™ playsets ™ playsets Malibu Deluxe I Model: 1500GWR (BOXES: 1501, 1504, 1506, 1515, 1528, 1529, X2, X3, 120, Rad Ride 7 Box & Slide Box) 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 - MALIBU DELUXE I Gorilla Playsets manufactures the finest quality products that are designed for outstanding strength and durability. We back our products with an unparalleled warranty. In the unlikely event that you will need to contact us about covered repairs, we must have a valid Warranty Registration on file.
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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: 1500GWR (BOXES: 1501, 1504, 1506, 1515, 1528, 1529, X2, X3, 120, Rad Ride 7 Box & Slide Box) REV: 4.6.
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...............................................
TABLE OF CONTENTS Sandbox Seats/Name Plate.................................................................................. Step 80 Tic Tac Toe Assembly/Installation………………………………..……............... Steps 81-82 Mounting the lower level Slide............................................................................... Step 83 Rock Wall Rope.....................................................................................................
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” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Carpenters Square ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel ___ Marker or Tape (See Step 20) ___ Saw (Hand Saw, Sabre Saw Or Circular Saw) KIT CONTENTS Swings, Slides,
1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" PAN HEAD SCREW QTY: 4 #8 X 1-3/4" WOOD SCREW QTY: 4 9 8 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 6 7 #8 X 3" WOOD SCREW QTY: 20 6 5 5/16" TEE NUT QTY: 22 4 3/8" LOCK NUT QTY: 19 3 TORQUE WASHER QTY: 17 3/8" WASHER QTY: 31 2 1 5/16 X 4-1/2" HEX BOLT QTY: 14 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 34 USE THE RULER TO THE RIGHT TO MEASURE YOUR
1501 HARDWARE 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 9 PAGE: 2 OF 2 REV A: 9/10/2014 JH 8 7 6 5 4 3 #2 SQUARE DRIVE BIT QTY: 1 2 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8 x 7" CARRIAGE BOLT QTY: 14 3/8 x 6-1/2" CARRIAGE BOLT QTY: 2 3/8 x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 19 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
1504 HARDWARE PAGE: 1 OF 1 PRELIMINARY 9/18/2012 J.H. 9 #8 X 2" WOOD SCREW QTY: 71 8 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3" WOOD SCREW QTY: 5 #14 x 3" PAN HEAD SCREW QTY: 3 7 #10 x 3-1/2" WOOD SCREW QTY: 2 6 5 4 5/16" TEE NUT QTY: 18 3 3/8" WASHER QTY: 4 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 31 5/16 X 4-1/2" HEX BOLT QTY: 18 3/8 X 5" HEX LAG SCREW QTY: 4 5/16" WASHER QTY: 49 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
#8 X 1-1/4" WOOD SCREW QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 104 1506 HARDWARE PAGE: 1 OF 1 REV A: 10/31/2014 J.H. #8 X 2" WOOD SCREW QTY: 31 9 8 #8 X 2-1/2" WOOD SCREW QTY: 6 7 #8 X 3" WOOD SCREW QTY: 2 6 5 4 5/16" TEE NUT QTY: 6 3 5/16" WASHER QTY: 6 2 1 5/16 X 4-1/2" HEX BOLT QTY: 5 5/16 X 2-1/2" HEX BOLT QTY: 1 3/8" X 5" LAG SCREW QTY: 9 3/8" WASHER QTY: 9 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
1515 HARDWARE PAGE: 1 OF 1 PRELIMINARY 9/19/2012 J.H. 9 8 7 6 5 4 5/16" TEE NUT QTY: 14 3 2 1 5/16 X 4-1/2" HEX BOLT QTY: 14 5/16" X 3-1/2" LAG SCREW QTY: 16 5/16" WASHER QTY: 30 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.
1528 HARDWARE PAGE 1 OF 1 1/16/2015 SO. #8 X 1" WOOD SCREW QTY: 2 9 #8 X 1-1/4" WOOD SCREW QTY: 25 #8 X 1-1/2" WOOD SCREW QTY: 110 8 #8 X 2" WOOD SCREW QTY: 25 7 #8 X 2-1/2" WOOD SCREW QTY: 12 6 5 #2 SQUARE DRIVE BIT QTY:1 4 3 5/16" WASHER QTY: 12 2 5/16" X 4-1/2" HEX BOLT QTY: 4 5/16" X 2-1/2" HEX BOLT QTY: 2 5/16" x 3-1/2" LAG SCREW QTY: 6 5/16" TEE NUT QTY: 6 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
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PICTURE 1528 DESCRIPTION QTY. 1 X 4 X 29.29" ROOF FINISHER FRONT 1-4-2929-RFFL 1-4-2929-RFFR 1 LEFT 1 RIGHT 1 X 4 X 76-7/8" ROOF STARTER REAR 1-4-7688-RSR 1 1 X 4 X 76-7/8" ROOF STARTER FRONT 1-4-7688-RSF 1 1 X 4 X 76-7/8" ROOF FINISHER REAR 1-4-7688-RFR 1 1 X 5 X 76-7/8" ROOF BOARD 1-5-7688-RB 14 1 X 2 X 32.
PICTURE DESCRIPTION QTY. 1 X 4 X 12-1/4" WALL PANEL BOARD 1-4-1225-WPB 2 1 X 4 X 15-3/4" WALL PANEL BOARD 1-4-1575-WPB 2 1 X 4 X 19-5/16" WALL PANEL BOARD 1-4-1931-WPB 2 5/4 X 5 X 10.
PICTURE DESCRIPTION 2 X 4 X 22.75" WALL PANEL SUPPORT (1 HOLE ON ON CENTER) 2-4-2275-WPSL 2-4-2275-WPSR 2 X 4 X 35.15" ROOF SUPPORT (1 HOLE OFFSET) 2-4-3515-RSL 2-4-3515-RSR 2 X 4 X 69.75" ROOF FINISHER SUPPORT (2 HOLES ON CENTER) 2-4-6975-RFS 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY 5-11-4697-RPRA 5 X 11 X 46.97" ROOF PANEL LEFT ASSEMBLY 5-11-4697-RPLA QTY.
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PICTURE DESCRIPTION 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD 2-6-3043-SBPB QTY.
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PICTURE HARDWARE BOXES: 1501, 1528, 1504, 1506, 1515 DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCK (5 ROCKS ARE IN ONE BAG) 07-0008 10 A-FRAME SWING LEG BRACKET 11-5010 1 1 INSTRUCTIONSEA.
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PICTURE (NOT SHOWN) DESCRIPTION MANUFACTURER LOGO PLATE GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004 QTY.
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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 108" CORNER POSTS AND 4 X 4 X 120" MIDDLE CORNER POST IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" SIDE SANDBOX BOARD- RIGHT ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SIDE SANDBOX BOARD - RIGHT MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 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 78" SIDE SANDBOX BOARD - LEFT ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SIDE SANDBOX BOARD - LEFT MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SIDE SANDBOX BOARD - LEFT 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. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER RUNNER TO THE T-NUTS INSTALLED IN THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD SHOULD BE OFFSET UP.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED IN THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" BACK PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE BACK PANEL BOARD MUST BE OFFSET DOWN.
STEP 7: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED.
STEP 8: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAGSCREWS WITH 5/16" WASHERS. 2 X 4 X 14" BOTTOM PANEL BOARD COUNTER-SUNK HOLES ON CENTER 5/16" WASHER 5/16" X 3-1/2" LAG SCREW FRONT OF FORT 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 UPAND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 9: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT. 2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE ANGLE SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 10: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER.
STEP 11: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND DRAW A LINE ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. 3: CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT ON THE LINE AND PUSH THE CENTER DECK SUPPORT FLUSH TO THE BOTTOM SIDE OF THE DECK SPACERS.
STEP 12: 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" 3 24" 3 18" 1 48" 1 48" 1 48" 1 48" 11 23 16 " 1 8" 2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT.
STEP 13: ROCK WALL 1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER.
STEP 14: ROCK WALL 1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2" WOOD SCREWS IN EACH SIDE. 3: CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS, FASTENING EACH BOARD WITH TWO 2" WOOD SCREWS ON EACH END. 4: THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE.
STEP 15: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
STEP 16: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT.
STEP 17: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE FRONT - LEFT CUT OUT AREA OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE FRONT FACE BOARD. 2: GO UNDERNEATH THE DECK TO INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE FRONT FACE BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
STEP 18: LADDER 2 X 4 X 66" LADDER SIDE 1: FIND TWO 2 X 4 X 66" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. T-NUT 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER. 2" WOOD SCREW 4: FIND FIVE 2 X 4 X 17" LADDER STEPS. 5: PLACE THE STEPS INTO THE SLOTS ON THE LADDER SIDES, AND FASTEN WITH 2" WOOD SCREWS. 2 X 4 X 17" LADDER STEP 6: CAREFULLY TURN THE LADDER OVER AND PUT THE SCREWS INTO THE OTHER SIDE.
STEP 19: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE LEFT SIDE OF THE FORT AS SHOWN BELOW. CENTER THE LADDER HORIZONTALLY ON THE 2 X 6. CENTER THE 90 BRACKETS VERTICALLY ON THE 2 X 6. USE THE HOLES IN THE LADDER BRACKETS AS A TEMPLATE TO DRILL 3/8" HOLES THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACK SIDE OF THE 3/8" HOLES ON THE BOTTOM PANEL BOARD. 3: ATTACH THE LADDER WITH 5/16" X 1-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 20: 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 21: UPPER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE UPPER LEVEL PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLY TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT POSTS PROPERLY. 4: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW.
STEP 22: LAG POSTS 1: TWO 4 X 4 60-1/4" LAG POSTS WILL BE USED TO EXTEND THE MIDDLE CORNER POSTS TO ACCEPT THE UPPER LEVEL ROOF. 2: MAKE SURE TO INSTALL THE T-NUTS INTO THE LAG POSTS TOP HOLES AS SHOWN IN THE DRAWING BELOW BEFORE MOUNTING IT TO THE MIDDLE POSTS. 3: REST THE BOTTOM OF EACH LAG POST ON TOP OF THE 2 X 6 X 70 BACK PANEL BOARD. 4: CENTER EACH LAG POST DIRECTLY OVER THE CENTER OF THE MIDDLE CORNER POSTS.
STEP 23: REAR CORNER POSTS & DECK SUPPORTS & SIDE TOP PANEL BOARDS TIP: BEFORE YOU INSTALL THESE BOARDS LEAVE THEM ALL A LITTLE LOOSE. WHEN YOU HAVE FASTENERS IN ALL THE BOARDS GO BACK AND TIGHTEN THEM ALL UP. 1: ATTACH THE BOTTOM OF THE REAR CORNER POSTS TO THE SIDE SANDBOX BOARDS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 2: PLACE THE 2 X 4 X 30-7/16" SIDE TOP PANEL BOARDS (OFFSET DOWN) AT THE TOP OF THE CORNER POSTS ON THE SIDES OF THE FORT.
STEP 24: UPPER LEVEL - RAILING & UNDER DECK SUPPORT 1: PLACE THE 2 X 4 X 70" UPPER LEVEL STEPS/RAILING BOARD (3 HOLES ON CENTER) AT THE TOP OF THE REAR CORNER POSTS. THIS BOARD WILL GET ATTACHED TO THE 2ND HOLE DOWN FROM THE TOP OF THE POSTS. THE T-NUT FOR THIS BOARD SHOULD BE ON THE INSIDE OF EACH POST ALREADY. FASTEN THE UPPER LEVEL RAILING BOARD TO THE REAR CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 25: CENTER DECK SUPPORT ASSEMBLY NOTE: IT IS BEST TO PLACE THESE BOARDS UPON A FLAT SURFACE BEFORE ATTACHING THEM TOGETHER. 1: PLACE ONE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET UP) ON THE RIGHT SIDE OF THE 4 X 4 X 30-1/2" UPPER LEVEL CENTER BLOCK SUPPORT. PLACE ONE MORE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET DOWN) ON THE LEFT SIDE OF THE 4 X 4 X 30-1/2" UPPER LEVEL CENTER BLOCK SUPPORT. 2: MAKE SURE THE ENDS AND BOTTOMS OF THE BOARDS ARE FLUSH TO ONE ANOTHER.
STEP 26: LOWER LEVEL CENTER POST 1: HAMMER A T-NUT INTO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST HOLE. 2: ATTACH THE LOWER LEVEL CENTER POST TO THE MIDDLE HOLE OF THE 2 X 6 X 70" BACK PANEL BOARD. USE A 5/16" X 4-1/2" HEX BOLT AND A 5/16" WASHER TO ATTACH THE BOARDS TOGETHER. 3: HAVE AN ASSISTANT HOLD THIS BOARD UP FOR YOU AND PROCEED TO STEP 27.
STEP 27: CENTER DECK SUPPORT ASSEMBLY INSTALLATION AND LAGS 1: PLACE THE CENTER DECK SUPPORT ASSEMBLY ON TOP OF THE 4 X 4 X 70" UPPER LEVEL UNDER DECK SUPPORT. THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST SHOULD FIT INSIDE THE CENTER DECK SUPPORT ASSEMBLY. 2: MAKE THE CENTER DECK SUPPORT ASSEMBLY LEVEL WITH THE CENTER DECK SUPPORTS. THE END OF THE CENTER DECK SUPPORT ASSEMBLY SHOULD BE FLUSH TO THE SIDE OF THE LOWER LEVEL CENTER POST.
STEP 28: UPPER LEVEL DECK SPACERS 1: MAKE SURE THE LOWER LEVEL CENTER POST HAS AN EQUAL OPENING ON EACH SIDE. 2: PLACE THE 5/4 X 4 X 29-1/2" UPPER DECK SPACERS BETWEEN THE LOWER LEVEL CENTER POST AND THE MIDDLE CORNER POSTS. ATTACH EACH UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2" WOOD SCREWS. 3: PLACE THE 5/4 X 4 X 63" UPPER DECK SPACER BETWEEN THE UPPER LEVEL LAG POSTS. ATTACH THE UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2" WOOD SCREWS.
STEP 29: SLIDE BLOCK 1: PLACE THE 4 X 4 X 23-1/2" SLIDE BLOCK AGAINST THE UPPER DECK SUPPORT ON THE LEFT SIDE (LADDER SIDE) OF THE PLAY SET. THE TOP OF THE BLOCK SHOULD BE FLUSH TO THE TOP OF THE DECK SUPPORT. THE BLOCK FITS BETWEEN THE LAG POST AND THE REAR CORNER POST. 2: HAVE AN ASSISTANT HOLD THE BOARD IN POSITION OR USE A CLAMP TO HOLD THE BOARD FIRMLY TO THE DECK SUPPORT. USE THE HOLES IN THE SLIDE BLOCK AS A TEMPLATE TO DRILL 3/8" HOLES THROUGH THE DECK SUPPORT.
STEP 30: ANGLE SUPPORT - UPPER LEVEL REAR 1: PLACE A 2 X 4 X 18" ANGLE SUPPORT -UPPER LEVEL REAR AGAINST THE 4 X 4 X 70 UPPER LEVEL UNDER DECK SUPPORT ON EACH SIDE AT THE REAR OF THE PLAY SET. 2: THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH TO THE TOP OF THE UNDER DECK SUPPORT. FASTEN THE TOP OF THE ANGLE SUPPORT TO THE UNDER DECK SUPPORT WITH FOUR #8 X 2-1/2" WOOD SCREWS. 3: FASTEN THE BOTTOM OF THE ANGLE SUPPORT TO THE REAR CORNER POST WITH ONE #8 X 2" WOOD SCREW AND ONE #8 X 3" WOOD SCREW.
STEP 31: SIDE REAR ANGLE SUPPORTS 1: (SEE DETAIL A) PLACE THE 2 X 4 X 18" ANGLE SUPPORT UPPER LEVEL RAD RIDE SIDE UNDER THE 4 X 4 X 231/2" SLIDE BLOCK ON THE LEFT SIDE OF THE FORT. THE ANGLE SUPPORT SHOULD BE FLUSH TO THE LEFT SIDE OF THE LEFT REAR CORNER POST. ATTACH THE ANGLE SUPPORT AT THE TOP AND AT THE BOTTOM WITH ONE #8 X 2" WOOD SCREW AND ONE #8 X 3" WOOD SCREW.
STEP 32: UPPER LEVEL DECK BOARDS 1: PLACE FOUR 5/4 X 6 X 69-7/8" UPPER DECK BOARDS ACROSS THE DECK SUPPORTS AS SHOWN. EQUALLY SPACE THE DECK BOARDS 5/16" FROM ONE ANOTHER AND FROM THE DECK SPACER. 2: SECURE EACH UPPER DECK BOARD TO THE DECK SUPPORTS WITH FIVE #8 X 2" WOOD SCREWS.
STEP 33: SLIDE POST ASSEMBLY 1: PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH IN THE 4 X 4 X 43-1/2" RAD RIDE CENTER POST. 2: PLACE ONE END OF THE 5/4 X 4 X 25" RAD RIDE DECK SPACER INTO THE NOTCH IN THE RAD RIDE CENTER POST. THE END WITHOUT ANY PREDRILLED HOLES GOES INTO THE NOTCH. 3: FASTEN THE RAD RIDE DECK SPACER TO THE RAD RIDE CENTER POST WITH TWO #8 X 3-1/2" WOOD SCREWS. 4 X 4 X 43-1/2" RAD RIDE CENTER POST PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH.
STEP 34: SLIDE POST INSTALLATION 1: PLACE THE END OF THE DECK SPACER AGAINST THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. FASTEN THE DECK SPACER TO THE DECK SUPPORT WITH #8 X 2" WOOD SCREWS. 2: MAKE THE DECK SPACER LEVEL WITH THE DECK BOARD BEHIND IT. DRIVE A 3/8" X 5" LAG SCREW WITH 3/8" WASHER THROUGH THE RAD RIDE CENTER POST INTO THE 4 X 4 X 70" UNDER DECK SUPPORT. 3: MEASURE THE BOTTOM OPENING AND RECORD THIS MEASUREMENT.
STEP 35: UPPER LEVEL REAR DECK SPACER 1: PLACE THE 5/4 X 4 X 35-1/2" REAR DECK SPACER ON TOP OF THE DECK SUPPORTS. THE END SHOULD BE FLUSH TO THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST/CENTER POST. 2: FASTEN THE REAR DECK SPACER TO THE DECK SUPPORTS WITH FOUR #8 X 2" WOOD SCREWS.
STEP 36: UPPER LEVEL CENTER POST 1: PLACE THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST AGAINST THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST. FLUSH THE TOPS AND SIDES OF THE POSTS TOGETHER. 2: ATTACH THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST TO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS.
STEP 37: RAILING 1: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD (RAILING) AGAINST THE MIDDLE POSTS, FLUSH WITH THE TOP END OF THE CENTER POST. 2: THE TOP OF THE RAILING SHOULD BE 33" ABOVE THE DECK BOARDS. 3: ATTACH THE RAILING TO THE LAG POSTS AND UPPER LEVEL CENTER POST WITH 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 38: RADICAL RIDE TUBE SLIDE 1: ASSEMBLE THE RADICAL RIDE TUBE SLIDE ACCORDING TO THE DIRECTIONS INCLUDED WITH THE SLIDE. 2: PLACE THE SLIDE FACEPLATE AT THE OPENING AT THE REAR OF THE PLAY SET. THE SIDE OF THE FACE PLATE SHOULD BE 3/4" AWAY FROM THE CORNER POST SIDE. 3: THE BOTTOM OF THE SLIDE OPENING SHOULD BE FLUSH WITH THE UPPER LEVEL DECK. 4: ATTACH THE SLIDE FACE PLATE TO THE CORNER POST AND RAD RIDE CENTER POST WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 39: UPPER LEVEL BOTTOM PANEL BOARDS 1: PLACE THE 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD (OFFSET UP) ON THE SWING BEAM SIDE (RIGHT SIDE) OF THE PLAYSET. ATTACH THE TOP HOLES OF THE BOARD TO THE POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. ATTACH THE BOTTOM HOLES WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2: PLACE THE 2 X 6 X 42-1/2" REAR BOTTOM PANEL BOARD (OFFSET DOWN) ON THE BACK SIDE OF THE UPPER LEVEL.
STEP 40: UPPER LEVEL REAR CENTER POST 1: PLACE THE 2 X 4 X 35-5/8" UPPER LEVEL REAR CENTER POST AGAINST THE REAR RAILING ON THE UPPER LEVEL. HAMMER A T-NUT INTO THE TOP HOLE IN THE UPPER LEVEL REAR CENTER POST. LINE UP THE HOLE IN THE UPPER LEVEL REAR CENTER POST WITH THE HOLE IN THE REAR RAILING. 2: ATTACH THE UPPER LEVEL CENTER POST TO THE RAILING AT THE TOP WITH A 5/16" X 21/2" HEX BOLT WITH A 5/16" WASHER.
STEP 41: UPPER LEVEL PANEL SLATS 1: 5/4 X 3 X 34-1/2" PANEL SLATS WILL BE INSTALLED ON THE LEFT, RIGHT AND REAR-RIGHT SIDES OF THE PLAY SET. THE PANEL SLATS WILL BE INSTALLED ON THE INSIDE OF THE BOTTOM PANEL BOARDS AND RAILINGS. 2: SPACE THE PANEL SLATS IN THE OPENINGS AS SHOWN BELOW. ATTACH EACH PANEL SLAT WITH TWO #8 X 2" WOOD SCREWS.
STEP 42: LOWER LEVEL FRONT CENTER POST 1: LOCATE THE 2 X 4 X 28-9/16" CENTER POST. PLACE THE 2 X 4 X 28-9/16" CENTER POST CENTERED BEHIND THE HOLE IN THE ROPE LADDER SUPPORT. 2: HAMMER A T-NUT INTO THE HOLE IN THE BACK SIDE OF THE CENTER POST. FASTEN THE CENTER POST TO THE ROPE LADDER SUPPORT WITH A 5/16" X 2-1/2" HEX BOLT AND A 5/16" WASHER. 3: SQUARE THE CENTER POST TO THE DECK. ATTACH THE CENTER POST TO THE FRONT FACE BOARD WITH TWO #8 X 2-1/2" WOOD SCREWS FROM THE REAR.
STEP 43: UPPER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" UPPER LEVEL STEP FLUSH WITH THE TOP OF THE UPPER LEVEL DECK SPACERS. UPPER LEVEL STEPS HAVE THREE HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16" WASHERS. 3: LEAVE A 3-3/8" GAP BETWEEN THE UPPER LEVEL STEP YOU JUST INSTALLED AND THE NEXT UPPER LEVEL STEP. ATTACH THE NEXT UPPER LEVEL STEP WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16" WASHERS.
STEP 44: LOWER LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FOUR SLATS ON THE LEFT SIDE, SIX SLATS ON THE RIGHT SIDE AND TWO SLATS ON THE FRONT OF THE LOWER LEVEL. 2: PLACE EACH SLAT AS SHOWN BELOW ON THE INSIDE OF THE PANEL BOARDS AND ATTACH EACH PANEL SLAT TO THE FORT WITH TWO #8 X 2" WOOD SCREWS.
STEP 45: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT USING 3/8" X 3-1/2" CARRIAGE BOLTS ON TOP AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. USE BOLT CAPS TO COVER ANY EXPOSED THREADS. 3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER. 4: IF NECESSARY USE LOCKING PLIERS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.
STEP 46: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
STEP 47: 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 48: REST SWING BEAM ON FORT 1: REST THE SWING BEAM ASSEMBLY ON TOP OF THE UPPER RAILING BOARDS OF THE FORT. 2: THE END OF THE SWING BEAM WITH 2 HOLES SHOULD OVERHANG THE SWING BEAM SIDE OF THE FORT. IN THE NEXT STEP YOU WILL ATTACH THE SWING BEAM LEGS ONTO THIS END OF THE SWING BEAM.
STEP 49: 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 50: MOUNT SWING BEAM TO FORT 1: PLACE A 3/8" X 9" CARRIAGE BOLT THROUGH A TORQUE WASHER. INSERT THE CARRIAGE BOLT INTO THE HOLE AT THE END OF THE SWING BEAM OVER THE SWING BEAM MOUNT. ALIGN THE SQUARE SHANK OF THE CARRIAGE BOLT WITH THE SQUARE HOLE IN THE TORQUE WASHER. HAMMER THE CARRIAGE BOLT TO SET THE TORQUE WASHER INTO THE SWING BEAM. 2: ON THE BOTTOM SIDE OF THE SWING BEAM MOUNT ATTACH A 3/8" FLAT WASHER AND A 3/8" LOCK NUT ONTO THE END OF THE CARRIAGE BOLT.
STEP 51: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THE LEGS ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY EITHER: A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
STEP 52: 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 53: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.
STEP 54: UPPER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE UPPER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LAG POSTS OR REAR CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS WITH 5/16" WASHERS.
STEP 55: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE UPPER LEVEL ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH TOP SIDE 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.
STEP 56: UPPER LEVEL ROOF 1: PLACE THE 1 X 6 X 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH FOUR #8 X 1-1/4" WOOD SCREWS.
STEP 57: UPPER LEVEL ROOF 1: PLACE THE TONGUE OF A 1 X 6 X 30-1/2" ROOF BOARD INTO THE SLOT OF THE ROOF FINISHER. ALIGN THE ENDS OF THE BOARDS. FASTEN THE ROOF BOARD TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREW. REPEAT THIS PROCESS FOR EIGHT MORE ROOF BOARDS. 2: PLACE A 1 X 4 X 30-1/2" ROOF FINISHER AT THE END OF THE ROOF. PLACE THE TONGUE OF THE ROOF FINISHER INTO THE GROOVE OF THE LAST ROOF BOARD, THEN ALIGN THE ENDS OF THE BOARDS.
STEP 58: SUN SUPPORT ASSEMBLY 1: CENTER A 2 X 6 X 13-5/8" SUN ON TOP OF A 5/4 X 3 X 42" SUN SUPPORT. THE BOTTOM OF THE SUN SHOULD BE 1" ABOVE THE BOTTOM OF THE SUN SUPPORT 2 X 6 X 13-5/8" SUN 5/4 X 3 X 42" SUN SUPPORT 1" 2: FASTEN THE SUN TO THE SUN SUPPORT WITH #8 X 2" WOOD SCREWS.
STEP 59: SUN SUPPORT INSTALLATION 1: PLACE A SUN SUPPORT ASSEMBLY ON THE INSIDE OF THE ROOF SUPPORTS AT THE FRONT OF THE UPPER LEVEL ROOF. THE SUN SHOULD FACE THE OUTSIDE AT THE FRONT OF THE UPPER LEVEL ROOF. 2: ATTACH THE SUN SUPPORT ASSEMBLY TO THE ROOF SUPPORTS WITH FOUR #8 X 2" WOOD SCREWS.
STEP 60: SUN RAYS 1: LOCATE SIX 5/4 X 2 X 10" SMALL RAYS AND ONE 5/4 X 2 X 16" LARGE RAY. 2: PLACE THE LARGE RAY CENTERED OVER THE MIDDLE OF THE SUN ON THE INSIDE OF THE SUN SUPPORT ASSEMBLY. FASTEN THE LARGE RAY TO THE ROOF SUPPORT AND SUN WITH TWO #8 X 2" WOOD SCREWS. 3: ARRANGE THREE SMALL RAYS ON EACH SIDE OF THE LARGE RAY. SPACE THE RAYS AS SHOWN IN THE SMALL PICTURE AT THE LEFT BELOW. FASTEN EACH SMALL RAY TO THE ROOF SUPPORT AND SUN WITH TWO #8 X 2" WOOD SCREWS.
STEP 61: CROWN 1: PLACE A PLASTIC CROWN OVER THE SUN ON THE FRONT SIDE OF THE UPPER LEVEL ROOF. 2: ATTACH THE PLASTIC CROWN TO THE SUN WITH #8 X 1-1/4" WOOD SCREWS.
STEP 62: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 35.15" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35.15" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN.
STEP 63: ROOF SUPPORTS (LOWER LEVEL) 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE LOWER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LOWER LEVEL CORNER POSTS WITH 5/16 X 4-1/2" HEX BOLTS WITH 5/16" WASHERS. ROOF PEAK SUPPORT (TRIANGLE) ON INSIDE.
STEP 64: ROOF STARTER REAR 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER BOARD AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER SHOULD BE PLACED FLUSH TO THE PEAK OF THE ROOF SUPPORTS. 2: FASTEN THE ROOF STARTER REAR TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS. WHEN ATTACHING THE ROOF STARTER DIM B AT THE ROOF PEAK SHOULD MATCH DIM A.
STEP 65: ROOF REAR SECTION 1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR. THIS SIDE OF THE ROOF GETS FOUR BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE THE 1 X 4 X 76-7/8" ROOF FINISHER AT THE END OF THE ROOF ASSEMBLY, AND FASTEN WITH 1-1/2" WOOD SCREWS.
STEP 66: ROOF FRONT SECTION 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPPING THE ROOF STARTER REAR. THE HOLES IN THE ROOF STARTER FRONT SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER FRONT SHOULD BE PLACED FLUSH TO THE TOP EDGE OF THE ROOF STARTER REAR. 2: FASTEN THE ROOF STARTER FRONT TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 67: DORMERS 1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE DORMERS. AFTER INSTALLING THE SEVENTH ROOF BOARD, INSTALL THE DORMER MOUNTING BLOCK 9-3/4" FROM THE SIDE EDGE OF THE ROOF TO THE SIDE EDGE OF THE DORMER MOUNTING BLOCK, AND 15" FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE TOP EDGE OF THE DORMER MOUNTING BLOCK. INSERT TWO #8 X 2" WOOD SCREWS THROUGH THE MOUNTING BLOCK INTO THE ROOF BOARD.
STEP 68: FRONT GABLE ASSEMBLY 1: FIND ONE 5 X 11 X 46.97" ROOF PANEL LEFT ASSEMBLY, ONE 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY, ONE 5/4 X 5 X 10.81 ROOF PANEL PEAK SUPPORT AND A FRONT PLASTIC ARCH. 2: PLACE THE ROOF PANEL ASSEMBLIES ON A FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP, ALIGN THE ANGLED ENDS OF THE ROOF PANEL ASSEMBLIES FLUSH AT THE PEAK AND LEAVING A GAP AT THE BOTTOM OF THE SEAM, THIS PROVIDES YOU FREEDOM FOR ADJUSTABILITY. FLUSH (AT THE PEAK) 5 x 11 x 46.
STEP 69: ATTACHING THE FRONT GABLE 1: MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE TOP PANEL BOARD, MAKE SURE THE GABLE ASSEMBLY IS FLUSH AGAINST THE FRONT CORNER POSTS. THE GABLE ROOF PEAK SHOULD BE RESTING ON TOP OF THE ROOF FRONT SECTION. TIP: MAKE SURE THE DISTANCE BETWEEN THE GABLE ASSEMBLY AND THE ROOF OVERHANG IS EQUAL ON BOTH SIDES. IT IS RECOMMENDED TO TEST FIT THE 1 X 4 X 29.29" ROOF FINISHERS FRONT LEFT AND RIGHT TO ASSURE THIS EQUAL DISTANCE (DO NOT FASTEN).
STEP 70: WALL PANEL SUPPORTS 1: PLACE THE 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE AND THE OPPOSITE END WITH THE COUNTERSUNK HOLE FLUSH AGAINST THE LEFT FRONT CORNER POST. MAKE SURE THE ANGLED END OF THE WALL PANEL SUPPORT IS FLUSH TO THE INSIDE OF THE GABLE ASSEMBLY. THE WALL PANEL SUPPORT TOP EDGE MUST BE PARALLEL AT 21-7/8" TO THE TOP EDGE OF THE ROPE LADDER SUPPORT. ATTACH THE WALL PANEL SUPPORT LEFT TO THE GABLE ASSEMBLY WITH ONE #8 X 2-1/2" WOOD SCREW.
STEP 71: ROOF FINISHERS FRONT 1: PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE. PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT ANGLED END ON TOP OF THE GABLE ASSEMBLY RIGHT SIDE. FIT THE TONGUE END INTO THE GROOVE OF THE ROOF BOARD ABOVE THEM. 2: MAKE SURE THAT BOTH ROOF FINISHERS ENDS ARE FLUSH ON BOTH SIDES OF THE ROOF AND TIGHT TO THE GABLE ASSEMBLY. TIP: DO THIS ONLY IF "THE ROOF FINISHERS ARE UNEVEN WITH THE OVERHANG".
STEP 72: ROOF BATTEN 1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE FRONT ROOF PANEL, CENTERED BETWEEN THE ROOF SUPPORTS, FLUSH THE BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD, MAKE SURE IS PARALLEL TO THE ROOF SUPPORTS. INSERT 1-1/4" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ALONG THE BATTEN. 2: THE REMAINING 1 X 2 X 32" ROOF BATTEN WILL BE CUT TO FIT THE REAR ROOF PANEL SECTION. MEASURE FROM THE BOTTOM END 22-1/2" TO THE TOP, MAKE A MARK WITH A PENCIL.
STEP 73: WALL PANEL BOARDS 1: START MOUNTING THE 1 X 4 X 19.31" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT,THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE FRONT LEFT CORNER POST. THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1" TO THE SIDE EDGE OF THE GABLE ROOF SUPPORT. FASTEN THE WALL PANEL BOARD WITH FOUR 1-1/2" WOOD SCREWS. 2: MOUNT THE 1 X 4 X 15.
STEP 74: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF, THE PLASTIC SUNBEAM MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS ON THE TOP AND SIX #8 X 2" WOOD SCREWS ON THE REMAINING HOLES.
STEP 75: SOLAR WALL LIGHTS 1: WITH A PENCIL MAKE A CENTER MARK ON THE OUTSIDE FACE OF THE 1 X 4 X 19.31 WALL PANEL BOARD, MEASURE 4-7/8" HORIZONTALLY FROM THE OUTSIDE EDGE OF THE CORNER POST TOWARDS THE CENTER OF THE WALL PANEL BOARD AND 2-3/8" FROM THE BOTTOM EDGE OF THE WALL PANEL SUPPORT TOWARDS THE CENTER OF THE WALL PANEL BOARD AS SHOWN IN THE DIAGRAM BELOW.
STEP 76: SAFETY BOARDS 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS. 2: PLACE THE 2 X 4 X 34" SAFETY BOARD (UPPER LEVEL) ON TOP OF THE 2 X 4 X 47-1/2" SAFETY BOARD (LOWER LEVEL). ATTACH IT WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 77: 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 78: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT 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 LEFT-MIDDLE CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSDE 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 LEFT-FRONT CORNER POST.
STEP 79: 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 80: SANDBOX SEATS AND NAME PLATE 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET. ATTACH THE NAME PLATE TO THE FRONT OF THE SWING BEAM WITH #8 X 1" WOOD SCREWS. PLACE NAME PLATE HERE AND ATTACH WITH #8 X 1" WOOD SCREWS.
STEP 81: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 3: LOCATE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS. EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIE TAC TOE MOUNT. GREEN BRACKET 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT TIC TAC TOE AFTER ASSEMBLING.
STEP 82: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAYSET ON THE INSIDE. THE 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. SWING BEAM #8 X 1-3/4" WOOD SCREW TIC TAC TOE WITH BOARDS ATTACHED. 4" NOTE: 2 X 6 X 102" ROPE LADDER SUPPORT REMOVED FOR CLARITY.
STEP 83: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENNING AT THE FRONT RIGHT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH #14 X 1-1/4" PAN HEAD SCREWS.
STEP 84: INSTALLING THE ROCK WALL ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE ROPE LADDER SUPPORT. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND. HINT: TO REDUCE THE AMOUNT OF SLACK IN THE ROPE, LIFT THE ROCK WALL ASSEMBLY SLIGHTLY WHEN TYING THE KNOT IN THE BOTTOM ROCK WALL BOARD.
STEP 85: SAFETY HANDLES (LOWER LEVEL) 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 86: SAFETY HANDLES (UPPER LEVEL) 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 LAG POSTS AND CENTER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 87: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK (UPPER LEVEL). 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2" LAG SCREW AND WASHER TO FASTEN THE STEERING WHEEL TO THE REAR CENTER POST. DO NOT OVER-TIGHTEN THE LAG SCREW OR THE STEERING WHEEL WILL NOT TURN. 5: PLACE THE STEERING WHEEL CAP OVER THE STEERING WHEEL AND SNAP IT INTO THE STEERING WHEEL INSERT.
STEP 88: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT ON THE ROCK WALL SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOP 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 89: HANGING THE SWINGS 1: START BY ATTACHING ONE SPRING CLIP TO EACH IRON DUCTILE ON THE SWING BEAM. 2: ATTACH ONE CHAIN PER ACCESSORY TO EACH SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED.
STEP 90: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. 2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #8 X 2" WOOD SCREW PROVIDED WITH THE GROUND STAKE.
APPENDIX 137
Jumbo Binoculars (07-0003) 1: Attach the Binocular Base to the top of the wood railing on your play set. Fasten with one 5/16" x 1-1/4" lag screw and one 8mm washers included with the Binoculars. 2: Place the bottom side of the Binoculars with the hole in it inside the Binocular Base. Line up the holes in the Binocular Base with the hole on the bottom side of the Binoculars. 3: Slide the 8mm diameter x 106mm length Pivot Rod through the holes.
Chalkboard (07-0018) 1. Chalkboard may be mounted with the checkerboard "horizontal" or "vertical". 2. Attach Chalkboard to wood slats or plywood with four of the 3/4" (20mm)long pan head screws provided. Please note: Chalkboard comes with a magnetic chalk holder which will stick to the chalkboard. This chalk holder is not shown below.
Phone (07-0014) 1. Place the Phone Base on the top or the side of an existing board on your play set. The board should be at least 1" thick. If the board is not 1" thick then trim the tip of the screw flush to the back side of the board after it is installed. 2. Place the black rubber washer over the end of the 1" long phillips head screw. Insert the screw into the hole in the phone base and screw it into the board. Do not overtighten screw. Over-tightening may cause the plastic to crack. 3.
1529 HARDWARE PAGE 1 OF 1 1/16/2015 S.O. #8 X 1-1/4" WOOD SCREW QTY: 22 9 #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 7 6 #2 SQUARE DRIVE BIT QTY:1 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.
STEP 1: DORMER SUNRAYS AND SIDES 1: FIND ONE DORMER SIDE LEFT ASSEMBLY AND ONE DORMER SIDE RIGHT ASSEMBLY. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY. ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW.
STEP 2: DORMER WINDOW 1: MOUNT THE DORMER WINDOW IN THE FRONT OF THE DORMER, THE WINDOW SHOULD FIT IN BETWEEN THE DORMER SIDES AND THE DORMER SUNRAY. THE BACK FACE OF THE WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS. 2: MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DORMER WINDOW AND FASTEN WITH #8 X 1-1/2" WOOD SCREWS.
STEP 3: DORMER ROOF PANELS 1: FIND TWO DORMER ROOF PANEL ASSEMBLIES. 2: PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY ASSEMBLIES, THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK, MAKE SURE THE PRE-DRILLED HOLES ON THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES. FASTEN WITH #8 X 1-1/2" WOOD SCREWS. 3: REPEAT THE PREVIOUS SUB-STEP FOR THE OTHER SIDE.
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.
Leftover Parts List 1500GWR Play Set Our 1500 series play sets are modular and include parts to construct many different models. Some of these parts included with your play set will not be used because they are for a different model. The list below includes parts for your play set that will be leftover when construction is completed. 2 pieces 125-3-2825-PS Panel Slats (We include these parts in case the customer wishes to fill in the area where the Tic Tac Toe is located.
