™ playsets ™ playsets Highcrest Model: 2500T (BOXES: 2500-1, 2500-2, 2501 & Slide Box) *51-0079-T* 51-0079-T 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 - HigHcrest Gorilla Playsets™ manufactures 3 Easy Ways To REgisTER the finest quality products that are designed for outstanding strength and durability. We back Fax this completed form to: option 1 (800) 880-3300 Mail this completed form to: Gorilla Playsets 190 Etowah Industrial Court Canton, GA 30114 OR our products with an unparalleled warranty. In the unlikely event that you will need to contact us Complete the online registration form at: option 2 http://www.
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IMPORTANT – PLEASE READ Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years. As your swing set acclimates to its new environment, natural characteristics of the wood can show in the form of checks, or “cracks” in the lumber.
IMPORTANT DOCUMENTS CUSTOMER MUST READ AND RETAIN Please go to the following links and read important SAFETY information prior to using your new play structure. http://www.gorillaplaysets.com/Swing-Set-Safety-s/85.htm https://www.gorillaplaysets.com/Maintenance-s/129.htm http://www.gorillaplaysets.com/manuals.html (Click on your specific model) http://www.gorillaplaysets.com/Warranty-s/82.htm NOTE: Your children’s safety is our #1 concern.
Model: 2500T (BOXES: 2500-1, 2500-2, 2501 & Slide Box) REV: 3.3.
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”, 11/64” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel KIT CONTENTS Swings, Slides, Accessories: ___ (Qty ) Description ___ (2) Swingbelt w/ Chains ___ (1) Trapeze Swing ___ (1) 8ft.
11-0057 2500 HARDWARE PAGE 1 OF 2 REV B: 9/16/2015 JH #14 X 1-1/4" PAN HEAD SCREW QTY: 3 #8 X 1-1/4" WOOD SCREW QTY: 2 #8 X 1-1/2" WOOD SCREW QTY: 10 9 #8 X 1-3/4" WOOD SCREW QTY: 4 8 #8 X 2" WOOD SCREW QTY: 212 #8 X 2-1/2" WOOD SCREW QTY: 12 7 #8 X 3" WOOD SCREW QTY: 10 6 5 5/16" TEE NUT QTY: 36 4 3/8" LOCK NUT QTY: 19 3 TORQUE WASHER QTY: 17 3/8" WASHER QTY: 31 2 1 5/16" X 4" HEX BOLT QTY: 28 5/16" X 2-1/2" HEX BOLT QTY: 4 5/16" X 1-1/2" HEX BOLT QTY: 4 5/16" WASHER QTY: 40 USE THE RUL
11-0057 2500 HARDWARE PAGE 2 OF 2 REV B: 9/16/2015 JH 5/16" X 3-1/2" HEX LAG SCREW QTY: 4 3/8" X 2-1/2" HEX LAG SCREW QTY: 8 3/8 X 3-1/2" HEX LAG SCREW QTY: 4 9 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 6-1/2" CARRIAGE BOLT QTY: 16 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.
11-0080 2501 HARDWARE PAGE 1 OF 1 3/2/2016 JH #8 X 1-1/2" WOOD SCREW QTY: 8 9 #8 X 2-1/2" WOOD SCREW QTY: 18 8 7 6 5 4 3 1/4" WASHER QTY: 8 2 5/16" TEE NUT QTY: 6 5/16" X 4" HEX BOLT QTY: 4 5/16" WASHER QTY: 6 1 5/16" X 2-1/2" HEX BOLT QTY: 2 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.
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PICTURE HARDWARE BOXES: 2500 / 2501 DESCRIPTION QTY.
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STEP 1: CORNER POST LAYOUT 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THE RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: LAY OUT EACH OF THE 3 X 3 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 2: INSERTING T-NUTS INTO CORNER POSTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
STEP 3: ATTACHING SANDBOX BOARD AND ROPE SUPPORT 1: THE 2 X 6 X 47-1/2" SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHT SIDE CORNER POSTS WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS OFFSET UP. 2: THE 2 X 4 X 47-1/2" ROPE SUPPORT (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE TOP SET OF HOLES ON THE RIGHT SIDE OF THE CORNER POSTS, OFFSET UP, WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS.
STEP 4: ATTACHING END SANDBOX BOARD 1: THE 2 X 6 X 95-1/2" END SANDBOX BOARD (WITH 6 PREDRILLED HOLES) ATTACHES TO THE BOTTOM OF THE LEFT SIDE CORNER POSTS OFFSET UP WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS.
STEP 5: ATTACHING THE SIDE SANDBOX BOARDS 1: THE 2 X 6 X 75" SIDE SANDBOX BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE FRONT AND REAR CORNER POSTS WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS. 2: THE STRUCTURE SHOULD BE ABLE TO STAND ON ITS OWN WITHOUT ANY SUPPORT AT THIS STAGE.
STEP 6: ATTACHING ARCH FACE BOARD AND DECK SUPPORTS 1: THE 2 X 6 X 47-1/2" ARCH FACE BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE SET OF HOLES BELOW THE TOP MOST HOLES. ATTACH THE TOP ARCH FACE BOARD HOLES USING 5/16" X 4" HEX BOLTS AND 5/16" WASHERS. SQUARE THE ARCH FACE BOARD TO THE CORNER POSTS. PREDRILL 9/64" HOLES 2-1/2" DEEP THROUGH THE BOTTOM HOLES INTO THE CORNER POSTS. ATTACH THE BOTTOM ARCH FACE BOARD HOLES USING 5/16" X 31/2" LAG SCREWS AND 5/16" WASHERS.
STEP 7: ATTACHING PANEL SUPPORT BOARDS AT REAR 1: THE 2 X 4 X 47-1/2" PANEL SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES BELOW THE TOP MOST HOLES ON THE REAR OF THE FORT WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS. HOLES SHOULD BE OFFSET DOWN ON BOTH PANEL SUPPORT BOARDS.
STEP 8: ATTACHING PANEL SUPPORTS AND SAFETY BOARD 1: THE 2 X 4 X 47-1/2" PANEL SUPPORTS SHOULD HAVE THE HOLES OFFSET UP. USE 5/16" X 4" HEX BOLTS AND 5/16" WASHERS TO SECURE THE BOARDS TO THE CORNER POSTS. 2: PLACE THE TOP OF THE PANEL SUPPORT (USED AS SAFETY BOARD) 24" FROM THE BOTTOM OF THE 2 X 6 BOARD. 3: FASTEN THE SAFETY BOARD TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 9: ATTACHING FORT SIDE SUPPORTS 1: LAY THE 2 X 4 X 47-1/2" FORT SIDE SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PLACE A T-NUT IN THE PRE-DRILLED HOLE ON THE END AND SECURE WITH HAMMER. 2: THE 2 X 4 X 47-1/2" FORT SIDE SUPPORT (WITH ANGLED ENDS) ATTACHES TO THE HOLES ON THE END OF THE END SANDBOX BOARD ON THE INSIDE WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS. THE ANGLED END SHOULD REST FLUSH AGAINST THE CORNER POST.
STEP 10: ATTACHING THE ROCK WALL SUPPORTS 1: LAY THE 2 X 6 X 53-1/2" ROCK WALL SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE PLAY SET. PLACE A T-NUT INTO THE PREDRILLED HOLE ON THE END AND SECURE WITH A HAMMER. 2: LINE UP THE HOLE IN THE BOTTOM OF EACH 2 X 6 X 53-1/2" ROCK WALL SUPPORT TO THE HOLE ON THE END OF EACH EXTENDED SANDBOX BOARD. ATTACH EACH ROCK WALL SUPPORT TO THE EXTENDED SANDBOX BOARD WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 11: ATTACHING THE ARCH ROCK WALL SIDE SUPPORTS 1: MOUNT THE ARCH ROCK WALL SIDE SUPPORT ON TOP OF THE ROCK WALL SUPPORT, MAKE SURE THAT THE TOP END OF THE ARCH ROCK WALL SIDE SUPPORT IS FLUSH WITH THE CORNER POST. 2: FIRST FASTEN THE 3" WOOD SCREW INTO THE ARCH ROCK WALL SIDE SUPPORT TOP HOLE INTO THE ROCK WALL SUPPORT, MAKE SURE THAT THIS BOARD IS ALIGNED WITH THE ROCK WALL SUPPORT. SECOND FASTEN THE 3" WOOD SCREW INTO THE ARCH ROCK WALL SIDE SUPPORT BOTTOM HOLE TO THE ROCK WALL SUPPORT.
STEP 12: ATTACHING THE ROCK WALL CENTER SUPPORT 1: BEGIN WITH THE 5/4 X 4 X 47-1/2" ROCK WALL BOARD AND SECURE IT TO THE ARCH ROCK WALL SIDE SUPPORT WITH TWO #8 X 2" WOOD SCREWS PER SIDE. THE ROUNDED EDGE OF THE ROCK WALL BOARD SHOULD BE AGAINST THE CORNER POSTS BEFORE ATTACHING. 2: NEXT THE 5/4 X 4 X 47-1/2" ROCK WALL BOARD WILL MOUNT AT THE BOTTOM. THIS BOARD WILL BE AT 44-3/16" FROM THE TOP ROCK WALL BOARD AND FLUSH TO THE ROCK WALL SIDE SUPPORTS. SECURE WITH #8 X 2" WOOD SCREWS.
STEP 13: ATTACHING THE ROCK WALL BOARDS 1: PLACE A 3/8" WASHER OR A QUARTER BETWEEN THE ROCK WALL BOARDS. MOUNT THE NEXT ROCK WALL BOARD TO THE ROCK WALL SUPPORTS WITH #8 X 2" WOOD SCREWS. 2: REMOVE THE WASHERS OR QUARTERS AND PLACE THEM BETWEEN THE NEXT ROCK WALL BOARD AND THE PREVIOUS ONE. MOUNT THE NEXT ROCK WALL BOARD TO THE ROCK WALL SUPPORTS WITH #8 X 2" WOOD SCREWS. 3: REPEAT SUBSTEP 2 UNTIL YOU GET TO THE LAST BOARD. THE LAST BOARD MAY NEED TO BE ADJUSTED.
STEP 14: ATTACHING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. MAKE SURE THE SCREWS ARE AWAY FROM THE EDGE OF THE BOARDS TO AVOID SPLITTING. 2: THE ROCKS INCLUDED WITH YOUR PLAYSET MAY VARY, IN ANY CASE, THE #14 X 1-1/4" PANHEAD SCREWS AND 1/4" WASHERS INCLUDED WITH THE ROCKS WILL BE USED TO ATTACH THE ROCKS.
STEP 15: ATTACHING THE DECK BOARDS AND DECK SPACERS 1: THE 5/4 X 3 X 41-1/4" DECK SPACER MOUNTS BETWEEN THE REAR CORNER POSTS AND BETWEEN THE FRONT CORNER POSTS FLUSH TO THE INSIDE EDGES. DRIVE THE 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS. 2: ELEVEN 5/4 X 4 X 47-1/2" DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS, FLUSH TO THE TOP ROCK WALL BOARD. 3: SPACE DECK BOARDS EVENLY ACROSS THE DECK SUPPORTS BETWEEN THE DECK SPACERS.
STEP 16: ATTACHING THE FRONT FACE BOARD 1: THE TOP SURFACE OF THE 2 X 4 X 47-1/2" FACE BOARD WILL BE FLUSH TO THE TOP OF THE DECK SPACER. SECURE THE FACE BOARD TO THE CORNER POSTS WITH THREE 2-1/2" WOOD SCREWS PER SIDE.
STEP 17: SWING BEAM PLATE 1: LAY THE SWING BEAM MOUNT ON A FLAT SURFACE WITH THE THREE COUNTER SUNK CENTER HOLES FACING THE GROUND, THE COUNTER SUNK HOLES ON THE ENDS MUST BE FACING TOWARDS YOU. 2: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP PILOT HOLES. 3: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT ON THE OUTSIDE HOLES USING 3/8" X 3-1/2" CARRIAGE BOLTS ON TOP AND 3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
STEP 18: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. 2: FASTEN THE IRON DUCTILE SWING HANGERS TO THE SWING BEAM USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM. PLACE BOLT CAPS OVER EXPOSED THREADS OFTER SECURING.
STEP 19: ATTACHING THE SWING BEAM MOUNT 1: THE 4 X 4 X 47-1/2" SWING BEAM MOUNT HAS COUNTER-SUNK HOLES IN THE CENTER AND ON THE ENDS. INSTALL THE SWING BEAM MOUNT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES AT THE CENTER FACE DOWN. 2: FASTEN THE SWING BEAM MOUNT TO THE CORNER POSTS USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS. PLACE THE CARRIAGE BOLT INTO THE TORQUE WASHER, THEN INTO THE HOLE OF THE CORNER POST AND SET WITH A HAMMER.
STEP 20: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57" LADDER SIDE ON A FLAT SURFACE WITH THE CHANNELS FACING DOWN. PLACE THE BARREL OF A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE AND SECURE WITH A HAMMER. REPEAT THIS STEP FOR THE OTHER LADDER SIDE. 2: FLIP THE LADDER SIDE OVER SO THAT THE CHANNELS ARE FACING UP. 3: PLACE THE LADDER STEP INTO THE CHANNELS, AND THEN PLACE THE SECOND LADDER SIDE ON TOP, WITH THE CHANNELS FACING DOWN. 4: NOW PLACE TWO 2" WOOD SCREWS IN EACH STEP.
STEP 21: LADDER TO FORT 1: THE LADDER ATTACHES TO THE FRONT SIDE AT THE RIGHT, FLUSH TO THE INSIDE EDGE OF THE CORNER POST. 2: THE BOTTOM EDGE OF EACH 90 GREEN BRACKET SHOULD BE 3/4" FROM THE BOTTOM OF THE 2 X 4. 3: MAKE SURE THE LADDER IS LEVEL, USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8" HOLE THROUGH THE 2 X 4. 4: INSERT T-NUTS IN THE BACK OF THE HOLES. 5: ATTACH THE BRACKET TO THE 2 X 4 WITH 1-1/2" HEX BOLTS WITH 5/16" WASHERS.
STEP 22: ATTACHING SWING LEGS TO BRACKET 1: PLACE THE 3 X 3 X 96" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: USING THE SWING LEG BRACKET AS A TEMPLATE, DRILL 11/64" PILOT HOLES 2-1/2" DEEP THROUGH EACH SWING LEG BRACKET HOLE. 3: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8" X 2-1/2 LAG SCREWS AND 3/8" WASHERS.
STEP 23: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: PREDRILL AN 11/64" PILOT HOLE 3" DEEP INTO THE CENTER HOLE. 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 24: MOUNT SWING BEAM TO FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE FREE END OF THE SWING BEAM TO THE SWING BEAM MOUNT ON THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES THE LEGS. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE OVER THE SWING BEAM MOUNT.
STEP 25: LEVEL SWING BEAM 1: PLACE THE LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE SWING LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
STEP 26: SWING LEG CROSS MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS MEMBER, AND MARK THROUGH THE HOLES ONTO THE LEGS. 3: PREDRILL 11/64" HOLES 2" DEEP AT EACH MARK. 4: SECURE THE CROSS MEMBER TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 27: ATTACHING TARP SUPPORT BOARDS 1: THE 2 X 4 X 83" FRONT AND BACK TARP SUPPORT BOARDS ATTACH TO THE CORNER POSTS WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS. THE HOLES SHOULD BE OFFSET DOWN ON BOTH BOARDS. NOTE THE FRONT AND BACK TARP SUPPORT BOARDS ARE DIFFERENT FROM EACH OTHER.
STEP 28: ATTACHING CENTER POSTS 1: THE 2 X 4 X 73-3/4" AND 2 X 4 X 29-1/8" CENTER POSTS WILL ATTACH TO THE ROOF SUPPORT BOARDS WITH 5/16" X 2-1/2" HEX BOLTS, 5/16" WASHERS, AND T-NUTS. 2: THE FRONT CENTER POST WILL SECURE TO THE ROOF SUPPORT WITH 5/16" X 2-1/2" HEX BOLT, 5/16" WASHER AND T-NUT. 3: MAKE SURE THE OPENINGS ON EITHER SIDE OF THE FRONT CENTER POST ARE EQUAL. SECURE THE MIDDLE OF THE FRONT CENTER POST TO THE ARCH FACE BOARD WITH TWO #8 X 2-1/2" WOOD SCREWS.
STEP 29: ATTACHING THE DECK STRINGER 1: FIND THE 2 X 4 X 47" STRINGER WITHOUT HOLES. 2: PLACE THE STRINGER UNDEREATH THE CENTER OF THE DECK BOARDS (USE THE HOLE AT THE CENTER AS A GUIDE) MAKE SURE THE END OF THE STRINGER IS FLUSH WITH THE FRONT FACE BOARD. 3: ATTACH EACH DECK BOARD AND DECK SPACER WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE STRINGER BELOW.
STEP 30: INSTALLING WINDOW SUPPORTS / WINDOWS IN THIS STEP THE WOOD COMPONENTS TO ATTACH THE WINDOWS WILL BE INSTALLED ON THE INSIDE OF THE FRONT OF THE PLAYSET. GO UP ON TOP OF THE FORT AND LOOK FOR THE FRONT OF THE PLAY SET. 1: ATTACH THE 5/4 X 4 X 20" VERTICAL WINDOW SUPPORTS NEXT TO THE CORNER POST ON BOTH SIDES WITH 2" WOOD SCREWS. 2: ATTACH THE 5/4 X 4 X 20" VERTICAL WINDOW SUPPORTS NEXT TO THE CENTER POSTS ON BOTH SIDES WITH 2" WOOD SCREWS.
STEP 31: PANEL SLATS 1: BEGIN ON THE REAR SIDE OF THE FORT WITH THE TWO INNER SLATS BOARDS. THEY ARE GOING TO BE 17-1/2" APART AFTER THEY ARE ATTACHED. THEY ARE SPACED 15" FROM THE OUTSIDE OF THE POSTS. SPACE THE REMAINING TWO SLATS ON EACH SIDE 2-1/4" AWAY FROM EACH OTHER. 2: ON THE SWING BEAM SIDE OF THE FORT START NEAR THE FRONT. THIS SLAT IS SPACED 2-1/2" FROM THE CORNER POST. SPACE THE REMAINING SLATS 2-3/16" APART FROM ONE ANOTHER.
STEP 32: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. FIND THE GREEN BRACKETS INSIDE AND THE SCREWS. 2: LOCATE THE 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT BOARDS. 3: CENTER THE GREEN BRACKETS ON THE TIC TAC TOE BOARDS AND KEEP THE LIP OF THE GREEN BRACKET AS FLUSH TO THE SIDE OF THE BOARD AS YOU CAN. ATTACH THE GREEN BRACKET TO THE BOARD WITH THE SHORTEST SCREWS PROVIDED IN THE TIC TAC TOE BOX. 4: NOW ASSEMBLE THE TIC TAC TOE ACCORDING TO THE INSTRUCTIONS IN THE BOX.
STEP 33: MOUNTING THE TIC TAC TOE PANEL 1: GO UP ONTO THE DECK AND PLACE THE TIC TAC TOE PANEL ASSEMBLY FROM THE PREVIOUS STEP ONTO THE BACK WALL. THE GREEN BRACKETS SHOULD FACE THE INSIDE OF THE FORT. THE BOTTOM OF THE LOWER TIC TAC TOE MOUNT BOARD SHOULD BE 4" ABOVE THE DECK. 2: ATTACH EACH TIC TAC TOE MOUNT TO THE PANEL SLATS WITH TWO #8 X 1-3/4 WOOD SCREWS. TIC TAC TOE MOUNT BOARD #8 X 1-3/4" WOOD SCREW PANEL SLAT BOTTOM OF BOARD IS 4" ABOVE THE DECK.
STEP 34: TARP BOARDS 1: THE 2 X 4 X 47-1/2" CENTER TARP BOARD WILL SECURE ON TOP OF THE CENTER POSTS WITH TWO 2-1/2" WOOD SCREWS PER SIDE. 2: THE TWO 2 X 4 X 50" TARP BOARDS WILL SECURE ON THE ENDS OF THE TARP SUPPORTS WITH TWO #8 X 2-1/2" WOOD SCREWS PER SIDE.
STEP 35: SUNBURST 1: PLACE THE 5/4 X 6 X 13-5/8" WOOD SUN ON TOP OF THE TARP SUPPORT LEANING AGAINST THE CENTER POST, MAKE SURE IT IS CENTERED AND SECURE WITH THREE #8 X 2" WOOD SCREWS. 2: ALL THE SUNRAY PIECES GET INSTALLED TO THE INSIDE SURFACE OF THE WOODEN SUN. 3: INSTALL THE TOP SUNRAYS ABOUT 55" FROM THE CENTER POST AND SECURE WITH #8 X 1-1/2" WOOD SCREWS. 4: PLACE THE BOTTOM SUNRAYS BELOW THE TOP SUNRAYS LEAVING A 1/4" GAP IN BETWEEN. 5: REPEAT SUBSTEPS 1 TO 4 FOR THE OTHER SIDE.
STEP 36: TARP 1: LAY TARP ACROSS TARP BOARDS, MAKE SURE THE HEM SIDE IS DOWN. HAVE AN ASSISTANT HELP YOU. WRAP THE TARP ENDS AROUND THE END TARP BOARDS TO THE INSIDE. LEAVE AN EQUAL AMOUNT OF THE END TARP BOARD EXPOSED OVER THE TARP ENDS. IF YOU WISH YOU MAY PREDRILL 1/8" HOLES AT THE EACH GROMMET LOCATION BEFORE INSTALLING THE SCREW AND WASHER AT THAT LOCATION. CAUTION! IF YOU DRILL THROUGH THE END TARP BOARD YOU WILL DRILL THROUGH THE TARP ON THE OUTSIDE. 2: BEGIN AT THE FRONT RIGHT SIDE CORNER.
STEP 37: SANDBOX SEATS 1: PLACE THE SANDBOX SEATS ON TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH EACH 5/4 X 6 X 22" SANDBOX SEAT TO THE TOP OF THE SANDBOX BOARD WITH FOUR #8 X 2" WOOD SCREWS.
STEP 38: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE END OF THE SWING BEAM. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN. 3: SNAP THE STEERING WHEEL CAP ONTO THE STEERING WHEEL INSERT.
STEP 39: INSTALLING THE SLIDE 1: LAY THE SLIDE ON DECK EXTENDING ONTO/OVER THE DECK SPACER. 2: SECURE THE SLIDE TO THE DECK SPACER WITH THREE #14 X 1-1/4" PAN HEAD SCREWS.
STEP 40: CLIMBING ROPE 1: THREAD ONE END OF THE 10" ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN ROPE TO AID IN CLIMBING. SET KNOTS ACCORDING TO YOUR CHILD'S NEEDS. 2-3 KNOTS SHOULD BE SUFFICIENT. 2: THREAD THE OTHER END OF THE ROPE THROUGH THE HOLE IN THE BOTTOM ROCK WALL BOARD. PULL THE ROPE TIGHT AND TIE A SECURE KNOT BEHIND THE BOTTOM ROCK WALL BOARD. 3 : ATTEMPT TO WRAP THE ROPE AROUND YOUR HAND.
STEP 41: FLAG KITS 1: INSTALL THE FLAG KITS IN THE DESIRED LOCATION ON YOUR PLAY SET. THE RECOMMENDED LOCATION IS ON THE CORNER POSTS AT THE FRONT OF THE FORT. ATTACH THE FLAG KITS WITH THE HARDWARE PROVIDED.
STEP 42: HANGING SWINGS 1: LOCATE TWO SWING BELTS WITH CHAINS ATTACHED AND ONE TRAPEZE BAR WITH CHAINS ATTACHED. 2: SNAP A SPRING CLIP THROUGH THE SWING HANGER LOOP ON THE SWING BEAM. 3: SNAP A CHAIN ONTO EACH SPRING CLIP. ADJUST EACH SWING UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS.
STEP 43: NAME PLATE 1: ATTACH THE NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO #8 X 1-1/2" WOOD SCREWS.
STEP 44: 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.
STEP 45: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. PLACE A SAFETY HANDLE ON THE CORNER POST AND FRONT CENTER POST. ADJUST THE HEIGHT TO SUIT THE NEEDS OF YOUR CHILD. 2: USE THE HARDWARE INCLUDED WITH THE SAFETY HANDLES TO ATTACH EACH HANDLE TO THE CORNER POST OR FRONT CENTER POST. #14 X 1-1/4" PAN HEAD SCREW AND 1/4" FLAT WASHER INCLUDED WITH SAFETY HANDLES.
STEP 46: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE ROCK WALL ROPE SUPPORT. 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 THE 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE.
