Caribou Model: 1200 (BOXES: 1200-1, 1200-2 & SLIDE BOX) Copyright © 2013 PlayNation Play Systems, Inc. All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.playnation.
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 use our “Quick Response Center” located at: www.playnation.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.
PLAYNATION WARRANTY - 2013 PlayNation Play Systems, Inc. warrants its Enchanted™, Dreamer™ and Majestic™ series of swing sets to be free from defects in workmanship and materials, under normal use and conditions, for the lifetime of the product for above ground structural wood components and for two years for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.) except PlayNation’s Super Scoop Slides™ and Super Tube Spiral Slides™.
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.
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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: 1200 (BOXES: 1200-1, 1200-2 & SLIDE BOX) REV: 4.15.
TABLE OF CONTENTS Safety Guidelines……………………………………….......……...........................Pages 3-6 Leveling fort, General Information, 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.
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”, 3/16”, 3/8”, 9/64”, 11/64”.
11-0029 1200 HARDWARE 12/4/2012 REV B. J.H. PAGE 1 OF 2 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 30 9 8 7 6 5 4 3 #2 SQUARE DRIVE BIT QTY: 1 2 1 3/8 x 9" 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" CARRIAGE BOLT CARRIAGE BOLT CARRIAGE BOLT CARRIAGE BOLT QTY: 1 QTY: 14 QTY: 2 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.
11-0029 1200 HARDWARE 12/4/2012 REV B. J.H. PAGE 2 OF 2 #8 X 1-1/2" WOOD SCREW QTY: 29 #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: 282 #8 X 2-1/2" WOOD SCREW QTY: 64 7 #8 X 3" WOOD SCREW QTY: 20 6 5 5/16" TEE NUT QTY: 38 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: 30 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 68 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
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PICTURE SEE STEP 14 IN MANUAL FOR MORE DETAILS ABOUT IDENTIFYING ROCK WALL BOARDS 1, 2 AND 3. 1 DESCRIPTION QTY.
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PICTURE NOT USED DESCRIPTION QTY.
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PICTURE DESCRIPTION 4 X 6 X 120" SWING BEAM QTY.
PICTURE DESCRIPTION QTY. TELESCOPE 1 07-0001 FLAG KIT (PAIR) 09-1014 SAFETY HANDLES PLASTIC (PAIR) 1 1 07-0005 SWING BEAM PLATE 11-5002 SWING LEG BRACKET 11-5010 ROCK WALL ROCKS (PACKAGE OF 5) 1 1 2 07-0008 NOTE: GROUND STAKES MAY BE PLASTIC OR WOOD AT OUR DISCRETION.
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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 SIDE OF THE PLAYSET. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. TOPMOST HOLES FACE FRONT TO BACK. T-NUTS FACE EACH OTHER BETWEEN POSTS. 2: LAY THE 2 X 6 X 80" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER ARE 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.
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" LEFT SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE LEFT SANDBOX BOARD ARE 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 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD ARE 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 DECK PANEL BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT DECK PANEL BOARD ARE OFFSET UP.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD ARE 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" REAR DECK PANEL BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE REAR DECK PANEL BOARD ARE OFFSET UP.
STEP 7: LAG SCREWS 1: AT THIS POINT THE FRAME IS UNSTABLE. YOU MUST HAVE AN ASSISTANT HELP YOU MOVE THE FRAME TO AVOID RACKING THE FRAME AND POTENTIALLY CRACKING BOARDS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. ONCE THE FRAME IS LEVEL, SQUARE, AND SET INTO POSITION; GO BACK AND INSERT THE 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS IN ALL OF THE REMAINING HOLES OF THE 2 X 6 PARTS.
STEP 8: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDERNEATH THE AREA WHERE THE DECK WILL BE LOCATED ON THE FRONT AND BACK OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE TOP OF THE ANGLE SUPPORT, AND ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POSTS. NOTE TOP OF ANGLE SUPPORT MUST NOT EXTEND PAST TOP OF DECK SUPPORT OR IT WILL INTERFERE WITH DECK BOARDS.
STEP 9: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS ON TOP OF THE ANGLE SUPPORT, AND ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POSTS. TOP OF ANGLE SUPPORT MUST NOT PROTRUDE ABOVE DECK SUPPORT OR IT WILL INTERFERE WITH DECK SPACERS.
STEP 10: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" BOTTOM 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. 5/16" WASHER 2 X 4 X 47-1/2" BOTTOM PANEL BOARD (OFFSET UP) 5/16 X 3-1/2" LAG SCREW 2: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 11: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-1/2" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/4" ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER.
STEP 12: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: PLACE THE CENTER DECK SUPPORT UNDERNEATH THE CENTER OF THE DECK SPACERS. (USE THE HOLE AT THE CENTER AS A GUIDE) 3: USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT. 4: USE THE HOLE AT THE CENTER OF THE DECK SUPPORT AS A GUIDE TO MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. MAKE SURE THE 2 X 4 X 70" CENTER DECK SUPPORT IS LINED UP ON THESE MARKS.
STEP 13: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 5/4 X 6 X 47-3/8" DECK BOARD 3 18" 1 8" 3 18" 3 24" 1 48" 1 48" 1 44" 1 44" 11 23 16 " 2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT.
STEP 14: ROCK WALL BOARD IDENTIFICATION 1: EVERY EFFORT HAS BEEN MADE TO PRE-LABEL YOUR ROCK WALL BOARDS PROPERLY. ROCK WALL BOARDS 1, 2 AND 3 SHOULD HAVE THE NUMBERS 1, 2 OR 3 PRINTED ON THE ENDS OF THE BOARDS. IN THE EVENT THAT A ROCK WALL BOARD DOES NOT HAVE ANY IDENTIFYING MARKS USE THIS CHART AS A GUIDE TO IDENTIFY THE BOARD.
STEP 15: ROCK WALL BOARD LAYOUT 1: LAY ALL THE ROCK WALL BOARDS OUT ON A FLAT SURFACE AS SHOWN BELOW. YOU ARE LOOKING AT THE BACK SIDE OF THE ROCK WALL. 2: PLACE THE 1 X 2 X 62-1/2" BATTEN ON THE BACK SIDE AS SHOWN. FASTEN THE BATTEN TO THE ROCK WALL BOARDS WITH #8 X 1-1/2" WOOD SCREWS.
STEP 16: ROCK WALL SIDES 1: LOCATE 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 17: ROCK WALL BOARDS 1: LAY OUT THE ROCK WALL SIDES ON THE FLAT SURFACE BESIDE THE ROCK WALL ASSEMBLY. THE OUTSIDE SURFACES OF THE ROCK WALL SIDES SHOULD BE 20 INCHES APART. T-NUTS SHOULD BE ON THE INSIDE OF THE ROCK WALL SIDES. 2: FLIP THE ROCK WALL ASSEMBLY OVER SO THAT THE BATTEN IS FACING THE GROUND. PLACE THE ROCK WALL ASSEMBLY ON TOP OF THE ROCK WALL BOARDS. 3: CENTER THE HOLES IN THE ROCK WALL BOARDS OVER THE CENTER OF THE ROCK WALL SIDES.
STEP 18: ROCK WALL BRACKETS 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 NUTS INTO THE T-NUTS AT THIS TIME.
STEP 19: ROCK WALL ROCKS 1: LOCATE TEN ROCK WALL ROCKS WITH HARDWARE INCLUDED. 2: MOUNT THE ROCKS IN A STAGGERED PATTERN ON THE ROCK WALL BOARDS. ATTACH EACH ROCK WALL ROCK TO THE ROCK WALL BOARDS WITH THE PAN HEAD SCREWS AND WASHERS PROVIDED WITH THE ROCKS. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL PATTERN MAY BE DIFFERENT FROM WHAT YOU SEE BELOW.
STEP 20: ROCK WALL TOP CAP 1: PLACE THE 5/4 X 3 X 21" ROCK WALL TOP CAP AT THE TOP OF THE ROCK WALL AS SHOWN. 2: ONE END OF THE ROCK WALL TOP CAP WILL EXTEND PAST THE ROCK WALL SIDE AS SHOWN BELOW. THE OUTSIDE FACE OF THE TOP ROCK WALL BOARD WILL BE FLUSH TO THE FRONT SURFACE OF THE ROCK WALL TOP CAP; SEE "FLUSH" BELOW. 3: FASTEN THE ROCK WALL TOP CAP TO THE TOP ROCK WALL BOARD AND THE ROCK WALL SIDES WITH #8 X 2" WOOD SCREWS. A THIS END EXTENDS PAST THE SIDE OF THE ROCK WALL SIDE.
STEP 21: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW; THE ROCK WALL SIDE IS 9-3/4" FROM THE END OF THE DECK PANEL BOARD. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE DECK PANEL BOARD. THE BOTTOM OF THE GREEN BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE DECK PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE DECK PANEL BOARD.
STEP 22: 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. 2 X 4 X 17" LADDER STEP 5: PLACE THE STEPS INTO THE SLOTS ON THE LADDER SIDES, AND FASTEN WITH 2" WOOD SCREWS. 6: CAREFULLY TURN THE LADDER OVER AND PUT THE SCREWS INTO THE OTHER SIDE.
STEP 23: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE REAR OF THE FORT AS SHOWN BELOW; THE SIDE OF THE LADDER SHOULD BE 10-1/2" FROM THE OUTSIDE OF THE CORNER POST. THE BOTTOM OF THE 90 DEGREE BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE REAR DECK PANEL BOARD. 2: USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8” HOLE THROUGH THE REAR DECK PANEL BOARD. 3: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE REAR DECK PANEL BOARD.
STEP 24: PANEL SLATS 1: FIND TWENTY-FOUR 5/4 X 2-5/8 X 28-1/2" 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. 1 SLAT HERE 6 SLATS THIS SIDE (RIGHT) 2" WOOD SCREW 7 SLATS THIS SIDE (REAR) 7 SLATS THIS SIDE (LEFT) 7 8 " GAP BOTH FRONT SIDES AND AT LEFT-REAR.
STEP 25: ROOF SUPPORTS 1: THE ROOF SUPPORTS (LEFT AND RIGHT) WILL BE ATTACHED ON THE OUTSIDE OF THE CORNER POSTS. 2: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 6 X 57-1/2" ROOF SUPPORTS TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A PEAK.
STEP 26: ROOF PEAK SUPPORTS 1: PLACE A 5/4 X 6 X 10-3/4" ROOF PEAK SUPPORT ON THE OUTSIDE OF THE ROOF SUPPORTS. 2: LEVEL THE ROOF PEAK SUPPORT. MAKE SURE THE ANGLED SURFACES ARE FLUSH OR SLIGHTLY BELOW THE TOP SURFACES OF THE ROOF SUPPORTS. 3: USE #8 X 2" WOOD SCREWS IN THE THE PREDRILLED HOLES TO ATTACH THE ROOF PEAK SUPPORTS TO THE ROOF SUPPORTS. 5/4 X 6 X 10-3/4" ROOF PEAK SUPPORT 5/4 X 6 X 10-3/4" ROOF PEAK SUPPORT A ANGLED SURFACE FLUSH OR SLIGHTLY BELOW TOP SURFACE OF ROOF SUPPORT ON BOTH SIDES.
STEP 27: 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 COUNTERBORED HOLES OF THE SWING BEAM SUPPORT. USE BOLT CAPS TO COVER ANY EXPOSED THREADS. 3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER.
STEP 28: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE 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 29: 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 30: REST SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT. 2: LINE UP THE PRE-DRILLED HOLES, AND REST THE SWING BEAM ON TOP OF THE FORT AND THE SWING BEAM LEGS. MAKE SURE THAT YOU HAVE THE BEAM FACING THE RIGHT WAY. LINE UP TWO HOLES IN THIS END WITH HOLES IN SWING LEG BRACKET.
STEP 31: 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 32: 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 HOLES AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLES ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT WITH A TORQUE WASHER ON TOP AND A 3/8" LOCK NUT AND WASHER ON THE BOTTOM.
STEP 33: 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). 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 34: 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 35: ROOF 1: PLACE THE TOP EDGE OF THE 1 X 5 X 53-1/2" ROOF STARTER BOARDS 54-1/2" AWAY FROM THE THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS. THE ROOF STARTER SHOULD OVERLAP THE SIDES OF THE ROOF SUPPORTS EQUALLY. THE BEVELED SIDE OF THE ROOF STARTER SHOULD LIE ON TOP OF THE ROOF SUPPORTS. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 36: ROOF 1: PLACE A 1 X 5 X 53-1/2" ROOF BOARD ON TOP OF THE ROOF STARTER. THE FRONT EDGE OF THE ROOF BOARD WILL BE 2-3/4" FROM THE FRONT EDGE OF THE ROOF STARTER. IT IS VERY IMPORTANT TO GET THIS BOARD POSITIONED EXACTLY SINCE IT WILL BEGIN THE ROOF PATTERN. 2: ATTACH THE ROOF BOARD TO THE ROOF SUPPORTS WITH TWO #8 X 2" WOOD SCREWS.
STEP 37: ROOF 1: LOCATE TWO SPACER BLOCKS AS SHOWN BELOW. VERIFY THAT THE SPACER BLOCKS HAVE THE CORRECT 3-3/4" 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 36. YOU WILL NEED A SPACER BLOCK ON EACH END OF THE ROOF BOARD.
STEP 38: ROOF PEAK 1: LOCATE THE 5 X 5 X 53-1/2" 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 #8 X 2-1/2" WOOD SCREWS.
STEP 39: SUNBURST 1: LOCATE ONE 5/4 X 3 X 17-1/2" LARGE RAY, TWO 5/4 X 3 X 11" SMALL RAYS AND ONE 5/4 X 4 X 42" RAY SUPPORT. 2: LAY ALL THE PARTS OUT ON A FLAT SURFACE AS SHOWN BELOW. 3: CENTER THE LARGE RAY WITH THE CENTER OF THE RAY SUPPORT. PAY ATTENTION TO THE HOLE LOCATIONS IN THIS PART SO YOU DO NOT PLACE IT UPSIDE DOWN. ATTACH THE LARGE RAY TO THE RAY SUPPORT WITH TWO #8 X 2-1/2" WOOD SCREWS. 4: PLACE A SMALL RAY ON EITHER SIDE OF THE LARGE RAY AS SHOWN.
STEP 40: SUNBURST INSTALLATION 1: EACH SUNBURST ASSEMBLY WILL BE LOCATED ON THE INSIDE OF THE ROOF SUPPORTS. 2: LEVEL THE SUNBURST SUPPORT. 3: FASTEN THE EACH SUNBURST ASSEMBLY TO THE ROOF SUPPORTS WITH #8 X 2" WOOD SCREWS.
STEP 41: 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 42: PICNIC TABLE 1: MEASURE UP 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 43: 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 44: 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 45: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT OF THE PLAY SET NEXT TO THE ROCK WALL. 2: THE FLARED END OF THE SLIDE WILL REST ON TOP OF THE BOTTOM PANEL BOARD. THE FLAT AREA OF THE SLIDE WITH THE FOUR INDENTATIONS WILL LIE ON TOP OF THE DECK BOARDS. 3: ALIGN THE HOLES IN THE SLIDE OVER THE DECK BOARDS AVOIDING GAPS. PREDRILL 1/8" PILOT HOLES THROUGH THE CENTER OF THE INDENTATIONS IN THE SLIDE INTO THE DECK BOARDS.
STEP 46: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS NEXT TO THE PANEL SLAT ON THE INSIDE OF THE FORT. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING SQUARE TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4" WOOD SCREWS.
STEP 47: INSTALLING ROCK WALL ROPE 1: TIE A KNOT IN ONE END OF THE 10 FOOT ROCK WALL ROPE. 2: THREAD THE ROPE THROUGH THE BACK SIDE OF THE FRONT TOP PANEL BOARD. 3: YOU MAY TIE UP TO TWO KNOTS TO AID YOUR CHILD WHEN CLIMBING. 4: THREAD THE LOWER END OF THE ROCK WALL ROPE THROUGH THE HOLE IN THE FRONT SIDE OF THE ROCK WALL. TIE A SECURE KNOT ON THE BACK SIDE OF THE ROCK WALL. TEST THE ROCK WALL ROPE BY ATTEMPTING TO WRAP IT AROUND YOUR HAND. IF THE ROPE WRAPS AROUND YOUR HAND IT IS TOO LOOSE.
STEP 48: 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 19" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS. EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIC TAC TOE MOUNT. GREEN BRACKET 5/4 X 3 X 19" TIC TAC TOE MOUNT TIC TAC TOE AFTER ASSEMBLING.
STEP 49: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAY SET ON THE INSIDE. THE LOWER TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS.
STEP 50: 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 51: FLAG KIT 1: PLACE THE PLASTIC BASE OF EACH FLAG ONTO THE FRONT CORNER POSTS AS SHOWN. 2: ATTACH THE PLASTIC BASE TO THE CORNER POST WITH THE 1/2" PAN HEAD SCREWS PROVIDED WITH THE FLAGS.
STEP 52: HANGING SWINGS 1: LOCATE THE SWING BELTS, TRAPEZE BAR AND SIX SPRING CLIPS. 2: SNAP A SPRING CLIP ONTO EACH IRON DUCTILE SWING HANGER. 3: HANG ONE CHAIN FROM EACH ACCESSORY ONTO EACH SPRING CLIP. 4: ADJUST SWINGS UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS.
STEP 53: GROUND STAKES AND NAME PLATE 1: HAMMER IN THE GROUND STAKES AT AN ANGLE NEXT TO THE SWING LEGS. 2: FASTEN EACH GROUND STAKE TO THE SWING LEG WITH THE 2" SCREW PROVIDED WITH THE GROUND STAKE.
STEP 54: SAFETY BOARD 1: ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD TO THE LEFT CORNER POSTS NEAR THE SWINGS. THIS BOARD IS A VISUAL DETERRENT AND IS MEANT TO PREVENT CHILDREN FROM RUNNING THROUGH THE BASE OF THE PLAY SET INTO OTHER CHILDREN ON THE SWINGS. 2: PLACE THE TOP OF THE SAFETY BOARD 24" UP FROM THE BOTTOM OF THE 2 X 6 BOARD. HOLES IN THE SAFETY BOARD SHOULD BE OFFSET UP. 3: FASTEN THE SAFETY BOARD TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 55: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. PLACE THE STEERING WHEEL AGAINST THE END OF THE SWING BEAM. 2: MARK THROUGH THE HOLE IN THE STEERING WHEEL INSERT ONTO THE END OF THE SWING BEAM. DRILL A 3/16" PILOT HOLE 2" DEEP INTO THE SWING BEAM. 3: USE THE 2-1/2" LAG SCREW AND WASHER TO FASTEN THE STEERING WHEEL TO THE SWING BEAM. DO NOT OVER-TIGHTEN THE LAG SCREW OR THE STEERING WHEEL WILL NOT TURN.
