™ playsets ™ playsets Sun Palace Model: 703 (BOXES: 701-1, 701-2, 703, 705 Tire Swing Box, & 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 - SUN PALACE 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: 703 (BOXES: 701-1, 701-2, 703, 705, Tire Swing Box & Slide Box) REV: 4.2.
TABLE OF CONTENTS Safety Guidelines……………………………………….......……...........................Pages 3-6 Leveling Fort, General Information and Definitions............................................Pages 6-8 How to Install T-Nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading........................................................................................Pages 9-13 Site Plan, Required Tool List and Kit Contents......………………………........
Safety and Maintenance Tips for Your New Play Set: NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with your children.
Safety and Maintenance Tips for Your New Play Set: (continued) Playgrounds should be inspected on a regular basis. If any of the following conditions are noted, they should be removed, corrected, or repaired immediately to prevent injuries. • Hardware that is loose, worn or that has protrusions or projections. • Exposed equipment footings. • Scattered debris, litter, rocks, or tree roots. • Splinters, large cracks, and decayed wood components.
Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6’ in all directions from the perimeter of the equipment. Swings should have a fall zone extending a minimum of 6’ from the outer edge of the support structure on each side.
General Info to Review Before Installation • Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly. • Identify all of the parts for your play set. Empty each box and lay out boards so you can see each part. Your instruction book will have detailed drawings that will make it easy for you to recognize individual parts.
This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board.
Common Installation Practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut This picture shows the T-nut inserted and installed flush to the wood. Flush (Correct) Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood. This picture shows an end view of the T-nut installed flush to the wood.
HOW A T-NUT WORKS THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS. THE T-NUT HAS A BARREL SHAPED END WHICH GOES INTO THE HOLE IN THE CORNER POST. THE T-NUT ALSO HAS AN FLANGE SHAPED END WITH TEETH.
BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled into place. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" • The 2 is the thickness of the board. "Nominal Lumber" at a home center will measure 11/2" for the thickness. We "remill" that lumber to 1-3/8" thick. • The 4 is the width of the board.
PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole. Pay attention to the DIAMETER of the lag screw you are installing. Your playset may come with two different diameter lag screws.
SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs. Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs. 2) The maximum allowable swinging weight at the Trapeze position is 125 lbs. 3) The MAXIMUM SWING BEAM LOAD IS 425 lbs.
701_703 - Wood Roof Overhead with Dimensions 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 ___ (1) Wiki Wave Slide ___ (2) Swingbelt w/ Chains ___ (1) Trapeze Swi
11-0011 701 Hardware REV: B 6/23/2011 JH Page 1 of 2 #8 X 2" WOOD SCREW QTY: 125 9 #8 X 2-1/2" WOOD SCREW QTY: 92 #14 X 1-1/4" PAN HEAD SCREW QTY: 20 #8 X 3" WOOD SCREW QTY: 4 8 #10 X 3-1/2" WOOD SCREW QTY: 15 7 6 5/16" TEE NUT QTY: 24 3/8" LOCK NUT QTY: 21 5 4 TORQUE WASHER QTY: 19 3 3/8" WASHER QTY: 72 2 1 5/16 X 6" HEX BOLT QTY: 12 5/16 X 4" HEX BOLT QTY: 12 1/4" WASHER QTY: 8 5/16" WASHER QTY: 24 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
11-0011 701 Hardware REV: B 6/23/2011 JH Page 2 of 2 3/8" X 3-1/2" HEX 3/8" X 5" LAG SCREW HEX LAG SCREW QTY: 37 QTY: 14 9 8 7 6 5 4 3 #2 SQUARE DRILL BIT QTY: 1 2 1 3/8" x 5-1/2" 3/8 x 9" 3/8 x 6-1/2" CARRIAGE BOLT CARRIAGE BOLT CARRIAGE BOLT QTY: 2 QTY: 1 QTY: 16 3/8" x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 21 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.
11-0012 703 Hardware REV B 2/28/2011 JH Page 1 of 1 #8 x 1-1/2" WOOD SCREW QTY: 204 #8 X 2" WOOD SCREW QTY: 14 9 3/8 X 3-1/2" HEX LAG SCREW QTY: 4 8 7 3/8" WASHER QTY: 4 6 5 #2 SQUARE DRIVE BIT QTY: 1 4 3 2 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION 2 X 6 X 41-1/4" DECK SPACER 2-6-4125-DS 2 X 6 X 50-3/4" DECK BOARD 2-6-5075-DB 2 X 6 X 79-1/4" INNER FORT SUPPORT QTY.
PICTURE DESCRIPTION 4 X 4 X 70" TIRE SWING SUPPORT QTY.
PICTURE DESCRIPTION 4 X 4 X 108" SWING LEG 4-4-10800-SL 4 X 4 X 120" SIDE RAIL 4-4-12000-SR 4 X 4 X 120" SWING BEAM SIDE RAIL QTY.
PICTURE DESCRIPTION 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55" ROOF STARTER 1-5-5500-RS 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 1 X 6 X 55" ROOF PEAK 1-6-5500-RP 2 X 6 X 16" SUN 2-6-1600-S 2 X 6 X 80-1/4" ROOF SUPPORT LEFT AND RIGHT 2-6-8025-RSL 2-6-8025-RSR 4 X 4 X 29-1/2" CENTER POST 4-4-2950-CP QTY.
PICTURE DESCRIPTION 4 X 4 X 61-1/4" CORNER POST 4-4-6125-CP 5/4 X 6 X 12" ROOF TRIANGLE QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 is a pkg of 5) A-FRAME SWING LEG BRACKET QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
STEP 1: ASSEMBLING THE LADDER 1: START WITH THE 4 X 4 X 80-1/4" LADDER SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE FIVE HOLES AND THE FIVE CHANNELS ON THE INSIDE TO FACE EACH OTHER, AND THE ANGLED ENDS SHOULD BE FACING THE SAME WAY. IT SHOULD ALSO BE NOTED THAT THERE ARE TWO 3/8" HOLES JUST ABOVE THE FIVE LADDER RUNG HOLES AND CHANNELS. 2: LAY THE LEFT LADDER SIDE ON THE GROUND AND PLACE THE FIVE 2 X 6 X 20-1/2" LADDER STEPS INSIDE THE CHANNELS. ATTACH WITH 3-1/2" WOOD SCREWS.
STEP 2: ATTACHING THE ROPE LADDER RUNNER 1: FIND THE 4 X 4 X 97" ROPE LADDER RUNNER. TAKE SPECIAL NOTE OF THE ROUNDED EDGE ON THE 7/8" HOLES ON THE END OF THE ROPE LADDER RUNNER. 2: LINE UP THE TWO 3/8" PILOT HOLES ON THE ROPE LADDER RUNNER TO THE COUNTER-SUNK HOLES ON THE LADDER SIDE PIECES. THE COUNTERSUNK HOLES OF THE LADDER ASSEMBLY WILL FACE OUTWARDS. 3: FIND TWO T-NUTS, AND SET WITH A HAMMER ON THE EXPOSED 3/8" HOLES OF THE ROPE LADDER RUNNER.
STEP 3: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE LADDER ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE LADDER ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE LADDER SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT. CENTER THE COUNTER-SUNK HOLES ON THEIR RESPECTIVE BOARDS BEFORE ATTACHING. 3: FASTEN THE ANGLED END TO THE LADDER SIDE WITH ONE 3/8 X 3-1/2" LAG SCREW WITH A 3/8" WASHER.
STEP 4: ASSEMBLING THE ROCK WALL 1: START WITH THE 4 X 4 X 80-1/4" ROCK WALL SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE ANGLED ENDS TO FACE THE SAME WAY. IT SHOULD ALSO BE NOTED THAT THERE ARE TWO 3/8" HOLES JUST BELOW THE ANGLED ENDS. 2: INSTALL T-NUTS INTO THE HOLES JUST BELOW THE ANGLED ENDS. THE BOTTOM HOLES WILL GET A T-NUT ON THE OUTSIDE, AND THE TOP HOLES WILL GET A T-NUT ON THE INSIDE. 3: FIND THE 4 X 4 X 74" ROCK WALL BOTTOM SUPPORT.
STEP 5: ASSEMBLING THE ROCK WALL 1: MEASURE 67" FROM THE BOTTOM OF EACH OF THE ROCK WALL SIDES AND MARK THIS LOCATION. 2: BEFORE INSTALLING BOARDS, MAKE SURE THAT THE ROCK WALL SIDES ARE SQUARE TO THE ROCK WALL BOTTOM SUPPORT. ONCE THE ROCK WALL SIDES ARE SQUARE, LAY THE 5/4 X 6 X 48" ROCK WALL BOARD ON THE ROCK WALL SIDES WITH THE TOP OF THE BOARD PLACED AT THE 67" MARK PREVIOUSLY MADE. ATTACH WITH TWO 2" WOOD SCREWS PER SIDE.
STEP 6: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE ROCK WALL ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE ROCK WALL ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE ROCK WALL SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT. CENTER THE COUNTER-SUNK HOLES ON THEIR RESPECTIVE BOARDS BEFORE ATTACHING. 3: FASTEN THE ANGLED END TO THE ROCK WALL SIDE WITH ONE 3/8 X 3-1/2" LAG SCREW WITH A 3/8" WASHER.
STEP 7: INSTALLING OUTER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 79-1/4" OUTER FORT SUPPORTS. THE EASIEST WAY TO DIFFERENTIATE THE OUTER SUPPORTS FROM THE INNER SUPPORTS IS TO LOOK FOR THE COUNTER-SUNK HOLES AT 12-1/4" FROM EACH END. THE TWO BOARDS WITH THE HOLES CLOSEST TO THE BOTTOM (LONGER) SIDE ARE THE OUTER FORT SUPPORTS, THE BOARDS WITH THE HOLES CLOSEST TO THE TOP (SHORTER) SIDE ARE THE INNER FORT SUPPORTS.
STEP 8: INSTALLING INNER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 79-1/4" INNER FORT SUPPORTS. 2: LINE UP THE 3/8" HOLE CLOSEST TO THE BOTTOM WITH THE BOTTOM HOLE OF THE INNER FORT SUPPORT. 3: ATTACH THE INNER FORT SUPPORT TO THE LADDER ASSEMBLY WITH 5/16 X 4" HEX BOLTS AND 5/16" WASHERS. 4: REPEAT STEPS 2 AND 3 TO FASTEN THE INNER FORT SUPPORT TO THE ROCK WALL ASSEMBLY.
STEP 9: INSTALLING T-NUTS ON CORNER POSTS 1: FIND FOUR 4 X 4 X 61-1/4" CORNER POSTS 2: USING THE DIAGRAM BELOW, INSTALL T-NUTS INTO THE APPROPRIATE HOLES. PLACE T-NUTS INTO THE HOLES OF THE CORNER POST AND SET WITH A HAMMER. 3: THE CORNER POSTS ARE SHOWN RELEVANT TO THEIR ORIENTATION ON THE UNIT.
STEP 10: INSTALLING INNER FORT SUPPORTS 1: TAKE THE CORNER POSTS WITH THE T-NUTS INSTALLED FROM THE PREVIOUS STEP AND ARRANGE THE POSTS IN THEIR PROPER ORIENTATION. (SHOWN BELOW WITH NUMBERS TO REFERENCE THE PREVIOUS STEP) 2: THE CORNER POSTS SHOULD BE ORIENTED WITH THE COUNTER-SUNK HOLES FACING TOWARD EACH OTHER ON BOTH SIDES. THE CORNER POSTS SHOULD BE PLACED BETWEEN THE INNER AND OUTER FORT SUPPORTS, AND REST FLUSH AGAINST THE ANGLED END OF THE LADDER AND ROCK WALL ASSEMBLIES.
STEP 11: ATTACHING THE SWING BEAM PLATE TO THE SWING BEAM SIDE RAIL 1: FIND THE 4 X 4 X 120" SWING BEAM SIDE RAIL. NOTE THE DIFFERENCE BETWEEN THE SWING BEAM SIDE RAIL AND THE SIDE RAIL. THE SWING BEAM SIDE RAIL WILL HAVE THREE MORE COUNTER SUNK HOLES ON ONE SIDE THAN THE SIDE RAIL. 2: FIND THE SWING BEAM PLATE. NOTICE THE TWO SQUARE HOLES ON THE SWING BEAM PLATE.
STEP 12: ATTACHING THE SWING BEAM SIDE RAIL 1: FIND TWO TORQUE WASHERS. PLACE A 6-1/2" CARRIAGE BOLT INSIDE THE TORQUE WASHER. PLACE THE TORQUE WASHER/CARRIAGE BOLT ASSEMBLY INTO THE HOLES OF THE CORNER POST SO THAT THE HEAD OF THE CARRIAGE BOLT IS INSIDE OF THE FORT. 2: TAKE THE 4 X 4 X 120" SWING BEAM SIDE RAIL WITH THE SWING BEAM PLATE AND LINE UP THE PILOT HOLES IN THE CORNER POSTS WITH THE HOLES IN THE SWING BEAM SIDE RAIL. PUSH THE CARRIAGE BOLTS THROUGH THE HOLES IN THE SWING BEAM SIDE RAIL.
STEP 13: ATTACHING THE SIDE RAIL 1: TAKE THE 4 X 4 X 120" SIDE RAIL AND LINE UP THE PILOT HOLES IN THE CORNER POSTS WITH THE HOLES IN THE SIDE RAIL. 2: FASTEN THE SIDE RAIL TO THE FORT WITH 5/16 X 6" HEX BOLTS AND 5/16" WASHERS INTO THE T-NUTS OF THE CORNER POSTS.
STEP 14: ATTACHING THE ROPE LADDER SUPPORT AND THE ROCK WALL ROPE SUPPORT 1: FIND THE 4 X 4 X 88" ROPE LADDER SUPPORT AND LAY IT ON TOP OF THE SIDE RAIL AND THE SWING BEAM SIDE RAIL ON THE LADDER SIDE OF THE FORT. 2: LINE UP THE COUNTER-SUNK HOLES OF THE ROPE LADDER SUPPORT WITH THE HOLES IN THE CORNER POSTS AND ATTACH WITH 5/16 X 6" HEX BOLTS WITH 5/16" WASHERS. THE THREE HOLES ON THE END OF THE ROPE LADDER SUPPORT SHOULD BE ON THE OPPOSITE SIDE OF THE SWING BEAM PLATE BEFORE INSTALLING.
STEP 15: INSTALLING LAG SCREWS 1: MAKE SURE THAT THE UNIT IS LEVEL AND SQUARE. 2: STARTING AT THE INNER AND OUTER FORT SUPPORTS, USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS IN THE EMPTY HOLES ON THE 2 X 6 PARTS TO SECURE THE BASE OF THE FORT. 3: THE UPPER PART OF THE FORT NEEDS TO BE SECURED WITH 3/8 X 5" LAG SCREWS WITH 3/8" WASHERS IN THE EMPTY HOLES OF THE 4 X 4 PARTS.
STEP 16: INSTALLING ROCK WALL BOARDS 1: FIND ELEVEN 5/4 X 6 X 48" ROCK WALL BOARDS. 2: LAY THE ROCK WALL BOARDS ACROSS THE ROCK WALL SIDES. 3: ATTACH THE ROCKS WITH TWO 2" WOOD SCREWS PER END. 4: THE FINAL BOARD WILL BE THE 5/4 X 6 X 48" BOTTOM ROCK WALL BOARD WITH ONE HOLE IN THE CENTER. IT WILL ATTACH IN THE SAME MANNER AS THE OTHER ROCK WALL BOARDS. 5: AFTER ASSEMBLY, YOUR ROCK WALL MAY HAVE A GAP AT THE BOTTOM. THIS IS NORMAL DUE TO MILLING VARIANCES AND WOOD SHRINKAGE.
STEP 17: INSTALLING TARP BOARDS 1: FIND TWO 2 X 4 X 54-1/2" TARP BOARDS. 2: CENTER THE BOARD ACROSS THE ENDS OF THE SWING BEAM SIDE RAIL AND THE SIDE RAIL. 3: ATTACH THE TARP BOARDS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 4: REPEAT THIS PROCESS ON THE OPPOSITE SIDE OF THE FORT.
STEP 18: DECK 1: FIND NINE 2 X 6 X 50-3/4" DECK BOARDS. 2: LAY THE DECK BOARDS ACROSS THE INNER FORT SUPPORTS, BETWEEN THE BOTTOM AND REAR BOTTOM PANEL BOARDS, AND INSIDE THE AREA BETWEEN THE CORNER POSTS. 3: FIND FOUR 2 X 6 X 41-1/4" DECK SPACERS. 4: LAY TWO DECK SPACERS ACROSS THE INNER FORT SUPPORTS ON THE LADDER AND ROCK WALL SIDES OF THE FORT. 5: MAKE SURE THAT ALL BOARDS ARE EVENLY SPACED ACROSS THE DECK AND ATTACH THE DECK BOARDS AND DECK SPACERS TO THE FORT WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
STEP 19: INSTALLING THE BOTTOM PANEL BOARDS 1: FIND THE 2 X 4 X 58" REAR BOTTOM PANEL BOARD. 2: LAY THE BOARD ACROSS THE DECK ON THE SWING BEAM SIDE OF THE FORT, CENTERED BETWEEN THE TWO CORNER POSTS. 3: ATTACH THE REAR BOTTOM PANEL BOARD WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 4: FIND THE 2 X 4 X 30-3/4" BOTTOM PANEL BOARD. 5: LAY THE BOARD ACROSS THE DECK ON THE FRONT OF THE FORT, FLUSH WITH THE OUTSIDE OF THE TWO CORNER POSTS.
STEP 20: CENTER POSTS 1: TAKE THE 4 X 4 X 29-1/2" CENTER POSTS, AND LINE UP THE HOLE IN THE POSTS WITH THE THROUGH HOLE IN THE SWING BEAM SIDE RAIL/SIDE RAIL. 2: WHEN THE CENTER POST IS LINED UP PROPERLY, INSTALL A 5/16" T-NUT INTO THE HOLE IN THE CENTER POSTS. 3: FASTEN THE CENTER POSTS TO THE FORT WITH 5/16 X 6" HEX BOLTS AND 5/16" WASHERS THROUGH THE SWING BEAM SIDE RAIL/SIDE RAIL, AND INTO THE T-NUTS OF THE CENTER POST.
STEP 21: ROOF SUPPORTS 1: FIND FOUR 2 X 6 X 80-1/4" ROOF SUPPORT BOARDS. THERE WILL BE TWO FOR THE LEFT, AND TWO FOR THE RIGHT. 2: LAY THE ANGLED ENDS (WITH THE ENGRAVED DESIGNS) ON TOP OF THE SWING BEAM SIDE RAIL, AND THE SIDE RAIL. ALLOW SOME OF THE BOARD TO HANG PAST THE SIDE RAILS SO THAT THERE WILL BE NO INTERFERENCE WITH THE TARP BOARDS AND THE ROOF BOARDS THAT WILL BE INSTALLED LATER. 3: ATTACH THE ROOF SUPPORTS TO THE CORNER POSTS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 22: PANEL SLATS 1: FIND NINE 5/4 X 4 X 28-1/2" PANEL SLATS, AND ARRANGE THEM SO THAT SIX OF THEM ARE EVENLY SPACED ACROSS THE SWING BEAM SIDE OF THE FORT, AND THREE OF THEM ARE EVENLY SPACED ALONG THE OPENING ON THE ROCK WALL SIDE ON THE FRONT OF THE FORT. LEAVE OFF THREE PANEL SLATS (SEE BELOW) IF YOUR PLAYSET COMES WITH MONKEY BARS. 2: ATTACH THE PANEL SLATS WITH TWO 2" WOOD SCREWS PER END.
STEP 23: CENTER DECK SUPPORTS 1: FIND THE 4 X 4 X 70" TIRE SWING SUPPORT, AND ARRANGE EVENLY UNDERNEATH THE DECK. 2: ATTACH THE TIRE SWING SUPPORT WITH A 3/8 X 5" LAG SCREW AND A 3/8" WASHER THROUGH THE LADDER CENTER. FROM THE TOP, ADD TWO 2-1/2" WOOD SCREWS THROUGH THE DECK BOARDS, INTO THE CENTER DECK SUPPORT. 3: FIND THE 2 X 4 X 58" ROCK WALL SUPPORT BOARD, AND CENTER IT ON THE BACK OF THE ROCK WALL. MAKE SURE THAT THE HOLE IN THE BOTTOM ROCK WALL BOARD IS NOT OBSTRUCTED BY THE ROCK WALL SUPPORT BOARD.
STEP 24: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWING BEAM. 2: FASTEN THE IRON DUCTILES TO THE SWING BEAM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS AND WASHERS ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
STEP 25: 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 26: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE FORT AND POSITION THE LEGS UNDERNEATH THE END OF THE BEAM. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND SWING LEGS. MAKE SURE THE IRON DUCTILES ARE FACING DOWN.
STEP 27: ATTACHING SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM LEG BRACKET USING 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: 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 28: ATTACHING THE SWING BEAM TO THE FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: AFTER THE LEGS ARE ATTACHED, HAVE ONE PERSON ON THE GROUND PICK UP THE SWING BEAM BY THE LEGS, AND ANOTHER PERSON PICK UP THE SWING BEAM FROM INSIDE THE FORT AND WALK OUT THE SWING BEAM. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
STEP 29: 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 30: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 70" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS-MEMBER, AND FASTEN TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 31: TIRE SWING 1: CENTER THE TIRE SWING SWIVEL ON THE CENTER DECK SUPPORT. 2: MARK THE LOCATION OF THE HOLES IN THE SWIVEL WITH A PENCIL, AND WITH A 3/8" DRILL BIT, DRILL HOLES THROUGH THE CENTER DECK SUPPORT AND DECK BOARD. 3: USE A 5-1/2" CARRIAGE BOLT TO CLEAR OUT ANY DEBRIS LEFT OVER FROM DRILLING, MATE WITH A TORQUE WASHER AND SET THE TORQUE WASHER ON TOP OF THE DECK WITH A HAMMER. 4: PLACE THE TIRE SWIVEL ON THE TWO CARRIAGE BOLTS, AND FASTEN WITH 3/8" LOCK NUTS WITH 3/8" WASHERS.
STEP 32: INSTALLING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. 2: THE ROCKS INCLUDED IN YOUR PLAYSET MAY VARY, IN ANY CASE, THE 1-1/4" PAN HEAD SCREWS WITH WASHERS WILL BE USED TO ATTACH THE ROCKS.
STEP 33: CLIMBING ROPE 1: THREAD ONE END OF THE ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE A SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN ROPE TO AID IN CLIMBING. SET KNOTS ACCORDING TO YOUR CHILD'S NEEDS. 2-3 KNOTS SHOULD BE SUFFICIENT. 2: 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. 3: WRAP ROPE AROUND YOUR HAND TO TEST FOR LOOSENESS AS DESCRIBED BELOW.
STEP 34: ROPE LADDER ASSEMBLY 1: FIND THE THREE ROPE LADDER ROPES OF EQUAL LENGTH. MEASURE 30" FROM ONE SIDE OF EACH PIECE OF ROPE AND MAKE A MARK AT THIS LOCATION. 2: TIE A KNOT ON THE OTHER SIDE OF THE ROPE THAT IS JUST ABOVE THE MARK THAT WAS MADE ON THE ROPE (SEE BELOW). 3: THREAD THE ROPE THROUGH THE HOLES OF THE 2 X 4 ROPE LADDER RUNG. YOU MAY NEED TO TWIST THE ROPE TO GET IT THROUGH.
STEP 35: INSTALLING THE ROPE LADDER 1: UNROLL THE ROPE LADDER ASSEMBLY. LOOK FOR THE BOARD THAT HAS KNOTS TIED ABOVE AND BELOW THE ROPE LADDER STEP. THIS WILL BE THE TOP OF THE ROPE LADDER. 2: THREAD THE TOP OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER SUPPORT, AND TIE A SECURE KNOT. 3: THREAD THE BOTTOM OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER, AND TIE A SECURE KNOT. 4: MAKE SURE THE ROPE LADDER ROPES WILL NOT LOOP AROUND YOUR HAND.
STEP 36: INSTALLING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: THE FLARED END OF THE SLIDE WILL REST AGAINST THE DECK BOARDS. 3: ATTACH THE SLIDE TO THE DECK WITH 1-1/4" PAN HEAD SCREWS.
STEP 37: ROOF 1: PRE-DRILL HOLES IN THE TWO 5/4 X 12" ROOF PEAK SUPPORTS TO THE PATTERN SHOWN BELOW. 5/4 X 12" ROOF PEAK SUPPORT 2: PLACE THE 5/4 X 12" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. REPEAT ON OTHER SIDE.
STEP 38: ROOF COMPONENTS 1: USING A 1/8" DRILL BIT, DRILL HOLES IN THE ROOF COMPONENTS TO THE DIMENSIONS SHOWN BELOW. Rounded Edge 13 2 16 " 1 X 5 X 55" ROOF STARTER 1 12" 1 32" Groove Side Tongue Side 13 2 16 " 3 52 16 " 1 X 6 X 55" ROOF BOARD 3 14" 3 34" Groove Side 3 52 16 " Rounded Edge 13 2 16 " 1 X 4 X 55" ROOF FINISHER 1 14" 3" Tongue Side 3 52 16 " 3 4" 5/4 X 3 X 53" SUN SUPPORT 3 14" 2 X 6 X 16" SUN 1" 4" 4" 8" Repeat drilling process for other end of each ray.
STEP 39: ROOF 1: PLACE THE 1 X 5 X 55" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 40: ROOF PEAK 1: PLACE THE 55" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH 1-1/2" WOOD SCREWS.
STEP 41: SUNBURST 1: PLACE THE 2 X 6 X 16" SUN CENTERED AGAINST THE 5/4 X 3 X 53" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2" WOOD SCREWS. REPEAT THIS PROCESS FOR THE OTHER SIDE OF THE FORT.
STEP 42: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP UNDERNEATH THE ROOF BOARDS, AND AGAINST THE ANGLED ROOF SUPPORTS. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP. 2: FASTEN THE SUN ASSEMBLY TO THE FORT WITH 2" WOOD SCREWS FROM THE OUTSIDE INTO THE ROOF SUPPORTS. 3: REPEAT ON THE OPPOSITE SIDE OF THE FORT.
STEP 43: SUNBURST 1: CENTER THE 5/4 X 2 X 17" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS. BOTH HOLES IN THE LARGE RAY SHOULD BE IN THE CENTER OF THE BOARD AT EACH END. FLIP THE BOARD OVER IF THEY ARE NOT. THE SLANTED HOLE DRILLED IN THE LARGE RAY SHOULD BE AT THE TOP. 2: FASTEN THE LARGE RAY WITH TWO 1-1/2" SCREWS. 3: EQUALLY SPACE THE SMALL AND MEDIUM RAYS ABOUT THE HALF SUN TO THE PATTERN SHOWN BELOW AND MARK THE POSITION OF EACH WITH A PENCIL.
STEP 44: ROOF 1: PLACE THE 1 X 6 X 55" 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 FOURTEEN ROOF BOARDS. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED OVER THE ROOF SUPPORTS. IF NECESSARY PLACE A SCRAP 2 X 4 BOARD AGAINST THE ROOF BOARD AND HAMMER ON IT TO SEAT THE TONGUE INTO THE GROOVE FOR THE ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 45: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE REAR CENTER POST, INTO THE SWING BEAM MOUNT. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN. 3: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL.
STEP 46: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS ONTO THE SIDE RAIL, ABOVE THE FRONT WALL PANELS CLOSEST TO THE ROCK WALL SIDE OF THE FORT. 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.
STEP 47: SAFETY HANDLES 1: FIND THE FOUR SAFETY HANDLES. 2: PLACE THE SAFETY HANDLE JUST ABOVE THE ROCK WALL OPENING, AND INSTALL WITH 1-1/4" PANHEAD SCREWS AND WASHERS. 3: REPEAT THIS PROCESS FOR THE LADDER SIDE OF THE FORT.
STEP 48: HANGING 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 ON 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 49: HANGING THE TIRE SWING 1: HANG THE THREE SPRING CLIPS FROM THE TIRE SWIVEL. 2: HANG ONE OF THE CHAINS IN ONE OF THE SPRING CLIPS AT THE DESIRED HEIGHT. 3: CONTINUE THE PROCESS WITH THE REMAINING CHAINS, MAKING SURE THAT THE TIRE SWING IS LEVEL WHEN FINISHED. 4: ANY EXCESS LENGTH OF CHAIN CAN BE LOOPED BACK AND HUNG MULTIPLE TIMES TO PREVENT THE EXCESS FROM HANGING DOWN AND CREATING A HAZARD.
STEP 50: FLAG KITS 1: INSTALL THE FLAG KITS IN THE DESIRED LOCATION ON YOUR PLAY SET. THE RECOMMENDED LOCATION IS ON THE CORNER POSTS AT THE FRONT OF THE FORT. ATTACH THE FLAG KITS WITH THE HARDWARE PROVIDED.
STEP 51: CHIMNEY AND DORMERS 1: iF YOU HAVE NOT ALREADY DONE SO USE THE INSTRUCTIONS PROVIDED TO INSTALL THE CHIMNEY AND DORMERS.
STEP 52: ROOF STRINGERS 1: PLACE 5/4 X 3 X 78" ROOF STRINGER AGAINST THE UNDERSIDE OF THE ROOF BOARDS IN THE CENTER. 2: ATTACH ROOF STRINGER TO ROOF BOARDS WITH ONE #8 X 1-1/2" WOOD SCREW PER ROOF BOARD. 3: REPEAT FOR OTHER SIDE OF ROOF.
STEP 53: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. IGNORE STEP 6 & 7 IN THE INSTRUCTIONS. 2: 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 BRACKET OBSERVING THE 1-5/8" DIMENSION SHOWN BELOW. 3: PLACE THE UNIT ON THE PANEL SLATS AS SHOWN.
STEP 54: NAMEPLATE 1: ATTACH THE MANUFACTURER NAMEPLATE CENTERED ON THE FRONT OF YOUR SWING BEAM WITH TWO 2" WOOD SCREWS. PLACE NAME PLATE HERE AND ATTACH.
STEP 55: 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.
