™ playsets ™ ets plays Treasure Trove - Wood Roof Timber Shield Post Option BOXES: 1500 (120” box), 1500 (108” box), CB *51-1021-W* 51-1021-W Model: 1500IW (BOXES: 1501, 1503N, 1504, 1506N, 1509N, 1509W, 1530, 1515, Rad Ride 7 Tube Slide Box & Slide Box) 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 - treasure trove - wood roof 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.
Model 1500IW shown. See cover of manual for the image of your model when it is completed. Timber Shield Post Option BOXES: 1500 (120” box), 1500 (108”box), CB Models: 1500IW 1500IWF (BOXES: 1501, 1503N, 1504, 1506N, 1509N, 1509W, 1530, 1515, 1525*, Rad Ride 7 Tube Slide Box & Slide Box) *1525 only included with 1500IWF Treehouse model REV: 1.31.
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 Rope Ladder.......................................................................................................... Step 72 Rock Wall Rope..................................................................................................... Step 73 Safety Handles (Lower Level) and Safety Handles (Upper Level)................. Steps 74-75 Flag Kit.................................................................................................................. Step 76 Telescope.............
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 https://www.cpsc.gov/s3fs-public/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.
1500IW Please familiarize yourself with the manual, parts/components and general MORE construction TEXT 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”, 3/16”, 3/8”, 7/64”, 9/64”, 11/64” and a 1” paddle bit ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Carpenters Square ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel ___ Marker or Tape (See Step 72) KIT CONTENTS Swings, Slides, Accessories: ___ (
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.
1503N HARDWARE PAGE: 1 OF 1 REV C: 8/10/2015 JH #8 X 1-1/4" WOOD SCREW QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 104 9 8 #8 X 2" WOOD SCREW QTY: 30 #8 X 2-1/2" WOOD SCREW QTY: 8 7 6 5 4 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 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.
1504 HARDWARE PAGE: 1 OF 1 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.
1515 HARDWARE PAGE: 1 OF 1 9/19/2012 J.H. 9 8 7 6 5 4 5/16" TEE NUT QTY: 14 3 2 1 5/16 X 4-1/2" HEX BOLT QTY: 14 5/16" X 3-1/2" LAG SCREW QTY: 16 5/16" WASHER QTY: 30 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.
11-2027 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 NOTE: ANYTHING ON THIS PAGE REFERRED TO AS "PLASTIC COATED" WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR WOOD OPTION. DESCRIPTION QTY.
PICTURE DESCRIPTION WAVE SLIDE 03-0013 PLASTIC DORMER SUNBURST 07-0031 RAD RIDE SLIDE 03-0002 QTY.
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PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCK (5 ROCKS ARE IN ONE BAG) 07-0008 A-FRAME SWING LEG BRACKET 11-5010 HARDWARE BOXES: 1501, 1503N, 1504, 1506N, 1509N, 1509W, 1515, 11-2027 HARDWARE BOXES INSTRUCTIONS 10 ROCKS 1 1 EA.
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PICTURE DESCRIPTION SAFETY HANDLE (2 HANDLES ARE IN ONE BAG) 07-0005 (NOT SHOWN) QTY.
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 TODIS-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 SIDE OF THE PLAYSET. 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 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 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 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 4: DRILL HOLES FOR BRIDGE CHAINS 1: 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 5: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES.
STEP 6: 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 ROPE LADDER RUNNER TO THE T-NUTS INSTALLED IN 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 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 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.
STEP 9: 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 10: 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 FRONT OF FORT 5/16" WASHER 5/16" X 3-1/2" LAG SCREW 2: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UPAND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 11: 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 A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO 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 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. 5/4 X 6 X 47-3/8" DECK BOARD 3 18" 3 24" 3 18" 1 48" 1 48" 1 48" 1 48" 11 23 16 " 1 8" 2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT.
STEP 14: 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 15: 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 16: 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 17: 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 18: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE FRONT - LEFT CUT OUT AREA 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 FRONT FACE 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 19: LADDER 2 X 4 X 66" LADDER SIDE 1: FIND TWO 2 X 4 X 66" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. T-NUT 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER. 2" WOOD SCREW 4: FIND FIVE 2 X 4 X 17" LADDER STEPS. 5: PLACE THE STEPS INTO THE SLOTS ON THE LADDER SIDES, AND FASTEN WITH 2" WOOD SCREWS. 2 X 4 X 17" LADDER STEP 6: CAREFULLY TURN THE LADDER OVER AND PUT THE SCREWS INTO THE OTHER SIDE.
STEP 20: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE LEFT SIDE OF THE 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 21: 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-ASSEMBLY 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 22: LAG POSTS 1: TWO 4 X 4 X 60-1/4" LAG POSTS WILL BE USED TO EXTEND THE MIDDLE CORNER POSTS TO ACCEPT THE UPPER LEVEL ROOF. 2: REST THE BOTTOM OF EACH LAG POST ON TOP OF THE 2 X 6 X 70 BACK PANEL BOARD. 3: CENTER EACH LAG POST DIRECTLY OVER THE CENTER OF THE MIDDLE CORNER POSTS. 4: ATTACH EACH LAG POST TO THE MIDDLE CORNER POST WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS. 4 X 4 X 60-1/4" LAG POST WOOD ROOF - RIGHT THIS POST HAS A HOLE HERE THAT THE LEFT ONE DOES NOT HAVE.
STEP 23: REAR CORNER POSTS & DECK SUPPORTS & SIDE TOP PANEL BOARDS 1: HAMMER A T-NUT INTO THE HOLES AT THE TOP OF THE LAG POSTS. 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. 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. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH EACH SIDE TOP PANEL BOARD TO THE LAG/CORNER POSTS.
STEP 24: 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 25: 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 26: LOWER LEVEL 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. 3: HAVE AN ASSISTANT HOLD THIS BOARD UP FOR YOU AND PROCEED TO STEP 27.
STEP 27: 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 UPPER LEVEL DECK SUPPORTS. THE END OF THE CENTER DECK SUPPORT ASSEMBLY SHOULD BE FLUSH TO THE SIDE OF THE LOWER LEVEL CENTER POST.
STEP 28: 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 29: 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 30: ANGLE SUPPORT - UPPER LEVEL 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 31: 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 231/2" 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 32: 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 33: 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 #8 X 31/2" WOOD SCREWS. 4 X 4 X 43-1/2" RAD RIDE CENTER POST PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH.
STEP 34: 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 35: 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 36: 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 37: RAILING 1: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD (RAILING) OFFSET UP INSIDE THE LAG POSTS OF THE UPPER LEVEL. 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. 2 X 4 X 70" REAR TOP PANEL BOARD (OFFSET UP) 5/16" X 3-1/2" LAG SCREW 5/16" WASHER NOTE: SOME RAILINGS REMOVED FROM PICTURE FOR CLARITY.
STEP 38: 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 39: 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 40: 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 21/2" HEX BOLT WITH A 5/16" WASHER.
STEP 41: UPPER LEVEL PANEL SLATS 1: 5/4 X 3 X 34-1/2" PANEL SLATS WILL BE INSTALLED ON THE LEFT, 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 42: 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 ROPE LADDER SUPPORT. 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 ROPE LADDER SUPPORT WITH A 5/16" X 4-1/2" HEX BOLT AND A 5/16" WASHER. 3: SQUARE THE CENTER POST TO THE DECK.
STEP 43: 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 44: 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 FOUR SLATS ON THE LEFT SIDE, SIX 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 45: 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 46: 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 47: 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 48: 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 49: 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 50: 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 51: 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 52: 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 53: 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 54: 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 55: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE APPROXIMATELY CENTERED (SEE BELOW) 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 #8 X 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS.
STEP 56: UPPER LEVEL ROOF 1: PLACE THE 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS.
STEP 57: UPPER LEVEL ROOF 1: PLACE THE 1 X 5 X 30-1/2" 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 ELEVEN ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 4 X 30-1/2" ROOF FINISHER AT THE ENDS OF THE ROOF ASSEMBLY AND FASTEN WITH #8 X 1-1/2" WOOD SCREWS. TIP: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE CHIMNEY.
STEP 58: SUNBURSTS 1: LOCATE TWO PLASTIC SUNBURST PIECES. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2" WOOD SCREWS. 4: REPEAT SUBSTEPS 2 AND 3 ON THE OTHER SIDE OF THE PLAY SET.
STEP 59: CLOSE OUT BOARDS 1: LOCATE TWO 2 X 4 X 18" CLOSE OUT BOARDS. PLACE A CLOSE OUT BOARD ON THE OUTSIDE OF THE UPPER LEVEL RAILING AS SHOWN BELOW. 2: MAKE THE TOP OF THE CLOSE OUT BOARD FLUSH TO THE TOP OF THE UPPER LEVEL RAILING. ATTACH THE TOP OF THE CLOSE OUT BOARD TO THE RAILING WITH #8 X 2-1/2" WOOD SCREWS. 3: MAKE THE BOTTOM OF THE CLOSE OUT BOARD FLUSH TO THE INSIDE OF THE LAG POST. ATTACH THE BOTTOM OF THE CLOSE OUT BOARD TO THE RAILING WITH ONE #8 X 2" WOOD SCREW AND ONE #8 X 3" WOOD SCREW.
STEP 60: LOWER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE LOWER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LOWER LEVEL CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS WITH 5/16" WASHERS. 5/16" WASHER 5/16" X 4-1/2" HEX BOLT DETAIL A ROOF PEAK SUPPORT (TRIANGLE) ON INSIDE.
STEP 61: LOWER LEVEL 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 APPROXIMATELY CENTERED (SEE BELOW) 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 #8 X 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS.
STEP 62: LOWER LEVEL ROOF 1: PLACE THE 1 X 6 X 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS.
STEP 63: LOWER LEVEL ROOF THE PICTURE BELOW SHOWS THE RIGHT SIDE ROOF WITH THE DORMER. THE LEFT SIDE ROOF GETS A DORMER ALSO. INSTRUCTIONS TO BUILD THE CHIMNEY AND DORMERS ARE IN THE APPENDIX AT THE BACK OF THIS MANUAL. PLEASE NOTE THAT EACH SIDE OF THE ROOF WILL HAVE 11 ROOF BOARDS AND 1 ROOF FINISHER. 1: PLACE THE 1 X 5 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 11 ROOF BOARDS.
STEP 64: PLASTIC SUNBURST (LOWER LEVEL) 1: LOCATE ONE PLASTIC SUNBURST PIECE. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2" WOOD SCREWS.
STEP 65: SAFETY BOARDS 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES 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 (LOWER LEVEL). ATTACH IT WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 66: 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 67: 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 INSDE 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 68: 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 69: 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 70: 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 TIC TAC TOE MOUNT. GREEN BRACKET 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT TIC TAC TOE AFTER ASSEMBLING.
STEP 71: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAYSET ON THE INSIDE. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS. SWING BEAM #8 X 1-3/4" WOOD SCREW TIC TAC TOE WITH BOARDS ATTACHED.
STEP 72: 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 73: ROCK WALL ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE ROPE LADDER SUPPORT. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND. HINT: TO REDUCE THE AMOUNT OF SLACK IN THE ROPE, LIFT THE ROCK WALL ASSEMBLY SLIGHTLY WHEN TYING THE KNOT IN THE BOTTOM ROCK WALL BOARD. WHEN YOU LOWER THE ASSEMBLY, THE KNOT WILL TIGHTEN.
STEP 74: SAFETY HANDLES (LOWER LEVEL) 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 75: SAFETY HANDLES (UPPER LEVEL) 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 LAG POSTS AND CENTER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 76: FLAG KIT 1: PLACE A FLAG ON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH 1/2" PHILLIPS HEAD SCREWS PROVIDED.
STEP 77: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT ON THE ROCK WALL SIDE OF THE CENTER POST. 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 78: 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 79: 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 80: 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.
PART II CLATTER BRIDGE 130
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 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 YOU DRILLED) 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: PRE-DRILL THE ENDS OF THE DECK SPACERS AND DECKBOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 3 4" 4" 4" 3 4" 1" 3 14" 3" 3 14" 2X 1 8" 4X 5/4 X 4 X 29-3/8" DECK SPACER 1 8" 5/4 X 6 X 36-1/2" DECK BOARD 2: PLACE THE 5/4 X 4 X 29-3/8" DECK SPACERS BETWEEN THE CORNER POSTS. MAKE EACH DECK SPACER FLUSH TO THE INSIDE SURFACE OF THE 2 X 6.
STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-1/2" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS, 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: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 2: FASTEN THE SAFETY BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 12: PANEL SLATS 1: FIND TEN 5/4 X 3 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: 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 IN THE PICTURE AT THE BOTTOM LEFT BELOW. 4: ATTACH THE PANEL SLATS WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES TO THE RIGHT SIDE OF THE TOWER. 1" D 1" 2X 2" WOOD SCREW.
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 PLAY SET 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. PRE-DRILL TWENTY 5/4 X 3 X 16" BRIDGE RAIL SLATS 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 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 SUBSTEPS 2-3 ON THE INSIDE OF THE OTHER POSTS AS POINTED OUT BELOW. 7 33 16 " 1" REPEAT THE MEASURE/MARK/DRILL PROCESS ON THE INSIDE OF THESE CORNER POSTS. USE 1-7/8" FOR GREEN POSTS. 13 1 16 " STAINED POSTS.
STEP 23: INSTALL 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 B OVERHANG OVERHANG SIDE VIEW 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.
Leftover Parts List 1500IW Play Set Our 1500 series play sets are modular and include parts to construct many different models. Some of these parts included with your play set will not be used because they are for a different model. The list below includes parts for your play set that will be leftover when construction is completed. 2 pieces 125-3-2825-PS Panel Slats (We include these parts in case the customer wishes to fill in the area where the Tic Tac Toe is located.
APPENDIX 160
Chimney and Dormers Hardware Kit 8/10/2015 JH 9 #8 X 2-1/2" WOOD SCREW QTY: 2 8 #8 X 2" WOOD SCREW QTY: 4 7 #8 X 1-1/2" WOOD SCREW QTY: 14 6 #8 X 1-1/4 WOOD SCREW QTY: 6 5 4 #2 SQUARE DRIVE BIT QTY: 1 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 QTY.
PICTURE DESCRIPTION QTY.
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: FOR 1500 SERIES UNITS LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 8TH ROOF BOARD. 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.
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 #8 X 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE FOR A SUGGESTED PLACE TO MOUNT THE 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 #8 X 1-1/2" WOOD SCREW IN EACH SIDE.
(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.
