™ playsets Ovation Model: 1702 (BOXES: 1700-1, 1700-2, 1702 & SLIDE BOX) Copyright © 2013 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.
Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our “Quick Response Center” located at: www.gorillaplaysets.com/support DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECTLY. THE RETAILER DOES NOT STOCK COMPONENTS. PLEASE RETAIN ALL INSTRUCTIONS FOR FUTURE REFERENCE.
GORILLA PLAYSETS WARRANTY - 2013 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set. As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury.
WARRANTY REGISTRATION - OVATION Gorilla Playsets manufactures ƚŚĞ ĮŶĞƐƚ ƋƵĂůŝƚLJ ƉƌŽĚƵĐƚƐ ƚŚĂƚ ĂƌĞ ĚĞƐŝŐŶĞĚ ĨŽƌ ŽƵƚƐƚĂŶĚŝŶŐ ƐƚƌĞŶŐƚŚ ĂŶĚ ĚƵƌĂďŝůŝƚLJ͘ tĞ ďĂĐŬ ŽƵƌ ƉƌŽĚƵĐƚƐ ǁŝƚŚ ĂŶ ƵŶƉĂƌĂůůĞůĞĚ ǁĂƌƌĂŶƚLJ͘ /Ŷ ƚŚĞ ƵŶůŝŬĞůLJ ĞǀĞŶƚ ƚŚĂƚ LJŽƵ ǁŝůů ŶĞĞĚ ƚŽ ĐŽŶƚĂĐƚ ƵƐ ĂďŽƵƚ ĐŽǀĞƌĞĚ ƌĞƉĂŝƌƐ͕ ǁĞ ŵƵƐƚ ŚĂǀĞ Ă ǀĂůŝĚ tĂƌƌĂŶƚLJ ZĞŐŝƐƚƌĂƟŽŶ ŽŶ ĮůĞ͘ 3 EASY WAYS TO REGISTER KWd/KE ϭ &Ădž ƚŚŝƐ ĐŽŵƉůĞƚĞĚ ĨŽƌŵ ƚŽ͗ (678) 880-3329 OR DĂŝů ƚŚŝƐ ĐŽŵƉůĞƚĞĚ ĨŽƌŵ ƚŽ͗ Gorilla Playsets ϭϵϬ ƚŽǁĂŚ /ŶĚƵƐƚƌŝ
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: 1702 (BOXES: 1700-1, 1700-2, 1702 & SLIDE BOX) REV: 3.8.
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.
1700 SERIES - WOOD ROOF Ovation/Passage Elite? Please familiarize yourself with the manual, parts/components and general 1 construction process Height -10' - 7- " of your new playset before getting started.
REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” and a 7/8” Paddle style bit.
1700/1701 HARDWARE #8 X 1-1/4" WOOD SCREW QTY: 6 PAGE: 1 OF 2 REV A: 10/29/2012 JH #8 X 1-1/2" WOOD SCREW QTY: 8 #14 X 1-1/4" PAN HEAD SCREW QTY: 8 #8 X 1-3/4" WOOD SCREW QTY: 20 9 8 #8 X 2" WOOD SCREW QTY: 161 7 #8 X 2-1/2" WOOD SCREW QTY: 28 #8 X 3" WOOD SCREW QTY: 14 6 5/16" TEE NUT QTY: 44 3/8" LOCK NUT QTY: 21 5 4 3/8" WASHER QTY: 33 TORQUE WASHER QTY: 19 3 2 5/16" WASHER QTY: 48 1 5/16 X 4-1/2" HEX BOLT QTY: 34 5/16 X 2-1/2" HEX BOLT QTY: 6 5/16 X 1-1/2" HEX BOLT QTY: 4 1/4" WASHE
1700/1701 HARDWARE PAGE: 2 OF 2 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 4 9 REV A: 10/29/2012 JH 8 7 6 5 4 3 #2 SQUARE DRIVE TIP QTY: 1 2 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8" x 7" CARRIAGE BOLT QTY: 8 3/8 x 6-1/2" CARRIAGE BOLT QTY: 6 3/8 x 5" CARRIAGE BOLT QTY: 4 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.
1702 HARDWARE PAGE: 1 OF 1 #8 X 1-1/4" WOOD SCREW QTY: 4 #14 X 1-1/4" PAN HEAD SCREW QTY: 16 REV A: 10/30/2012 JH #8 X 1-1/2" WOOD SCREW QTY: 2 9 8 #8 X 1-3/4" WOOD SCREW QTY: 7 7 #8 X 2" WOOD SCREW QTY: 86 #8 X 2-1/2" WOOD SCREW QTY: 2 6 #8 X 3" WOOD SCREW QTY: 2 5 4 #2 SQUARE DRIVE TIP QTY: 1 3 2 1/4" WASHER QTY: 16 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 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 29" REAR CENTER POST 2-4-2900-RCP 2 X 4 X 47" STRINGER 2-4-4700-S 2 X 4 X 47-1/2" FRONT FACE BOARD 2-4-4750-FFB QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION 5/4 X 6 X 13-5/8" OUTING SUN 125-6-1363-OS QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION 8' WAVE SLIDE 03-0010 SWINGS W/CHAINS 04-0002 TRAPEZE BAR W/CHAINS 04-0005 QTY.
PICTURE DESCRIPTION QTY. SWING PLATE 1 11-5002 CLIMBING ROCKS 07-0008 A-FRAME SWING LEG BRACKET 11-5010 1700-1701,1702 10 1 1 INSTRUCTIONS EA.
PICTURE DESCRIPTION IRON DUCTILE SWING HANGERS QTY.
PICTURE DESCRIPTION 10' ROPE SCREEN FLAG KIT 09-1014 GROUND STAKE 07-0016 QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION TIC TAC TOE (UNASSEMBLED) QTY.
STEP 1: CORNER POST LAYOUT 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THE RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: LAY OUT EACH OF THE 4 X 4 X 96" CORNER POST IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POST SHOULD FACE.
STEP 2: INSERTING T-NUTS INTO CORNER POSTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
STEP 3: ATTACHING SANDBOX AND ROPE SUPPORT 1: THE 2 X 6 X 47-1/2" SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHT SIDE CORNER POSTS WITH 4-1/2" HEX BOLTS AND 5/16" WASHERS. 2: THE 2 X 4 X 47-1/2" ROPE SUPPORT (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE TOP SET OF HOLES ON THE RIGHT SIDE OF THE CORNER POSTS, OFFSET HOLES UP, WITH 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 4: ATTACHING END SANDBOX BOARD 1 1: THE 2 X 6 X 95 " END SANDBOX BOARD (WITH SIX PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE 2 1 5 LEFT SIDE CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS.
STEP 5: ATTACHING THE SIDE SANDBOX BOARDS 1: THE 2 X 6 X 75" SIDE SANDBOX BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE 1 5 FRONT AND REAR CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. 2 16 2: THE STRUCTURE SHOULD BE ABLE TO STAND ON ITS OWN, WITHOUT ANY SUPPORT, AT THIS STAGE.
STEP 6: ATTACHING TARP SUPPORT BOARDS 1: THE 2 X 4 X 83" TARP SUPPORT BOARDS (WITH THE PRE-DRILLED HOLES) ATTACH TO THE TOP OF THE FRONT 5 1 AND REAR CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. 2 16 2: OFFSET HOLES SHOULD BE POINTED DOWN ON BOTH BOARDS. 3: THE SHORTEST END FROM THE COUNTER-SUNK HOLES WILL POINT TOWARD THE SWING BEAM SIDE OF THE FORT.
STEP 7: ATTACHING ARCH FACE BOARD AND DECK SUPPORT 1: THE 2 X 6 X 4712" ARCH FACE BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE SET OF HOLES BELOW THE TARP SUPPORT BOARD. ATTACH THE TOP ARCH FACE BOARD HOLES USING 4 12" HEX BOLTS AND 516" WASHERS AND 3 12" LAG SCREWS AND 516" WASHERS THROUGH THE BOTTOM HOLES.
STEP 8: ATTACHING REAR PANEL SUPPORT BOARDS 1: THE 2 X 4 X 47 12" PANEL SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES BELOW THE TARP SUPPORT BOARD ON THE REAR OF THE FORT WITH 516" X 4 12" HEX BOLTS AND 516" WASHERS. 2: HOLES SHOULD BE OFFSET DOWN.
STEP 9: ATTACHING PANEL SUPPORTS AND SAFETY BOARD 1: THE 2 X 4 X 47-1/2" PANEL SUPPORT BOARDS SHOULD HAVE THE HOLES OFFSET UPWARDS. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO SECURE THE BOARDS TO THE CORNER POSTS. 2: PLACE THE TOP OF THE PANEL SUPPORT (USED AS SAFETY BOARD) 24" FROM THE BOTTOM OF THE 2 X 6 BOARD. 3: FASTEN THE SAFETY BOARD TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 10: ATTACHING FORT SIDE SUPPORTS 1: LAY THE 2 X 4 X 47-1/2" FORT SIDE SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PLACE A T-NUT IN THE PRE-DRILLED HOLE ON EACH END AND SECURE WITH HAMMER. 2: THE 2 X 4 X 47-1/2" FORT SIDE SUPPORT (WITH ANGLED ENDS) ATTACHES TO THE HOLES ON THE END OF THE END SANDBOX BOARD ON THE INSIDE WITH 2-1/2" HEX BOLTS AND 5/16" WASHERS. THE ANGLED END SHOULD REST FLUSH AGAINST THE CORNER POSTS. SEE DETAIL A AND B.
STEP 11: ATTACHING THE ROCK WALL SUPPORTS 1: LAY THE 2 X 6 X 53-1/2" ROCK WALL SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE PLAY SET. PLACE A T-NUT INTO THE PRE-DRILLED HOLE ON THE END AND SECURE WITH A HAMMER. 2: LINE UP THE HOLE IN THE BOTTOM OF EACH 2 X 6 X 53-1/2" ROCK WALL SUPPORT TO THE HOLE ON THE END OF EACH EXTENDED SANDBOX BOARD. ATTACH EACH ROCK WALL SUPPORT TO THE EXTENDED SANDBOX BOARD WITH 2-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 12: ATTACHING THE ARCH ROCK WALL SIDE SUPPORTS 1: MOUNT THE ARCH ROCK WALL SIDE SUPPORT ON TOP OF THE ROCK WALL SUPPORT, MAKE SURE THAT THE TOP END OF THE ARCH ROCK WALL SIDE SUPPORT IS FLUSH WITH THE CORNER POST. 2: FIRST FASTEN THE 3" WOOD SCREW INTO THE ARCH ROCK WALL SIDE SUPPORT TOP HOLE INTO THE ROCK WALL SUPPORT, MAKE SURE THAT THIS BOARD IS ALIGNED WITH THE ROCK WALL SUPPORT. SECOND FASTEN THE 3" WOOD SCREW INTO THE ARCH ROCK WALL SIDE SUPPORT BOTTOM HOLE TO THE ROCK WALL SUPPORT.
STEP 13: ATTACHING THE ROCK WALL CENTER SUPPORT 1: BEGIN WITH THE 5/4 X 6 X 47-1/2" ROCK WALL BOARD AND SECURE IT TO THE ARCH ROCK WALL SIDE SUPPORT WITH TWO #8 X 2" WOOD SCREWS PER SIDE. THE ROUNDED EDGE OF THE ROCK WALL BOARD SHOULD BE AGAINST THE CORNER POSTS BEFORE ATTACHING. 2: NEXT THE 5/4 X 6 X 47-1/2" BOTTOM ROCK WALL BOARD WITH ONE HOLE WILL MOUNT AT THE BOTTOM WITH THE 7/8" HOLE TOWARDS THE BOTTOM. THIS BOARD WILL BE AT 44" FROM THE TOP ROCK WALL BOARD AND FLUSH TO THE ROCK WALL SIDE SUPPORTS.
STEP 14: ATTACHING THE ROCK WALL BOARDS 1: MOUNT THE REMAINING ROCK WALL BOARDS TO THE ROCK WALL SUPPORTS FROM TOP TO BOTTOM WITH #8 X 2" WOOD SCREWS. 2: WHEN YOU GET TO THE LAST ROCK WALL BOARD MAKE SURE THE GAP BETWEEN THIS BOARD AND THE BOTTOM ROCK WALL BOARD IS NO BIGGER THAN 1/4". IF NECESSARY UNSCREW THE BOTTOM ROCK WALL BOARD AND SHIFT THE TOP FLUSH TO THE LAST ROCK WALL BOARD.
STEP 15: ATTACHING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. 2: THE ROCKS INCLUDED WITH YOUR PLAYSET MAY VARY, IN ANY CASE, THE 1-1/4" PANHEAD SCREWS AND WASHERS INCLUDED WITH THE ROCKS WILL BE USED TO ATTACH THE ROCKS.
STEP 16: ATTACHING THE DECK BOARDS AND DECK SPACERS 1: THE 5/4 X 4 X 40-3/8" DECK SPACER MOUNTS BETWEN THE REAR CORNER POSTS AND BETWEEN THE FRONT CORNER POSTS FLUSH TO THE EDGES. DRIVE THE 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS. 2: SEVEN 5/4 X 6 X 47-1/2" DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS, FLUSH TO THE TOP ROCK WALL BOARD. 3: SPACE DECK BOARDS EVENLY ACROSS THE DECK SUPPORTS BETWEEN THE DECK SPACERS.
STEP 17: ATTACHING THE DECK STRINGER 1: FIND THE 2 X 4 X 47-1/2" STRINGER WITHOUT HOLES. 2: PLACE THE STRINGER UNDEREATH THE CENTER OF THE DECK BOARDS (USE THE HOLE AT THE CENTER AS A GUIDE) MAKE SURE THE END OF THE STRINGER IS FLUSH WITH THE DECK SPACER ROUND EDGE. 3: ATTACH IT WITH 2" WOOD SCREWS TROUGH THE DECK BOARDS PREDRILLED HOLES AND IN TO THE STRINGER BELOW.
STEP 18: ATTACHING THE FRONT FACE BOARD 1: THE EDGE OF THE 2 X 4 X 47-1/2" FACE BOARD WILL BE FLUSH TO THE TOP OF THE DECK SPACER. SECURE THE FACE BOARD TO THE CORNER POSTS WITH THREE 2-1/2" WOOD SCREWS PER SIDE. 2: INSTALL TWO 2-1/2" WOOD SCREWS THROUGH THE CENTER OF THE FACE BOARD INTO THE CENTER DECK STRINGER AS SHOWN BELOW.
STEP 19: SWING BEAM PLATE 1: LAY THE SWING BEAM SUPPORT ON A FLAT SURFACE WITH THE THREE COUNTER SUNK CENTER HOLES FACING THE GROUND, THE COUNTER SUNK HOLES ON THE ENDS MUST BE FACING TOWARDS YOU. 2: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT ON THE OUTSIDE HOLES USING 3/8" X 3-1/2" CARRIAGE BOLTS, AND 3/8" WASHERS AND LOCK NUTS ON THE BOTTOM. PLACE GREEN BOLT COVERS OVER EXPOSED THREADS AFTER SECURING.
STEP 20: 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 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" WASHERS AND LOCK NUTS ON THE BOTTOM. PLACE BOLT COVERS OVER EXPOSED THREADS OFTER SECURING.
STEP 21: ATTACHING THE SWING BEAM SUPPORT AND TRAP ARM 1: THE 4 X 4 X 47-1/2" SWING BEAM SUPPORT HAS COUNTER-SUNK HOLES IN THE CENTER AND ON THE ENDS. INSTALL THE SWING BEAM SUPPORT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES AT THE CENTER FACE DOWN. 2: FASTEN THE SWING BEAM SUPPORT TO THE CORNER POSTS USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS.
STEP 22: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57" LADDER SIDE ON A FLAT SURFACE WITH THE CHANNELS FACING DOWN. PLACE THE BARREL OF A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE AND SECURE WITH A HAMMER. REPEAT THIS STEP FOR THE OTHER LADDER SIDE. 2: FLIP THE LADDER SIDE OVER SO THAT THE CHANNELS ARE FACING UP. 3: PLACE THE LADDER STEP INTO THE CHANNELS, AND THEN PLACE THE SECOND LADDER SIDE ON TOP, WITH THE CHANNELS FACING DOWN. 4: NOW PLACE TWO 2" WOOD SCREWS IN EACH STEP.
STEP 23: LADDER TO FORT 1: THE LADDER ATTACHES TO THE FRONT SIDE AT THE RIGHT, FLUSH TO THE INSIDE EDGE OF THE CORNER POST. 2: THE BOTTOM EDGE OF EACH 90 GREEN BRACKET SHOULD BE 3/4" FROM THE BOTTOM OF THE 2 X 4. 3: MAKE SURE THE LADDER IS LEVEL, USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8" HOLE THROUGH THE 2 X 4. 4: INSERT T-NUTS IN THE BACK OF THE HOLES. 5: ATTACH THE BRACKET TO THE 2 X 4 WITH 1-1/2" HEX BOLTS WITH 5/16" WASHERS.
STEP 24: ATTACHING SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 96" SWING LEGS FLUSH TO THE TOP OF THE SWING BRACKET. 2: USING THE SWING LEG BRACKET AS A TEMPLATE, DRILL 3/16" PILOT HOLES THROUGH EACH SWING LEG BRACKET HOLE. 3: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8" X 3-1/2 LAG SCREWS AND 3/8" WASHERS.
STEP 25: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8: WASHERS 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 26: MOUNT SWING BEAM TO FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END ON THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES THE LEGS. 2: LINE UP THE PILOT HOLE ON 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 SWING BEAM SUPPORT USING A 3/8" X 9" CARRIAGE BOLT WITH TORQUE WASHER ON TOP AND A 3/8" LOCK NUT AND WASHER ON THE BOTTOM.
STEP 27: LEVEL SWING BEAM 1: PLACE THE LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
STEP 28: SWING LEG CROSS MEMBER 1: POSITION THE 2 X 4 X 58" CROSS MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS MEMBER, AND SECURE TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 29: ATTACHING CENTER POSTS 1: THE 2 X 4 X 73-3/4" AND 2 X 4 X 29" CENTER POSTS WILL ATTACH TO THE TARP SUPPORT BOARDS WITH 5/16" X 2-1/2" HEX BOLTS, 5/16" WASHERS, AND T-NUTS. 2: THE FRONT CENTER POST WILL SECURE AT THE BOTTOM TO THE DECK SPACER, FROM UNDERNEATH, WITH TWO 2-1/2" WOOD SCREWS, THEN TO THE FRONT TARP SUPPORT WITH 5/16" X 2-1/2" HEX BOLT, 5/16" WASHER AND T-NUT. 3: THE REAR CENTER POST WILL SECURE TO THE REAR TARP SUPPORT WITH A 5/16" X 2-1/2" HEX BOLT, 5/16" WASHER AND A T-NUT.
STEP 30: INSTALLING WINDOW SUPPORTS / WINDOWS IN THIS STEP THE WOOD COMPONENTS TO ATTACH THE WINDOWS WILL BE INSTALLED ON THE INSIDE OF THE FRONT OF THE PLAYSET. GO UP ON TOP OF THE FORT AND LOOK FOR THE FRONT OF THE PLAY SET. 1: ATTACH THE 5/4 X 4 X 20" VERTICAL WINDOW SUPPORTS NEXT TO THE FRONT CENTER POST IN BOTH SIDES WITH 2" WOOD SCREWS. 2: ATTACH THE 5/4 X 4 X 20" VERTICAL WINDOW SUPPORTS NEXT TO THE CORNER POSTS IN BOTH SIDES WITH 2" WOOD SCREWS.
STEP 31: TARP BOARDS 1: THE TWO 2 X 4 X 50" TARP BOARDS WILL SECURE ON THE ENDS OF THE TARP SUPPORTS WITH TWO 2-1/2" WOOD SCREWS PER SIDE 2 X 4 X 50" TARP BOARD TARP SUPPORTS 62
STEP 32: PANEL/WALL SLATS 1: BEGIN ON THE REAR SIDE OF THE FORT WITH THE TWO OUTER SLATS BOARDS. THEY ARE SPACED 3" FROM THE CORNER POSTS. THE CUTOUT MUST BE FACING THE OPPOSITE DIRECTION. 2: PLACE THE INNER SLAT FLUSH TO THE OUTER SLAT. THE INNER SLAT CUTOUT MUST BE FACING THE OUTER SLAT CUTOUT, CREATING A DIAMOND SHAPE OPENING IN BETWEEN. 3: ON THE SWING BEAM SIDE OF THE FORT START WITH THE TWO OUTER SLATS. THEY ARE SPACED 2-3/16" FROM THE CORNER POSTS, THE CUTOUT MUST BE FACING THE OPPOSITE DIRECTION.
STEP 33: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. ASSEMBLE THE TIC TAC TOE ACCORDING TO THE INSTRUCTIONS IN THE BOX. IGNORE STEPS 6 AND 7 IN THE INSTRUCTIONS. 2: LOCATE THE 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. DRILL A 1/8" HOLE IN EACH END OF THE MOUNT AS SHOWN BELOW. 3: FASTEN THE TIC TAC TOE MOUNTS TO THE GREEN TIC TAC TOE BRACKETS WITH THE SCREWS PROVIDED IN THE TIC TAC TOE BOX.
STEP 34: MOUNTING TIC TAC TOE PANEL 1: PLACE THE TIC TAC TOE PANEL ASSEMBLY FROM THE PREVIOUS STEP ONTO THE BACK WALL. THE LOWER TIC TAC TOE MOUNT BOARD SHOULD BE 4" ABOVE THE DECK. 2: ATTACH EACH TIC TAC TOE MOUNT TO THE PANEL SALTS WITH #8 X 1-3/4 WOOD SCREWS.
STEP 35: ROOF SUPPORTS 1: ON A FLAT SURFACE LAY THE LEFT ROOF SUPPORT WITH THE NOTCHED TIP END POINTING DOWN. 2: PLACE THE RIGHT ROOF SUPPORT NEXT TO THE LEFT ROOF SUPPORT WITH THE NOTCHED TIP FACING DOWN. MAKE SURE THE TOP ENDS ARE FLUSH TOGETHER. 3: PLACE THE ROOF PEAK SUPPORT ON TOP WHERE THE TWO ROOF SUPPORTS MEET TOGETHER, MAKE SURE THE ANGLED SURFACES ARE FLUSH TO THE TOP SURFACES OF THE ROOF SUPPORTS.
STEP 36: ROOF SUPPORTS TO FORT 1: GRAB THE FRONT SET OF ROOF SUPPORTS, AND PLACE THEM ON TOP OF THE TARP SUPPORT. THE LONG ROOF SUPPORT (RIGHT ROOF SUPPORT) MUST BE MOUNTED ON TOP OF THE LONG SIDE OF THE TARP SUPPORT. 2: MAKE SURE FRONT ASSEMBLY IS CENTERED ON TOP OF THE TARP SUPPORT AND LEANING AGAINST THE CENTER POST. 3: MOVE TO THE RIGHT SIDE (RIGHT ROOF SUPPORT).
STEP 37: SUN AND PLASTIC SUN 1: PLACE THE WOOD SUN ON TOP OF THE TARP SUPPORT, MAKE SURE IT IS LEANING AGAINST THE CENTER POST, CENTER IT WITH THE CENTER POST AND SECURE USING TWO #8 X 2" WOOD SCREWS. 2: REPEAT SUB-STEP 1 ON THE OPPOSITE SIDE. 3: PLACE THE PLASTIC SUN ON TOP OF THE WOOD SUN AND SECURE USING #8 X 1-1/4" WOOD SCREWS.
STEP 38: SUN RAYS 1: ALL THE SUN RAY PIECES GET INSTALLED TO THE INSIDE SURFACE OF THE ROOF SUPPORTS AND SUN PIECE AT THE FRONT ONLY. 2: START FROM THE LEFT SIDE OF THE FORT PLACING THE 15-1/2" SUN RAY AT AN APPROXIMATE 60 ANGLE FROM THE CENTER POST, SECURE WITH TWO #8 X 2" WOOD SCREWS . 3: PLACE THE SECOND 15-1/2" SUN RAY AT AN APPROXIMATE 35 ANGLE FROM THE CENTER POST, SECURE WITH TWO #8 X 2" WOOD SCREWS.
STEP 39: ROOF STARTER BOARDS 1: GRAB ONE 1 X 6 X 52" ROOF BOARD AND PLACE IT ON THE RIGHT SIDE OF THE ROOF (LONG SIDE). 2: PLACE THE TOP EDGE 56-1/4" AWAY FROM THE PEAK OF THE ROOF. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED ON THE ROOF SUPPORTS. THE ROOF BOARD SHOULD OVERLAP THE SIDES OF THE ROOF SUPPORTS EQUALLY. THE HOLES OF THE ROOF BOARD SHOULD BE OFFSET TO THE TOP POINTING TOWARDS THE PEAK OF THE ROOF. 3: FASTEN THE ROOF BOARD TO THE ROOF SUPPORTS WITH #8 X 2" WOOD SCREWS.
STEP 40: SPACER BLOCK AND ROOF ROARDS 1: LOCATE TWO SPACER BLOCKS AS SHOWN BELOW. VERIFY THAT THE SPACER BLOCKS HAVE THE CORRECT 4" DIMENSION SHOWN. 2: YOU WILL NEED SOME CLAMPS FOR THIS STEP. WE USE HAND OPERATED 2-1/2" SPRING CLAMPS. YOU CAN PURCHASE THIS TYPE OF CLAMP FROM YOUR LOCAL HOME CENTER. 3: PLACE A SPACER BLOCK ON TOP OF THE ROOF BOARD YOU INSTALLED IN STEP 39. YOU WILL NEED A SPACER BLOCK ON EACH END OF THE ROOF BOARD.
STEP 41: ROOF BOARDS 1: USING THE SAME SPACER BLOCK AND CLAMPS, REPEAT THE SAME PROCEDURE FROM STEP 40 FOR THE REMAINING ROOF BOARDS UNTIL YOU GET ALMOST TO THE PEAK. NOTE: IN THIS STEP, YOU WILL HAVE FOURTEEN ROOF BOARDS INSTALLED FOR THE RIGHT SIDE OF THE ROOF AND TEN ROOF BOARDS INSTALLED FOR THE LEFT SIDE OF THE ROOF.
STEP 42: ROOF FINISHER BOARDS NOTE: IN THIS STEP YOU WON'T NEED THE SPACER BLOCK OR CLAMP. 1: PLACE THE ROOF FINISHER BOARD ON TOP OF THE LAST ROOF BOARD FROM STEP 41, MAKE SURE THAT THE ROOF FINISHER BOARD TOP EDGE IS FLUSH WITH THE ROOF PEAK SUPPORT TOP EDGE AND FLUSH TO BOTH ENDS OF THE ROOF BOARD FROM THE PREVIOUS STEP. 2: FASTEN THE FINISHER BOARD TO THE ROOF SUPPORT WITH TWO #8 X 2" WOOD SCREWS.
STEP 43: ROOF PEAK 1: LOCATE THE 1 X 4 X 52" ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ON TOP OF THE LAST ROOF BOARDS. 3: USE A 1/8" DRILL BIT TO PREDRILL HOLES IN THE ROOF BOARDS USING THE ROOF PEAK HOLES AS A GUIDE. 4: ATTACH THE ROOF PEAK TO THE ROOF BOARDS WITH TWO #8 X 2" WOOD SCREWS PER SIDE.
STEP 44: SUNBURST MESH SCREEN 1: LOCATE THE SUNBURST MESH SCREEN. ATTACH THE MESH SCREEN BEHIND THE SUN RAYS WITH #14 X 1-1/4" PAN HEAD SCREWS WITH 1/4" WASHERS. 2: THE NOTCHES IN THE SUNBURST MESH SCREEN WILL FIT AROUND THE TOPS OF THE CORNER POSTS.
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 END OF THE SWING BEAM. 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: 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: ATTACH THE SLIDE TO THE DECK WITH 1-1/4" WOOD SCREWS.
STEP 47: CLIMBING ROPE 1: THREAD ONE END OF THE 10" ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE 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 : ATTEMPT TO WRAP THE ROPE AROUND YOUR HAND.
STEP 48: 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 49: NAME PLATE 1: ATTACH THE NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO 1-1/4" WOOD SCREWS. ATTACH NAME PLATE HERE WITH TWO 1-1/4" WOOD SCREWS.
STEP 50: HANGING SWINGS 1: LOCATE TWO SWING BELTS WITH CHAINS ATTACHED. 2: SNAP A SPRING CLIP THROUGH THE SWING HANGER LOOP ON THE SWING BEAM. 3: SNAP A CHAIN ONTO EACH SPRING CLIP. ADJUST EACH SWING UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS. 4: LOCATE ONE TRAPEZE BAR WITH CHAINS ATTACHED. 5: SNAP A SPRING CLIP THROUGH THE SWING HANGER LOOP ON THE TRAPEZE ARM. 6: SNAP A CHAIN ONTO EACH SPRING CLIP. ADJUST THE TRAPEZE BAR UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS.
STEP 51: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: HAMMER EACH GROUND STAKE IN AT AN ANGLE SIMILAR TO WHAT IS SHOWN. USE CAUTION WHEN HAMMERING SO THAT YOU DO NOT MAR THE WOOD. LEAVE THE TOP PORTION OF THE GROUND STAKE ABOVE THE GROUND FAR ENOUGH SO THAT YOU CAN STILL GET THE SCREW INTO THE HOLE AT THE TOP OF THE STAKE. 3: SECURE EACH STAKE TO THE SWING LEGS WITH THE SCREWS PROVIDED WITH THE STAKES.
STEP 52: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. PLACE A SAFETY HANDLE ON THE CORNER POST AND FRONT CENTER POST. ADJUST THE HEIGHT TO SUIT THE NEEDS OF YOUR CHILD. 2: USE THE HARDWARE INCLUDED WITH THE SAFETY HANDLES TO ATTACH EACH HANDLE TO THE CORNER POST OR FRONT CENTER POST. #14 X 1-1/4" PAN HEAD SCREW AND 1/4" FLAT WASHER INCLUDED WITH SAFETY HANDLES.
