 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 REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 3: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 10: DECK 1: INSTALL THE 5/4 X 4 X 36-1/2" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS.
STEP 11: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE LEFT SIDE 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" WASHERS. 3: PLACE THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS.
STEP 12: PANEL SLATS 1: INSTALL THE FIRST PANEL SLAT 2-1/2" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8" APART AS SHOWN. 2: ATTACH THE PANEL SLATS ONTO THE FRONT AND RIGHT SIDES OF THE TOWER WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES.
STEP 13: BRIDGE RAILS 1: PLACE THE TOP SURFACE OF THE UPPER TWO 2 X 4 X 66" BRIDGE RAILS 5-1/2" BENEATH THE TOP SURFACE OF THE TOP PANEL BOARD. THE COUNTERSUNK HOLE IN THE END OF THE BRIDGE RAIL SHOULD FACE THE INSIDE. FASTEN THE BRIDGE 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.
STEP 14: BRIDGE RAILS TO PLAYSET 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER CORNER 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: MAKE THE BOTTOM OF EACH LOWER BRIDGE RAIL 16" FROM THE TOP OF THE TOP BRIDGE RAIL. 4: ATTACH EACH LOWER BRIDGE RAIL TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 15: BRIDGE RAIL SLATS 1: 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. 2: ATTACH THE REMAINING SLATS TO THE UNIT WITH 3" SPACING BETWEEN THE SLATS.
STEP 16: BRIDGE DECK AND CHAIN ASSEMBLY 1: FIND FIFTEEN 2 X 4 X 29" BRIDGE DECK BOARDS AND INSERT T-NUTS INTO THE PRE-DRILLED HOLES. USE A HAMMER TO SEAT THE T-NUTS INTO THE BOARDS. T-NUT 2 X 4 X 29" BRIDGE DECK BOARD T-NUT FLANGE 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 17: BRIDGE DECK AND CHAIN ASSEMBLY 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 THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES.
STEP 18: BRIDGE DECK AND CHAIN ASSEMBLY 1: PLACE A 5/16" WASHER BETWEEN THE 18TH CHAIN LINK AND THE BRIDGE DECK BOARD. 2: PLACE A 5/16" X 1-3/4" HEX BOLT WITH 5/16" WASHER THROUGH THE 18TH 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. 3: COUNT OVER 4 CHAIN LINKS FROM THE LAST HEX BOLT. AT THIS CHAIN LINK PLACE A 5/16" WASHER BETWEEN THE CHAIN LINK AND THE BRIDGE DECK BOARD.
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. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE BOTTOM PANEL BOARD ON THE TOWER. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP.
STEP 20: BRIDGE DECK / CHAIN INSTALLATION 1: TWO PEOPLE MAY BE REQUIRED FOR THIS STEP. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE FRONT FACE BOARD ON THE PLAY SET. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP. IN ORDER TO ACHIEVE THE GAP YOUR ASSISTANT MAY HAVE TO LIFT UP THE BRIDGE DECK ASSEMBLY WHILE YOU CONNECT THE CHAINS TOGETHER WITH THE QUICK LINK UNDER THE PLAY SET DECK.
STEP 21: ROOF SUPPORT ASSEMBLIES 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.
STEP 22: DRILLING CORNER POST HOLES 1: CHECK THE DIMENSION OF THE ROOF SUPPORT ASSEMBLIES AS SHOWN BELOW BEFORE DRILLING HOLES. 2: MEASURE 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 SUB STEPS 2-3 ON THE INSIDE OF THE OTHER POSTS AS POINTED OUT BELOW. REPEAT THE MEASURING/MARK/DRILL PROCESS ON THE INSIDE OF THESE CORNER POSTS.
STEP 23: INSTALLING THE 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 ASSEMBLY TO THE HOLES DRILLED ON THE INSIDE OF THE CORNER POSTS WITH TWO 5/16" X 3-1/2" LAG SCREWS WITH TWO 5/16" WASHERS.
STEP 24: 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 OVERHANG THE SAME ON EACH SIDE OF THE STARTER. 2: PLACE THE STARTERS AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THEM OVERLAPPING. 3: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. ROOF STARTER OVERHANG B SIDE VIEW A OVERHANG ROOF SUPPORT BEFORE INSTALLING THE ROOF STARTERS MAKE SURE DIMENSIONS A AND B MATCH.
STEP 25: ROOF PEAK 1: FASTEN ROOF PEAK BOARD 1 TO ROOF PEAK BOARD 2 WITH FOUR #8 X 1-1/2" WOOD SCREWS TO MAKE A ROOF PEAK ASSEMBLY 2: PLACE THE ROOF PEAK ASSEMBLY ON TOP OF THE ROOF STARTERS. FASTEN THE ROOF PEAK ASSEMBLY TO THE ROOF STARTERS WITH EIGHT #8 X 1-1/4" WOOD SCREWS.
STEP 26: ROOF BOARDS AND ROOF FINISHERS 1: LOCATE TEN 1 X 5 X 36-3/4" ROOF BOARDS. SLIDE THE TONGUE OF THE ROOF BOARD INTO THE GROOVE OF THE ROOF STARTER. SECURE THE ROOF BOARD TO THE ROOF SUPPORTS WITH FOUR #8 X 1-1/2" WOOD SCREWS. 2: SLIDE THE NEXT ROOF BOARD TONGUE INTO THE GROOVE OF THE PREVIOUS ROOF BOARD. SECURE THE ROOF BOARD TO 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).
STEP 27: PLASTIC SUNBURST 1: LOCATE TWO OF THE PLASTIC DORMER SUNBURST PIECES AS SHOWN. 2: PLACE THE PIECES AGAINST THE UNDERSIDE OF THE CLATTER BRIDGE ROOF OVERHANG. 3: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION 4: INSTALL A #8 X 1/2" 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.
STEP 28: ATTACHING WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING OF THE CLATTER BRIDGE TOWER AS SHOWN WITH THE LIP OF THE SLIDE RESTING ON TOP OF THE DECK BOARDS. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS.
APPENDIX 207
1529 HARDWARE PAGE 1 OF 1 1/16/2015 S.O. #8 X 1-1/4" WOOD SCREW QTY: 22 9 #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 7 6 5 #2 SQUARE DRIVE BIT QTY:1 4 3 2 1 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.
PICTURE DESCRIPTION DORMER SUNRAY ASSEMBLY QTY.
PICTURE DESCRIPTION QTY.
STEP 1: DORMER SUNRAYS AND SIDES 1: FIND ONE DORMER SIDE LEFT ASSEMBLY AND ONE DORMER SIDE RIGHT ASSEMBLY. 2: FIND 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 THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW.
STEP 2: DORMER WINDOW 1: MOUNT THE DORMER WINDOW IN THE FRONT OF THE DORMER, THE WINDOW SHOULD FIT IN BETWEEN THE DORMER SIDES AND THE DORMER SUNRAY. THE BACK FACE OF THE 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 DORMER WINDOW AND FASTEN WITH #8 X 1-1/2" WOOD SCREWS.
STEP 3: DORMER ROOF PANELS 1: FIND TWO DORMER ROOF 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 THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES. FASTEN WITH #8 X 1-1/2" WOOD SCREWS. 3: REPEAT THE PREVIOUS SUB-STEP FOR THE OTHER SIDE.
STEP 4: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW. USE A 2" WOOD SCREW IN THIS LOCATION CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY. 2: ATTACH THE REAR AND RIGHT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW.
STEP 5: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS.
STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING 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 CHIMNEY MOUNTING BLOCK, PLACE THE CHIMNEY ASSEMBLY ON THE ROOF SO THAT THE INSIDE OF THE BACK WALL RESTS AGAINST THE BLOCK. 3: FASTEN THE CHIMNEY TO THE CHIMNEY MOUNTING BLOCK WITH A 1-1/2" WOOD SCREW IN EACH SIDE.
Jumbo Binoculars (07-0003) 1: Attach the Binocular Base to the top of the wood railing on your play set. Fasten with one 5/16" x 1-1/4" lag screw and one 8mm washers included with the Binoculars. 2: Place the bottom side of the Binoculars with the hole in it inside the Binocular Base. Line up the holes in the Binocular Base with the hole on the bottom side of the Binoculars. 3: Slide the 8mm diameter x 106mm length Pivot Rod through the holes.
Chalkboard (07-0018) 1. Chalkboard may be mounted with the checkerboard "horizontal" or "vertical". 2. Attach Chalkboard to wood slats or plywood with four of the 3/4" (20mm)long pan head screws provided. Please note: Chalkboard comes with a magnetic chalk holder which will stick to the chalkboard. This chalk holder is not shown below.
(06-2004) Clatter Bridge Mesh Panels Tools Required: #2 Phillips Bit or screwdriver 1/8" drill bit Pencil Drill Kit Contents: 2 - Green Mesh Panels 66" x 24" 44 - Phillips Pan Head Screws 5.5mm x 25.4mm long 44 - Washers 16mm O.D. X 7.1mm I.D. Note: Your mesh panels will be completely green. The pictures below show white border and black mesh panels but they are solely for the purposes of demonstrating how the mesh should be installed. 1) Center the mesh on the inside of the lower clatter bridge rail.
5) It will be very helpful to have an assistant at this stage. We recommend predrilling holes for the screws on the bottom of the deckboards fastened to the chains. Align the edge of the mesh border with the end of the bridge deck boards. Mark through the center grommet onto the deck board. Drill a 1/8" hole by 1" deep. Have your assistant push down on the board while you install a pan head screw and washer into the hole.
PICTURE DESCRIPTION QTY.
STEP 1: DORMER 1: OVERLAP THE LEFT DORMER SIDE ONTO THE PEAK SUPPORT OF THE RIGHT DORMER SIDE. 2: MAKE SURE THE FRONT ROOF EDGES ARE FLUSH TO ONE ANOTHER 3: FASTEN THE LEFT DORMER SIDE TO THE PEAK SUPPORT WITH #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1-3 TO CONSTRUCT ANOTHER ROOF ASSEMBLY. #8 X 1-1/2" WOOD SCREW DORMER ROOF (LEFT SIDE) DORMER ROOF (RIGHT SIDE) COMPLETED ROOF ASSEMBLY FRONT ROOF EDGES FLUSH TO ONE ANOTHER HERE.
STEP 2: DORMER 1: PLACE THE PLASTIC DORMER SUNBURST AGAINST THE FRONT FACE SUPPORT ON THE LEFT AND RIGHT ROOF SIDES. 2: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION. 3: INSTALL #8 X 1/2" PAN HEAD SCREWS TO FASTEN THE SUNBURST TO THE ROOF SIDES. REPEAT SUBSTEPS 1 THROUGH 3 TO CONSTRUCT THE SECOND DORMER. PREDRILL 7/64" HOLES X 1/2" DEEP AT EACH HOLE LOCATION ON BOTH SIDES OF THE PLASTIC SUNBURST. INSTALL A #8 X 1/2" PAN HEAD SCREW AT EACH HOLE LOCATION.
STEP 3: DORMER 1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 6TH ROOF BOARD AS SHOWN IN YOUR MANUAL ON STEP 81. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF. 4: ATTACH THE DORMER TO THE ROOF WITH ONE #8 X 2-1/2" WOOD SCREW AT THE REAR PEAK OF THE ROOF. ATTACH THE DORMER SUNBURST TO THE ROOF WITH TWO #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1 THROUGH 4 FOR THE DORMER ON THE OTHER SIDE OF THE ROOF.
