381 - Five Star DLX ™ playsets ™ playsets The Five Star II Deluxe Timber Shield Post Option BOXES: 380, 381, 1100 Model: 381 (BOXES: 380-1, 380-2, 320, 381 & Slide Box) *51-0081-W* 51-0081-W Copyright © 2017 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 – 2017 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.
Product registration - the five star ii deluxe Gorilla Playsets ™ manufactures 3 Easy Ways To REgisTER the finest quality products that are designed for outstanding strength and durability. We back Complete the online registration form at: oPtion 1 http://www.gorillaplaysets.com/register our products with unparalleled warranties.
THIS PAGE INTENTIONALLY LEFT BLANK
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.
381 - Five Star DLX Timber Shield Post Option BOXES: 380, 381, 1100 Model: 381 (BOXES: 380-1, 380-2, 320, 381 & SLIDE BOX) REV: 3.14.
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 Rear Top Panel Board and Sandbox Board.......................................................... Step 48 Panel Boards....…………………............................................................................ Step 49 Deck Supports....................................................................................................... Step 50 Upper Level Under Deck Support.......................................................................... Step 51 Extreme Slide Post and Deck Spacer........
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/PageFiles/122149/325.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 Five Star Duo Level Dimensions 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 ___ (1) 8ft.
11-0083 380 Hardware PAGE 1 OF 2 REV: A 10/20/2016 S.O.
11-0083 380 Hardware PAGE 2 OF 2 REV: A 10/20/2016 S.O. 5/16" X 3-1/2" HEX LAG SCREW QTY: 22 3/8 X 3-1/2" HEX LAG SCREW QTY: 12 9 8 7 6 5 4 #2 SQUARE DRILL BIT QTY: 1 3 2 PLASTIC BOLT CAP QTY: 19 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8 x 7" CARRIAGE BOLT QTY: 12 3/8 x 6-1/2" CARRIAGE BOLT QTY: 4 3/8 x 3-1/2" CARRIAGE 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.
11-0084 381 Hardware PAGE 1 OF 2 REV: A 10/20/2016 S.O. #14 X 2-1/2" PAN HEAD SCREW QTY: 4 9 #8 X 1-1/4" WOOD SCREW QTY: 4 #8 X 1-1/2" WOOD SCREW QTY: 110 8 #8 X 2" WOOD SCREW QTY: 100 7 #8 X 2-1/2" WOOD SCREW QTY: 20 #8 X 3" WOOD SCREW QTY: 5 6 5 5/16" TEE NUT QTY: 23 4 TORQUE WASHER QTY: 5 3/8" LOCK NUT QTY: 5 3 3/8" WASHER QTY: 34 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 4 5/16 X 4-1/2" HEX BOLT QTY: 23 2 1 5/16" WASHER QTY: 68 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
11-0084 381 Hardware PAGE 2 OF 2 REV: A 10/20/2016 S.O. 5/16" X 3-1/2" HEX LAG SCREW QTY: 11 3/8 X 5" HEX LAG SCREW QTY: 12 9 8 7 6 5 4 #2 SQUARE DRILL BIT QTY: 1 3 2 PLASTIC BOLT CAP QTY: 5 3/8 x 6-1/2" CARRIAGE BOLT QTY: 3 1 3/8 x 3-1/2" CARRIAGE 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.
380 PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY. 5/4 X 5 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 2 5/4 X 5-1/8 X 23-7/8" BOTTOM ROCK WALL BOARD 125-5-2388-BRWB 1 5/4 X 5-1/8 X 23-7/8" ROCK WALL BOARD 125-5-2388-BRWB 10 5/4 X 5-1/2 X 20" VERTICAL WINDOW SUPPORT 125-6-2000-VWS 3 5/4 X 5-1/2 X 47-3/8" DECK BOARD 125-6-4738-DB 7 1 X 3.
PICTURE DESCRIPTION QTY.
381 PICTURE DESCRIPTION QTY. 1 X 4 X 30.50" ROOF FINISHER 1-4-3050-RF 2 1 X 4 X 30.50" ROOF STARTER 1-4-3050-RS 2 1 X 5 X 30.50" ROOF BOARD 1-5-3050-RB 22 1 X 6 X 30.50" ROOF PEAK 1-6-3050-RP 1 5-4 X 2.625 X 28" PANEL SLAT 125-3-2800-PS 3 5-4 X 2.625 X 32" PANEL SLAT 125-3-3200-PS 3 5/4 X 4 X 23.
PICTURE DESCRIPTION QTY. 5/4 X 4 X 36.75" UPPER REAR DECK SPACER 125-4-3675-URDS 1 5/4 X 3.5 X 40.25" UPPER DECK SPACER 125-4-4025-UDS 2 5/4 X 4 X 63" UPPER DECK SPACER 125-4-6300-UDS 1 5-4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 2 5-4 X 6 X 69.
PICTURE DESCRIPTION 2 X 4 X 21.50" UPPER LEVEL SWING SIDE ANGLE SUPPORT 2-4-2150-ULSAS QTY. 1 2 X 4 X 30.625" PANEL AND DECK SUPPORT 2-4-3063-PDS 4 2 X 4 X 37.50" UPPER LEVEL STRINGER 2-4-3750-ULS 1 2 X 4 X 37.125" CENTER DECK SUPPORT 2-4-3713-CDS 1 2 X 4 X 37.188" DECK SUPPORT 2-4-3718-DS 1 2 X 4 X 42.50" REAR BOTTOM PANEL BOARD 2-4-4250-RBPB 1 2 X 4 X 51.
PICTURE DESCRIPTION QTY. 2 X 4 X 51.125" ROOF SUPPORT RIGHT 2-4-5113-RSR 2 2 X 4 X 70" REAR TOP PANEL BOARD 2-4-7000-RTPB 1 2 X 6 X 22.625" BOTTOM PANEL BOARD 2-6-2263-BPB 1 2 X 6 X 30.625" SANDBOX BOARD 2-6-3063-SB 1 2 X 6 X 70" SANDBOX BOARD 2-6-7000-SB 1 4 X 4 X 23.50" SLIDE BLOCK 4-4-2350-SB 4 X 4 X 33.
PICTURE DESCRIPTION QTY. 4 X 4 X 39.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 1 CLIMBING ROCKS (07-0008 IS A PACK OF 5) HARDWARE BOXES: 380 & 381 10 ROCKS A-FRAME SWING LEG BRACKET 11-5010 1 HARDWARE BOXES 1 INSTRUCTIONS EA.
PICTURE DESCRIPTION IRON DUCTILE SWING HANGERS 11-4012 7 TELESCOPE 07-0001 1 10' ROCK WALL ROPE 1 CHAIN (CHAIN NOT SHOWN) QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
STEP 1: LEFT CORNER POST (FRONT POSITION) AND SAND BOX BOARDS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET DOWN) TO THE FRONT SIDE OF THE LEFT CORNER POSTS USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER. 3: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET UP) TO THE LEFT SIDE OF THE LEFT CORNER POST USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER.
STEP 2: LEFT CORNER POST (REAR POSITION) AND SAND BOX BOARDS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET UP) TO THE LEFT BOTTOM OF THE LEFT CORNER POSTS USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER. 3: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET DOWN) TO THE REAR BOTTOM OF THE LEFT CORNER POST USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER.
STEP 3: RIGHT CORNER POSTS AND SAND BOX BOARDS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET DOWN) TO THE FRONT BOTTOM OF THE RIGHT CORNER POSTS USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER. 3: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET DOWN) TO THE REAR BOTTOM OF THE RIGHT CORNER POST USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER.
STEP 4: OUTRIGGER 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE 2 X 6 X 86" OUTRIGGER (HOLES OFFSET UP) ATTACHES TO THE SIDE OF THE RIGHT CORNER POSTS WITH TWO 5/16" X 4-1/2" HEX BOLTS AND TWO 5/16" WASHERS.
STEP 5: PANEL SUPPORTS AND ROCK WALL SIDE TOP PANEL BOARD 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE 2 X 4 X 47-3/8" PANEL SUPPORTS (OFFSET HOLES UP) ATTACH TO THE SIDES OF THE FRONT AND REAR CORNER POSTS WITH TWO 5/16" X 4-1/2" HEX BOLTS AND TWO 5/16" WASHERS. 3: THE 2 X 4 X 47-3/8" ROCK WALL SIDE TOP PANEL BOARD (OFFSET HOLES UP) ATTACHES TO THE SIDE OF THE LEFT CORNER POSTS WITH TWO 5/16" X 4-1/2" HEX BOLTS AND TWO 5/16" WASHERS.
STEP 6: PANEL SUPPORTS AND DECK SUPPORTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE 2 X 6 X 47-3/8" FRONT ARCH BOARD ATTACHES TO THE FRONT OF THE LEFT AND RIGHT CORNER POSTS WITH TWO 5/16" X 4-1/2" HEX BOLTS AND TWO 5/16" WASHERS. 3: ATTACH THE 2 X 4 X 47-3/8" DECK SUPPORTS (OFFSET HOLES DOWN) TO THE INSIDE OF THE LEFT AND RIGHT CORNER POSTS WITH TWO 5/16" X 4-1/2" HEX BOLTS AND TWO 5/16" WASHERS.
STEP 7: LEVELING THE PLAY SET AND INSTALLING LAG SCREWS 1: LEVEL YOUR PLAY SET FRAME. LEVEL SIDE TO SIDE AND FRONT TO BACK. CHECK THE DIAGONALS FOR SQUARE. ONCE YOU HAVE A LEVEL AND SQUARE PLAY SET FRAME YOU MAY INSTALL LAG SCREWS. 2: INSTALL ONE 5/16" X 3-1/2" LAG SCREW WITH 5/16" WASHER INTO THE EMPTY HOLES IN ALL OF THE SAND BOX BOARDS AND THE FRONT ARCH BOARD.
STEP 8: FORT SUPPORTS 1: PLACE A 5/16" T-NUT INTO THE HOLE IN THE FORT SUPPORTS AS SHOWN. 2: FROM THE INSIDE OF THE RIGHT PANEL BOARD LOOSELY ATTACH EACH FORT SUPPORT WITH ONE 5/16" X 2-1/2" HEX BOLT AND ONE 5/16" WASHER. 3: MEASURE 2" AND 3-1/2" DOWN FROM THE TIP OF EACH FORT SUPPORT AND DRILL A 1/8" HOLE THROUGH THE FORT SUPPORT ALONG THE CENTER. (SEE DETAIL A) 4: PLACE EACH FORT SUPPORT AGAINST THE CORNER POST. THE SIDE OF THE FORT SUPPORT SHOULD BE FLUSH WITH THE RIGHT SIDE OF THE RIGHT CORNER POSTS.
STEP 9: DECK SPACERS 1: PLACE A 5/4 X 4 X 40-1/4" DECK SPACER BETWEEN THE LEFT AND RIGHT CORNER POSTS ON TOP OF THE DECK SUPPORTS AS SHOWN BELOW. 2: THE DECK SPACER SIDE SHOULD BE FLUSH WITH THE INSIDE OF THE PANEL SUPPORT. 3: ATTACH EACH DECK SPACER TO THE DECK SUPPORTS WITH TWO 2" WOOD SCREWS.
STEP 10: ROCK WALL 1: LOCATE TWO 2 X 4 X 57 ROCK WALL SIDE BOARDS. LAY THE BOARDS OUT AS SHOWN AND INSERT A 5/16” T-NUT INTO THE HOLE ON THE INSIDE OF EACH BOARD. USE A HAMMER TO SET EACH T-NUT FLUSH WITH THE BOARD.
STEP 11: ROCK WALL 1. LOCATE TEN 5/4 X 5 X 23-7/8” ROCK WALL BOARDS AND ONE 5/4 X 5 X 23-7/8” BOTTOM ROCK WALL BOARD WITH ONE BIG HOLE IN IT. 2. PLACE ONE ROCK WALL BOARD AT THE TOP OF THE ROCK WALL SIDES NEAREST THE HOLES WHERE YOU PREVIOUSLY INSTALLED THE TEE NUTS. MAKE SURE THE ROCK WALL BOARD IS FLUSH WITH THE ENDS AND SIDES OF THE ROCK WALL SIDE BOARDS. 3. ATTACH THE ROCK WALL BOARD WITH FOUR 2” WOOD SCREWS. 4.
STEP 12: ROCK WALL 1: LOCATE TWO 90 GREEN BRACKETS, TWO 5/16” WASHERS AND TWO 5/16” X 1-1/2” HEX BOLTS. 2: FASTEN THE TAPERED SIDE OF EACH 90 GREEN BRACKET TO EACH ROCK WALL SIDE WITH A 5/16” X 1-1/2” HEX BOLT AND 5/16” WASHER.
STEP 13: ROCK WALL 1: LOCATE TWO BAGS OF CLIMBING ROCKS. INSIDE EACH BAG SHOULD BE FIVE ROCKS, FIFTEEN #14 X 1-1/4” PAN HEAD SCREWS AND FIFTEEN 1/4” FLAT WASHERS. 2: PLACE THE CLIMBING ROCKS IN A STAGGERED PATTERN ON THE ROCK WALL BOARDS. PLACE ONE ROCK ON EACH BOARD EXCEPT FOR THE BOTTOM ROCK WALL BOARD WITH THE HOLE IN IT. 3: ATTACH EACH CLIMBING ROCK WITH THREE #14 X 1-1/4” PAN HEAD SCREWS AND THREE 1/4” FLAT WASHERS.
STEP 14: ROCK WALL 1: PLACE THE 5/4 X 3 X 23-7/8” ROCK WALL TOP CAP ON TOP OF THE ROCK WALL SIDES FLUSH WITH THE TOP ROCK WALL BOARD. 2: FASTEN THE 5/4 X 3 X 23-7/8” ROCK WALL TOP CAP TO THE ROCK WALL SIDES AND THE TOP ROCK WALL BOARD WITH FOUR 2” WOOD SCREWS.
STEP 15: ATTACHING THE ROCKWALL 5 1: THE ROCKWALL ATTACHES TO THE REAR OF THE PLAY SET, 11 8 " FROM THE OUTSIDE EDGE OF THE REAR-LEFT CORNER POST. 2: MAKE SURE THE ROCKWALL IS LEVEL. THE BOTTOM EDGE OF THE 90 BRACKETS SHOULD BE 3/4" UP FROM THE BOTTOM EDGE OF THE 2 X 4. MARK THE POSITION OF THE BRACKET HOLES ON THE 2 X 4. 3: DRILL 3/8" HOLES WHERE MARKED. 4: INSERT T-NUTS IN THE BACK OF THE HOLES. 5: ATTACH THE 90 BRACKETS TO THE 2 X 4 WITH TWO 5/16" X 1-1/2" HEX BOLTS AND TWO 5/16" WASHERS.
STEP 16: DECK STRINGER 1: CENTER THE 2 X 4 X 47-3/8" DECK STRINGER UNDERNEATH THE DECK SPACERS. 2: ATTACH THE DECK STRINGER TO THE DECK SPACERS WITH TWO 2" WOOD SCREWS.
STEP 17: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDERNEATH THE DECK ON THE LEFT AND RIGHT OF THE FORT. (THESE ARE CALLED OUT BY THE LETTER "X") 2: ATTACH EACH ANGLE SUPPORT (X) TO THE DECK WITH TWO 2-1/2" WOOD SCREWS AT THE TOP GOING THROUGH THE ANGLE SUPPORT (X) INTO THE DECK SUPPORT. ATTACH THE BOTTOM OF THE ANGLE SUPPORT (X) TO THE CORNER POST WITH ONE 2" WOOD SCREW AND ONE 3" WOOD SCREW.
STEP 18: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57” LADDER SIDE ON A FLAT SURFACE WITH 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 STEPS 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 19: ATTACHING THE LADDER 1: LAY THE 2 X 4 X 47-3/8" FACE BOARD ON A FLAT SURFACE AND PLACE THE LADDER ON TOP OF IT. MAKE SURE THE LEFT SIDE OF THE LADDER IS 3-1/2" FROM THE LEFT END OF THE FACE BOARD. THE BOTTOM EDGE OF THE 90 BRACKETS SHOULD BE 3/4" UP FROM THE BOTTOM EDGE OF THE 2 X 4. MARK THE POSITION OF THE BRACKET HOLES ON THE 2 X 4 AS SHOWN BELOW. 2: DRILL 3/8" HOLES WHERE MARKED. 3: INSERT 5/16" T-NUTS IN THE BACK OF THE HOLES.
STEP 20: FACE BOARDS 1: PLACE THE FACE BOARD (WITH LADDER) ONTO THE FRONT OF THE PLAY SET MAKING SURE THE TOP SIDE IS FLUSH WITH THE TOP SIDE OF THE PANEL SUPPORTS. ATTACH IT TO THE CORNER POSTS USING SIX #8 X 2-1/2" WOOD SCREWS. 2: ATTACH THE ANOTHER FACE BOARD TO THE REAR OF THE PLAY SET MAKING SURE THE TOP SIDE IS FLUSH WITH THE TOP SIDE OF THE PANEL SUPPORTS. ATTACH IT TO THE CORNER POSTS USING SIX #8 X 2-1/2" WOOD SCREWS.
STEP 21: DECK BOARDS 1: SEVEN 5/4" X 6 X 47-3/8" DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS, FLUSH TO THE FACE BOARDS. THERE WILL BE APPROXIMATELY A 1/4" GAP BETWEEN EACH DECK BOARD. 2: SPACE THE DECK BOARDS EVENLY ACROSS THE SUPPORTS. 3: SECURE EACH DECK BOARD TO THE DECK SUPPORTS AND THE DECK STRINGER WITH FIVE 2" WOOD SCREWS, TWO PER END AND ONE IN THE CENTER.
STEP 22: PANEL BOARDS 1: PLACE THE 2 X 4 X 12" BOTTOM PANEL BOARD - LEFT AND 2 X 4 X 12" BOTTOM PANEL BOARD - RIGHT ON TOP OF THE 2 X 4 AT THE LEFT SIDE OF THE PLAY SET AS SHOWN BELOW WITH OFFSET HOLES UP. ATTACH EACH BOTTOM PANEL BOARD WITH ONE 5/16" X 3-1/2" LAG SCREW AND ONE 5/16" WASHER. 2: PLACE THE 2 X 4 X 47-3/8" PANEL SUPPORT WITH OFFSET HOLES UP AT THE RIGHT SIDE OF PLAY SET. ATTACH THE PANEL SUPPORT USING 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 23: PANEL SLATS 1: FIND SEVENTEEN 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES.
STEP 24: CENTER POST 1: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 28-5/8" CENTER POST. 2: PLACE THE CENTER POST INSIDE THE FRONT ARCHED BOARD. LINE UP THE HOLES IN THE CENTER POST WITH THE HOLE IN THE FRONT ARCHED BOARD. 3: FASTEN THE CENTER POST TO THE FRONT ARCHED BOARD WITH A 5/16" X 2-1/2" HEX BOLT AND 5/16" WASHER AT THE TOP. 4: SQUARE EACH CENTER POST TO THE DECK AND SECURE THE BOTTOM OF THE CENTER POST TO THE DECK BOARDS WITH TWO #8 X 2-1/2" WOOD SCREWS.
STEP 25: 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 ON THE OUTSIDE HOLES USING 3/8" X 3-1/2" CARRIAGE BOLTS FROM THE TOP AND 3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM. PLACE BOLT CAPS OVER EXPOSED THREADS AFTER SECURING. 3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER.
STEP 26: SWING BEAM MOUNT 1: THE 4 X 4 X 47-3/8" SWING BEAM MOUNT HAS COUNTER-SUNK HOLES IN THE CENTER AND ON THE ENDS. INSTALL THE SWING BEAM SUPPORT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES IN THE CENTER FACE DOWN. 2: FASTEN THE SWING BEAM MOUNT TO THE RIGHT CORNER POST USING 3/8" X 6-1/2" CARRIAGE BOLTS AND TORQUE WASHERS. PLACE THE CARRIAGE BOLT INTO THE TORQUE WASHER, THEN INTO THE HOLE OF THE CORNER POST AND SET WITH A HAMMER.
STEP 27: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 96" 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 28: 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 29: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP. 1: SIT THE SWING BEAM LEGS UPRIGHT. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE FORT AND SWING LEGS. MAKE SURE THE IRON DUCTILES ARE FACING DOWN.
STEP 30: 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 31: SWING BEAM TO FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP. 1: HAVE ONE PERSON LINE UP THE HOLE IN THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. THE OTHER PERSON MAY HAVE TO CARRY THE OTHER END WHERE THE LEGS ARE LOCATED TO ACCOMPLISH THIS TASK. 2: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM MOUNT USING A 3/8" X 9" CARRIAGE BOLT WITH A TORQUE WASHER ON TOP AND A 3/8" LOCK NUT AND WASHER ON THE BOTTOM.
STEP 32: LEVEL THE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
STEP 33: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING LEGS. 2: LEVEL THE SWING LEG CROSS-MEMBER, AND SECURE TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 34: ARCHED SIDE TOP BOARD 1: PLACE ONE ARCHED SIDE TOP BOARD ON THE LEFT / RIGHT SIDE OF THE PLAY SET AT THE TOP. 2: ATTACH EACH ARCHED SIDE TOP BOARD THROUGH THE TOP HOLE INTO THE T-NUT IN THE CORNER POST WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 3: ATTACH EACH ARCHED SIDE TOP BOARD THROUGH THE BOTTOM HOLE INTO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 35: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 35.50" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35.50" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10.50" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTER-SUNK 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 36: ROOF SUPPORT ASSEMBLIES 1: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 37: ROOF STARTERS / ROOF PEAK 1: PLACE THE 1 X 5 X 52" (GROOVE ONLY) ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS. THE FLAT SIDE OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TOGETHER AS POSSIBLE BEAR THE PEAK WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 38: ROOF BOARDS / ROOF FINISHERS AND DORMERS 1: PLACE THE 1 X 5 X 52" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE INTO THE GROOVE OF THE ROOF STARTER. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED OVER THE ROOF SUPPORTS. THERE ARE SEVEN ROOF BOARDS ON EACH SIDE OF THE ROOF. IF NECESSARY PLACE A SCRAP 2 X 4 BOARD AGAINST THE ROOF BOARD AND HAMMER ON IT TO SEAT THE TONGUE INTO GROOVE FOR THE ROOF BOARDS. FASTEN EACH ROOF BOARD TO THE ROOF SUPPORTS WITH FOUR 1-1/2" WOOD SCREWS.
STEP 39: PLASTIC SUNBURST 1: LOCATE TWO PLASTIC SUNBURST PIECES. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2" WOOD SCREWS.
STEP 40: SUNBURST FILLER BOARD 1: PLACE THE 2 X 4 X 39.50" SUNBURST FILLER BOARD IN BETWEEN THE ROOF SUPPORTS. FASTEN USING #8 X 2-1/2" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ON EACH END, MAKE SURE THERE ARE NO GAPS IN BETWEEN THE SUNBURST FILLER BOARD AND THE ROOF SUPPORTS. ROOF SUPPORT 2 X 4 X 39.
STEP 41: WINDOW SUPPORTS / WINDOWS IN THIS STEP THE WOOD COMPONENTS TO ATTACH WINDOWS WILL BE INSTALLED ON THE INSIDE OF THE FRONT OF THE PLAY SET. 1: ATTACH THE 5/4 X 6 X 20" VERTICAL WINDOW SUPPORT IN THE CENTER WITH #8 X 2" WOOD SCREWS. 2: ATTACH THE 5/4 X 6 X 20" VERTICAL WINDOW SUPPORTS ON THE SIDES WITH #8 X 2" WOOD SCREWS. 3: ATTACH THE 5/4 X 2-1/4 X 11-1/2" HORIZONTAL WINDOW SUPPORTS AT THE BOTTOM AND TOP WITH # 8 X 2" WOOD SCREWS.
STEP 42: SAFETY BOARD THIS BOARD IS MEANT TO BE A VISUAL DETERRENT TO PREVENT CHILDREN FROM RUNNING THROUGH THE BASE OF THE PLAY SET INTO OTHER CHILDREN ON THE SWING SET. 1: MEASURE 17-1/4" FROM THE TOP OF THE RIGHT SANDBOX BOARD AND MAKE A MARK ON THE RIGHT CORNER POSTS. 2: PLACE THE BOTTOM OF A 2 X 4 X 47-3/8" PANEL SUPPORT WITH OFFSET HOLES DOWN ON THE MARKS. 3: ATTACH THE PANEL SUPPORT TO THE RIGHT CORNER POSTS WITH TWO 5/16" X 3-1/2" LAG SCREWS AND TWO 5/16" WASHERS.
STEP 43: CONNECTOR LAG POSTS 1: THE 4 X 4 X 33.813" CONNECTOR LAG POSTS HAS 3 COUNTER SUNK HOLES HOLES. INSTALL THE CONNECTOR LAG POSTS SO THAT THE COUNTER SUNK HOLES FACE OUT MAKING SURE THAT THE TWO CLOSEST COUNTER SUNK HOLES WILL BE POSITIONED AT THE TOP, 2: FASTEN THE CONNECTOR LAG POSTS TO THE CORNER POSTS USING 3/8" X 6-1/2" CARRIAGE BOLTS AND TORQUE WASHERS. PLACE THE CARRIAGE BOLTS INTO THE TORQUE WASHER, THEN INTO THE HOLE OF THE CORNER POST AND SET WITH A HAMMER.
STEP 44: CONNECTOR SUPPORTS 1: THE 4 X 4 X 70" CONNECTOR SUPPORTS HAVE 3 COUNTER SUNK HOLES, TWO AT THE FRONT AND ONE AT THE BACK. INSTALL THE CONNECTOR SUPPORTS SO THAT TWO OF THE COUNTER SUNK HOLES FACE OUT AND THE COUNTER SUNK HOLE ON THE OPPOSITE SIDE FACE IN. 2: PLACE THE CONNECTOR SUPPORTS AGAINST THE CORNER POSTS AT THE REAR OF THE PLAY SET. ONE WILL BE MOUNTED AT THE TOP END OF THE CONNECTOR LAG POSTS AND THE OTHER ONE WILL BE MOUNTED AT THE BOTTOM END OF THE SAME CONNECTOR LAG POSTS.
STEP 45: LAG POST 1: FIND A 4 X 4 X 41" LAG POST. INSERT ONE T-NUT AT THE TOP HOLE ON THE BACK FACE AND SET WITH A HAMMER. 2: PLACE THE LAG POST AGAINST THE CONNECTOR LAG POST AT THE SIDE OF THE PLAY SET. MAKE SURE IT IS FLUSH AND PARALLEL TO THE CONNECTOR LAG POST AND FASTEN USING 3/8" X 5" LAG SCREWS AND 3/8" WASHERS.
STEP 46: UPPER LEVEL CORNER POST 1: FIND ONE 4 X 4 X 96" UPPER LEVEL CORNER POST AND FASTEN TO THE CONNECTOR SUPPORTS USING 3/8" X 6-1/2" CARRIAGE BOLT AND TORQUE WASHER. PLACE THE CARRIAGE BOLT INTO THE TORQUE WASHER, THEN INTO THE HOLE OF THE CORNER POST AND SET WITH A HAMMER. USE 3/8" LOCK NUT AND 3/8" WASHER TO SECURE THE UPPER LEVEL CORNER POST FROM THE OTHER SIDE. PLACE A BOLT CAP OVER THE EXPOSED THREADS AFTER SECURING.
STEP 47: PANEL BOARD AND SANDBOX BOARD 1: FIND ONE 4 X 4 X 96" UPPER LEVEL CORNER POST AND PLACE BEHIND THE PREVIOUSLY INSTALLED CORNER POST. 2: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 3: CONNECT THE TWO UPPER LEVEL CORNER POSTS WITH ONE 2 X 4 X 30.625" PANEL/DECK SUPPORT AND FASTEN WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 4: ATTACH THE 2 X 6 X 30.
STEP 48: REAR TOP PANEL BOARD AND SANDBOX BOARD 1: FIND ONE 4 X 4 X 96" UPPER LEVEL CORNER POST AND PLACE IT BESIDE THE PREVIOUSLY INSTALLED LAG POST. 2: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 3: CONNECT THE TWO UPPER LEVEL CORNER POSTS WITH ONE 2 X 4 X 70" REAR TOP PANEL BOARD (OFFSET UP) AND FASTEN WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 49: PANEL BOARD 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: CONNECT THE UPPER LEVEL CORNER POST AND THE LAG POST WITH ONE 2 X 4 X 30.625" PANEL/DECK SUPPORT AT THE TOP OF THE POSTS AND FASTEN WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 3: FIND ANOTHER 2 X 4 X 30.
STEP 50: DECK SUPPORTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: FIND THE 2 X 4 X 37.188" DECK SUPPORT (WITH ONE END HOLE OFFSET DOWN) AND MOUNT TO THE RIGHT SIDE OF THE FORT AS SHOWN BELOW. FASTEN TO THE UPPER LEVEL CORNER POST AND TO THE LAG POST USING TWO 5/16" X 4-1/2" HEX BOLTS WITH 5/16" WASHERS THROUGH THE REAR COUNTER SUNK HOLE AND THROUGH THE MIDDLE COUNTER SUNK HOLE.
STEP 51: UPPER LEVEL UNDER DECK SUPPORT 1: FIND ONE 4 X 4 X 70" UPPER LEVEL UNDER DECK SUPPORT WITH TWO COUNTERBORE HOLES FACING OUT. PLACE IT AGAINST THE REAR UPPER LEVEL CORNER POSTS AND FLUSH UNDERNEATH THE TWO DECK SUPPORTS PREVIOUSLY INSTALLED. 2: HOLD THE UPPER LEVEL UNDER DECK SUPPORT TIGHT AGAINST THE CORNER POSTS AND DECK SUPPORTS. FASTEN USING 3/8" X 5" LAG SCREWS AND 3/8" WASHERS.
STEP 52: EXTREME SLIDE POST AND DECK SPACER 1: USE A HAMMER TO SEAT THE T-NUT AFTER INSERTING IT INTO THE REAR TOP PANEL BOARD PRE-DRILLED HOLE SHOWN IN THE DIAGRAM BELOW. 2: FIND ONE 4 X 4 X 39.875" EXTREME SLIDE POST AND MOUNT TO THE REAR TOP PANEL BOARD USING ONE 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHER THROUGH THE COUNTER-SUNK HOLE. REAR TOP PANEL BOARD T-NUT 5/16" WASHER 3: FIND A 5/4 X 4 X 36.
STEP 53: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 37-1/8" CENTER DECK SUPPORT AND MOUNT AT THE CENTER ON TOP OF THE UPPER LEVEL UNDER DECK SUPPORT AND THE CONNECTOR SUPPORT, MAKE SURE THAT THE COUNTER SUNK HOLES ON THE ENDS ARE FACING OUT FROM THE EXTREME SLIDE POST AND THE LOWER LEVEL CORNER POST. 2: FASTEN USING TWO 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 54: SLIDE BLOCK 1: FIND THE 4 X 4 X 23.5" SLIDE BLOCK WITH TWO COUNTER SUNK HOLES AND TEMPORARILY PLACE IT AGAINST THE DECK SUPPORT. USE THE COUNTER SUNK HOLES AS A DRILL TEMPLATE AND DRILL TWO 3/8" HOLES INTO THE DECK SUPPORT. 2: REMOVE THE SLIDE BLOCK. USE A HAMMER TO SEAT THE T-NUT AFTER INSERTING IT INTO THE DECK SUPPORT PRE-DRILLED HOLES FROM THE BACK.
STEP 55: ANGLE SUPPORTS 1: FIND ONE 2 X 4 X 21.5" UPPER LEVEL SWING SIDE ANGLE SUPPORT, TWO 2 X 4 X 18" UPPER LEVEL REAR ANGLE SUPPORT AND ONE 2 X 4 X 18" UPPER LEVEL RAD RIDE ANGLE SUPPORT. MOUNT TO THE UPPER LEVEL FRAME USING #8 X 2" WOOD SCREWS, #8 X 2-1/2" WOOD SCREWS AND #8 X 3" WOOD SCREWS FOLLOWING THE DIAGRAMS BELOW.
STEP 56: DECK SPACERS AND UPPER LEVEL STRINGER 1: FIND TWO 5/4 X 3.5 X 40-1/4" UPPER DECK SPACERS AND INSTALL THEM BETWEEN THE LOWER LEVEL CORNER POSTS AND THE CONNECTOR LAG POSTS. FASTEN THEM TO THE DECK SUPPORTS USING #8 X 2" WOOD SCREWS. 2: FIND ONE 5/4" X 4 X 63" UPPER DECK SPACER AND INSTALL IT BETWEEN THE LAG POST AND THE UPPER LEVEL CORNER POST. FASTEN IT TO THE DECK SUPPORTS USING #8 X 2" WOOD SCREWS. 3: FIND ONE 5/4 X 4 X 23.
STEP 57: UPPER 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 SIX #8 X 2" WOOD SCREWS. 5/4 X 6 X 69.
STEP 57A: CONNECTOR STEPS 1: TO MAKE THE CONNECTOR STEPS YOU WILL NEED TO FIND TWO 2 X 4 X 47.375" PANEL / DECK SUPPORTS. 2: PLACE ONE PANEL SUPPORT (CONNECTOR STEP) AGAINST THE CORNER POSTS AND FLUSH TO THE TOP FACE OF THE UPPER LEVEL DECK SPACERS. FASTEN USING 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS THROUGH EACH ONE OF THE COUNTERSUNK HOLES. 3: PLACE THE SECOND PANEL SUPPORT (STEP) AGAINST THE CORNER POSTS BELOW THE FIRST PANEL SUPPORT (CONNECTOR STEP).
STEP 58: ATTACHING THE EXTREME TUBE SLIDE 1: ASSEMBLE THE EXTREME TUBE SLIDE ACCORDING TO THE INSTRUCTIONS PROVIDED. SEE BELOW FOR PLACEMENT OF YOUR SLIDE. 2: ATTACH THE ENTRY OF THE SLIDE TO UPPER LEVEL CORNER POST AND EXTREME SLIDE POST. USE 3/8" X 3-1/2" LAG SCREWS AND 3/8" FENDER WASHERS TO ATTACH THE SLIDE. 11 1 16 " 5 8" EXTREME SLIDE POST 7 8" UPPER LEVEL CORNER POST 3/8" X 3-1/2" LAG SCREW 3/8" FENDER WASHER MAKE THE SLIDE FLUSH WITH DECK BOARD.
STEP 59: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 42.5" REAR BOTTOM PANEL BOARD AT THE REAR OF THE FORT AND MAKE IT LEVEL WITH THE PANEL / DECK SUPPORT ON THE SIDE OF THE UPPER LEVEL. 2: ATTACH THE 2 X 4 X 42.5" REAR BOTTOM PANEL BOARD USING 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 3: MOVE TO THE FRONT OF THE UPPER LEVEL AND MEASURE UP 6-3/8" FROM THE BOTTOM CONNECTOR SUPPORT AND MAKE A MARK ON THE UPPER LEVEL CORNER POST. 4: PLACE THE TOP OF THE 2 X 6 X 22.625" BOTTOM PANEL BOARD ON THE MARK.
STEP 60: UPPER LEVEL PANEL SLATS 1: FIND TEN 5/4 X 2.625 X 28" PANEL SLATS AND THREE 5/4 X 2.625 X 32" PANEL SLATS. 2: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. EXTREME SLIDE POST 2 X 4 X 70" REAR TOP PANEL BOARD 3" 1 24" 3" 3" 5/4 X 2.625 X 28" PANEL SLAT 3" 2 X 4 X 30.625" PANEL / DECK SUPPORT 2 X 4 X 42.
STEP 61: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 51.125" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51.125" ROOF SUPPORT (RIGHT), TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES AND TWO PLASTIC SUNBURST PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH COUNTERSUNK HOLES FACING UP. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.
STEP 62: INSTALLING ROOF SUPPORT ASSEMBLIES 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 63: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE APPROXIMATELY CENTERED (SEE BELOW) ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS.
STEP 64: UPPER LEVEL ROOF PEAK 1: PLACE THE 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARD. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS.
STEP 65: UPPER LEVEL ROOF 1: PLACE THE 1 X 5 X 30.5" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS ELEVEN ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 4 X 30.5" ROOF FINISHER ON THE ENDS OF THE ROOF ASSEMBLY AND FASTEN WITH #8 X 1-1/2" WOOD SCREWS. TIP: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE CHIMNEY.
STEP 66: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE LEFT SIDE OF THE FORT UPPER LEVEL. 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 67: PUNCHING BALL IRON DUCTILE 1: LOCATE THE IRON DUCTILE SWING HANGER. YOU ARE GOING TO USE THE IRON DUCTILE AS A TEMPLATE IN THIS STEP TO DRILL HOLES THROUGH TWO DECK BOARDS. 2: DRILL TWO HOLES WITH A 3/8" DIAMETER DRILL BIT THROUGH THE IRON DUCTILE INTO THE DECK BOARDS. 3: PLACE A 3/8" X 3-1/2" CARRIAGE BOLT THROUGH A TORQUE WASHER. PLACE THE CARRIAGE BOLT INTO A 3/8" HOLE IN THE TOP OF THE DECK. HAMMER THE CARRIAGE BOLT HEAD TO SET THE TORQUE WASHER TEETH INTO THE DECK BOARDS.
STEP 68: PUNCHING BALL 1: PLACE THE 1 FOOT SECTION OF CHAIN THROUGH THE HOLE IN THE PUNCHING BALL. 2: SNAP THE SPRING CLIP ONTO THE IRON DUCTILE SWING HANGER UNDER THE PLAY SET DECK. 3: SNAP THE ENDS OF THE CHAIN INTO THE SPRING CLIP.
STEP 69: TELESCOPE 1: USE THE 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE TO FASTEN ONE OF THE HALF-CIRCLE SHAPED TELESCOPE BRACKETS ON TOP OF THE CONNECTOR SUPPORT AS SHOWN IN THE DIAGRAM BELOW. 2: PLACET THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING HALF-CIRCLE SHAPED TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED. USE THE 1-1/4" WOOD SCREWS PROVIDED WITH THE TELESCOPE TO ATTACH THE TELESCOPE BRACKET.
STEP 70: 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 17.5" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS. EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIC TAC TOE MOUNT. GREEN BRACKET 5/4 X 3 X 17.5" TIC TAC TOE MOUNT TIC TAC TOE AFTER ASSEMBLING GREEN BRACKET 5/4 X 3 X 17.
STEP 71: TIC TAC TOE ASSEMBLY 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT 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.
STEP 72: SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT-RIGHT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: PRE-DRILL 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 73: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: PREDRILL AN 11/64" HOLE ABOUT 2" DEEP INTO THE END OF THE SWING BEAM. USE THE HARDWARE INCLUDE (ONE 3/8 X 2-1/2" LAG SCREW AND ONE 3/8" WASHER) 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 INSERT OR THE STEERING WHEEL WILL NOT TURN.
STEP 74: FLAG KIT 1: PLACE THE FLAGS ON THE FRONT SIDE OF THE PLAY SET CENTERED ON THE CORNER POSTS. 2: ATTACH THE PLASTIC BASE OF EACH FLAG TO THE CORNER POST WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED WITH THE FLAGS.
STEP 75: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES CENTERED ONTO THE POSTS. ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 2: ATTACH EACH SAFETY HANDLE WITH TWO 1-1/4" PAN HEAD SCREWS AND TWO 1/4" WASHERS PROVIDED WITH EACH SAFETY HANDLE.
STEP 76: CLIMBING ROPE 1: THREAD ONE END OF THE ROPE THROUGH THE HOLE IN THE ROCK WALL SIDE TOP PANEL BOARD. 2: TIE A SECURE KNOT ON THE INSIDE OF THE ROCK WALL SIDE TOP PANEL BOARD. 3: 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. 4: NOTE: YOU MAY TIE TWO KNOTS IN THE ROPE TO AID IN CLIMBING IF YOU WISH. DO THIS BEFORE PERFORMING SUB STEP 3.
STEP 77: HANGING THE SWINGS 1: CLIP EACH OF THE SPRING CLIPS ONTO THE IRON DUCTILE SWING HANGERS, THEN CLIP ONTO THE SWING CHAINS. 2: USE THE CLIPS TO ADJUST THE HEIGHT OF THE SWING BY CLIPPING ONTO HIGHER OR LOWER LINKS. 3: COUNT BACK THE SAME NUMBER OF LINKS ON THE OPPOSITE SIDE TO ENSURE THAT SWING IS LEVEL, AND ADJUST TO FIT YOUR NEEDS.
STEP 78: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: 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 79: NAME PLATE 1: ATTACH THE MANUFACTURER NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO 2" WOOD SCREWS.
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.
APPENDIX 120
Chimney and Dormers Hardware Kit 8/10/2015 JH 9 #8 X 2-1/2" WOOD SCREW QTY: 2 8 #8 X 2" WOOD SCREW QTY: 4 7 #8 X 1-1/2" WOOD SCREW QTY: 14 6 #8 X 1-1/4 WOOD SCREW QTY: 6 5 4 #2 SQUARE DRIVE BIT QTY: 1 3 2 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
STEP 1: DORMER 1: OVERLAP THE LEFT DORMER SIDE ONTO THE PEAK SUPPORT OF THE RIGHT DORMER SIDE. 2: MAKE SURE THE FRONT ROOF EDGES ARE FLUSH TO ONE ANOTHER 3: FASTEN THE LEFT DORMER SIDE TO THE PEAK SUPPORT WITH #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1-3 TO CONSTRUCT ANOTHER ROOF ASSEMBLY. #8 X 1-1/2" WOOD SCREW DORMER ROOF (LEFT SIDE) DORMER ROOF (RIGHT SIDE) COMPLETED ROOF ASSEMBLY FRONT ROOF EDGES FLUSH TO ONE ANOTHER HERE.
STEP 2: DORMER 1: PLACE THE PLASTIC DORMER SUNBURST AGAINST THE FRONT FACE SUPPORT ON THE LEFT AND RIGHT ROOF SIDES. 2: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION. 3: INSTALL #8 X 1/2" PAN HEAD SCREWS TO FASTEN THE SUNBURST TO THE ROOF SIDES. REPEAT SUBSTEPS 1 THROUGH 3 TO CONSTRUCT THE SECOND DORMER. PREDRILL 7/64" HOLES X 1/2" DEEP AT EACH HOLE LOCATION ON BOTH SIDES OF THE PLASTIC SUNBURST. INSTALL A #8 X 1/2" PAN HEAD SCREW AT EACH HOLE LOCATION.
STEP 3: DORMER 1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: FOR 1500 SERIES UNITS LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 8TH ROOF BOARD. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF. 4: ATTACH THE DORMER TO THE ROOF WITH ONE #8 X 2-1/2" WOOD SCREW AT THE REAR PEAK OF THE ROOF. ATTACH THE DORMER SUNBURST TO THE ROOF WITH TWO #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1 THROUGH 4 FOR THE DORMER ON THE OTHER SIDE OF THE ROOF.
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 #8 X 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE FOR A SUGGESTED PLACE TO MOUNT THE 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 #8 X 1-1/2" WOOD SCREW IN EACH SIDE.
