™ playsets ™ playsets Pioneer Peak Timber Shield Post Option BOXES: CB, W-1, TSB, 120 Model: 1500DW [BOXES: 1501, 1503N, 1509N, 1509W, 1510, 1511, 1523 1530, Tire Swing & Slide Box] *51-0006-W* 51-0006-W Copyright © 2016 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 – 2016 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set. As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury.
WARRANTY REGISTRATION - PIONEER PEAK Gorilla Playsets™ manufactures 3 EASY WAYS TO REGISTER the finest quality products that are designed for outstanding strength and durability. We back Fax this completed form to: OPTION 1 (800) 880-3300 Mail this completed form to: Gorilla Playsets 190 Etowah Industrial Court Canton, GA 30114 OR our products with an unparalleled warranty. In the unlikely event that you will need to contact us Complete the online registration form at: OPTION 2 http://www.
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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 1500DW shown. See cover of manual for the image of your model when it is completed. Timber Shield Post Option BOXES: CB, W-1, TSB, 120 Models: 1500DW 1500DWF (BOXES: 1501, 1503N, 1509N, 1509W, 1510, 1511, 1525*, 1530, 1523, Tire Swing & Slide Box) *1525 only included with 1500DWF Treehouse Model REV: 9.17.
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 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.
1500 SERIES Please familiarize yourself with the- manual, parts/components and general 1500DW PIONEER PEAK/CIMMARON WOOD ROOF 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”, 7/64”, 11/64” and a 1” and 7/8” Paddle style bit.
1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" PAN HEAD SCREW QTY: 4 #8 X 1-3/4" WOOD SCREW QTY: 4 9 8 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 6 7 #8 X 3" WOOD SCREW QTY: 20 6 5 5/16" TEE NUT QTY: 22 4 3/8" LOCK NUT QTY: 19 3 TORQUE WASHER QTY: 17 3/8" WASHER QTY: 31 2 1 5/16 X 4-1/2" HEX BOLT QTY: 14 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 34 USE THE RULER TO THE RIGHT TO MEASURE YOUR B
1501 HARDWARE 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 9 PAGE: 2 OF 2 REV A: 9/10/2014 JH 8 7 6 5 4 3 #2 SQUARE DRIVE BIT QTY: 1 2 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8 x 7" CARRIAGE BOLT QTY: 14 3/8 x 6-1/2" CARRIAGE BOLT QTY: 2 3/8 x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 19 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
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.
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.
3/8 X 3-1/2" HEX LAG SCREW QTY: 11 1510 HARDWARE PAGE: 1 OF 1 REV B 8/19/2014 JH 9 TORQUE WASHER QTY: 4 8 5/16" TEE NUT QTY: 2 7 5/16" PLASTIC BOLT CAP QTY: 2 3/8" PLASTIC BOLT CAP QTY: 4 6 5 3/8" LOCK NUT QTY: 4 4 3/8" WASHER QTY: 17 3 2 5/16 X 7" HEX BOLT QTY: 2 3/8 x 7" CARRIAGE BOLT QTY: 4 1/2" WASHER QTY: 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.
1511 HARDWARE PAGE: 1 OF 1 REV A 2/4/2013 J.H. 9 8 #8 X 2" WOOD SCREW QTY: 20 7 6 5 4 5/16" TEE NUT QTY: 10 3 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 14 5/16 X 4-1/2" HEX BOLT QTY: 12 5/16" WASHER QTY: 26 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.
5/16" X 2-1/2" LAG SCREW QTY: 4 5/16" X 2-1/2" HEX BOLT QTY: 6 5/16" X 1-1/2" HEX BOLT QTY: 4 1523 HARDWARE PAGE 1 OF 1 9/10/2014 JH 9 8 7 #8 X 3-1/2" WOOD SCREW QTY: 4 #8 X 1-1/4" PAN HEAD SCREW SQUARE DRIVE QTY: 16 #8 X 2-1/2" WOOD SCREW QTY: 124 6 3/8"-16 X 3/4" DIA. I.D. X 2-1/2" L EYE BOLT QTY: 2 5 4 3 5/16"-18 x 5/8" L T-NUT QTY: 10 3/8-16 x 5/8" L T-NUT QTY: 2 2 5/16" WASHER QTY: 10 3/8" WASHER QTY: 2 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
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PICTURE DESCRIPTION 5 QTY.
PICTURE DESCRIPTION 1 472" ROOF PEAK 1-6-4750-RP QTY.
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PICTURE DESCRIPTION NOTE: ANYTHING ON THIS PAGE REFERRED TO AS "PLASTIC COATED" WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR WOOD OPTION. HOLE AT TOP 4 X 4 X 96" PLASTIC COATED CORNER POST (FORT) 4 X 4 X 96" PLASTIC COATED CORNER POST (CLATTER BRIDGE) QTY.
PICTURE DESCRIPTION 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES 2-4-3675-SBH QTY.
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PICTURE 1509W DESCRIPTION QTY.
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PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCKS (07-0008 IS A PACK OF 5) 10 A-FRAME SWING LEG BRACKET 11-5010 HARDWARE BOXES: 1501, 1503N, 1523, 1509N, 1509W, 1510, 1511 ROCKS 1 1 INSTRUCTIONSEA.
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PICTURE DESCRIPTION UNASSEMBLED CHIMNEY (1530 BOX) UNASSEMBLED DORMER (1530 BOX) GROUND STAKE (PAIR) 07-0016-P CLATTERBRIDGE CHAIN 96" FLAG KIT 09-1014 QTY.
PICTURE DESCRIPTION PLASTIC SUNBURST 07-0028-G (NOT SHOWN) (NOT SHOWN) MANUFACTURER LOGO PLATE CLATTER BRIDGE MESH PANELS 06-2004 TIC TAC TOE (UNASSEMBLED) 07-0010 PLASTIC DORMER SUNBURST 07-0031 STEERING WHEEL 07-0004 TIRE SWING SWIVEL 11-4010 TIRE SWING W/CHAINS 04-0014 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 TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS.
STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 3A: DRILL HOLES FOR BRIDGE CHAINS 1: LOCATE ONE 2 X 4 X 70" DECK SUPPORT AND ONE 2 X 6 X 70" FRONT FACE BOARD. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD. 3: PLACE A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES WITH A SPADE BIT.
STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT HOLES FOR CLATTER BRIDGE CHAIN.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD SHOULD BE OFFSET UP.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" BOTTOM PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD MUST BE OFFSET UP.
STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE FRAME HAS BEEN LEVELED AND SQUARED.
STEP 6B: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT. 2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE ANGLE SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" END PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2 X 4 X 47-1/2" END PANEL BOARD OFFSET HOLES UP FRONT OF FORT 5/16" WASHER 5/16" X 3-1/2" LAG SCREW 2: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" IS THE CENTER OF THE BOARD AND ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER.
STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. 3: USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT.
STEP 10: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 3 18" 3 24" 1 8" 3 18" 1 48" 1 48" 1 48" 1 48" 11 23 16 " 2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT.
STEP 11: ROCK WALL 1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER.
STEP 12: ROCK WALL 1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2" WOOD SCREWS IN EACH SIDE. 3: CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS, FASTENING EACH BOARD WITH TWO 2" WOOD SCREWS ON EACH END. 4: THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE.
STEP 13: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT.
STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT - RIGHT OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: GO UNDERNEATH THE DECK TO INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE FRONT FACE BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
STEP 16: CLIMBING RAMP 1: LAY OUT THE 2 X 4 X 96" RAMP SIDE BOARDS MAKING SURE THE LARGE HOLES ON TEH ENDS ARE CLOSEST TO THE FLOOR. 2: FIRST PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE SQUARE END OF THE 2 X 4 X 96" RAMP SIDE BOARDS. OFFSET THE BOARD 1" FROM THE END. FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SIDE. 3: SECOND PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE ROUND END OF THE 2 X 4 X 96" RAMP SIDE BOARDS.
STEP 16A: CLIMBING RAMP 1: PLACE THE RAMP SIDE ON A FIRM LEVEL SURFACE. HAMMER A 5/16" T-NUT INTO EACH HOLE ON THE INSIDE OF THE RAMP SIDE. 2: REPEAT FOR THE OTHER RAMP SIDE. 5/16" T-NUT 5/16" T-NUT 5/16" T-NUT 5/16" T-NUT PLACE THIS SIDE ON A FIRM SURFACE. THEN HAMMER IN THE 5/16" T-NUTS. REPEAT FOR THE OTHER RAMP SIDE.
STEP 17: CLIMBING RAMP 1: PLACE ONE 2 X 6 X 95-1/2" FLOOR BOARD AGAINST EACH OF THE RAMP SIDE BOARDS. FASTEN THE FLOOR BOARDS TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SUPPORT. THE BOARDS SHOULD BE FLUSH AT THE SQUARE END OF THE RAMP SIDES. 2: PLACE THE 2 X 4 X 95-1/2" MIDDLE FLOOR BOARD ON THE CENTER OF THE RAMP. FASTEN THE FLOOR BOARD TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER RAMP SUPPORT.
STEP 17A: CLIMBING RAMP 1: HAMMER A 3/8" T-NUT INTO THE INSIDE OF EACH POST. NOTE THIS IS THE SIDE OF THE POST THAT DOES NOT HAVE THE COUNTERBORED HOLE. 2: SCREW A 3/8" EYE BOLT WITH A WASHER INTO THE T-NUT SO IT LOOKS LIKE THE BOTTOM PICTURE. DO NOT TIGHTEN THE EYE BOLT SO TIGHTLY THAT IT CRACKS THE WOOD. JUST SNUG IT UP.
STEP 18: CLIMBING RAMP 1: ATTACH THE 2 X 2 X 16" FLOOR SUPPORT BOARDS TO THE FLOOR BOARDS WITH 2-1/2" WOOD SCREWS. (SEE DETAIL VIEW BELOW) 2: FASTEN THE 90 GREEN BRACKET TO THE RAMP SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. A 2-1/2" WOOD SCREW 2 X 2 X 16" FLOOR SUPPORT BOARD 90 GREEN BRACKET 5/16" WASHER 5/16" X 1-1/2" HEX BOLT DETAIL A SCALE 1 : 6 PLACE ONE 2-1/2" WOOD SCREW IN EACH END OF THE FLOOR SUPPORT BOARDS.
STEP 18A: CLIMBING RAMP 1: ATTACH A RAMP POST TO EACH RAMP SIDE WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS. THE EYE BOLTS SHOULD BE ON THE OUTSIDE OF THE RAMP POSTS 2: SQUARE THE RAMP POST TO THE RAMP SIDE AND DRIVE IN TWO 2-1/2" WOOD SCREWS TO SECURE IT. RAMP POST 90.
STEP 18B: CLIMBING RAMP 1: FASTEN A BRACKET AS SHOWN UNDERNEATH THE RAMP TO THE RAMP POST AND THE RAMP SUPPORT. 2: USE #8 X 1-1/4" PAN HEAD SQUARE DRIVE SCREWS TO ATTACH THE BRACKET. 3: REPEAT FOR THE RAMP POST ON THE OTHER SIDE.
STEP 18C: CLIMBING RAMP 1: LOCATE FOUR 2 X 4 X 18" RAMP POST SUPPORTS. 2: PLACE A RAMP POST SUPPORT AGAINST THE RAMP POST AND THE RAMP SIDE AS SHOWN BELOW. 3: THE BOTTOM OF THE RAMP POST SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE RAMP SIDE. THE TOP-END OF THE RAMP POST SUPPORT SHOULD BE FLUSH TO THE SIDE OF THE RAMP POST. 4: ATTACH THE TOP OF THE RAMP POST SUPPORT TO THE RAMP POST WITH ONE #8 X 2-1/2" WOOD SCREW AND ONE #8 X 3-1/2" WOOD SCREW.
STEP 19: CLIMBING RAMP TO FORT 1: PLACE THE CLIMBING RAMP INTO POSITION CENTERED ON THE RIGHT SIDE ON THE FORT. THE BOTTOM EDGE OF THE GREEN BRACKETS SHOULD BE 1-1/2" ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD. USING THE BRACKETS AS A TEMPLATE DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE BOTTOM PANEL BOARD. 3: ATTACH THE CLIMBING RAMP WITH 5/16 X 1-1/2” HEX BOLTS AND 5/16” WASHERS.
STEP 19A: ROPE MOUNT 1: PLACE THE 4 X 4 X 8" ROPE MOUNTS ONTO THE FRONT OF THE ARCHED TOP PANEL BOARD FLUSH TO THE TOP. EACH ROPE MOUNT SHOULD BE 8-3/4" FROM THE END OF THE ARCHED TOP PANEL BOARD AS SHOWN IN DETAIL B BELOW. YOU MAY CHOOSE TO USE 5/16" X 2-1/2" LAG SCREWS WITH WASHERS OR T-NUTS WITH BOLTS TO ATTACH THE ROPE BLOCKS. IF YOU USE LAG SCREWS THEN CONTINUE READING BELOW. IF YOU USE BOLTS THEN GO TO 2 BELOW.
STEP 19B: RAMP ROPE HANDRAILS 1: LOCATE THE RAMP ROPES THAT ARE IDENTICAL IN LENGTH. THEY SHOULD BE APPROXIMATELY 12 TO 13 FEET IN LENGTH. IF YOU HAVE FIVE 13 FOOT ROPES THAT IS FINE, HOWEVER IF TWO ARE 12 FEET THEN USE THEM. 2: TIE A KNOT IN ONE END OF A ROPE WITH THE END HANGING OUT ABOUT 2" FROM THE END OF THE KNOT. THREAD THE OTHER END OF THE ROPE THROUGH THE OUTSIDE OF THE RAMP SIDE. NOW THREAD IT THROUGH THE EYE BOLT. NOW THREAD IT THROUGH THE HOLE IN THE ROPE MOUNT ON THE ROPE LADDER SUPPORT.
STEP 20: CENTER POSTS FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 28-9/16" CENTER POST. 2: PLACE THE CENTER POST INSIDE THE RAILING AT THE REAR OF THE PLAYSET. LINE UP THE HOLE IN THE CENTER POST WITH THE HOLE IN THE RAILING. FASTEN THE CENTER POST TO THE RAILING WITH A 5/16" X 21/2" HEX BOLT AND A 5/16" WASHER AT THE TOP. SQUARE THE CENTER POST TO THE DECK AND SECURE THE BOTTOM OF THE CENTER POST TO THE BOTTOM PANEL BOARD WITH #8 X 2-1/2" WOOD SCREWS.
STEP 21: PANEL SLATS 1: FIND TWENTY-TWO 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. ROCK WALL SIDE PANEL REAR PANEL SLAT SPACING MAKE THIS SLAT FLUSH TO THE END OF THE 2 X 4 X 14" BOTTOM PANEL BOARD. SPACE THE NEXT SLAT EQUALLY BETWEEN THE FIRST SLAT AND THE CORNER POST.
STEP 22: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH, IN THE COUNTER-SUNK HOLESOF THE SWING BEAM SUPPORT. USE BOLT CAPS TO COVER ANY EXPOSED THREADS. 3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER. 4: IF NECESSARY USE LOCKING PLIERS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.
STEP 23: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
STEP 24: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 25: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM. THESE TWO HOLE LOCATIONS WILL BE EMPTY ON YOUR SWING BEAM. LINE THEM UP WITH THE HOLES IN THE SWING LEG BRACKET UNDER THE SWING BEAM.
STEP 26: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET. 3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.
STEP 27: MOUNT SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND THE SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT WITH A TORQUE WASHER AND A 3/8" LOCK NUT WITH A 3/8" WASHER ON THE BOTTOM.
STEP 28: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THE LEGS ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY EITHER: A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
STEP 29: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS.
STEP 30: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING 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 30A: INSTALLING ROOF SUPPORT ASSEMBLIES 1: PLACE THE ROOF SUPPORT ASSEMBLIES ON TOP OF THE DECK OF THE PLAY SET. CLIMB ONTO THE DECK TO INSTALL THE ROOF SUPPORT ASSEMBLIES. 2: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 31: ROOF STARTERS 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 32: ROOF PEAK 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS.
STEP 33: ROOF NOTE: THE SMALL PICTURE BELOW IS A GENERIC VIEW OF A PLAY SET IN OUR 1500 MODEL LINE. TYPICALLY THE ROCK WALL AND/OR SLIDE IS LOCATED ON THE FRONT OF THE 1500 SERIES PLAY SETS. THE BIG PICTURE BELOW SHOWS THE RIGHT SIDE ROOF WITH THE DORMER AND CHIMNEY. THE LEFT SIDE ROOF ONLY GETS A DORMER. 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.
STEP 34: 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 35: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS. NOTE: THE OFFSET HOLES CAN BE PLACED UP OR DOWN IN THIS STEP.
STEP 36: 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 37: PICNIC TABLE 1: MEASURE 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS. 3: PLACE THE TOP OF THE LEFT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT REAR CORNER POST.
STEP 38: 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 39: TIRE SWING 1: PLACE THE 4 X 4 X 72" TIRE SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 40: TIRE SWING 1: LINE UP THE HOLES OF THE TIRE SWIVEL WITH THE HOLES IN THE TIRE SWING BEAM. 2: FASTEN THE TIRE SWIVEL TO THE TIRE SWING BEAM USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
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STEP 42: TIRE SWING IMPORTANT: NOTE THE TIRE SWING LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE. (ALSO SEE STEP 44) AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT.
STEP 43: TIRE SWING IN THIS STEP YOU WILL BE MOUNTING THE TIRE SWING BEAM TO THE FORT. AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: INSTALL T-NUTS IN THE PREVIOUSLY DRILLED HOLES AS SHOWN BELOW. 2: LINE UP THE PILOT HOLES AT THE END OF THE TIRE SWING BEAM WITH THE PREVIOUSLY DRILLED HOLES IN THE CORNER POST. 3: FASTEN THE TIRE SWING BEAM TO THE CORNER POST USING 5/16 X 7" HEX BOLTS WITH 5/16" AND 1/2" WASHERS THROUGH THE TIRE SWING BEAM AND CORNER POST, INTO THE T-NUTS.
STEP 44: LEVEL TIRE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE TIRE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE TIRE SWING BEAM LEVEL. IMPORTANT: NOTE THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A)DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
STEP 45: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 47-1/2" TIRE SWING LEG CROSS-MEMBER AGAINST THE SWING LEGS. 2: LEVEL THE TIRE SWING CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSSMEMBER HOLES ONTO THE SWING LEGS. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE TIRE SWING CROSS-MEMBER TO THE SWING BEAM LEGS.
STEP 46: HANGING THE TIRE SWING 1: START BY ATTACHING THREE SPRING CLIPS TO THE TIRE SWIVEL ON THE SWING BEAM. 2: ATTACH ONE CHAIN AT A TIME TO ONE SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED.
STEP 47: 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 48: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS TO THE TOP OF THE CENTER POST ON THE FRONT OF THE PLAY SET . 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE.
STEP 49: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 50: INSTALLING CLIMBING ROPES 1: DRILL A 7/8" HOLE THROUGH THE ROPE LADDER SUPPORT (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE ROPE LADDER SUPPORT. 3: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
STEP 51: FLAG KIT 1: PLACE A FLAGON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED.
STEP 52: SANDBOX SEATS AND NAMEPLATE 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET. ATTACH THE NAME PLATE TO THE FRONT OF THE SWING BEAM WITH #8 X 1" WOOD SCREWS. ATTACH NAME PLATE HERE WITH TWO #8 X 1" WOOD SCREWS.
STEP 53: PLASTIC SUNBURST 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 SUBTEPS 2 AND 3 ON THE OTHER SIDE OF THE PLAY SET.
STEP 54: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE AGAINST THE SWING LEG. FINALLY INSTALL THE SCREW AND WASHER.
STEP 55: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK. 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2" LAG SCREW AND WASHER TO FASTEN THE STEERING WHEEL TO THE REAR CENTER POST. DO NOT OVER-TIGHTEN THE LAG SCREW OR THE STEERING WHEEL WILL NOT TURN. 5: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL AND SNAP IT INTO THE STEERING WHEEL INSERT.
PART 2 CLATTER BRIDGE ASSEMBLY 107
STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE TOWER OF THE CLATTER BRIDGE.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: LAY THE 2 X 4 X 36-3/4" TOP PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS.
STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: LAY THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS.
STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 36-3/4" DECK SUPPORTS TO THE HOLES AT 54-1/2" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST. D C LEFT SIDE FRAME RIGHT SIDE FRAME B A 2 X 4 X 36-3/4" DECK SUPPORT (WITH HOLES) 2 X 4 X 36-3/4" DECK SUPPORT 5/16" WASHER 5/16 X 4-1/2" HEX BOLT 2 X 6 BOTTOM PANEL BOARD NOT SHOWN FOR CLARITY.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 4 X 36-3/4" TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 4 X 36-3/4" TOP PANEL BOARD ON THE REAR OF THE CORNER POSTS.
STEP 7: LAG SCREWS 1: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. TO SQUARE AND LEVEL THE DECK OF THE TOWER TO THE DECK OF THE FORT PLACE A DECK BOARD ACROSS THE 2 X 4'S. THEN PLACE A 2 X 4 X 66" BRIDGE RAIL ON TOP OF THE DECK BOARD AND ON TOP OF THE FORT DECK. PLACE A LEVEL ON TOP OF THE 66" BRIDGE RAIL, THEN MAKE THE DECKS LEVEL TO ONE ANOTHER.
STEP 8: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: IF YOUR DECK SPACERS AND DECKBOARDS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THEM TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 1 1 48" 48" 3 3 4" 4" 1" 3" 3 14" 3 14" 2X 1 8" 4X 5/4 X 4 X 29-3/8" DECK SPACER 1 8" 5/4 X 4 X 36-11/16" DECK BOARD 2: PLACE THE 5/4 X 4 X 29-3/8" DECK SPACERS BETWEEN THE CORNER POSTS.
STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-1/2" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS. THE TOP OF THE BOTTOM PANEL BOARD SHOULD FLUSH TO THE TOP OF THE DECK. 3: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. LEAVE THE LAG SCREWS LOOSE UNTIL THE NEXT STEP.
STEP 10: REAR BOTTOM PANEL BOARD 1: LOOSEN UP THE FASTENERS IN THE 2 X 6 ON THE LEFT SIDE OF THE TOWER. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH HOLES) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 3: FASTEN THE BOTTOM PANEL BOARD (WITH HOLES) TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. LEAVE THE LAG SCREWS LOOSE. 4: TIGHTEN THE FASTENERS IN THE 2 X 6 AT THE FRONT OF THE TOWER AND IN THE BOTTOM PANEL BOARD (WITH HOLES).
STEP 11: DECK 1: INSTALL THE 5/4 X 6 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 2" WOOD SCREWS.
STEP 12: PANEL SLATS 1: FIND FOUR 5/4 X 3 X 28-1/2" PANEL SLATS. 2: IF THE SLATS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: ON THE LEFT SIDE OF THE TOWER INSTALL TWO PANEL SLATS 1-3/4" AWAY FROM EACH CORNER POST. THEN INSTALL THE REMAINING TWO PANEL SLATS AS SHOWN IN THE PICTURE AT THE BOTTOM LEFT BELOW. ATTACH THE PANEL SLATS WITH 2" WOOD SCREWS.
STEP 13: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 3: LOCATE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS. EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIE TAC TOE MOUNT. GREEN BRACKET 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT TIC TAC TOE AFTER ASSEMBLING.
STEP 14: TIC-TAC-TOE PANEL 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE TOWER ON THE INSIDE. THE TIC TAC TOE SHOULD BE APPROXIMATELY 3" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS.
STEP 15: BRIDGE RAILS 1: PLACE THE TOP SURFACE OF THE UPPER TWO 2 X 4 X 66" BRIDGE RAILS 5-1/2" BENEATH THE TOP SURFACE OF THE TOP PANEL BOARD. THE COUNTERSUNK HOLE IN THE END OF THE BRIDGE RAIL SHOULD FACE THE INSIDE. FASTEN THE BRIDGE RAIL TO THE CORNER POST WITH 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2: MEASURE 16" FROM THE TOP OF EACH BRIDGE RAIL AND MAKE A PENCIL MARK ON THE INSIDE OF THE CORNER POSTS. 3: PLACE THE BOTTOM OF EACH LOWER 2 X 4 X 66" BRIDGE RAIL ON THE MARK ON THE CORNER POST.
STEP 16: MOUNTING BRIDGE RAILS TO FORT 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 3: ATTACH EACH LOWER BRIDGE RAIL TO THE CORNER POSTS USING THE 16" DIMENSION AT THE FORT AS SHOWN ON STEP 15 AND BELOW. ATTACH EACH LOWER BRIDGE RAIL WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 17: BRIDGE RAIL SLATS 1. IF THE BRIDGE RAIL SLATS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THEM ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2. PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS. 3. ATTACH THE REMAINING SLATS TO THE UNIT WITH 3" SPACING BETWEEN THE SLATS.
STEP 18: BRIDGE DECK AND CHAIN ASSEMBLY 1: FIND FIFTEEN 2 X 4 X 29" BRIDGE DECK BOARDS AND INSERT T-NUTS INTO THE PRE-DRILLED HOLES. USE A HAMMER TO SEAT THE T-NUTS INTO THE BOARDS. T-NUT 2 X 4 X 29" BRIDGE DECK BOARD T-NUT FLANGE 2: FLIP ALL 15 BRIDGE DECK BOARDS OVER SO THAT THE FLANGE OF THE T-NUT IS FACING DOWN. LAY THE BRIDGE DECK BOARDS OUT ON A FLAT SURFACE AS SHOWN BELOW.
STEP 19: BRIDGE DECK AND CHAIN ASSEMBLY 1: LOCATE TWO 96" CHAIN SECTIONS THAT SHIPPED WITH THE CLATTER BRIDGE. 2: PLACE THE CHAINS OVER THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW. 3: LINE UP THE 18TH LINK IN THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES.
STEP 20: BRIDGE DECK AND CHAIN ASSEMBLY 1: PLACE A 5/16" WASHER BETWEEN THE 18TH CHAIN LINK AND THE BRIDGE DECK BOARD. 2: PLACE A 5/16" X 1-3/4" HEX BOLT WITH 5/16" WASHER THROUGH THE 18TH CHAIN LINK, THEN THROUGH THE 5/16" WASHER, THEN THROUGH THE HOLE IN THE BRIDGE DECK BOARD AND SCREW IT INTO THE T-NUT. TIGHTEN THE BOLT BUT NOT SO TIGHT THAT YOU CRACK THE WOOD. 3: COUNT OVER 4 CHAIN LINKS FROM THE LAST HEX BOLT. AT THIS CHAIN LINK PLACE A 5/16" WASHER BETWEEN THE CHAIN LINK AND THE BRIDGE DECK BOARD.
STEP 21: BRIDGE DECK/CHAIN INSTALLATION 1: LAY THE BRIDGE DECK/CHAINS ASSEMBLY BETWEEN THE PLAY SET AND THE TOWER WITH THE CHAINS FACING THE GROUND. THREAD THE CHAIN ENDS IN THE BRIDGE DECK ASSEMBLY THROUGH THE HOLES IN THE BOTTOM PANEL BOARD AND DECK SUPPORT BOARD ON THE TOWER. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE BOTTOM PANEL BOARD ON THE TOWER. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP.
STEP 22: 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 DOWN. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.
STEP 23: 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.
STEP 24: 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 OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TOTHE 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 25: 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 SIDE VIEW OVERHANG ROOF SUPPORT BEFORE INSTALLING THE ROOF STARTERS MAKE SURE DIMENSIONS A AND B MATCH.
STEP 26: 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 27: 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 28: 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 29: MOUNTING THE LADDER 1: PLACE THE TOP OF THE BRACKETS 1-1/2" DOWN FROM THE TOP OF THE 2 X 6. 2: CENTER THE LADDER SIDE TO SIDE. 3: MARK THROUGH EACH BRACKET ONTO THE 2 X 6. 4: DRILL 3/8" HOLES AT EACH MARK THROUGH THE 2 X 6. 5: INSTALL T-NUTS INTO THE BACK SIDE OF THE 2 X 6. 6: FASTEN THE BRACKETS TO THE 2 X 6 WITH 5/16" X 1-1/2" HEX BOLTS AND 5/16" WASHERS. A DETAIL A SCALE 1 : 8 MARK THROUGH HOLE ONTO 2 X 6. DRILL 3/8" HOLE THROUGH 2 X 6.
STEP 30: SAFETY HANDLES 1: PLACE A PLASTIC SAFETY HANDLE ON EACH CORNER POST ABOVE THE LADDER. 2: ADJUST THE SAFETY HANDLE UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: FASTEN EACH SAFETY HANDLE WITH THE 1/4" FLAT WASHERS AND #14 X 1-1/4" PAN HEAD SCREWS PROVIDED WITH THE SAFETY HANDLES.
STEP 31: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT RIGHT OF THE CLATTER BRIDGE. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK SPACER. 2: PREDRILL 1/8" HOLES INTO THE DECK SPACER AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK SPACER WITH 1-1/4" PAN HEAD SCREWS.
STEP 32: PANEL SLAT 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLAT FLUSH TO THE SIDE OF THE BRIDGE RAILS AS SHOWN BELOW. 2: ATTACH THE PANEL SLAT TO THE ROPE LADDER SUPPORT AND FRONT FACE BOARD ON THE INSIDE WITH #8 X 2" WOOD SCREWS. ATTACH PANEL SLAT FLUSH TO SIDE OF BRIDGE RAILS.
STEP 33: PLASTIC PLUGS 1: LOCATE FOUR PLASTIC PLUGS. 2: APPLY A DAB OF CLEAR SILICONE ONTO EACH PLUG AND TAP THEM INTO THE FRONT AND BACK SIDE OF THE HOLES SHOWN BELOW. PLASTIC PLUG (4) APPLY CLEAR SILICONE ONTO PLUGS AND TAP THEM INTO EACH END OF THESE HOLES.
Leftover Parts List 1500DW/DWR/DT Play Sets 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. 7 pieces 125-3-2850-PS Panel Slats (We include these parts for various ways of building the clatter bridge tower.
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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.
