™ playsets Pioneer Peak Model: 1500DW [BOXES: 1501, 1503, (105 or 1508), (106 or 1509), (107 or 1510), 1511, (110 or 1513) & SLIDE BOX] Copyright © 2013 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 - 2013 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.
WARRANTY REGISTRATION - PIONEER PEAK Gorilla Playsets manufactures ƚŚĞ ĮŶĞƐƚ ƋƵĂůŝƚLJ ƉƌŽĚƵĐƚƐ ƚŚĂƚ ĂƌĞ ĚĞƐŝŐŶĞĚ ĨŽƌ ŽƵƚƐƚĂŶĚŝŶŐ ƐƚƌĞŶŐƚŚ ĂŶĚ ĚƵƌĂďŝůŝƚLJ͘ tĞ ďĂĐŬ ŽƵƌ ƉƌŽĚƵĐƚƐ ǁŝƚŚ ĂŶ ƵŶƉĂƌĂůůĞůĞĚ ǁĂƌƌĂŶƚLJ͘ /Ŷ ƚŚĞ ƵŶůŝŬĞůLJ ĞǀĞŶƚ ƚŚĂƚ LJŽƵ ǁŝůů ŶĞĞĚ ƚŽ ĐŽŶƚĂĐƚ ƵƐ ĂďŽƵƚ ĐŽǀĞƌĞĚ ƌĞƉĂŝƌƐ͕ ǁĞ ŵƵƐƚ ŚĂǀĞ Ă ǀĂůŝĚ tĂƌƌĂŶƚLJ ZĞŐŝƐƚƌĂƟŽŶ ŽŶ ĮůĞ͘ 3 EASY WAYS TO REGISTER KWd/KE ϭ &Ădž ƚŚŝƐ ĐŽŵƉůĞƚĞĚ ĨŽƌŵ ƚŽ͗ (678) 880-3329 OR DĂŝů ƚŚŝƐ ĐŽŵƉůĞƚĞĚ ĨŽƌŵ ƚŽ͗ Gorilla Playsets ϭϵϬ ƚŽǁĂŚ /ŶĚ
IMPORTANT – PLEASE READ As fresh lumber acclimates to its new environment, the natural tendencies of the tree can show itself in the form of checks, or “cracks” in the lumber. In almost all cases this is normal and it will not affect the structural integrity of your play set.
Model: 1500DW [BOXES: 1501, 1503, (105 or 1508), (106 or 1509), (107 or 1510), 1511, (110 or 1513) & SLIDE BOX] REV: 5.10.
TABLE OF CONTENTS Safety Guidelines………………………………………...............................……...Pages 3-6 Leveling Fort, General Information and Definitions……………………...............Pages 6-8 How to Install T-Nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading........................................................................................Pages 9-13 Site Plan, Required Tool List and Kit Contents...............................................
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/cpscpub/pubs/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 into place. 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. • The 4 is the width of the board.
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.
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” and 7/8” Paddle style bit.
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: 1 OF 2 9/20/2012 J.H. 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.
1501 HARDWARE PAGE: 2 OF 2 #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" PAN HEAD SCREW QTY: 4 9/20/2012 J.H. #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 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 BOLTS AND SCREWS.
1503 HARDWARE PAGE: 1 OF 1 #8 X 1-1/4" WOOD SCREW QTY: 6 9/20/2012 J.H. #8 X 1-1/2" WOOD SCREW QTY: 88 9 8 #8 X 2" WOOD SCREW QTY: 50 #8 X 2-1/2" WOOD SCREW QTY: 4 7 6 5 4 3 5/16" TEE NUT QTY: 6 2 1 5/16 X 4-1/2" HEX BOLT QTY: 4 5/16 X 2-1/2" HEX BOLT QTY: 2 5/16" WASHER QTY: 6 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.
1508 HARDWARE PAGE: 1 OF 1 9 9/19/2012 J.H. 8 7 #8 x 2-1/2" WOOD SCREW QTY: 92 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.
1509 HARDWARE PAGE: 1 OF 1 1/3/2013 J.H. 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 5/16" TEE NUT QTY: 55 1/4" WASHER QTY: 6 QUICK LINK QTY: 2 5 4 3 5/16" WASHER QTY: 109 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 24 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.
3/8 X 3-1/2" HEX LAG SCREW QTY: 11 1510 HARDWARE PAGE: 1 OF 1 9/20/2012 J.H. 9 TORQUE WASHER QTY: 4 8 5/16" TEE NUT QTY: 2 7 PLASTIC BOLT CAP QTY: 4 6 5 3/8" LOCK NUT QTY: 4 4 3/8" WASHER QTY: 17 3 2 1/2" WASHER QTY: 2 5/16 X 7" HEX BOLT QTY: 2 1 3/8 x 7" CARRIAGE BOLT QTY: 4 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.
1511 HARDWARE PAGE: 1 OF 1 9 9/19/2012 J.H. 8 #8 X 2" WOOD SCREW QTY: 20 7 6 5 4 5/16" TEE NUT QTY: 10 3 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 14 5/16 X 4-1/2" HEX BOLT QTY: 10 5/16" WASHER QTY: 24 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 NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET. QTY.
PICTURE DESCRIPTION QTY. 2 X 4 X 32-1/2" PICNIC TABLE LEG 2-4-3250-PTL 2 1 2 X 4 X 472" SAFETY BOARD/ END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 51-1/8" ROOF SUPPORT (1 HOLE OFFSET) 2-4-5113-RSL 2-4-5113-RSR 2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON CENTER) 2-4-5800-CM NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET.
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PICTURE DESCRIPTION NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET. 5/4 X 3 X 18-3/4" LADDER BACK 125-3-1875-LB 5 1 7 X 3 X 238" ROCK WALL CAP 125-3-2387-RWC 4 5 5 5 5 1 X 28 X 284" 4 PANEL SLAT 125-3-2825-PS X 28 X 42" SUN SUPPORT 125-3-4200-SS 4 5 QTY.
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PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCKS (07-0008 IS A PACK OF 5) 10 A-FRAME SWING LEG BRACKET 11-5010 HARDWARE BOXES: 1501, 1503, 1508, 1509, 1510, 1511 ROCKS 2 1 INSTRUCTIONSEA.
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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 FORT. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST 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: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS.
STEP 3: 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 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 3A: DRILL HOLES FOR BRIDGE CHAINS 1: LOCATE ONE 2 X 4 X 70" DECK SUPPORT AND ONE 2 X 6 X 70" FRONT FACE BOARD. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD. 3: PLACE A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES WITH A SPADE BIT.
STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT HOLES FOR CLATTER BRIDGE CHAIN.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER 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 ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD SHOULD BE OFFSET UP.
STEP 6: 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 ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" BOTTOM PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD MUST BE OFFSET UP.
STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE FRAME HAS BEEN LEVELED AND SQUARED.
STEP 6B: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT. 2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE ANGLE SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" END PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2 X 4 X 47-1/2" END PANEL BOARD OFFSET HOLES UP FRONT OF FORT 5/16" WASHER 5/16" X 3-1/2" LAG SCREW 2: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" IS THE CENTER OF THE BOARD AND ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER.
STEP 9: 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 MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. 3: USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT.
STEP 10: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 3 18" 3 24" 1 8" 3 18" 1 48" 1 48" 1 48" 1 48" 11 23 16 " 2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT.
STEP 11: ROCK WALL 1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER.
STEP 12: 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 13: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL 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 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT - RIGHT OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: GO UNDERNEATH THE DECK TO INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE FRONT FACE BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
STEP 16: CLIMBING RAMP 1: LAY OUT THE 2 X 4 X 96" RAMP SIDE BOARDS MAKING SURE THE ANGLED END FACES ALIGN WITH ONE ANOTHER. THE SHORT FACE ON THE ANGLED END SHOULD FACE DOWN. 2: FIRST PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE SQUARE END OF THE 2 X 4 X 96" RAMP SIDE BOARDS. OFFSET THE BOARD 1" FROM THE EDGE. FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
STEP 17: CLIMBING RAMP 1: FLIP THE CLIMBING RAMP OVER. PLACE ONE 2 X 6 X 94" FLOOR BOARD AGAINST EACH OF THE RAMP SIDE BOARDS. FASTEN THE FLOOR BOARDS TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SUPPORT. 2: PLACE THE 2 X 4 X 94" MIDDLE FLOOR BOARD ON THE CENTER OF THE RAMP. THE HOLE AT 7" SHOULD BE TOWARDS THE ANGLED END OF THE RAMP. FASTEN THE FLOOR BOARD TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SUPPORT.
STEP 18: CLIMBING RAMP 1: ATTACH THE 2 X 2 X 16" FLOOR SUPPORT BOARDS TO THE FLOOR BOARDS WITH 2-1/2" WOOD SCREWS. (SEE DETAIL VIEW BELOW) 2: PLACE T-NUTS ON THE INSIDE OF THE HOLES IN THE RAMP SIDE BOARDS. SET THE T-NUTS WITH A HAMMER FLUSH/NEAR FLUSH WITH THE RAMP SIDES. 3: FASTEN THE 90 GREEN BRACKET TO THE RAMP SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 19: CLIMBING RAMP TO FORT 1: PLACE THE CLIMBING RAMP INTO POSITION CENTERED ON THE RIGHT SIDE ON THE FORT. THE BOTTOM EDGE OF THE GREEN BRACKETS SHOULD BE 1-1/2" ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD. USING THE BRACKETS AS A TEMPLATE DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE BOTTOM PANEL BOARD. 3: ATTACH THE CLIMBING RAMP WITH 5/16 X 1-1/2” HEX BOLTS AND 5/16” WASHERS.
STEP 20: CENTER POSTS FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 28-9/16" CENTER POST. 2: PLACE THE CENTER POST INSIDE THE RAILING AT THE REAR OF THE PLAYSET. LINE UP THE HOLE IN THE CENTER POST WITH THE HOLE IN THE RAILING. FASTEN THE CENTER POST TO THE RAILING WITH A 5/16" X 21/2" HEX BOLT AND A 5/16" WASHER AT THE TOP. SQUARE THE CENTER POST TO THE DECK AND SECURE THE BOTTOM OF THE CENTER POST TO THE BOTTOM PANEL BOARD WITH #8 X 2-1/2" WOOD SCREWS.
STEP 21: PANEL SLATS 1: FIND TWENTY-TWO 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. ROCK WALL SIDE PANEL REAR PANEL SLAT SPACING MAKE THIS SLAT FLUSH TO THE END OF THE 2 X 4 X 14" BOTTOM PANEL BOARD. SPACE THE NEXT SLAT EQUALLY BETWEEN THE FIRST SLAT AND THE CORNER POST.
STEP 22: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH, IN THE COUNTER-SUNK HOLESOF THE SWING BEAM SUPPORT. 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 23: 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 24: 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 25: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM. THESE TWO HOLE LOCATIONS WILL BE EMPTY ON YOUR SWING BEAM. LINE THEM UP WITH THE HOLES IN THE SWING LEG BRACKET UNDER THE SWING BEAM.
STEP 26: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET. 3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.
STEP 27: MOUNT SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND THE SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT WITH A TORQUE WASHER AND A 3/8" LOCK NUT WITH A 3/8" WASHER ON THE BOTTOM.
STEP 28: 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 29: 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.
STEP 30: ROOF SUPPORTS 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 51-1/8" ROOF SUPPORTS TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE. 2: CONNECT THE ENDS WITH A 2" WOOD SCREW.
STEP 31: ROOF PEAK SUPPORT 1: PRE-DRILL HOLES IN THE TWO 5/4 X 6 X 10" ROOF PEAK SUPPORTS TO THE PATTERN SHOWN BELOW. 5/4 X 6 X 10" ROOF PEAK SUPPORT 2: PLACE THE 5/4 X 6 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 2" WOOD SCREWS. REPEAT ON OTHER SIDE.
STEP 32: ROOF 1: PLACE THE 1 X 4 X 47-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 33: ROOF 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH 1-1/2" WOOD SCREWS.
STEP 34: ROOF 1: PLACE THE 1 X 6 X 47-1/2" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 4 X 47-1/2" ROOF FINISHER ON EACH END OF THE ROOF, AND FASTEN WITH 1-1/2" WOOD SCREWS. 4: USE THE INSTRUCTIONS PROVIDED WITH THE CHIMNEY AND DORMERS TO BUILD THEM.
STEP 35: SUNBURST 1: PLACE THE 2 X 6 X 13-5/8" SUN CENTERED AGAINST THE 5/4 X 3 X 42" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2" WOOD SCREWS. REPEAT THIS PROCESS FOR THE OTHER SIDE OF THE FORT.
STEP 36: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP UNDERNEATH THE ROOF BOARDS ON THE INSIDE OF THE ROOF SUPPORTS. THE SUN SHOULD BE ON THE OUTSIDE. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP. 2: FASTEN THE SUN ASSEMBLY TO THE FORT WITH 2" WOOD SCREWS FROM THE INSIDE INTO THE ROOF SUPPORTS. 3: REPEAT ON THE OPPOSITE SIDE OF THE FORT. SUN ON OUTSIDE ATTACH WITH 2" WOOD SCREWS ON EACH SIDE OF THE INSIDE OF THE ROOF SUPPORTS.
STEP 37: SUNBURST 1: PREDRILL ALL SUNRAYS AT 3/4" ON CENTER FROM EACH END. 2: CENTER THE 5/4 X 1-1/2 X 16" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS AND FASTEN WITH TWO 2" SCREWS. 3: EQUALLY SPACE THE 5/4 X 1/1/2 X 10" SMALL RAYS ABOUT THE HALF SUN (THREE ON EACH SIDE OF LARGE RAY) AND MARK THE POSITION OF THE SMALL SUNRAYS WITH A PENCIL. 4: SECURE THE SMALL SUNRAYS ONE AT A TIME TO THE HALF SUN AND THE ROOF SUPPORT BEAMS AND LINE THEM UP WITH THE MARK DRAWN.
STEP 38: 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 39: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS. NOTE: THE OFFSET HOLES CAN BE PLACED UP OR DOWN IN THIS STEP.
STEP 40: 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 41: PICNIC TABLE 1: MEASURE 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT 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 RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS. 3: PLACE THE TOP OF THE LEFT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT REAR CORNER POST.
STEP 42: 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 43: TIRE SWING 1: PLACE THE 4 X 4 X 72" TIRE SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 44: TIRE SWING 1: LINE UP THE HOLES OF THE TIRE SWIVEL WITH THE HOLES IN THE TIRE SWING BEAM. 2: FASTEN THE TIRE SWIVEL TO THE TIRE SWING BEAM USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
STEP 45: TIRE SWING 1: FASTEN THE TIRE SWING BEAM TO THE SWING BEAM BRACKET USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE TIRE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. PLACE A BOLT CAP OVER ANY EXPOSED THREADS. 2: USE A 3/8" X 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET.
STEP 46: TIRE SWING IMPORTANT: NOTE THE TIRE SWING LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE. (ALSO SEE STEP 48) AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT.
STEP 47: TIRE SWING IN THIS STEP YOU WILL BE MOUNTING THE TIRE SWING BEAM TO THE FORT. AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: INSTALL T-NUTS IN THE PREVIOUSLY DRILLED HOLES AS SHOWN BELOW. 2: LINE UP THE PILOT HOLES AT THE END OF THE TIRE SWING BEAM WITH THE PREVIOUSLY DRILLED HOLES IN THE CORNER POST. 3: FASTEN THE TIRE SWING BEAM TO THE CORNER POST USING 5/16 X 6-1/2" HEX BOLTS WITH 5/16" AND 1/2" WASHERS THROUGH THE TIRE SWING BEAM AND CORNER POST, INTO THE T-NUTS.
STEP 48: LEVEL TIRE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE TIRE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE TIRE SWING BEAM LEVEL. IMPORTANT: NOTE THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A)DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
STEP 49: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 47-1/2" TIRE SWING LEG CROSS-MEMBER AGAINST THE SWING LEGS. 2: LEVEL THE TIRE SWING CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSSMEMBER HOLES ONTO THE SWING LEGS. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE TIRE SWING CROSS-MEMBER TO THE SWING BEAM LEGS.
STEP 50: HANGING THE TIRE SWING 1: START BY ATTACHING THREE SPRING CLIPS TO THE TIRE SWIVEL ON THE SWING BEAM. 2: ATTACH ONE CHAIN AT A TIME TO ONE SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED.
STEP 51: ROPE LADDER 1: FIND THREE ROPE LADDER ROPES. MAKE A KNOT IN THE END OF EACH ROPE AND THREAD THE FREE END THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT. PULL EACH ROPE TAUGHT. 2: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 6 INCHES AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 6 INCHES BELOW THE ROPE LADDER SUPPORT. SLIDE EACH ROPE THROUGH THE HOLES IN ONE ROPE LADDER RUNG. SLIDE THE RUNG UP AGAINST THE BOTTOM OF THE KNOTS. 3: TIE THREE KNOTS BELOW THE ROPE LADDER RUNG.
STEP 52: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS TO THE TOP OF THE CENTER POST ON THE FRONT OF THE PLAY SET . 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 53: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 54: INSTALLING CLIMBING ROPES 1: DRILL A 7/8" HOLE THROUGH THE ROPE LADDER SUPPORT (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE ROPE LADDER SUPPORT. 3: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
STEP 55: FLAG KIT 1: PLACE A FLAGON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED.
STEP 56: SANDBOX SEATS AND NAMEPLATE 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.
STEP 57: CROWN 1: PLACE THE CROWN OVER THE SUN PIECE ON THE FRONT OF THE PLAY SET ABOVE THE SLIDE AND ROCK WALL. 2: ATTACH THE CROWN TO THE SUN WITH #8 X 1-1/4" WOOD SCREWS.
STEP 58: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. 2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #8 X 2" WOOD SCREW PROVIDED WITH THE GROUND STAKE.
STEP 59: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK. 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 CENTER OF THE STEERING WHEEL AND SNAP IT INTO THE STEERING WHEEL INSERT.
PART 2 CLATTER BRIDGE ASSEMBLY 101
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 4 X 36-3/4" TOP PANEL BOARD ON TOP OF THE RIGHT SIDE 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 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 LEFT SIDE CORNER POSTS IN THE MIDDLE OF THE 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 54-1/2" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST. D C LEFT SIDE FRAME RIGHT SIDE FRAME B A 2 X 4 X 36-3/4" DECK SUPPORT (WITH HOLES) 2 X 4 X 36-3/4" DECK SUPPORT 5/16" WASHER 5/16 X 4-1/2" HEX BOLT 2 X 6 BOTTOM PANEL BOARD NOT SHOWN FOR CLARITY.
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 THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: IF YOUR DECK SPACERS AND DECKBOARDS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THEM TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 1 1 48" 48" 3 3 4" 4" 1" 3" 3 14" 3 14" 2X 1 8" 4X 5/4 X 4 X 29-3/8" DECK SPACER 1 8" 5/4 X 4 X 36-11/16" DECK BOARD 2: PLACE THE 5/4 X 4 X 29-3/8" DECK SPACERS BETWEEN THE CORNER POSTS.
STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-11/16" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS. THE TOP OF THE BOTTOM PANEL BOARD SHOULD BE 1/4" ABOVE THE 2 X 6 ON THE LEFT SIDE OF THE TOWER. 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 6 X 36-11/16" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH 2" WOOD SCREWS.
STEP 11: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH HOLES) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 2: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 3: REPEAT THIS PROCESS FOR THE BOTTOM PANEL BOARDLOCATED ON THE RIGHT SIDE OF THE TOWER.
STEP 12: PANEL SLATS 1: FIND NINE 5/4 X 3 X 28-1/2" PANEL SLATS. 2: IF THE SLATS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: ON THE LEFT SIDE OF THE TOWER INSTALL THE FIRST PANEL SLAT 2-5/8" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8" APART AS SHOWN IN THE PICTURE AT THE MIDDLE LEFT BELOW. ATTACH THE PANEL SLATS WITH 2" WOOD SCREWS.
STEP 13: 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 14: TIC-TAC-TOE PANEL 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE FRONT OF THE PLAY SET ON THE INSIDE. THE TIC TAC TOE SHOULD BE APPROXIMATELY 3" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS.
STEP 15: 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 16: MOUNTING BRIDGE RAILS TO FORT 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 3: ATTACH EACH LOWER BRIDGE RAIL TO THE CORNER POSTS USING THE 16" DIMENSION AT THE FORT AS SHOWN ON STEP 15 AND BELOW. ATTACH EACH LOWER BRIDGE RAIL WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 17: BRIDGE RAIL SLATS 1. IF THE BRIDGE RAIL SLATS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THEM ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2. PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS. 3. ATTACH THE REMAINING SLATS TO THE UNIT WITH 3" SPACING BETWEEN THE SLATS.
STEP 18: 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 19: 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 20: 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 21: 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 22: VERTICAL TARP SUPPORTS 1: PLACE THE 2 X 4 X 33" VERTICAL TARP SUPPORTS ON THE INSIDE OF THE TOP PANEL BOARDS. THE END OF EACH VERTICAL TARP SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE TOP PANEL BOARD. CENTER EACH VERTICAL TARP SUPPORT WITH THE CENTER OF THE TOP PANEL BOARD. SQUARE EACH VERTICAL TARP SUPPORT TO THE TOP PANEL BOARD. 2: ATTACH THE VERTICAL TARP SUPPORTS TO THE TOP PANEL BOARDS WITH 2-1/2" WOOD SCREWS.
STEP 23: TARP BOARDS 1: LOCATE THREE 2 X 4 X 36-3/4" TARP BOARDS. 2: PLACE ONE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE END OF THE TARP BOARD SHOULD BE FLUSH WITH THE SIDES OF THE VERTICAL TARPS SUPPORTS. 3: ATTACH THE TARP BOARD TO THE VERTICAL TARP SUPPORTS WITH 2-1/2" WOOD SCREWS. 4: PLACE ONE TARP BOARD ON TOP OF THE CORNER POSTS. THE TARP BOARD SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. 5: ATTACH THE TARP BOARD TO THE TOP OF THE CORNER POSTS WITH 2-1/2" WOOD SCREWS.
STEP 24: CLATTER BRIDGE TARP 1: LOCATE THE 34-1/4" X 57-1/2" CLATTER BRIDGE TARP. 2: PLACE THE TARP OVER THE TOP OF THE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE HEMS SHOULD FACE THE INSIDE. 3: THE TARP WILL OVERLAP THE SIDE OF THE TARP BOARDS ON TOP OF THE CORNER POSTS. 4: ATTACH THE TARP THROUGH THE GROMMETS TO THE TARP BOARDS WITH #14 X 1-1/4" PAN HEAD SCREWS AND 1/4" FLAT WASHERS.
STEP 25: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT RIGHT OF THE CLATTER BRIDGE. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK SPACER. 2: PREDRILL 1/8" HOLES INTO THE DECK SPACER AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK SPACER WITH 1-1/4" PAN HEAD SCREWS.
STEP 26: PANEL SLAT 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLAT FLUSH TO THE SIDE OF THE BRIDGE RAILS AS SHOWN BELOW. 2: ATTACH THE PANEL SLAT TO THE ROPE LADDER SUPPORT AND FRONT FACE BOARD ON THE INSIDE WITH #8 X 2" WOOD SCREWS. ATTACH PANEL SLAT FLUSH TO SIDE OF BRIDGE RAILS.
