™ playsets ™ playsets Malibu Frontier Timber Shield Post Option BOXES: X1, TSB, 120 Model: 1500BWR (BOXES: 1501, 1510, 1511, 1523, 1528, 1529 & Slide Box) *51-0075-W* 51-0075-W Copyright © 2016 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.
Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our “Quick Response Center” located at: www.gorillaplaysets.com/support DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECTLY. THE RETAILER DOES NOT STOCK COMPONENTS. PLEASE RETAIN ALL INSTRUCTIONS FOR FUTURE REFERENCE.
GORILLA PLAYSETS WARRANTY – 2016 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set. As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury.
Warranty registration - MaLiBU Frontier 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.
Timber Shield Post Option BOXES: X1, TSB, 120 Model: 1500BWR (BOXES: 1501, 1510, 1511, 1523, 1528, 1529 & Slide Box) REV: 12.17..
TABLE OF CONTENTS Safety Guidelines……………………………………….......……...........................Pages 3-6 Leveling Fort, General Information and Definitions…………………...................Pages 6-8 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading........................................................................................Pages 9-13 Site Plan, Required Tool List and Kit Contents...............................................
Safety and Maintenance Tips for Your New Play Set: NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with your children.
Safety and Maintenance Tips for Your New Play Set: (continued) Playgrounds should be inspected on a regular basis. If any of the following conditions are noted, they should be removed, corrected, or repaired immediately to prevent injuries. • Hardware that is loose, worn or that has protrusions or projections. • Exposed equipment footings. • Scattered debris, litter, rocks, or tree roots. • Splinters, large cracks, and decayed wood components.
Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6’ in all directions from the perimeter of the equipment. Swings should have a fall zone extending a minimum of 6’ from the outer edge of the support structure on each side.
General Info to Review Before Installation • Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly. • Identify all of the parts for your play set. Empty each box and lay out boards so you can see each part. Your instruction book will have detailed drawings that will make it easy for you to recognize individual parts.
This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board.
Common Installation Practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut This picture shows the T-nut inserted and installed flush to the wood. Flush (Correct) Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood. This picture shows an end view of the T-nut installed flush to the wood.
HOW A T-NUT WORKS THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS. THE T-NUT HAS A BARREL SHAPED END WHICH GOES INTO THE HOLE IN THE CORNER POST. THE T-NUT ALSO HAS AN FLANGE SHAPED END WITH TEETH.
BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" • The 2 is the thickness of the board. "Nominal Lumber" at a home center will measure 11/2" for the thickness. We "remill" that lumber to 1-3/8" thick.
PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole. Pay attention to the DIAMETER of the lag screw you are installing. Your playset may come with two different diameter lag screws.
SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs. Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs. 2) The maximum allowable swinging weight at the Trapeze position is 125 lbs. 3) The MAXIMUM SWING BEAM LOAD IS 425 lbs.
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”, 7/64”, 11/64” and a 7/8” Paddle style bit.
1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" PAN HEAD SCREW QTY: 4 #8 X 1-3/4" WOOD SCREW QTY: 4 9 8 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 6 7 #8 X 3" WOOD SCREW QTY: 20 6 5 5/16" TEE NUT QTY: 22 4 3/8" LOCK NUT QTY: 19 3 TORQUE WASHER QTY: 17 3/8" WASHER QTY: 31 2 1 5/16 X 4-1/2" HEX BOLT QTY: 14 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 34 USE THE RULER TO THE RIGHT TO MEASURE YOUR B
1501 HARDWARE 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 9 PAGE: 2 OF 2 REV A: 9/10/2014 JH 8 7 6 5 4 3 #2 SQUARE DRIVE BIT QTY: 1 2 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8 x 7" CARRIAGE BOLT QTY: 14 3/8 x 6-1/2" CARRIAGE BOLT QTY: 2 3/8 x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 19 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
3/8 X 3-1/2" HEX LAG SCREW QTY: 11 1510 HARDWARE PAGE: 1 OF 1 REV B 8/19/2014 JH 9 TORQUE WASHER QTY: 4 8 5/16" TEE NUT QTY: 2 7 5/16" PLASTIC BOLT CAP QTY: 2 3/8" PLASTIC BOLT CAP QTY: 4 6 5 3/8" LOCK NUT QTY: 4 4 3/8" WASHER QTY: 17 3 2 5/16 X 7" HEX BOLT QTY: 2 3/8 x 7" CARRIAGE BOLT QTY: 4 1/2" WASHER QTY: 2 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
1511 HARDWARE PAGE: 1 OF 1 REV A 2/4/2013 J.H. 9 8 #8 X 2" WOOD SCREW QTY: 20 7 6 5 4 5/16" TEE NUT QTY: 10 3 2 1 5/16" X 3-1/2" HEX LAG SCREW QTY: 14 5/16 X 4-1/2" HEX BOLT QTY: 12 5/16" WASHER QTY: 26 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
5/16" X 2-1/2" LAG SCREW QTY: 4 5/16" X 2-1/2" HEX BOLT QTY: 6 5/16" X 1-1/2" HEX BOLT QTY: 4 11-0065 1523 Hardware 9/17/2014 JH 9 8 7 #8 X 3-1/2" WOOD SCREW QTY: 4 #8 X 1-1/4" PAN HEAD SCREW SQUARE DRIVE QTY: 16 #8 X 2-1/2" WOOD SCREW QTY: 127 6 3/8"-16 X 3/4" DIA. I.D. X 2-1/2" L EYE BOLT QTY: 2 5 4 3 5/16"-18 x 5/8" L T-NUT QTY: 10 3/8-16 x 5/8" L T-NUT QTY: 2 2 5/16" WASHER QTY: 10 3/8" WASHER QTY: 2 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
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.
PICTURE NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET. DESCRIPTION QTY.
PICTURE DESCRIPTION QTY. 2 X 4 X 28-9/16" CENTER POST FRONT/REAR 2-4-2856-CPFR 2 2 X 4 X 32-1/2" PICNIC TABLE LEG 2-4-3250-PTL 2 2 X 4 X 35.15" ROOF SUPPORT (1 HOLE OFFSET) 2-4-3515-RSL 2-4-3515-RSR NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION 2 X 6 X 102" ROPE LADDER SUPPORT FRONT RIGHT 2-6-10200-RLSFR 2 X 6 X 47-1/2" TOP PANEL BOARD 2-6-4750-TPB 2 X 6 X102" ROPE LADDER RUNNER - FRONT RIGHT 2-6-10200-RLRFR 4 X 4 X 47-1/2" SWING BEAM MOUNT 4-4-4750-SBM QTY. 1 1 1 1 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY 5-11-4697-RPRA 1 5 X 11 X 46.
PICTURE DESCRIPTION 5 4 5 1 X 28 X 172" TIC TAC TOE MOUNT 125-3-1750-TTTM 5 4 5 5 4 1 7 X 3 X 238" ROCK WALL CAP 125-3-2387-RWC 5 4 1 3 X 4 X 408" DECK SPACER 125-4-4038-DS 5 4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 5 4 24 3 X 3 X 184" LADDER BACK 125-3-1875-LB 5 4 2 1 X 28 X 284" PANEL SLAT 125-3-2825-PS NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET. QTY. X 5 X 10.
PICTURE DESCRIPTION 5 4 X 6 X 22" SANDBOX SEAT 125-6-2200-SS 5 4 2 7 X 6 X 238" BOTTOM ROCK WALL BOARD 125-6-2387-BRW 5 4 QTY.
PICTURE DESCRIPTION 1 X 4 X 12-1/4" WALL PANEL BOARD 1-4-1225-WPB QTY. 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 1 X 4 X 29.
PICTURE DESCRIPTION 1 X 5 X 76-7/8" TONGUE-ANDGROOVE ROOF BOARD 1-5-7688-RB 4 X 4 X 72" TIRE SWING LEG 4-4-7200-AFL 2 X 4 X 47-1/2" TIRE SWING CROSS MEMBER 2-4-4750-CM NOTE: ANYTHING ON THIS PAGE REFERRED TO AS "PLASTIC COATED" WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR WOOD OPTION. 4 X 6 X 108" PLASTIC COATED TIRE SWING BEAM QTY.
PICTURE 1523 DESCRIPTION 2 X 2 X 16" RAMP FLOOR SUPPORT 2-2-1600-FS 4 X 4 X 8" ROPE MOUNT 4-4-0800-RM QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCKS (07-0008 IS A PACK OF 5) A-FRAME SWING LEG BRACKET 11-5010 HARDWARE BOXES: 1501, 1510, 1511, 1523, 1528 HARDWARE BOXES 10 ROCKS 2 1 EA32.
PICTURE DESCRIPTION IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION FRONT PLASTIC ARCH 07-0027-G PLASTIC SUNBURST 07-0028-G PLASTIC DORMER WINDOW 07-0029-G SOLAR WALL LIGHT 09-2003 QTY.
PICTURE DESCRIPTION QTY.
STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 108" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS.
STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD SHOULD BE OFFSET UP.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 3: PLACE THE 2 X 6 X 70" BOTTOM PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET UP.
STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOUR LIFT THE FRAME AS REQUIRED.
STEP 6B: ANGLE SUPPORTS 1: FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. 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 ANGLE SUPPORT INTO THE BOTTOM PANEL BOARD. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" END PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. FRONT OF FORT 5/16" WASHER 2 X 4 X 47-1/2" END PANEL BOARD OFFSET HOLES UP 5/16" X 3-1/2" LAG SCREW 2: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
! ATTENTION ! IN THE FOLLOWING THREE STEPS YOU WILL BEGIN THE INSTALLATION OF THE DECK SPACERS AND DECK BOARDS. IF YOU HAVE DIFFICULTY GETTING THE DECK BOARDS/DECK SPACERS TO FIT BETWEEN THE FRONT FACE BOARD AND BOTTOM PANEL BOARD DO THE FOLLOWING: 1: LOOSEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET. REMOVE THE SCREWS ON ONE SIDE OF EACH DECK SPACER. 2: ALLOW THE DECK BOARDS TO DROP DOWN IN BETWEEN THE FRONT FACE BOARD AND BOTTOM PANEL BOARD.
STEP 8: DECK SPACERS 1: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE CORNER POSTS AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER.
STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE. 3: USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT.
STEP 10: DECK BOARDS 1: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW. LEAVE A UNIFORM (APPROX. 1/4") SPACE BETWEEN THE DECK BOARDS. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK BOARDS. LAY ALL DECK BOARDS ACROSS THE DECK SUPPORTS BEFORE SECURING THEM TO THE FORT.
STEP 11: ROCK WALL 1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER.
STEP 12: ROCK WALL 1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2" WOOD SCREWS IN EACH SIDE. 3: CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS, FASTENING EACH BOARD WITH TWO 2" WOOD SCREWS ON EACH END. 4: THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE.
STEP 13: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT.
STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE RIGHT SIDE OF THE FORT AS SHOWN BELOW. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: GO UNDERNEATH THE DECK TO INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE BOTTOM PANEL BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
STEP 16: CLIMBING RAMP 1: LAY OUT THE 2 X 4 X 96" RAMP SIDE BOARDS MAKING SURE THE LARGE HOLES ON TEH ENDS ARE CLOSEST TO THE FLOOR. 2: FIRST PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE SQUARE END OF THE 2 X 4 X 96" RAMP SIDE BOARDS. OFFSET THE BOARD 1" FROM THE END. FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SIDE. 3: SECOND PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE ROUND END OF THE 2 X 4 X 96" RAMP SIDE BOARDS.
STEP 16A: CLIMBING RAMP 1: PLACE THE RAMP SIDE ON A FIRM LEVEL SURFACE. HAMMER A 5/16" T-NUT INTO EACH HOLE ON THE INSIDE OF THE RAMP SIDE. 2: REPEAT FOR THE OTHER RAMP SIDE. 5/16" T-NUT 5/16" T-NUT 5/16" T-NUT 5/16" T-NUT PLACE THIS SIDE ON A FIRM SURFACE. THEN HAMMER IN THE 5/16" T-NUTS. REPEAT FOR THE OTHER RAMP SIDE.
STEP 17: CLIMBING RAMP 1: PLACE ONE 2 X 6 X 95-1/2" FLOOR BOARD AGAINST EACH OF THE RAMP SIDE BOARDS. FASTEN THE FLOOR BOARDS TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SUPPORT. THE BOARDS SHOULD BE FLUSH AT THE SQUARE END OF THE RAMP SIDES. 2: PLACE THE 2 X 4 X 95-1/2" MIDDLE FLOOR BOARD ON THE CENTER OF THE RAMP. FASTEN THE FLOOR BOARD TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER RAMP SUPPORT.
STEP 17A: CLIMBING RAMP 1: HAMMER A 3/8" T-NUT INTO THE INSIDE OF EACH POST. NOTE THIS IS THE SIDE OF THE POST THAT DOES NOT HAVE THE COUNTERBORED HOLE. 2: SCREW A 3/8" EYE BOLT WITH A WASHER INTO THE T-NUT SO IT LOOKS LIKE THE BOTTOM PICTURE. DO NOT TIGHTEN THE EYE BOLT SO TIGHTLY THAT IT CRACKS THE WOOD. JUST SNUG IT UP.
STEP 18: CLIMBING RAMP 1: ATTACH THE 2 X 2 X 16" FLOOR SUPPORT BOARDS TO THE FLOOR BOARDS WITH 2-1/2" WOOD SCREWS. (SEE DETAIL VIEW BELOW) 2: PLACE T-NUTS ON THE INSIDE OF THE HOLES IN THE RAMP SIDE BOARDS. SET THE T-NUTS WITH A HAMMER FLUSH/NEAR FLUSH WITH THE RAMP SIDES. 3: FASTEN THE 90 GREEN BRACKET TO THE RAMP SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 18A: CLIMBING RAMP 1: ATTACH A RAMP POST TO EACH RAMP SIDE WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS. THE EYE BOLTS SHOULD BE ON THE OUTSIDE OF THE RAMP POSTS 2: SQUARE THE RAMP POST TO THE RAMP SIDE AND DRIVE IN TWO 2-1/2" WOOD SCREWS TO SECURE IT. RAMP POST 90.
STEP 18B: CLIMBING RAMP 1: FASTEN A BRACKET AS SHOWN UNDERNEATH THE RAMP TO THE RAMP POST AND THE RAMP SUPPORT. 2: USE #8 X 1-1/4" PAN HEAD SQUARE DRIVE SCREWS TO ATTACH THE BRACKET. 3: REPEAT FOR THE RAMP POST ON THE OTHER SIDE.
STEP 18C: CLIMBING RAMP 1: LOCATE FOUR 2 X 4 X 18" RAMP POST SUPPORTS. 2: PLACE A RAMP POST SUPPORT AGAINST THE RAMP POST AND THE RAMP SIDE AS SHOWN BELOW. 3: THE BOTTOM OF THE RAMP POST SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE RAMP SIDE. THE TOP-END OF THE RAMP POST SUPPORT SHOULD BE FLUSH TO THE SIDE OF THE RAMP POST. 4: ATTACH THE TOP OF THE RAMP POST SUPPORT TO THE RAMP POST WITH ONE #8 X 2-1/2" WOOD SCREW AND ONE #8 X 3-1/2" WOOD SCREW.
STEP 19: CLIMBING RAMP TO FORT 1: PLACE THE CLIMBING RAMP INTO POSITION CENTERED IN THE FRONT RIGHT OPENING ON THE FORT. USING THE RAMP BRACKETS AS A TEMPLATE DRILL A 3/8” HOLE THROUGH THE FRONT FACE BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE FRONT FACE BOARD. 3: ATTACH THE CLIMBING RAMP WITH 5/16 X 1-1/2” HEX BOLTS AND 5/16” WASHERS.
STEP 19A: ROPE MOUNT 1: PLACE THE 4 X 4 X 8" ROPE MOUNTS ONTO THE FRONT OF THE ROPE LADDER SUPPORT. THE LEFT ONE SHOULD BE EVEN WITH THE EDGE OF THE COUNTERBORED HOLE. THE RIGHT ONE SHOULD BE 1-1/4" AWAY FROM THE RIGHT CORNER POST. YOU MAY CHOOSE TO USE 5/16" X 2-1/2" LAG SCREWS WITH WASHERS OR T-NUTS WITH BOLTS TO ATTACH THE ROPE BLOCKS. IF YOU USE LAG SCREWS THEN CONTINUE READING BELOW. IF YOU USE BOLTS THEN GO TO 2 BELOW.
STEP 19B: RAMP ROPE HANDRAILS 1: LOCATE THE RAMP ROPES THAT ARE IDENTICAL IN LENGTH. THEY SHOULD BE APPROXIMATELY 12 TO 13 FEET IN LENGTH. IF YOU HAVE FIVE 13 FOOT ROPES THAT IS FINE, HOWEVER IF TWO ARE 12 FEET THEN USE THEM. 2: TIE A KNOT IN ONE END OF A ROPE WITH THE END HANGING OUT ABOUT 2" FROM THE END OF THE KNOT. THREAD THE OTHER END OF THE ROPE THROUGH THE OUTSIDE OF THE RAMP SIDE. NOW THREAD IT THROUGH THE EYE BOLT. NOW THREAD IT THROUGH THE HOLE IN THE ROPE MOUNT ON THE ROPE LADDER SUPPORT.
STEP 20: CENTER POST FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF EACH 2 X 4 X 28-9/16" CENTER POST FRONT/REAR. 2: PLACE THE CENTER POSTS INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET. LINE UP THE HOLES IN THE CENTER POSTS WITH THE HOLES IN THE RAILINGS. 3: FASTEN THE CENTER POSTS TO THE RAILINGS WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS AT THE TOP. 4: SQUARE EACH CENTER POST TO THE DECK AND SECURE THE BOTTOM OF THE CENTER POST TO THE BOTTOM PANEL BOARDS WITH #8 X 2-1/2" WOOD SCREWS.
STEP 21: PANEL SLATS 1: FIND TWENTY-TWO 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. ROCK WALL SIDE PANEL REAR PANEL SLAT SPACING MAKE THIS SLAT FLUSH TO THE END OF THE 2 X 4 X 14" BOTTOM PANEL BOARD. SPACE THE NEXT SLAT EQUALLY BETWEEN THE FIRST SLAT AND THE CORNER POST.
STEP 22: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH, IN THE COUNTER-SUNK HOLESOF THE SWING BEAM SUPPORT. USE BOLT CAPS TO COVER ANY EXPOSED THREADS. 3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER. 4: IF NECESSARY USE LOCKING PLIERS TO HOLE CARRIAGE BOLTS IN PLACE WHEN INSTALLING.
STEP 23: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
STEP 24: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 25: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM. THESE TWO HOLE LOCATIONS WILL BE EMPTY ON YOUR SWING BEAM. LINE THEM UP WITH THE HOLES IN THE SWING LEG BRACKET UNDER THE SWING BEAM.
STEP 26: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET. 3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.
STEP 27: MOUNT SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND THE SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT WITH A TORQUE WASHER AND A 3/8" LOCK NUT WITH A 3/8" WASHER ON THE BOTTOM.
STEP 28: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THE LEGS ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY EITHER: A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
STEP 29: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS.
STEP 30: ROOF SUPPORTS 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 35.15" ROOF SUPPORTS TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE. 2: CONNECT THE ENDS WITH A 2-1/2" WOOD SCREW. 2-1/2" WOOD SCREW 2 X 4 X 35.15" ROOF SUPPORT RIGHT SIDE 2 X 4 X 35.
STEP 31: ROOF PEAK SUPPORT 1: PLACE THE 5/4 X 6 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 2" WOOD SCREWS. REPEAT ON OTHER SIDE.
STEP 32: ROOF STARTER REAR 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER REAR 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 FLUSHED 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 33: ROOF REAR SECTION AND CHIMNEY 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 SEVEN ROOF 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 34: ROOF FRONT SECTION 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPING 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 35: 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 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 36: 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 37: ATTACHING THE FRONT GABLE 1: MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE ROPE LADDER SUPPORT, 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 38: 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 39: 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 40: ROOF BATTEN 1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE 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 IT IS PARALLEL TO THE ROOF SUPPORTS. INSERT 1-1/2" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ALONG THE BATTEN. 2: REPEAT THE PREVIOUS SUB-STEP FOR THE OTHER SIDE.
STEP 41: 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" FROM 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 42: 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 43: 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 44: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS. NOTE: THE OFFSET HOLES CAN BE PLACED UP OR DOWN IN THIS STEP.
STEP 45: 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 46: PICNIC TABLE 1: MEASURE 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS. 3: PLACE THE TOP OF THE LEFT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT REAR CORNER POST.
STEP 47: 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 48: TIRE SWING 1: PLACE THE 4 X 4 X 72" TIRE SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 49: TIRE SWING 1: LINE UP THE HOLES OF THE TIRE SWIVEL WITH THE HOLES IN THE TIRE SWING BEAM. 2: FASTEN THE TIRE SWIVEL TO THE TIRE SWING BEAM USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
STEP 50: TIRE SWING 1: FASTEN THE TIRE SWING BEAM TO THE SWING BEAM BRACKET USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE TIRE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. PLACE A BOLT CAP OVER ANY EXPOSED THREADS. 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.
STEP 51: TIRE SWING IMPORTANT: NOTE THE TIRE SWING LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE. (ALSO SEE STEP 48) AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT.
STEP 52: TIRE SWING IN THIS STEP YOU WILL BE MOUNTING THE TIRE SWING BEAM TO THE FORT. AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: INSTALL T-NUTS IN THE PREVIOUSLY DRILLED HOLES AS SHOWN BELOW. 2: LINE UP THE PILOT HOLES AT THE END OF THE TIRE SWING BEAM WITH THE PREVIOUSLY DRILLED HOLES IN THE CORNER POST. 3: FASTEN THE TIRE SWING BEAM TO THE CORNER POST USING 5/16 X 7" HEX BOLTS WITH 5/16" AND 1/2" WASHERS THROUGH THE TIRE SWING BEAM AND CORNER POST, INTO THE T-NUTS.
STEP 53: LEVEL TIRE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE TIRE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE TIRE SWING BEAM LEVEL. IMPORTANT: NOTE THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A)DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
STEP 54: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 47-1/2" TIRE SWING LEG CROSS-MEMBER AGAINST THE SWING LEGS. 2: LEVEL THE TIRE SWING CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSSMEMBER HOLES ONTO THE SWING LEGS. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE TIRE SWING CROSS-MEMBER TO THE SWING BEAM LEGS.
STEP 55: HANGING THE TIRE SWING 1: START BY ATTACHING THREE SPRING CLIPS TO THE TIRE SWIVEL ON THE SWING BEAM. 2: ATTACH ONE CHAIN AT A TIME TO ONE SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED.
STEP 56: 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 57: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT-LEFT 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 1-1/4" PAN HEAD SCREWS.
STEP 58: 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 SLIDE SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE.
STEP 59: 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 60: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE PLAY SET 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 TIC TAC TOE WITH BOARDS ATTACHED. #8 X 1-3/4" WOOD SCREWS 4.
STEP 61: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 62: SAFETY HANDLES (RAMP) 1: LOCATE THE SECOND 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 CENTER POST AND PANEL SLAT WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
STEP 63: INSTALLING CLIMBING ROPE 1: DRILL A 7/8" HOLE THROUGH THE END PANEL BOARD (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE END PANEL BOARD. 3: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
STEP 64: SANDBOX SEATS AND NAMEPLATE 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET. ATTACH THE NAME PLATE TO THE FRONT OF THE SWING BEAM WITH #8 X 1" WOOD SCREWS. ATTACH NAME PLATE HERE WITH #8 X 1" WOOD SCREWS.
STEP 65: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK. 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2" LAG SCREW AND WASHER TO FASTEN THE STEERING WHEEL TO THE REAR CENTER POST. DO NOT OVER-TIGHTEN THE LAG SCREW OR THE STEERING WHEEL WILL NOT TURN. 5: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL AND SNAP IT INTO THE STEERING WHEEL INSERT.
STEP 66: 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 BELLOW.
STEP 67: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE AGAINST THE SWING LEG. FINALLY INSTALL THE SCREW AND WASHER.
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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 5 #2 SQUARE DRIVE BIT QTY:1 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 DORMER SUNRAY ASSEMBLY 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.
