™ playsets ™ playsets Sun Palace Deluxe Model: 723 (BOXES: 701N-1, 701N-2, 703N, 705, 721-1, 721-2, 723, 725, Rad Ride 7 Box & Slide Box) *51-0044-W* 51-0044-W Copyright © 2015 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 – 2015 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set. As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury.
Warranty registration - sun palace Deluxe 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: 723 (BOXES: 701N-1, 701N-2, 703N, 705, 721-1, 721-2, 723, 725, Rad Ride 7 Box & Slide Box) REV: 3.10.
TABLE OF CONTENTS Safety Guidelines……………………………………….......……...........................Pages 4-7 Leveling Fort, General Information and Definitions............................................Pages 7-9 How to Install T-Nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading......................................................................................Pages 10-14 Site Plan, Required Tool List and Kit Contents......………………………........
Part II Upper Level TABLE OF CONTENTS Hardware, Lumber and Accessory Checklists……………………………….....Pages 83-98 Framing the Upper Level………………..…………………………..……............... Steps 1-4 Connecting the levels with Deck Supports and leveling the Upper Level..….......... Step 5 Corner Posts, Safety Bar, Center Post and Center Deck Supports.................. Steps 6-10 Deck Blocks/Deck Support, Center Post/Center Deck Support...................... Steps 11-12 Install Iron Ductile for Punching Bag....................
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”, 3/8”, 9/64”, 11/64” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel KIT CONTENTS Swings, Slides, Accessories: ___ (Qty ) Description ___ (2) Swingbelt w/ Chains ___ (1) Trapeze Swing w/ Chains ___ (10) Ro
PART I 701-703 LOWER LEVEL 17
11-0073 701N Hardware REV C 9/19/2014JH Page 1 of 2 #8 X 2" WOOD SCREW QTY: 125 9 #8 X 2-1/2" WOOD SCREW QTY: 92 #14 X 1-1/4" PAN HEAD SCREW QTY: 20 #8 X 3" WOOD SCREW QTY: 4 8 #10 X 3-1/2" WOOD SCREW QTY: 15 7 6 5/16" TEE NUT QTY: 24 3/8" LOCK NUT QTY: 21 5 4 TORQUE WASHER QTY: 19 3 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 4 3/8" WASHER QTY: 72 2 1 5/16 X 6" HEX BOLT QTY: 12 5/16 X 4" HEX BOLT QTY: 12 1/4" WASHER QTY: 8 5/16" WASHER QTY: 24 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS
11-0073 701 Hardware REV C 9/19/2014JH Page 2 of 2 3/8" X 5" 3/8" X 3-1/2" HEX LAG SCREW HEX LAG SCREW QTY: 14 QTY: 37 9 8 7 6 5 4 3 #2 SQUARE BIT QTY: 1 2 1 3/8" x 7" 3/8 x 9" CARRIAGE BOLT CARRIAGE BOLT QTY: 16 QTY: 1 3/8" x 5-1/2" CARRIAGE BOLT QTY: 2 3/8" x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 21 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
11-0074 703N Hardware REV C 9/19/2014 JH Page 1 of 1 #8 x 1-1/4" WOOD SCREW QTY: 8 #8 x 1-1/2" WOOD SCREW QTY: 165 9 #8 X 2" WOOD SCREW QTY: 52 8 3/8 X 3-1/2" HEX LAG SCREW QTY: 4 3/8" WASHER QTY: 4 7 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 2 X 2 X 10-5/8" TIC TAC TOE BOARD 2-2-1063-TTTB 2 X 4 X 24" ROPE LADDER STEP THIS ITEM WONT BE USED ON THIS PLAYSET QTY.
PICTURE DESCRIPTION 2 X 6 X 41-1/4" DECK SPACER 2-6-4125-DS 2 X 6 X 50-3/4" DECK BOARD 2-6-5075-DB 2 X 6 X 78-3/4" INNER FORT SUPPORT QTY.
PICTURE DESCRIPTION 4 X 4 X 70" TIRE SWING SUPPORT QTY.
PICTURE DESCRIPTION 4 X 4 X 108" SWING LEG 4-4-10800-SL 4 X 4 X 120" SIDE RAIL 4-4-12000-SR 4 X 4 X 120" SWING BEAM SIDE RAIL QTY.
PICTURE DESCRIPTION 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55" ROOF STARTER 1-5-5500-RS 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 1 X 6 X 55" ROOF PEAK 1-6-5500-RP 2 X 6 X 16" SUN 2-6-1600-S 2 X 6 X 80-1/4" ROOF SUPPORT LEFT AND RIGHT 2-6-8025-RSL 2-6-8025-RSR 4 X 4 X 29-1/2" CENTER POST 4-4-2950-CP QTY.
PICTURE DESCRIPTION CORNER POST FRONT 4 X 4 X 61-1/4" HAS AN EXTRA HOLE HERE. CORNER POST FRONT/REAR 4-4-6125-CPF QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 is a pkg of 5) A-FRAME SWING LEG BRACKET QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
STEP 1: ASSEMBLING THE LADDER 1: START WITH THE 4 X 4 X 80-1/4" LADDER SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE FIVE HOLES AND THE FIVE CHANNELS ON THE INSIDE TO FACE EACH OTHER, AND THE ANGLED ENDS SHOULD BE FACING THE SAME WAY. IT SHOULD ALSO BE NOTED THAT THERE ARE TWO 3/8" HOLES JUST ABOVE THE FIVE LADDER RUNG HOLES AND CHANNELS. 2: LAY THE LEFT LADDER SIDE ON THE GROUND AND PLACE THE FIVE 2 X 6 X 20-1/2" LADDER STEPS INSIDE THE CHANNELS. ATTACH WITH 2-1/2" WOOD SCREWS.
STEP 2: ATTACHING THE ROPE LADDER RUNNER 1: FIND THE 4 X 4 X 97" ROPE LADDER RUNNER. TAKE SPECIAL NOTE OF THE ROUNDED EDGE ON THE 7/8" HOLES ON THE END OF THE ROPE LADDER RUNNER. 2: LINE UP THE TWO 3/8" PILOT HOLES ON THE ROPE LADDER RUNNER TO THE COUNTER-SUNK HOLES ON THE LADDER SIDE PIECES. THE COUNTERSUNK HOLES OF THE LADDER ASSEMBLY WILL FACE OUTWARDS. 3: FIND TWO T-NUTS, AND SET WITH A HAMMER ON THE EXPOSED 3/8" HOLES OF THE ROPE LADDER RUNNER.
STEP 3: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE LADDER ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE LADDER ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE LADDER SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT. CENTER THE COUNTER-SUNK HOLES ON THEIR RESPECTIVE BOARDS BEFORE ATTACHING. 3: FASTEN THE ANGLED END TO THE LADDER SIDE WITH ONE 3/8 X 3-1/2" LAG SCREW WITH A 3/8" WASHER.
STEP 4: ASSEMBLING THE ROCK WALL 1: START WITH THE 4 X 4 X 80-1/4" ROCK WALL SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE ANGLED ENDS TO FACE THE SAME WAY. IT SHOULD ALSO BE NOTED THAT THERE ARE TWO 3/8" HOLES JUST BELOW THE ANGLED ENDS. 2: INSTALL T-NUTS INTO THE HOLES JUST BELOW THE ANGLED ENDS. THE BOTTOM HOLES WILL GET A T-NUT ON THE OUTSIDE, AND THE TOP HOLES WILL GET A T-NUT ON THE INSIDE. 3: FIND THE 4 X 4 X 74" ROCK WALL BOTTOM SUPPORT.
STEP 5: ASSEMBLING THE ROCK WALL 1: MEASURE 67" FROM THE BOTTOM OF EACH OF THE ROCK WALL SIDES AND MARK THIS LOCATION. 2: BEFORE INSTALLING BOARDS, MAKE SURE THAT THE ROCK WALL SIDES ARE SQUARE TO THE ROCK WALL BOTTOM SUPPORT. ONCE THE ROCK WALL SIDES ARE SQUARE, LAY THE 5/4 X 6 X 48" ROCK WALL BOARD ON THE ROCK WALL SIDES WITH THE TOP OF THE BOARD PLACED AT THE 67" MARK PREVIOUSLY MADE. ATTACH WITH TWO 2" WOOD SCREWS PER SIDE.
STEP 6: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE ROCK WALL ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE ROCK WALL ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE ROCK WALL SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT. CENTER THE COUNTER-SUNK HOLES ON THEIR RESPECTIVE BOARDS BEFORE ATTACHING. 3: FASTEN THE ANGLED END TO THE ROCK WALL SIDE WITH ONE 3/8 X 3-1/2" LAG SCREW WITH A 3/8" WASHER.
STEP 7: INSTALLING OUTER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 79-1/4" OUTER FORT SUPPORTS. THE EASIEST WAY TO DIFFERENTIATE THE OUTER SUPPORTS FROM THE INNER SUPPORTS IS TO LOOK FOR THE COUNTER-SUNK HOLES AT 12-1/4" FROM EACH END. THE TWO BOARDS WITH THE HOLES CLOSEST TO THE BOTTOM (LONGER) SIDE ARE THE OUTER FORT SUPPORTS, THE BOARDS WITH THE HOLES CLOSEST TO THE TOP (SHORTER) SIDE ARE THE INNER FORT SUPPORTS.
STEP 8: INSTALLING INNER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 78-3/4" INNER FORT SUPPORTS. 2: LINE UP THE 3/8" HOLE CLOSEST TO THE BOTTOM WITH THE BOTTOM HOLE OF THE INNER FORT SUPPORT. 3: ATTACH THE INNER FORT SUPPORT TO THE LADDER ASSEMBLY WITH 5/16 X 4" HEX BOLTS AND 5/16" WASHERS. 4: REPEAT STEPS 2 AND 3 TO FASTEN THE INNER FORT SUPPORT TO THE ROCK WALL ASSEMBLY. 5/16" WASHER 5/16 X 4" HEX BOLT 2 X 6 X 78-3/4" INNER FORT SUPPORT NOTE: EACH "LEG" HAS TWO HOLES IN IT.
STEP 9: INSTALLING T-NUTS ON CORNER POSTS 1: FIND FOUR 4 X 4 X 61-1/4" CORNER POSTS. FRONT CORNER POSTS HAVE AN EXTRA HOLE AT 30-1/2" FROM THE BOTTOM. 2: USING THE DIAGRAM BELOW, INSTALL T-NUTS INTO THE APPROPRIATE HOLES. PLACE T-NUTS INTO THE HOLES OF THE CORNER POST AND SET WITH A HAMMER. 3: THE CORNER POSTS ARE SHOWN RELEVANT TO THEIR ORIENTATION ON THE UNIT.
STEP 10: INSTALLING CORNER POSTS 1: TAKE THE CORNER POSTS WITH THE T-NUTS INSTALLED FROM THE PREVIOUS STEP AND ARRANGE THE POSTS IN THEIR PROPER ORIENTATION. (SHOWN BELOW WITH NUMBERS TO REFERENCE THE PREVIOUS STEP) 2: THE CORNER POSTS SHOULD BE ORIENTED WITH THE COUNTER-SUNK HOLES FACING TOWARD EACH OTHER ON BOTH SIDES. THE CORNER POSTS SHOULD BE PLACED BETWEEN THE INNER AND OUTER FORT SUPPORTS, AND REST FLUSH AGAINST THE ANGLED END OF THE LADDER AND ROCK WALL ASSEMBLIES.
STEP 11: ATTACHING THE SWING BEAM PLATE TO THE SWING BEAM SIDE RAIL 1: FIND THE 4 X 4 X 120" SWING BEAM SIDE RAIL. NOTE THE DIFFERENCE BETWEEN THE SWING BEAM SIDE RAIL AND THE SIDE RAIL. THE SWING BEAM SIDE RAIL WILL HAVE THREE MORE COUNTER SUNK HOLES ON ONE SIDE THAN THE SIDE RAIL. 2: FIND THE SWING BEAM PLATE. NOTICE THE TWO SQUARE HOLES ON THE SWING BEAM PLATE.
STEP 12: ATTACHING THE SWING BEAM SIDE RAIL 1: FIND TWO TORQUE WASHERS. PLACE A 7" CARRIAGE BOLT INSIDE THE TORQUE WASHER. PLACE THE TORQUE WASHER/CARRIAGE BOLT ASSEMBLY INTO THE HOLES OF THE CORNER POST SO THAT THE HEAD OF THE CARRIAGE BOLT IS INSIDE OF THE FORT. 2: TAKE THE 4 X 4 X 120" SWING BEAM SIDE RAIL WITH THE SWING BEAM PLATE AND LINE UP THE PILOT HOLES IN THE CORNER POSTS WITH THE HOLES IN THE SWING BEAM SIDE RAIL. PUSH THE CARRIAGE BOLTS THROUGH THE HOLES IN THE SWING BEAM SIDE RAIL.
STEP 13: ATTACHING THE SIDE RAIL 1: TAKE THE 4 X 4 X 120" SIDE RAIL AND LINE UP THE PILOT HOLES IN THE CORNER POSTS WITH THE HOLES IN THE SIDE RAIL. 2: FASTEN THE SIDE RAIL TO THE FORT WITH 5/16 X 6" HEX BOLTS AND 5/16" WASHERS INTO THE T-NUTS OF THE CORNER POSTS.
STEP 14: ATTACHING THE ROPE LADDER SUPPORT AND THE ROCK WALL ROPE SUPPORT 1: FIND THE 4 X 4 X 88" ROPE LADDER SUPPORT AND LAY IT ON TOP OF THE SIDE RAIL AND THE SWING BEAM SIDE RAIL ON THE LADDER SIDE OF THE FORT. 2: LINE UP THE COUNTER-SUNK HOLES OF THE ROPE LADDER SUPPORT WITH THE HOLES IN THE CORNER POSTS AND ATTACH WITH 5/16 X 6" HEX BOLTS WITH 5/16" WASHERS. THE THREE HOLES ON THE END OF THE ROPE LADDER SUPPORT SHOULD BE ON THE OPPOSITE SIDE OF THE SWING BEAM PLATE BEFORE INSTALLING.
STEP 15: INSTALLING LAG SCREWS 1: MAKE SURE THAT THE UNIT IS LEVEL AND SQUARE. 2: STARTING AT THE INNER AND OUTER FORT SUPPORTS, USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS IN THE EMPTY HOLES ON THE 2 X 6 PARTS TO SECURE THE BASE OF THE FORT. 3: THE UPPER PART OF THE FORT NEEDS TO BE SECURED WITH 3/8 X 5" LAG SCREWS WITH 3/8" WASHERS IN THE EMPTY HOLES OF THE 4 X 4 PARTS.
STEP 16: INSTALLING ROCK WALL BOARDS 1: FIND ELEVEN 5/4 X 6 X 48" ROCK WALL BOARDS. 2: LAY THE ROCK WALL BOARDS ACROSS THE ROCK WALL SIDES. 3: ATTACH THE ROCKS WITH TWO 2" WOOD SCREWS PER END. 4: THE FINAL BOARD WILL BE THE 5/4 X 6 X 48" BOTTOM ROCK WALL BOARD WITH ONE HOLE IN THE CENTER. IT WILL ATTACH IN THE SAME MANNER AS THE OTHER ROCK WALL BOARDS. 5: AFTER ASSEMBLY, YOUR ROCK WALL MAY HAVE A GAP AT THE BOTTOM. THIS IS NORMAL DUE TO MILLING VARIANCES AND WOOD SHRINKAGE.
STEP 17: INSTALLING TARP BOARDS 1: FIND TWO 2 X 4 X 54-1/2" TARP BOARDS. 2: CENTER THE BOARD ACROSS THE ENDS OF THE SWING BEAM SIDE RAIL AND THE SIDE RAIL. 3: ATTACH THE TARP BOARDS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 4: REPEAT THIS PROCESS ON THE OPPOSITE SIDE OF THE FORT.
STEP 18: DECK 1: FIND NINE 2 X 6 X 50-3/4" DECK BOARDS. 2: LAY THE DECK BOARDS ACROSS THE INNER FORT SUPPORTS, BETWEEN THE BOTTOM AND REAR BOTTOM PANEL BOARDS, AND INSIDE THE AREA BETWEEN THE CORNER POSTS. 3: FIND FOUR 2 X 6 X 41-1/4" DECK SPACERS. 4: LAY TWO DECK SPACERS ACROSS THE INNER FORT SUPPORTS ON THE LADDER AND ROCK WALL SIDES OF THE FORT. 5: MAKE SURE THAT ALL BOARDS ARE EVENLY SPACED ACROSS THE DECK AND ATTACH THE DECK BOARDS AND DECK SPACERS TO THE FORT WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
STEP 19: INSTALLING THE BOTTOM PANEL BOARDS 1: FIND TWO 2 X 4 X 58" REAR BOTTOM PANEL BOARDS. 2: LAY ONE BOARD ACROSS THE DECK ON THE SWING BEAM SIDE OF THE FORT, CENTERED BETWEEN THE TWO CORNER POSTS (INSTALL OUTSIDE). 3: ATTACH THE REAR BOTTOM PANEL BOARD WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 4: LAY ONE BOARD ACROSS THE DECK ON THE OPPOSITE SIDE OF THE FORT, CENTERED BETWEEN THE TWO CORNER POSTS (INSTALL INSIDE). 5: ATTACH THE REAR BOTTOM PANEL BOARD WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 20: CENTER POSTS 1: TAKE THE 4 X 4 X 29-1/2" CENTER POSTS, AND LINE UP THE HOLE IN THE POSTS WITH THE THROUGH HOLE IN THE SWING BEAM SIDE RAIL/SIDE RAIL. 2: WHEN THE CENTER POST IS LINED UP PROPERLY, INSTALL A 5/16" T-NUT INTO THE HOLE IN THE CENTER POSTS. 3: FASTEN THE CENTER POSTS TO THE FORT WITH 5/16 X 6" HEX BOLTS AND 5/16" WASHERS THROUGH THE SWING BEAM SIDE RAIL/SIDE RAIL, AND INTO THE T-NUTS OF THE CENTER POST.
STEP 21: ROOF SUPPORT ASSEMBLIES 1: IF YOUR ROOF PEAK SUPPORTS ARE NOT PREDRILLED THEN DRILL 1/8" HOLES IN THEM TO THE PATTERN SHOWN BELOW. 2: PLACE THE ENDS OF THE ROOF SUPPORTS TOGETHER AS SHOWN BELOW. THE HOLES SHOULD BE ABOUT 55" CENTER TO CENTER. 3: PLACE THE ROOF PEAK SUPPORT (TRIANGLE) ON TOP OF THE ROOF SUPPORTS. ATTACH THE ROOF PEAK SUPPORT TO THE ROOF SUPPORTS WITH #8 X 2" WOOD SCREWS. 4: REPEAT THIS PROCESS TO MAKE ANOTHER ROOF SUPPORT ASSEMBLY.
STEP 21A: ROOF SUPPORTS 1: HAVE AN ASSISTANT HELP YOU LIFT THE ROOF SUPPORT ASSEMBLIES ON TOP OF THE SIDE RAIL OR SWING BEAM SIDE RAIL. DO THEM ONE AT A TIME. 2: PLACE A RULER OR BOARD ON TOP OF THE SIDE RAILS TO CHECK AND MAKE SURE THERE IS NO INTERFERENCE WITH THE END TARP BOARDS. DO THIS ON BOTH SIDES. 3: THE HOLES IN THE ROOF SUPPORTS SHOULD BE CLOSE TO BEING CENTERED ON EACH CORNER POST. ATTACH THE ROOF SUPPORTS TO THE CORNER POSTS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 22: PANEL SLATS 1: FIND SIX 5/4 X 4 X 28-1/2" PANEL SLATS, AND ARRANGE THEM SO THAT THEY ARE EVENLY SPACED ACROSS THE SWING BEAM SIDE OF THE FORT. 2: ATTACH THE PANEL SLATS WITH TWO 2" WOOD SCREWS PER END.
STEP 23: CENTER DECK SUPPORTS 1: FIND THE 4 X 4 X 70" TIRE SWING SUPPORT, AND ARRANGE EVENLY UNDERNEATH THE DECK. 2: ATTACH THE TIRE SWING SUPPORT WITH A 3/8 X 5" LAG SCREW AND A 3/8" WASHER THROUGH THE LADDER CENTER. FROM THE TOP, ADD TWO 2-1/2" WOOD SCREWS THROUGH THE DECK BOARDS, INTO THE CENTER DECK SUPPORT. 3: FIND THE 2 X 4 X 58" ROCK WALL SUPPORT BOARD, AND CENTER IT ON THE BACK OF THE ROCK WALL. MAKE SURE THAT THE HOLE IN THE BOTTOM ROCK WALL BOARD IS NOT OBSTRUCTED BY THE ROCK WALL SUPPORT BOARD.
STEP 24: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWING BEAM. 2: FASTEN THE IRON DUCTILES TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS AND WASHERS ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
STEP 25: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 26: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE FORT AND POSITION THE LEGS UNDERNEATH THE END OF THE BEAM. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND SWING LEGS. MAKE SURE THE IRON DUCTILES ARE FACING DOWN.
STEP 27: ATTACHING SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM LEG BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS UNDERNEATH. 2: USE A 3/8 X 3-1/2" LAG SCREW AND 3/8" WASHER IN THE MIDDLE HOLE OF THE SWING LEG BRACKET. 3: PLACE BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
STEP 28: ATTACHING THE SWING BEAM TO THE FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: AFTER THE LEGS ARE ATTACHED, HAVE ONE PERSON ON THE GROUND PICK UP THE SWING BEAM BY THE LEGS, AND ANOTHER PERSON PICK UP THE SWING BEAM FROM INSIDE THE FORT AND WALK OUT THE SWING BEAM. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
STEP 29: LEVEL THE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
STEP 30: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 70" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS-MEMBER, AND FASTEN TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 31: TIRE SWING 1: GO UNDER THE DECK. PLACE THE TIRE SWING SWIVEL ON THE TIRE SWING SUPPORT. CENTER THE TIRE SWING SWIVEL BELOW THE MIDDLE DECK BOARD. 2: MARK THE LOCATION OF THE HOLES IN THE SWIVEL WITH A PENCIL, AND WITH A 3/8" DRILL BIT, DRILL HOLES THROUGH THE TIRE SWING SUPPORT AND MIDDLE DECK BOARD. 3: USE A 5-1/2" CARRIAGE BOLT TO CLEAR OUT ANY DEBRIS LEFT OVER FROM DRILLING, MATE WITH A TORQUE WASHER AND SET THE TORQUE WASHER ON TOP OF THE MIDDLE DECK BOARD WITH A HAMMER.
STEP 32: INSTALLING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. 2: THE ROCKS INCLUDED IN YOUR PLAYSET MAY VARY, IN ANY CASE, THE 1-1/4" PAN HEAD SCREWS WITH WASHERS WILL BE USED TO ATTACH THE ROCKS.
STEP 33: CLIMBING ROPE 1: THREAD ONE END OF THE ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE A SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN ROPE TO AID IN CLIMBING. SET KNOTS ACCORDING TO YOUR CHILD'S NEEDS. 2-3 KNOTS SHOULD BE SUFFICIENT. 2: THREAD THE OTHER END OF THE ROPE THROUGH THE HOLE IN THE BOTTOM ROCK WALL BOARD. PULL THE ROPE TIGHT AND TIE A SECURE KNOT BEHIND THE BOTTOM ROCK WALL BOARD. 3: WRAP ROPE AROUND YOUR HAND TO TEST FOR LOOSENESS AS DESCRIBED BELOW.
STEP 34: ROPE LADDER ASSEMBLY 1: FIND THE THREE ROPE LADDER ROPES OF EQUAL LENGTH. MEASURE 30" FROM ONE SIDE OF EACH PIECE OF ROPE AND MAKE A MARK AT THIS LOCATION. 2: TIE A KNOT ON THE OTHER SIDE OF THE ROPE THAT IS JUST ABOVE THE MARK THAT WAS MADE ON THE ROPE (SEE BELOW). 3: THREAD THE ROPE THROUGH THE HOLES OF THE 2 X 4 ROPE LADDER RUNG. YOU MAY NEED TO TWIST THE ROPE TO GET IT THROUGH.
STEP 35: INSTALLING THE ROPE LADDER 1: UNROLL THE ROPE LADDER ASSEMBLY. LOOK FOR THE BOARD THAT HAS KNOTS TIED ABOVE AND BELOW THE ROPE LADDER STEP. THIS WILL BE THE TOP OF THE ROPE LADDER. 2: THREAD THE TOP OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER SUPPORT, AND TIE A SECURE KNOT. 3: THREAD THE BOTTOM OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER, AND TIE A SECURE KNOT. 4: MAKE SURE THE ROPE LADDER ROPES WILL NOT LOOP AROUND YOUR HAND.
STEP 36: ROOF COMPONENTS 1: USING A 1/8" DRILL BIT, DRILL HOLES IN THE ROOF COMPONENTS TO THE DIMENSIONS SHOWN BELOW. Rounded Edge 13 2 16 " 1 X 5 X 55" ROOF STARTER 1 12" 1 32" Groove Side 3 52 16 " Tongue Side 13 2 16 " 1 X 6 X 55" ROOF BOARD 9 1 16 " 9 3 16 " Groove Side 3 52 16 " Rounded Edge 13 2 16 " 1 X 4 X 55" ROOF FINISHER 1 14" 3" Tongue Side 3 52 16 " 3 4" 5/4 X 3 X 53" SUN SUPPORT 1" 3 14" 2 X 6 X 16" SUN 8" 4" 4" Repeat drilling process for other end of each ray.
STEP 37: ROOF PEAK 1: PLACE THE 55" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH WOOD SCREWS. #8 X 1-1/4" WOOD SCREW 55" ROOF PEAK PREDRILL 1/8" HOLES HERE THROUGH THE ROOF PEAK ONLY.
STEP 38: ROOF 1: PLACE THE 1 X 6 X 55" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS FOURTEEN ROOF BOARDS. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED OVER THE ROOF SUPPORTS. IF NECESSARY PLACE A SCRAP 2 X 4 BOARD AGAINST THE ROOF BOARD AND HAMMER ON IT TO SEAT THE TONGUE INTO THE GROOVE FOR THE ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 39: SUNBURST 1: PLACE THE 2 X 6 X 16" SUN CENTERED AGAINST THE 5/4 X 3 X 53" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2" WOOD SCREWS. REPEAT THIS PROCESS FOR THE OTHER SIDE OF THE FORT.
STEP 40: SUNBURST 1: PLACE THE ASSEMBLY MADE IN A PRIOR STEP UNDERNEATH THE ROOF BOARDS, AND AGAINST THE ANGLED ROOF SUPPORTS. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP. 2: FASTEN THE SUN ASSEMBLY TO THE FORT WITH 2" WOOD SCREWS FROM THE OUTSIDE INTO THE ROOF SUPPORTS. 3: REPEAT ON THE OPPOSITE SIDE OF THE FORT. NOTE: ROOF BOARDS AND OTHER DETAILS OMITTED FOR CLARITY.
STEP 41: SUNBURST 1: CENTER THE 5/4 X 2 X 17" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS. IF YOU HAVE A 703N ROOF KIT THEN THE HOLES IN THE LARGE RAY ARE PRE-DRILLED AND ARE OFFSET TO THE SIDE ON EACH END. PROCEED TO SUBSTEP 2 IF YOU HAVE THESE. 2: FASTEN THE LARGE RAY WITH TWO SCREWS. 3: EQUALLY SPACE THE SMALL AND MEDIUM RAYS ABOUT THE HALF SUN TO THE PATTERN SHOWN BELOW AND MARK THE POSITION OF EACH WITH A PENCIL.
STEP 42: ROOF STRINGERS 1: PLACE 5/4 X 3 X 78" ROOF STRINGER AGAINST THE UNDERSIDE OF THE ROOF BOARDS IN THE CENTER. 2: ATTACH ROOF STRINGER TO ROOF BOARDS WITH ONE #8 X 1-1/2" WOOD SCREW PER ROOF BOARD. 3: REPEAT FOR OTHER SIDE OF ROOF.
STEP 43: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE REAR CENTER POST ON THE SWING BEAM SIDE. 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 44: SAFETY HANDLES 1: FIND FOUR SAFETY HANDLES. 2: PLACE A SAFETY HANDLE JUST ABOVE THE ROCK WALL OPENING ON EACH SIDE, AND INSTALL WITH 1-1/4" PANHEAD SCREWS AND WASHERS. 3: REPEAT THIS PROCESS FOR THE LADDER SIDE OF THE FORT.
STEP 45: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. IGNORE STEP 6 & 7 IN THE INSTRUCTIONS. 2: ATTACH THE TWO 1-3/8" X 1-5/8" X 10-1/2"L TIC TAC TOE BOARDS TO THE GREEN PLASTIC BRACKETS WITH THE 1"L PHILLIPS HEAD SCREWS PROVIDED IN THE TIC TAC TOE BOX. IMPORTANT: MAKE SURE THE TIC TAC TOE BOARD IS MOUNTED TO THE GREEN BRACKET OBSERVING THE 1-5/8" DIMENSION SHOWN BELOW. 3: PLACE THE UNIT ON THE PANEL SLATS AS SHOWN.
STEP 46: HANGING SWINGS 1: CLIP EACH OF THE SPRING CLIPS ONTO THE IRON DUCTILE SWING HANGERS, THEN CLIP ONTO THE SWING CHAINS. 2: USE THE CLIPS TO ADJUST THE HEIGHT OF THE SWING BY CLIPPING ON HIGHER OR LOWER LINKS. 3: COUNT BACK THE SAME NUMBER OF LINKS ON THE OPPOSITE SIDE TO ENSURE THAT THE SWING IS LEVEL, AND ADJUST TO FIT YOUR NEEDS.
STEP 47: HANGING THE TIRE SWING 1: HANG THREE SPRING CLIPS FROM THE TIRE SWIVEL. 2: HANG ONE OF THE CHAINS IN ONE OF THE SPRING CLIPS AT THE DESIRED HEIGHT. 3: CONTINUE THE PROCESS WITH THE REMAINING CHAINS, MAKING SURE THAT THE TIRE SWING IS LEVEL WHEN FINISHED. 4: ANY EXCESS LENGTH OF CHAIN CAN BE LOOPED BACK AND HUNG MULTIPLE TIMES TO PREVENT THE EXCESS FROM HANGING DOWN AND CREATING A HAZARD.
STEP 48: 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 49: NAMEPLATE 1: ATTACH THE MANUFACTURER NAMEPLATE CENTERED ON THE FRONT OF YOUR SWING BEAM WITH TWO 2" WOOD SCREWS. PLACE NAME PLATE HERE AND ATTACH.
PART II 721-723 UPPER LEVEL 82
721 HARDWARE PAGE 1 OF 2 2/6/2015 S.O. 9 8 3/8" WASHER QTY: 28 7 5/16 X 2-1/2" HEX BOLT QTY: 2 5/16 X 1-1/2" HEX BOLT QTY: 4 TORQUE WASHER QTY: 2 5/16" WASHER QTY:85 6 5 1/4" WASHER QTY: 7 4 3 2 1 3/8 X 4-1/2" CARRIAGE BOLT QTY: 2 5/16 X 4-1/2" HEX BOLT QTY: 39 5/16" X 3-1/2" HEX LAG SCREW QTY: 34 3/8 X 3-1/2" HEX LAG SCREW QTY: 13 3/8 X 5" HEX LAG SCREW QTY: 13 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
721 HARDWARE PAGE 2 OF 2 2/6/2015 S.O. 9 #8 X 2" WOOD SCREW QTY: 207 8 BLACK PLUG QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 49 #8 X 3" WOOD SCREW QTY: 9 7 5/16" TEE NUT QTY: 47 6 5 3/8" LOCK NUT QTY: 2 4 3 PLASTIC BOLT CAP QTY: 2 2 #14 X 3" PAN HEAD SCREW QTY: 3 #14 X 1" PAN HEAD SCREW QTY: 4 1 #2 SQUARE DRIVE BIT QTY: 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.
723 HARDWARE PAGE 1 OF 1 2/5/2015 S.O. #8 X 1-1/4" WOOD SCREW QTY: 14 9 #8 X 1-1/2" WOOD SCREW QTY: 140 #8 X 2" WOOD SCREW QTY: 35 8 #8 X 2-1/2" WOOD SCREW QTY: 8 #8 X 3" WOOD SCREW QTY: 4 7 6 5 4 5/16" WASHER QTY: 4 3 2 5/16" X 4-1/2" HEX BOLT QTY: 4 5/16" TEE NUT QTY: 4 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 5/4 X 4 X 23.88" DECK SPACER 125-4-2388-DS 5/4 X 4 X 51.25" DECK SPACER 125-4-5125-DS 5/4 X 4 X 58.13" DECK FILLER 125-4-5813-DF 5/4 X 6 X 22" SANDBOX SEAT 125-6-2200-SS 5/4 X 6 X 26" PANEL SLAT 125-6-2600-PS 5/4 X 6 X 30.5" PANEL SLAT 125-6-3050-PS 5/4 X 6 X 58.13" DECK BOARD 125-6-5813-DB QTY.
PICTURE DESCRIPTION 2 X 4 X 18" ANGLE SUPPORT QTY. 6 2-4-1800-AS 2 X 4 X 19.38" LADDER STEP 2-4-1938-LS 2 X 4 X 21.5" ANGLE SUPPORT 12 2 2-4-2150-AS 2 X 4 X 27.55" LADDER RIGHT SIDE 2 2-4-2755-LLS 2 X 4 X 27.55" LADDER LEFT SIDE 2 2-4-2755-LRS 2 X 4 X 31" DECK SUPPORT/ PANEL BOARD 7 2-4-3100-DSPB 2 X 4 X 42.
PICTURE DESCRIPTION 2 X 4 X 49.19" CENTER DECK SUPPORT QTY. 2 2-4-4919-CDS 2 X 4 X 49.19" DECK SUPPORT 2-4-4919-DS 2 X 4 X 58" FILLER PANEL BOARD 2 1 2-4-5800-FPB 2 X 4 X 58.38" SAFETY BAR 2-4-5838-SB 2 X 4 X 58.
PICTURE DESCRIPTION QTY. 2 X 6 X 31" SANDBOX BOARD/ BOTTOM PANEL BOARD 2-6-3100-SBBPB 4 2 X 6 X 58.38" TOP PANEL BOARD 1 2-6-5838-TPB 2 X 6 X 58.38" SANDBOX BOARD 2 2-6-5838-SBB 4 X 4 X 10.13" CENTER POST 4-4-1013-CP 4 X 4 X 21.13" DECK BLOCK 4-4-2113-DB 4 X 4 X 23.88" CENTER DECK SUPPORT/ SLIDE BLOCK 1 2 2 4-4-2388-CDSSB 4 X 4 X 35.
PICTURE DESCRIPTION 4 X 4 X 42.28" CENTER POST 4 X 4 X 4228-CP 4 X 4 X 45.68" CENTER POST 4-4-4568-CP 4 X 4 X 58.38" DECK SUPPORT 4-4-5838-DS 4 X 4 X 38.88" CENTER POST 4-4-3888-CP 4 X 4 X 117.84" MIDDLE POST 4-4-11784-MP 4 X 4 X 121.88" CORNER POST 4-4-12188-CP QTY.
PICTURE DESCRIPTION 2 X 4 X 58" FILLER PANEL BOARD 2-4-5800-FPB 2 X 4 X 58.38" TARP BOARD 2-4-5838-TB 4 X 4 X 24.38" FILLER POST 4-4-2438-FP QTY.
PICTURE DESCRIPTION QTY. 1 X 3 X 11.25" WINDOW TOP & BOTTOM BOARD 1-3-1125-WTBB 4 1 X 4 X 10.5" WALL PANEL BOARD 2 1-4-1050-WPB 1 X 4 X 14.25" WALL PANEL BOARD 2 1-4-1425-WPB 1 X 4 X 17.75" WALL PANEL BOARD 2 1-4-1775-WPB 1 X 4 X 21.38" WALL PANEL BOARD 2 1-4-2138-WPB 1 X 4 X 24.75" WALL PANEL BOARD 2 1-4-2475-WPB 1 X 4 X 65.
PICTURE DESCRIPTION 1 X 4 X 65.38" ROOF FINISHER 1-4-6538-RF 1 X 5 X 65.38" ROOF PEAK 1-5-6538-RP 1 X 6 X 65.38" ROOF BOARD 1-6-6538-RB 5/4 X 2 X 8" RUN RAY 125-2-0800-SR 5/4 X 6 X 10" ROOF PEAK SUPPORT QTY. 2 1 17 12 2 125-6-1000-RPS 2 X 4 X 31.19" SUN SUPPORT 2-4-3119-SS 2 2 X 4 X 50.
PICTURE DESCRIPTION QTY. 2 X 4 X 50.77" ROOF SUPPORT RIGHT 2 2-4-5077-RSR 2 X 6 X 13.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION PUNCHING BAG 09-0002 SUPER SCOOP 03-0007 QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION WINDOW 07-0013 CROWN 07-0019 721 & 723 HARDWARE BOXES HARDWARE BOXES QTY.
STEP 1: ATTACHING T-NUTS TO THE 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 117.84" MIDDLE POSTS AND 4 X 4 X 121.875 CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE UPPER LEVEL SIDE OF THE PLAYSET.
STEP 2: ASSEMBLING THE UPPER LEVEL SIDE FRAME 1: LAY THE POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 31.00 SANDBOX BOARD ON TOP OF THE CORNER POST AT THE BOTTOM. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 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 POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: LAY THE 2 X 4 X 31.00 DECK SUPPORT/PANEL BOARD ON TOP OF THE CORNER POSTS AT THE TOP.
STEP 3: SANDBOX BOARDS AND TOP PANEL BOARD YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE FRONT AND BACK SIDE ASSEMBLIES. 2: ATTACH ONE 2 X 6 X 58.38" SANDBOX BOARD TO THE BOTTOM OF THE POSTS OF BOTH FRAME ASSEMBLIES ON EACH SIDE , THE HOLES IN THE SANDBOX BOARDS MUST BE OFFSET UP. 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 POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: ATTACH THE 2 X 6 X 58.
STEP 4: UPPER LEVEL UNDER DECK SUPPORTS 1: PLACE THE 4 X 4 X 58.38" UNDER DECK SUPPORT DIRECTLY UNDERNEATH THE DECK SUPPORTS. ATTACH THE UNDER DECK SUPPORT TO THE MIDDLE POSTS AND CORNER POSTS WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS AS SHOWN IN THE DIAGRAM BELOW. CORNER POSTS MIDDLE POSTS LOWER LEVEL UPPER LEVEL 4 X 4 X 58.38" UNDER DECK SUPPORT 3/8" X 5" LAG SCREW RIGHT (LOWER LEVEL) SIDE OF THE FORT ***IMPORTANT*** SQUARE ALL BOARDS TO POSTS; THEN INSTALL LAG SCREWS AND WASHERS.
STEP 5: CONNECTING THE DECK SUPPORTS 1: PLACE THE 2 X 4 X 49.19 DECK SUPPORTS AGAINST THE UPPER LEVEL MIDDLE POSTS AND THE PLAYSET CORNER POSTS UNDERNEATH THE SIDE RAIL. USE 5/16" X 4-1/2" HEX BOLTS TO ATTACH THE DECK SUPPORTS TO THE T-NUTS INSTALLED ON THE CORNER POSTS. 2: PLACE THE UPPER LEVEL FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED.
STEP 6: UPPER LEVEL CORNER POSTS 1: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 2: USING THE DIAGRAM BELOW, LAY OUT BOTH 4 X 4 X 38.88 CORNER POSTS IN A FLAT SURFACE. 3: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 4: THE BARREL OF THE T-NUTS SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS. NO T-NUTS IN THIS HOLE AT THIS MOMENT NO T-NUT IN THIS HOLE. 4 X 4 X 38.
STEP 7: SAFETY BAR 1: LAY THE 2 X 4 X 58.38" SAFETY BAR ON A FLAT SURFACE, USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. THE BARREL OF THE T-NUTS SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH TO THE SAFETY BAR. 2: PLACE THE 2 X 4 X 58.38" SAFETY BAR ON THE RIGHT SIDE, IN BETWEEN THE CORNER UPPER LEVEL CORNER POSTS AND THE PLAY SET ROOF SUPPORTS, THE ANGLES ENDS SHOULD BE OFFSET UP.
STEP 8: CENTER POST 1: LAY THE 4 X 4 X 45.68" CENTER POST ON A FLAT SURFACE, USE A HAMMER TO SEAT THE T-NUT AFTER INSERTING IT INTO THE HOLE SHOWN IN THE DIAGRAM BELOW. THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE SAFETY BAR. 2: PLACE THE 4 X 4 X 45.68" CENTER POST INSIDE AGAINST THE 2 X 6 TOP PANEL BOARD, FASTEN THE CENTER POST TO THE TOP PANEL BOARD CENTER HOLE USING ONE 5/16" X 4-1/2" HEX BOLT AND ONE 5/16" WASHER.
STEP 9: CENTER DECK SUPPORTS 1: PLACE THE THE 4 X 4 X 10.13" CENTER POST AGAINST THE 4 X 4 X 58.38" DECK SUPPORT, MAKING SURE IT IS FLUSH ON THE BOTTOM AND EQUALLY SPACED BETWEEN THE TWO CORNER POSTS. FASTEN USING ONE 3/8" X 5" LAG SCREW AND ONE 3/8" WASHER. 2: MOUNT THE 4 X 4 X 23.88" CENTER DECK SUPPORT ON TOP OF THE DECK SUPPORTS IN BETWEEN THE TWO CENTER POSTS. ATTACH TWO 2 X 4 X 31.00" DECK SUPPORT / PANEL BOARDS ON EACH SIDE OF THE CENTER DECK SUPPORT.
STEP 10: CONNECTING THE CENTER DECK SUPPORT PLACE THE 2 X 4 X 49.19" CENTER DECK SUPPORT (OFFSET DOWN) AGAINST THE 4 X 4 X 10.13" CENTER POST. THE 10" END SHOWN BELOW SHOULD BE ON TOP OF THE DECK SUPPORT ON THE UPPER LEVEL. THE 10" END SHOULD BE FLUSH TO THE SIDE OF THE 10.13" CENTER POST. THE 16" END SHOULD BE BENEATH THE 4 X 4 PLAY SET SIDE RAIL. THE 16" END SHOULD BE FLUSH TO THE SIDE OF THE PLAY SET CENTER POST.
STEP 11: ATTACHING DECK BLOCKS AND DECK SUPPORT 1: INSERT THE 4 X 4 X 21.13" DECK BLOCKS IN BETWEEN THE 2 X 4 CENTER DECK SUPPORTS AND THE 2 X 4 DECK SUPPORTS, UNDERNEATH THE PLAY SET SIDE RAIL. MAKE SURE THE C-BORE HOLES ARE FACING DOWN AND FASTEN TO THE SIDE RAIL USING 3/8" X 5" LAG SCREWS AND 3/8" WASHERS. 2: MOUNT THE 4 X 4 X 58.38" DECK SUPPORT FLUSH UNDERNEATH THE DECK BLOCKS.
STEP 12: CENTER POST AND CENTER DECK SUPPORT 1: MOUNT THE 4 X 4 X 42.28" CENTER POST IN BETWEEN THE TWO 2 X 4 CENTER DECK SUPPORTS AGAINST THE SAFETY BAR AND THE 4 X 4 DECK SUPPORT. THE COUNTERSUNK HOLE (WITH NO ROUNDED EDGES) SHOULD BE AT THE TOP AND THE DEEP C-BORE HOLE (WITH ROUNDED EDGES) SHOULD BE AT THE BOTTOM.USE A 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER TO ATTACH THE TOP COUNTERSUNK HOLE OF THE CENTER POST TO THE T-NUT INSTALLED IN THE SAFETY BAR.
STEP 13: IRON DUCTILE 1: LINE UP THE HOLES OF THE IRON DUCTILE WITH THE HOLES IN THE CENTER DECK SUPPORT, THE IRON DUCTILE WILL BE ON THE BOTTOM. 2: FASTEN THE IRON DUCTILE TO THE SWING BEAM USING 3/8" X 4-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS. 3/8" X 4-1/2" CARRIAGE BOLT 4 X 4 X 35.
STEP 14: TOP AND BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 70.00" TOP PANEL BOARD ON THE TOP LOWER HOLES ON THE CORNER POSTS. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE END HOLES OF THE TOP PANEL BOARD TO THE T-NUTS INSTALLED IN THE CORNER POSTS. THE CENTER HOLE WILL BE USED LATER. 2: INSERT TWO #8 X 2-1/2" WOOD SCREWS THROUGH THE TOP PANEL BOARD INTO THE MIDDLE POST. 3: REPEAT SUB-STEP 1 AND 2 FOR THE OPPOSITE SIDE. 4: FASTEN THE 2 X 4 X 42.
STEP 15: DECK FILLER, DECK SPACERS AND DECK BOARDS 1: CENTER THE 5/4 X 4 X 58.13" DECK FILLER ABOVE THE DECK SUPPORTS, FLAT AGAINST THE MIDDLE POSTS AND CENTER POST. FASTEN USING #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE MIDDLE POSTS AND CENTER POST AS SHOWN BELOW. 2: PLACE THE 5/4 X 4 X 23.88" DECK SPACER CENTERED BETWEEN THE CENTER POSTS AND THE CORNER POSTS AND ATTACH USING #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS BELOW.
STEP 16: ANGLE SUPPORTS 1: FIND SIX 2 X 4 X 18.00" ANGLE SUPPORTS AND MOUNT THEM UNDER THE DECK ON THE FRONT, REAR AND SIDES OF THE FORT. THE TOP OF THE ANGLE SUPPORTS SHOULD BE FLUSH OR LOWER THAN THE BOTTOM OF THE DECK BOARDS. AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE ANGLE SUPPORTS INTO THE DECK SUPPORTS. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST OR MIDDLE POST. 2: FIND TWO 2 X 4 X 21.
STEP 17: BOTTOM AND TOP PANEL BOARDS 1: PLACE THE 2 X 6 X 31.00" SANDBOX BOARD/BOTTOM PANEL BOARD (OFFSET HOLES UP)(1) AT THE MIDDLE OF THE CORNER POST AND BOTTOM OF CENTER POST. USE A 5/16" X 4-1/2" HEX BOLT AND A 5/16" WASHER TO ATTACH THE TOP LEFT HOLE TO THE T-NUT INSTALLED IN THE CORNER POST. MAKE SURE THE BOTTOM PANEL BOARD IS LEVEL AND USE 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS TO ATTACH THE REMAINING HOLES OF THE BOTTOM PANEL BOARD TO THE CORNER POST AND CENTER POST. 2: PLACE THE 2 X 6 X 31.
STEP 18: LADDER 1: FIND FOUR 2 X 4 X 27.55" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 2 X 4 X 27.55" LADDER SIDE 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER. T-NUT #8 X 2" WOOD SCREW LADDER RIGHT SIDE 4: FIND TWELVE 2 X 4 X 19.38" LADDER STEPS. 2 X 4 X 19.38" LADDER STEP 5: PLACE THE STEPS INTO THE SLOTS ON THE LADDER SIDES, AND FASTEN WITH #8 X 2" WOOD SCREWS.
STEP 19: LADDER TO FORT 1: PLACE THE LADDERS INTO POSITION ON TOP OF THE LOWER LEVEL DECK RESTING AGAINST THE DECK BLOCKS BELOW THE SIDE RAIL. ATTACH USING #14 X 1" PAN HEAD SCREWS AND 1/4" WASHERS THROUGH THE HOLES IN THE LADDER BRACKETS INTO THE DECK BLOCKS. 2: UNDERNEATH THE DECK ATTACH THE DECK BOARDS TO EACH LADDER SIDE WITH #8 X 2-1/2" WOOD SCREWS.
STEP 20: CENTER POSTS AND BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 42.50" BOTTOM PANEL BOARD ABOVE THE ROPE LADDER SUPPORT, CENTERED BETWEEN THE CORNER POST AND THE MIDDLE POST. USE 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS TO ATTACH THE BOTTOM PANEL BOARD TO THE POSTS. 2: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 68.00" CENTER POST PLACE IT INSIDE THE FORT ON TOP OF THE DECK, MAKE SURE THE SET OF SMALL PREDRILLED HOLES ARE ON THE BOTTOM.
STEP 21: PANEL SLATS 1: FIND SIX 5/4 X 6 X 30.50" PANEL SLATS. 2: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE TOP AND BOTTOM PANEL BOARDS WITH #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES. REAR AND SIDE PANEL SLAT SPACING SLAT DIMENSIONS (VIEW FROM OUTSIDE THE PLAYSET) 3 14" 2" 3 14" 2" 2" WOOD SCREW 5/4 X 6 X 30.
STEP 22: PANEL SLATS 1: FIND FOUR 5/4 X 6 X 30.50" PANEL SLATS AND PLACE THEM AT THE FRONT OF THE FORT AGAINST THE TOP AND BOTTOM PANEL BOARDS. ATTACH WITH #8 X 2" WOOD SCREWS. 2: FIND FOUR 5/4 X 6 X 26.00" PANEL SLATS AND PLACE THEM AT THE REAR OF THE FORT AGAINST THE TOP AND BOTTOM PANEL BOARD LOCATED ABOVE THE ROPE LADDER SUPPORT. ATTACH WITH #8 X 2" WOOD SCREWS.
STEP 23: SANDBOX SEATS AND SAFETY BAR 1:l MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE MIDDLE POSTS. ATTACH THE 2 X 4 X 58.38" SANDBOX SAFETY BAR TO THE MIDDLE POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2: PLACE THE 5/4 X 6 X 22.00" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 3: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 2 X 4 X 58.
STEP 24: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 50.77" ROOF SUPPORT LEFT, TWO 2 X 4 X 50.77" ROOF SUPPORT RIGHT AND TWO 5/4 X 5 X 10.00" 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.
STEP 25: ROOF SUPPORTS 1: INSERT T-NUTS INTO THE UPPER HOLES OF THE CORNER POSTS FROM THE INSIDE OF THE FORT AND SET WITH A HAMMER. 2: PLACE THE ROOF SUPPORT ASSEMBLY OUTSIDE THE FORT AGAINST THE CORNER POSTS. ATTACH USING 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHERS INTO THE COUNTERSUNK HOLES OF THE ROOF SUPPORTS INTO THE T-NUTS INSTALLED IN THE CORNER POSTS. 3: INSERT TWO #8 X 2-1/2" WOODSCREWS THROUGH THE CENTER POST INTO THE ROOF SUPPORT ASSEMBLY AS SHOWN BELOW.
STEP 26: ROOF STARTERS 1: PLACE THE 1 X 4 X 65.38" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS. 1 X 4 X 65.
STEP 27: ROOF PEAK 1: PLACE THE 1 X 4 X 65.38" 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. 1 X 4 X 65.
STEP 28: ROOF BOARDS, ROOF FINISHER AND DORMER 1: PLACE THE 1 X 6 X 65.38" ROOF BOARDS ON TOP OF THE RIGHT SIDE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. THIS SIDE GETS EIGHT ROOF BOARDS. FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS. 2: PLACE A 1 X 4 X 65.38" ROOF FINISHER ON THE END OF THE ROOF, AND FASTEN USING #8 X 1-1/2" WOOD SCREWS. 3: PLACE THE 1 X 6 X 65.
STEP 29: SUNBURST 1: PLACE THE 2 X 6 X 13.63" SUN CENTERED ON TOP OF THE 2 X 4 X 31.19" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH #8 X 3" WOOD SCREWS. REPEAT THIS PROCESS FOR THE OTHER SIDE OF THE FORT. #8 X 3" WOOD SCREW 2 X 6 X 13.63 SUN 2 X 4 X 31.
STEP 30: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP CENTERED UNDERNEATH THE ROOF SUPPORTS. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP. 2: FASTEN THE SUN ASSEMBLY TO THE FORT WITH #8 X 2-1/2" WOOD SCREWS FROM THE BOTTOM INTO THE ROOF SUPPORTS. 3: REPEAT ON THE OTHER SIDE OF THE FORT.
STEP 31: SUNRAYS 1: EQUALLY SPACE THE 5/4 X 2 X 8.00" SUNRAYS ABOUT THE HALF SUN (THREE ON EACH SIDE OF THE CENTER POST) AND MARK THE POSITION OF THE SMALL SUNRAYS WITH A PENCIL. 2: SECURE THE SUNRAYS ONE AT A TIME TO THE HALF SUN AND THE ROOF SUPPORT BEAMS AND LINE THEM UP WITH THE MARK DRAWN. FASTEN THE SUNRAYS WITH TWO #8 X 2" WOOD SCREWS EACH. REPEAT ON OTHER SIDE OF FORT. 5/4 X 2 X 8.
STEP 32: WALL PANEL BOARDS 1: FIND TWO 1 X 3 X 11.25" WINDOW TOP/BOTTOM BOARDS AND PLACE THEM AGAINST THE TOP PANEL BOARD AND SUN SUPPORT, FOLLOW THE DIMENSIONS OF THE DIAGRAM BELOW AND ATTACH USING #8 X 1-1/2" WOOD SCREWS. NOTE: THE PREDRILLED HOLES MUST BE OFFSET UP FOR THE TOP BOARDS AND OFFSET DOWN FOR THE BOTTOM BOARDS. 2: FIND TWO 1 X 4 X 24.75" WALL PANEL BOARDS, PLACE THEM AGAINST THE ROOF SUPPORT AND TOP PANEL BOARD, THE ANGLED END MUST BE POINTING UP FOLLOWING THE PITCH OF THE ROOF BOARDS.
STEP 33: PLASTIC WINDOWS AND PLASTIC CROWN 1: FIND TWO PLASTIC WINDOWS, PLACE EACH WINDOW IN THE OPENING BETWEEN THE WALL PANEL BOARDS AND THE CENTER POST. MAKE SURE THE 1" WIDE SECTION OF THE WINDOW FRAME IS POSITIONED AT THE TOP. ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS. NOTE: IF THE PLASTIC WINDOWS FIT TOO TIGHT OR TOO LOOSE IN BETWEEN THE BOARDS, YOU CAN UNSCREW AND ADJUST THE WALL PANEL BOARDS . 2: PLACE THE PLASTIC CROWN ON TOP OF THE SUN ABOVE THE SUN SUPPORT.
STEP 34: WALL PANEL BOARDS 1: FIND ONE 1 X 4 X 21.38" WALL PANEL BOARD AND PLACE IT NEXT TO THE PREVIOUSLY INSTALLED WALL PANEL BOARD LEAVING APPROXIMATELY A 1/4" GAP IN BETWEEN. MAKE SURE THE ANGLED END IS POINTING UP FOLLOWING THE ROOF SUPPORT PITCH. THE BOTTOM END MUST BE FLUSH TO THE PREVIOUS ONE. ATTACH USING FOUR #8 X 1-1/2" WOOD SCREWS. 2: FIND ONE 1 X 4 X 17.75" WALL PANEL BOARD AND PLACE IT NEXT TO THE PREVIOUSLY INSTALLED WALL PANEL BOARD LEAVING APPROXIMATELY A 1/4" GAP IN BETWEEN.
STEP 35: ATTACHING THE RAD RIDE TO THE FORT 1: REMOVE LAGS AND WASHERS FROM THE WALL PANEL (CENTER POST ONLY). 2: ASSEMBLE THE RAD RIDE ACCORDING TO THE INSTRUCTIONS PROVIDED. SEE BELOW FOR PLACEMENT OF YOUR SLIDE. 3: ATTACH THE ENTRY OF THE SLIDE TO THE FORT CORNER END CENTER POST. REPLACE THE REMOVED LAGS AND WASHER, INSERT 5/16" X 3-1/2" LAGS AND 5/16" WASHER INTO THE REMAINING HOLES.
STEP 36: ATTACHING THE SUPER SCOOP SLIDE 1: PLACE THE SUPER SCOOP SLIDE IN THE OPENING OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH #14 X 3" PAN HEAD SCREWS.
STEP 37: PUNCHING BAG 1: THE PUNCHING BAG COMES WITH A SHORT SECTION OF CHAIN ATTACHED TO IT WITH AN "S"HOOK. 2: ATTACH THE END OF THE CHAIN TO THE IRON DUCTILE WITH A SPRING CLIP.
STEP 38: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE FRONT TOP PANEL BOARD ON THE REAR SIDE TOP PANEL BOARD. 2: PLACE THE TELESCOPE STAND AND THE 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 39: SAFETY HANDLES (UPPER LEVEL) 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLE UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE UPPER LEVEL CORNER POSTS AND CENTER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 40: FLAG KITS 1: INSTALL THE FLAG KITS IN THE DESIRED LOCATION ON YOUR PLAY SET. THE RECOMENDED LOCATION IS ON THE SIDE RAIL BETWEEN THE LOWER AND UPPER LEVEL. ATTACH THE FLAG KITS WITH THE HARDWARE PROVIDED. ATTACH WITH PHILLIPS PAN HEAD SCREWS PROVIDED WITH THE FLAGS.
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9 8 #8 X 1-1/4" WOOD SCREW QTY: 22 #8 X 1-1/2" WOOD SCREW QTY: 8 7 6 #8 X 2" WOOD SCREW QTY: 6 5 4 3 2 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
STEP 1: DORMER 1: FIND TWO LEFT SIDE AND TWO RIGHT SIDE DORMER ROOF ASSEMBLIES. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE LEFT AND RIGHT ROOF ASSEMBLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW. 4: ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1-1/4" WOOD SCREWS FROM THE ROOF BOARDS OF THE ROOF ASSEMBLIES.
STEP 2: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/4" WOOD SCREWS.
STEP 3: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE A 2" WOOD SCREW TO FASTEN THE DORMER PEAK TO THE ROOF. 3: USE 1-1/2" WOOD SCREWS TO FASTEN THE FACE OF THE DORMER TO THE ROOF. USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE) USE 1-1/2" WOOD SCREWS IN THESE LOCATIONS (EACH SIDE) THE UNIT SHOWN ABOVE MAY NOT BE YOUR EXACT PLAYSET.
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 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR 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 1-1/2" WOOD SCREW IN EACH SIDE.
