™ playsets Double Down Model: 301D (BOXES: 301-1, 301-2, 310 & SLIDE BOX) Copyright © 2014 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 – 2014 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 - DOUBLE DOWN Gorilla Playsets manufactures the finest quality products that are designed for outstanding strength and durability. We back our products with an unparalleled warranty. In the unlikely event that you will need to contact us about covered repairs, we must have a valid Warranty Registration on file.
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: 301D (BOXES: 301-1, 301-2, 310 & SLIDE BOX) REV: 1.9.
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) T he 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” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel KIT CONTENTS Swings, Slides, Accessories: ___ (Qty ) Description ___ (2) Swingbelt w/ Chains ___ (2) 8ft.
11-0020 301/301D Hardware PAGE 1 OF 2 REV: A 12/19/2013 JH 9 #8 X 1-1/4" WOOD SCREW QTY: 12 #8 X 1-1/2" WOOD SCREW QTY: 106 8 #8 X 2" WOOD SCREW QTY: 191 7 #8 X 2-1/2" WOOD SCREW QTY: 34 #8 X 3" WOOD SCREW QTY: 14 6 5 5/16" TEE NUT QTY: 42 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: 32 5/16" x 2-1/2" HEX BOLT QTY: 2 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 68 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
11-0020 301/301D Hardware PAGE 2 OF 2 REV: A 12/19/2013 JH 5/16" X 3-1/2" HEX LAG SCREW QTY: 26 3/8 X 3-1/2" HEX LAG SCREW QTY: 12 9 8 7 6 5 4 #2 SQUARE DRILL BIT QTY: 1 3 2 PLASTIC BOLT CAP QTY: 19 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8 x 7" CARRIAGE BOLT QTY: 12 3/8 x 6-1/2" CARRIAGE BOLT QTY: 4 3/8 x 3-1/2" CARRIAGE BOLT QTY: 2 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 QTY. 1 X 5 X 52" ROOF FINISHER (TONGUE ONLY) 1-5-5200-RF 2 1 X 5 X 52" ROOF STARTER (GROOVE ONLY) 1-5-5200-RS 2 1 X 5 X 52" ROOF BOARD (TONGUE AND GROOVE) 1-5-5200-RB 14 3-1/2 X 3-1/2 X 52" ROOF PEAK 1-6-5200-RP 1 NOTE: 1 PIECE IS EXTRA AND WILL BE LEFTOVER. 2 X 4 X 12" BOTTOM PANEL BOARD - LEFT 2-4-1200-BPBL 3 NOTE: 1 PIECE IS EXTRA AND WILL BE LEFTOVER.
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PICTURE DESCRIPTION 4 X 6 X 108" SWING BEAM 4-6-10800-SB 1 5/4 X 2 X 13" SMALL RAY 125-2-1300-SR 12 5/4 X 2 X 17" LARGE RAY 125-2-1700-LR 2 5/4 X 2-1/4 X 111/2" HORIZONTAL WINDOW SUPPORT 125-225-1150HWS NOTE: 4 PIECES ARE EXTRA AND WILL BE LEFTOVER. QTY.
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PICTURE DESCRIPTION 10' ROPE (GREEN) DORMERS AND CHIMNEY (UNASSEMBLED) 310 BOX FLAG KIT 09-1014 GROUND STAKE (PAIR) 07-0016 QTY.
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STEP 1: CORNER POST LAYOUT 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: Lay out each of the 4 x 4 x 96” Corner Posts in the area you intend on building the fort side of the playset. 3: Use the diagram below to correctly identify and orient the necessary direction the posts should face.
STEP 2: INSERTING T-NUTS INTO CORNER POSTS 1: Use a hammer to seat the t-nuts after inserting them into the holes shown in the diagram below. 2: The barrel of the t-nut should go in the hole first. Hammer the t-nut until it is flush/almost flush to the corner posts. No t-nuts will be installed in the Right Corner Posts where shown below.
STEP 3: SANDBOX AND PANEL BOARD 1: The top holes of the 2 x 6 x 47-3/8” End Sandbox Board (with four pre-drilled holes) attach to the bottom of the Left Corner Posts, offset holes down with two 5/16” x 4-1/2” hex bolts and two 5/16” washers. 2: The 2 x 4 x 47-3/8” Rock Wall Side Top Panel Board (with two pre-drilled holes) attaches to the side of the Left Corner Posts, offset holes down, with two 5/16” x 4-1/2” hex bolts and two 5/16” washers.
STEP 4: REAR SANDBOX/PANEL SUPPORT BOARD 1: The 2 x 4 x 47-3/8” Panel Support (offset holes down) attaches to the side of the Right Corner Posts with two 5/16” x 4-1/2” hex bolts and two 5/16” washers. 2: The 2 x 6 x 86” Right Sandbox Board (offset holes down) attaches to the side of the Right Corner Posts with two 5/16” x 4-1/2” hex bolts and two 5/16” washers into the topmost holes in the Right Sandbox Board.
STEP 5: SANDBOX BOARDS AND PANEL SUPPORT 1: The 2 x 4 x 47-3/8” Panel Supports (offset holes up) attach to the sides of the front and rear corner posts with two 5/16” x 4-1/2” hex bolts and two 5/16” washers. 2: Attach the top holes in the 2 x 6 x 47-3/8” End Sandbox Boards (offset holes up) to the sides of the front and rear corner posts with two 5/16” x 4-1/2” hex bolts and two 5/16” washers. The structure should be able to stand on its own, without any support, at this stage.
STEP 6: DECK SUPPORTS 1: Attach one Deck Support (offset holes down) to the inside of the Left and Right Corner Posts with two 5/16” x 4-1/2” hex bolts and 5/16” washers. Note: One Panel Support Board was removed for clarity. 2 X 4 X 47-3/8" DECK SUPPORT (OFFSET HOLES DOWN) 5/16" WASHER 5/16" X 4-1/2" HEX BOLT NOTE: PANEL SUPPORT BOARD REMOVED FOR CLARITY.
STEP 7: LEVELING THE PLAY SET AND INSTALLING LAG SCREWS 1: Level your play set frame. Level side to side and front to back. Check the diagonals for square. Once you have a level and square play set frame you may install lag screws. 2: Install one 5/16” x 3-1/2” Lag Screw with 5/16” washer into the empty holes in all of the 2 x 6 parts at the base of the play set frame.
STEP 8: FORT SUPPORTS 1: Place a 5/16” Tee Nut into the hole in the Fort Supports as shown. 2: From the inside of the Right Panel Board loosely attach each Fort Support with one 5/16” x 2-1/2” Hex Bolt and one 5/16” washer. 3: Measure 2” and 3-1/2” down from the tip of each Fort Support and drill a 1/8” hole through the Fort Support along the center. (See Detail A) 4: Place each Fort Support against the Corner Post. The side of the Fort Support should be flush with the right side of the Right Corner posts.
STEP 9: DECK SPACERS 1: Place a 5/4 x 4 x 40-1/2” Deck Spacer between the Left and Right Corner Posts on top of the Deck Supports as shown below. 2: The Deck Spacer side should be flush with the inside of the Panel Support. 3: Attach each Deck Spacer to the Deck Supports with two 2” Wood Screws.
STEP 10: DECK STRINGER 1: Center the 2 x 4 x 47-3/8” Deck Stringer underneath the Deck Spacers. 2: Attach the Deck Stringer to the Deck Spacers with two 2” Wood Screws.
STEP 11: FACE BOARDS 1: Locate two 2 x 4 x 47-3/8” Face Boards. 2: Attach a Face Board to the front of the Left Corner posts making sure the top side is flush with the top side of the Panel Supports. 3: Attach the Face Board with six 2-1/2” wood screws. 4: Repeat this process attaching the other Face Board to the right side of the Right Corner posts.
STEP 12: 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 13: ATTACHING THE LADDER 1: The Ladder attaches to the rear of the play set, 14-7/16” from the outside edge of the Rear-Left corner post. 2: Make sure the ladder is level. The bottom edge of the 90 brackets should be 3/4” up from the bottom edge of the 2 x 4. Mark the position of the bracket holes on the 2 x 4. 3: Drill 3/8” holes where marked. 4: Insert 5/16” T-nuts in the back of the holes. 5: Attach the 90 brackets to the 2 x 4 with two 5/16” x 1-1/2” hex bolts and two 5/16” washers.
STEP 14: DECK BOARDS 1: Seven 5/4 x 6 x 47 3/8” Deck Boards will lay across the Deck Supports, flush to the Face Boards. There will be approximately a 1/4” gap between each Deck Board. 2: Space the Deck Boards evenly across the supports. 3: Secure each Deck Board to the Deck Supports and the Deck Stringer with five 2” wood screws, two per end and one in the center.
STEP 15: ANGLE SUPPORTS 1: Four 2 x 4 x 13” Angle Supports are mounted underneath the deck on the left and right of the fort. (These are called out by the letter “X”) 2: Attach each Angle Support (X) to the Deck Support with two 2-1/2” wood screws at the top going through the Deck Support first and then into the Angle Support (X). Attach the bottom of the Angle Support (X) to the corner post with one 2” wood screw and one 3” wood screw.
STEP 16: PANEL AND PANEL SUPPORT BOARDS 1: Place the 2 x 4 x 12” Bottom Panel Board - Left and 2 x 4 x 12” Bottom Panel Board - Right on top of the 2 x 4’s as shown below with offset holes up. Attach each Bottom Panel Board with one 5/16” x 3-1/2” lag screw and 5/16” washer. 2: Place the 2 x 4 x 47-3/8” Panel Support against the rear of the play set with offset holes up. Attach the Panel Support with two 5/16” x 4-1/2” hex bolts and 5/16” washers.
STEP 17: PANEL BOARDS 1: Place the 2 x 4 x 12” Bottom Panel Board - Left and 2 x 4 x 12” Bottom Panel Board - Right on top of the 2 x 4 at the left side of the play set as shown below with offset holes down. Attach each Bottom Panel Board with one 5/16” x 3-1/2” lag screw and one 5/16” washer. 2: Place the 2 x 4 x 47-3/8” Panel Support on top of the 2 x 4 at the right side of the play set with offset holes down. Attach the Panel Support with two 5/16” x 3-1/2” lag screws and two 5/16” washers.
STEP 18: PANEL SLATS 1: Locate fifteen 5/4 x 3 x 28” Panel Slats. Four Panel Slats will be installed at both the left and rear of the play set. Seven Panel Slats will be installed at the right of the play set. 2: At the right of the play set center one Panel Slat over the center of each deck board. Square each Panel Slat to the Panel Support. Attach each Panel Slat to the inside of the Panel Supports with two 2” wood screws for each Panel Slat.
STEP 19: ROCK WALL 1: Locate two 2 x 4 x 57 Rock Wall Side boards. Lay the boards out as shown and insert a 5/16” t-nut into the hole on the inside of each board. Use a hammer to set each t-nut flush with the board.
STEP 20: ROCK WALL 1. Locate ten 5/4 x 5 x 23-7/8” Rock Wall Boards and one 5/4 x 5 x 23-7/8” Bottom Rock Wall Board with one big hole in it. 2. Place one Rock Wall Board at the top of the Rock Wall Sides nearest the holes where you previously installed the tee nuts. Make sure the Rock Wall Board is flush with the ends and sides of the Rock Wall Side boards. 3. Attach the Rock Wall Board with four 2” wood screws. 4.
STEP 21: ROCK WALL 1: Locate two 90 Green Brackets, two 5/16” washers and two 5/16” x 1-1/2” hex bolts. 2: Fasten the tapered side of each 90 Green Bracket to each Rock Wall Side with a 5/16” x 1-1/2” hex bolt and 5/16” washer.
STEP 22: ROCK WALL 1: Locate two bags of Climbing Rocks. Inside each bag should be five rocks, fifteen #14 x 11/4” pan head screws and fifteen 1/4” flat washers. 2: Place the Climbing Rocks in a staggered pattern on the Rock Wall Boards. Place one rock on each board except for the bottom rock wall board with the hole in it. 3: Attach each Climbing Rock with three #14 x 1-1/4” pan head screws and three 1/4” flat washers.
STEP 23: ROCK WALL 1: Place the 5/4 x 3 x 23-7/8” Rock Wall Top Cap on top of the Rock Wall Sides flush with the top Rock Wall Board. 2: Fasten the 5/4 x 3 x 23-7/8” Rock Wall Top Cap to the Rock Wall Sides and the top Rock Wall Board with four 2” wood screws.
STEP 24: ATTACHING ROCK WALL 1: The Rock Wall attaches to the left side of the play set, 11-3/4” from the outside edge of the front corner post. 2: Make sure the Rock Wall is level. The bottom edge of the 90 brackets should be 3/4” up from the bottom edge of the 2 x 4. Mark the position of the bracket holes on the 2 x 4. Drill 3/8” holes where marked. 3: Insert 5/16” t-nuts in the back of the holes. 4: Attach the 90 brackets to the 2 x 4 with two 5/16" x 1-1/2” hex bolts and two 5/16” washers.
STEP 25: SWING BEAM SUPPORT 1. The 4 x 4 x 47-3/8” Swing Beam Support has counter-sunk holes in the center and on the ends. Install the Swing Beam Support so that the counter-sunk holes on each end of the beam face out, and the counter-sunk holes in the center face down. 2. Fasten the Swing Beam Support to the right corner posts using 3/8” x 6-1/2” carriage bolts and torque washers. Place the carriage bolt into the torque washer, then into the hole of the corner post and set with a hammer.
STEP 26: 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 on the outside holes using 3/8” x 3-1/2” carriage bolts from the top and 3/8” washers with 3/8” lock nuts on the bottom. Place bolt caps over exposed threads after securing. 3: Leave the middle hole empty, it will be used later.
STEP 27: ATTACH SWING LEGS TO BRACKET 1: Place the 4 x 4 x 96” Swing Legs flush to the top of the Swing Leg Bracket. 2: Predrill 11/64" pilot holes into the Swing Legs through the holes in the Swing Leg Bracket. 3: Fasten the Swing Legs to the Swing Leg Bracket with eight 3/8” x 3-1/2” lag screws and eight 3/8” washers.
STEP 28: IRON DUCTILE SWING HANGERS 1: Line up the holes of the Iron Ductile Swing Hangers with the holes in the Swing Beam. 2: Fasten the Iron Ductile Swing Hangers to the Swing Beam using 3/8” x 7” carriage bolts with torque washers on top of the Swing Beam, and 3/8” lock nuts with 3/8” washers on the bottom. Place bolt caps over exposed threads after securing.
STEP 29: REST SWING BEAM ON FORT *Two people are required for this step. 1. Sit the swing beam legs upright. 2. Line up the pre-drilled holes and rest the swing beam on top of the fort and swing legs. Make sure the iron ductiles are facing down.
STEP 30: SWING BEAM TO SWING LEGS 1: Fasten the Swing Beam to the Swing Leg Bracket using 3/8” x 6-1/2” carriage bolts with torque washers on top of the Swing Beam, and 3/8” lock nuts with 3/8” washers underneath. 2: Predrill an 11/64" hole through the middle hole in the swing leg bracket. Use a 3/8 x 3-1/2” lag screw and 3/8” washer in the middle hole of the Swing Leg Bracket. 3: Place bolt caps over exposed threads after securing.
STEP 31: SWING BEAM TO FORT *An extra person is required for this step. 1: Have one person line up the hole in the end of the Swing Beam with the middle hole on the Swing Beam plate. The other person may have to carry the other end where the legs are located to accomplish this task. 2: Fasten the Swing Beam to the Swing Beam Plate and Swing Beam Support using a 9” carriage bolt with a torque washer on top and a 3/8” lock nut and washer on the bottom.
STEP 32: LEVEL THE SWING BEAM 1: Place a level on top of the Swing Beam and adjust the legs in or out as needed to make the Swing Beam level.
STEP 33: SWING LEG CROSS-MEMBER 1: Position the 2 x 4 x 58” Swing Leg Cross-Member against the Swing Legs. 2: Level the Swing Leg Cross-Member, and secure to the Swing Legs with 3/8” x 3-1/2” lag screws and 3/8” washers.
STEP 34: ARCHED SIDE TOP BOARDS 1: Place one Arched Side Top Board on the front/rear side of the play set at the top. 2: Attach each Arched Side Top Board through the top hole into the t-nut in the corner post with 5/16” x 4-1/2” hex bolts and 5/16” washers. 3: Attach each Arched Side Top Board through the bottom hole into the corner posts with 5/16” x 3-1/2” lag screws and 5/16” washers.
STEP 35: ROOF SUPPORTS 1: Attach one 2 x 4 x 35-1/2” Roof Support-Left and one 2 x 4 x 35-1/2” Roof Support-Right to the left and right of the play set with 5/16” x 4-1/2” hex bolts and 5/16” washers. Note the counter-sunk holes face out. The roof supports will meet to form a 90 angle at the peak. 2: Place a 5/4 x 6 x 10-1/2” Roof Peak Support at the peak of the roof supports on the outside. Attach the roof supports to the Roof Peak Support with four 2” wood screws from the inside.
STEP 36: ROOF STARTERS/ROOF PEAK 1: Place the 1 x 5 x 52” (groove only) Roof Starter Boards at the peak of the roof. The holes in the Roof Starters should be centered on the Roof Supports. The flat side of the Roof Starters should be placed as close together as possible near the peak without the boards overlapping. 2: Fasten the Roof Starter Boards to the Roof Supports with 1-1/2” wood screws.
STEP 37: ROOF BOARDS/ROOF FINISHERS AND CHIMNEY AND DORMERS 1: Place the 1 x 5 x 52” Roof Boards on top of the Roof Supports, fitting the tongue into the groove of the Roof Starter. The holes in the Roof Boards should be centered over the Roof Supports. There are seven Roof Boards on each side of the roof. If necessary place a scrap 2 x 4 board against the Roof Board and hammer on it to seat the tongue into groove for the Roof Boards. Fasten each Roof Board to the Roof Supports with four 1-1/2” wood screws.
STEP 38: SUN SUPPORT AND SUN 1: Place a 2 x 4 x 43-3/4” Sun Support underneath the 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 two 2-1/2” wood screws. Repeat for the other side of the roof. 2: Place a 2 x 6 x 16” Sun centered on top of the Sun Support. The face of the Sun should be flush with the face of the Sun Support. Fasten the Sun to the Sun Support with two 3” wood screws.
STEP 39: SUN RAYS 1: All the sun ray pieces get installed to the inside surface of the Roof Supports and Sun pieces. 2: Place the 5/4 x 2 x 17” Large Ray centered under the peak of the Roof Supports. Attach the Large Ray to the Roof Support and Sun with two 1-1/2” wood screws. 3: Arrange six 5/4 x 2 x 13” Small Rays on either side of the Large ray (three small rays per side) as shown below. Attach each Small Ray to the Roof Support and Sun with two 1-1/2” wood screws.
STEP 40: WINDOW SUPPORTS/WINDOWS In this step the wood components to attach windows will be installed on the inside of the left of the playset. Go up on top of the deck and look out the left of the play set. 1: Attach the 5/4 x 6 x 20” Vertical Window Support in the center with 2” wood screws. 2: Attach the 5/4 x 6 x 20” Vertical Window Supports on the sides with 2” wood screws. 3: Attach the 5/4 x 2-1/4 x 11-1/2” Horizontal Window Supports at the bottom with 2” wood screws.
STEP 41: SAFETY BOARD This board is meant to be a visual deterrent to prevent children from running through the base of the play set into other children on the swing set. 1: Measure 17-1/4” from the top of the Right Sandbox Board and make a mark on the right corner posts. 2: Place the bottom of a 2 x 4 x 47-3/8” Panel Support with offset holes down on the marks. 3: Attach the Panel Support to the right corner posts with two 5/16” x 3-1/2” lag screws and two 5/16” washers.
STEP 42: SLIDES 1: Lay Slides on deck with the lip extending onto/over the Deck Spacer. 2: Secure each Slide to the Deck Spacer with two #8 x 1-1/4” wood screws * DO NOT OVER TIGHTEN* 3: Once slide is installed DO NOT lift the end of the slide. DO NOT bump the slide with a lawn mower. These actions and any other actions which crack the slide where the screws are fastened to the deck are not covered by your warranty.
STEP 43: HANGING THE SWINGS 1: Clip each of the Spring Clips onto the Iron Ductile Swing Hangers, then clip onto the swing chains. 2: Use the clips to adjust the height of the swing by clipping onto higher or lower links. 3: Count back the same number of links on the opposite side to ensure that the swing is level, and adjust to fit your needs.
STEP 44: CLIMBING ROPE 1: Thread one end of the Rope through the hole in the Rock Wall Side Top Panel Board. 2: Tie a secure knot on the inside of the Rock Wall Side Top Panel Board. 3: Thread the other end of the Rope through the hole in the Bottom Rock Wall Board. Pull the Rope tight and tie a secure knot behind the Bottom Rock Wall Board. 4: Note: you may tie two knots in the Rope to aid in climbing if you wish. Do this before performing sub step 3.
STEP 45: FLAG KIT 1: Place the Flags on the FRONT side of the play set centered on the corner posts. 2: Attach the plastic base of each Flag to the corner post with the 1/2” phillips head screws provided with the Flags.
STEP 46: STEERING WHEEL 1: Place the Steering Wheel Insert inside the Steering Wheel. 2: Predrill an 11/64" hole about 2" deep into the end of the Swing Beam. Use the hardware included (one 3/8 x 2-1/2” lag screw and one 3/8” washer) with the Steering Wheel to mount the Steering Wheel to the end of the Swing Beam. DO NOT over-tighten the lag screw into the Steering Wheel Insert or the Steering Wheel will not turn.
STEP 47: TELESCOPE 1: Place one of the L-shaped Telescope Mounting Brackets centered on the Panel Support. 2: Attach the L-shaped bracket with two screws provided with the Telescope. 3: Place the base of the Telescope into the cut out area of the L-shaped bracket. 4: Attach another L-shaped Telescope Mounting Bracket directly across from the previously installed bracket and secure with the provided hardware.
STEP 48: SAFETY HANDLES 1: Place the Safety Handles centered onto the Panel Slats above the Ladder. Adjust the Safety Handles up or down to suit the needs of your child. 2: Attach each Safety Handle with two 1-1/4” pan head screws and two 1/4” washers provided with each Safety Handle.
STEP 49: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: HAMMER EACH GROUND STAKE IN AT AN ANGLE SIMILAR TO WHAT IS SHOWN. USE CAUTION WHEN HAMMERING SO THAT YOU DO NOT MAR THE WOOD. LEAVE THE TOP PORTION OF THE GROUND STAKE ABOVE THE GROUND FAR ENOUGH SO THAT YOU CAN STILL GET THE SCREW INTO THE HOLE AT THE TOP OF THE STAKE. 3: SECURE EACH STAKE TO THE SWING LEGS WITH THE SCREWS PROVIDED WITH THE STAKES.
STEP 50: TIC TAC TOE 1: Attach the two 1-3/8” x 1-5/8” x 10-1/2”L Tic Tac Toe Boards to the Green Plastic Brackets with the 1”L phillips head screws provided in the Tic Tac Toe box. IMPORTANT: Make sure the Tic Tac Toe Board is mounted to the Green Plastic Bracket observing the 1-5/8” dimension shown below. 2: Assemble the Tic Tac Toe panel according to the instructions in the box. IGNORE Step 6 and Step 7 in the instructions. 3: Center the unit on the panel slats on the swing beam side of the play set.
STEP 51: NAME PLATE 1: ATTACH THE MANUFACTURER NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO 2" WOOD SCREWS.
STEP 52: CROWN 1: PLACE THE PLASTIC CROWN OVER THE SUN WOOD PART.
