® Woodbridge ASSEMBLY MANUAL Copyright © 2011 Gorilla Playsets All Rights Reserved Gorilla Playsets • 190 Etowah Industrial Court Canton, GA 30114 (800) 882-0272 • www.gorillaplaysets.
TABLE OF CONTENTS Warranty and Safety Guidelines……………………………………….......……...Pages 4-11 Kit Contents and Tool List…………..………………………………………........Pages 11-31 Framing the play set………………………………………..............................…... Steps 1-7 Constructing Deck and Upper Panel Boards…………………..………...…....... Steps 8-11 Constructing Rock Wall and securing to fort..………………………….…….... Steps 12-16 Constructing and attaching Ladder…………....……………….…………...…... Steps 17-18 Installing Panel Slats………………………...…..……..……...….…….......
IMPORTANT – PLEASE READ As fresh lumber acclimates to its new environment, the natural tendencies of the tree can show itself in the form of checks, or “cracks” in the lumber. In almost all cases this is normal and it will not affect the structural integrity of your play set.
Thank you for choosing Gorilla Playsets® We’ve included everything you need, except tools, to build your very own professional looking play set. When complete, your new play set should far exceed the quality of play set kits from other build-your-own companies. Our engineers and design team have over 30 years of playground experience. What we’ve developed is a play set that doesn’t compromise quality for simplicity.
Limited Manufacturers Warranty Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions at its original installation, for 10 years for structural wood components and for one year for all other components (e.g., hardware, plastics, tarps, rope ladder, etc.) except Super Scoop SlidesTM and Super Tube Spiral SlidesTM.
IMPORTANT SAFETY GUIDELINES 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. Gorilla recommends you follow all tool manufacturers’ safety guidelines.
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 Gorilla Playsets 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 insert and installed flush to the wood. 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 insert and installed flush to the wood.
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) ___ 1/8” Drill Bit ___ 3/8” Drill Bit ___ 1” Spade/Paddle Bit ___ 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) Swingbelts w/ Chains ___ (1) 10ft.
5/16 X 4" EYEBOLT LAG QTY: 3 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 24 QTY: 24 9 8 7 6 5 4 3 #2 SQUARE DRIVE BIT QTY: 1 2 1 3/8 x 9" 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" CARRIAGE BOLT CARRIAGE BOLT CARRIAGE BOLT CARRIAGE BOLT QTY: 1 QTY: 14 QTY: 4 QTY: 2 PLASTIC BOLT CAP QTY: 21 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
#8 X 1" WOOD SCREW QTY: 8 9 #8 X 1-1/4" WOOD SCREW QTY: 16 #14 X 1-1/4" PAN HEAD SCREW QTY: 16 #8 X 1-1/2" WOOD SCREW QTY: 390 8 #8 X 2" WOOD SCREW QTY: 165 #14 x 1" PAN HEAD SCREW QTY: 4 #8 X 2-1/2" WOOD SCREW QTY: 83 7 #8 X 3" WOOD SCREW QTY: 12 6 5 5/16" TEE NUT QTY: 36 4 3/8" LOCK NUT QTY: 21 3 TORQUE WASHER QTY: 19 3/8" WASHER QTY: 45 2 1 5/16 X 4-1/2" HEX BOLT QTY: 28 5/16 X 1-1/2" HEX BOLT QTY: 8 5/16" WASHER QTY: 60 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
PICTURE DESCRIPTION 1 X 4 X 25" PANEL SLAT QTY.
PICTURE DESCRIPTION 1 X 6 X 14-1/4" FRONT PANEL SLAT QTY.
PICTURE DESCRIPTION 1 X 6 X 55" ROOF BOARD 1-6-5500-RB QTY.
PICTURE DESCRIPTION 2 X 4 X 31" BENCH SUPPORT 2-4-3100-BS 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD QTY.
PICTURE DESCRIPTION 2 X 4 X 70" CENTER DECK SUPPORT QTY.
PICTURE DESCRIPTION 2 X 6 X 67-1/4" SUNBURST BOARD QTY.
PICTURE DESCRIPTION 4 X 4 X 47-1/2" SWING BEAM MOUNT QTY.
PICTURE DESCRIPTION 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB 5/4 X 6 X 10" ROOF PEAK SUPPORT QTY.
PICTURE DESCRIPTION QTY.
PICTURE NOT SHOWN DESCRIPTION QTY. SWING PLATE 1 CLIMBING ROCKS 10 A-FRAME SWING LEG BRACKET 1 1 INSTRUCTIONSEA.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
STEP 1: ATTACHING THE T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE PLAY SET PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DISASSEMBLE THEN REASSEMBLE TO MAKE YOUR CORRECTIONS. MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 2: LAY OUT EACH OF THE 4 X 4 X 108" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE PLAYSET. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS SHOULD FACE.
STEP 2: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" ROPE LADDER RUNNER ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE DOWNWARD. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 3: ASSEMBLING THE RIGHT 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" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE DOWNWARD. 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 TNUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
STEP 3A: DRILL HOLES FOR BRIDGE CHAINS 1: LOCATE ONE 2 X 4 X 70" DECK SUPPORT AND ONE 2 X 6 X 70" FRONT FACE BOARD. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD. 3: PLACE A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES WITH A SPADE BIT.
STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE PLAY SET. 5/16" WASHER HOLES FOR CLATTER BRIDGE CHAIN.
STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD SHOULD FACE 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 TNUTS 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 OFFSET HOLES IN THE FRONT FACE BOARD SHOULD FACE UP.
STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE UP. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHER TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. 2: PLACE THE 2 X 6 X 70" BOTTOM PANEL BOARD ON THE REAR CORNER POSTS. THE OFFSET HOLES IN THE BOTTOM PANEL BOARD MUST FACE 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. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE FRAME HAS BEEN LEVELED AND SQUARED.
STEP 7: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT. 2: AT THE TOP USE TWO 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE ANGLE SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.
STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-1/2" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/4" ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE DECK SPACER.
STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: USE THE HOLE IN THE CENTER OF THE DECK SPACER AS A GUIDE TO DRAW A LINE ON THE OUTSIDE OF THE BOTTOM PANEL BOARD ON EACH SIDE OF THE PLAY SET. (SEE DETAIL B) PLACE THE CENTER DECK SUPPORT UNDERNEATH THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED. 3: CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT UNDER THE HOLE IN THE DECK SPACER. USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT.
STEP 10: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES DOWN AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2: DO THE SAME PROCEDURE FOR THE OTHER SIDE USING A 2 X 4 X 47-1/2" BOTTOM PANEL BOARD, 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 11: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 3 18" 1 48" 11 23 16 " 1 48" 5/4 X 6 X 47-3/8" DECK BOARD 1 48" 3 24" 3 18" 1 48" 1 8 " DIAMETER 5 PLACES 2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT.
STEP 12: 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 13: 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 ON 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 14: ROCK WALL 1: FASTEN THE 90 BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
STEP 15: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND THIRTY 1/4" WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH THREE 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 THAN WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT. BE CREATIVE.
STEP 16: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT SIDE - RIGHT OF THE PLAY SET AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 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 ON THE FRONT FACE BOARD. 3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
STEP 17: LADDER 2 X 4 X 66" LADDER SIDE 1: FIND TWO 2 X 4 X 66" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. T-NUT 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER. 2" WOOD SCREW 4: FIND FIVE 2 X 4 X 17" LADDER STEPS. 5: PLACE THE STEPS INTO THE SLOTS ON THE LADDER SIDES, AND FASTEN WITH 2" WOOD SCREWS. 2 X 4 X 17" LADDER STEP 6: CAREFULLY TURN THE LADDER OVER AND PUT THE SCREWS INTO THE OTHER SIDE.
STEP 18: LADDER TO PLAY SET 1: THE LADDER WILL ATTACH TO THE REAR OF THE PLAY SET. PLACE THE LADDER AGAINST THE BOTTOM PANEL BOARD CENTERED IN THE NOTCHED OUT AREA. 2: THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE BOTTOM PANEL BOARD. USING THE 90 BRACKETS AS A TEMPLATE DRILL A 3/8" HOLE THROUGH THE BOTTOM PANEL BOARD. 3: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8" HOLES ON THE BOTTOM PANEL BOARD.
STEP 19: FRONT PANEL SLATS 1: FIND ONE 1 X 4 X 25" FRONT PANEL SLATS AND ONE 4 X 4 X 26" CENTER POST. 2: PREDRILL THE SLAT 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3: INSTALL THE PANEL SLAT AS SHOWN ON THE FIGURE BELOW AND ATTACH WITH 2" WOOD SCREWS. 4: PLACE THE 4 X 4 X 26" CENTER POST 29-3/4" AWAY FROM THE LEFT FRONT CORNER POST AS SHOWN. 5: ATTACH THE CENTER POST TO THE TOP PANEL BOARD WITH TWO 3" WOOD SCREWS.
STEP 20: SIDE PANEL SLATS 1: FIND ELEVEN 1 X 6 X 27-3/4" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END WITH TWO EQUALLY SPACED HOLES WITH A 1/8" DRILL BIT. 3. INSTALL THE PANEL SLATS AS SHOWN LEAVING 1/4" GAP BETWEEN EACH PANEL SLAT OR A 1/4" GAP BETWEEN THE CORNER POST AND PANEL SLAT. 4. ATTACH THE PANEL SLATS TO THE PLAY SET WITH 1-1/2" WOOD SCREWS IN THE PREDRILLED HOLES.
STEP 21: TIC TAC TOE SUPPORT 1:FIND TWO 1 X 6 X 16" TIC TAC TOE SUPPORT SLATS. 2: PRE-DRILL THE SLATS 2" FROM EACH END, AND 4" OVER FROM THE FIRST HOLE AS SHOWN ON THE DIAGRAM USING A 1/8" DRILL BIT. 3: INSTALL THE SLATS IN THE GAP LEFT FROM THE PREVIOUS INSTALLATION LEAVING A 3/4" GAP ON THE END. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 1-1/2" WOOD SCREWS IN THE PRE-DRILLED HOLES LEAVING A 16-13/16" OPENING BETWEEN THE TIC TAC TOE SUPPORT SLATS. 2.000 .125 DIAMETER 4 PLACES 4.000 1.500 5.500 16.
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 THE TOP, AND 3/8" WASHERS, 3/8" LOCK NUTS ON THE BOTTOM, IN THE COUNTER-SUNK HOLES OF 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 VICE GRIPS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.
STEP 23: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE 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: 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 26: MOUNT SWING BEAM TO 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 HOLES AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLES ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT WITH A TORQUE WASHER ON TOP, AND A 3/8" LOCK NUT AND WASHER ON THE BOTTOM.
STEP 27: 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). THEY 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. ADJUST IN OR OUT. ADJUST IN OR OUT.
STEP 28: 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 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 29: ROOF SUPPORT 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 51" 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: DO NOT CONNECT THE ENDS AT THIS TIME.
STEP 30: ROOF PEAK SUPPORT 1: PRE-DRILL HOLES IN THE TWO 5/4 X 10" ROOF PEAK SUPPORTS TO THE PATTERN SHOWN BELOW. 5/4 X 10" ROOF PEAK SUPPORT 2: PLACE THE 5/4 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 1-1/2" WOOD SCREWS. REPEAT ON OTHER SIDE.
STEP 31: ROOF 1: PLACE THE 1 X 5 X 55" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING. 2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
STEP 32: ROOF PEAK 1: PLACE THE 55" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH EIGHT 1-1/2" WOOD SCREWS.
STEP 33: ROOF 1: PLACE THE 1 X 6 X 55" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2. FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 5 X 55" ROOF FINISHER AT THE END OF THE ROOF ASSEMBLY, AND FASTEN WITH 1-1/2" WOOD SCREWS. EACH SIDE OF THE ROOF GETS ONE ROOF FINISHER. 4: REPEAT SUBSTEPS 1-3 FOR THE OTHER SIDE OF THE ROOF.
STEP 34: SUNBURST BOARD 1: FIND TWO 2 X 6 X 56-1/2" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS. 4: INSTALL USING 2" WOOD SCREWS. ROOF PANELS REMOVED FOR CLARITY.
STEP 35: BOTTOM SUNBURST BOARD 1: FIND TWO 2 X 6 X 67-1/4" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS. 4: INSTALL USING 2" WOOD SCREWS. ROOF BOARDS REMOVED FOR CLARITY.
STEP 36: FRONT TOP PANEL SLATS 1: FIND SIX 1 X 6 X 26" AND TWO 1 X 4 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT THE DIMENSIONS SHOWN ON THE DIAGRAM. 4: ATTACH THE SLATS TO THE FORT WITH 1-1/2" WOOD SCREWS IN THE PRE-DRILLED HOLES. ROOF PANELS REMOVED FOR CLARITY. VIEW WITH DIMENSIONS IS FROM REAR OF FORT LOOKING FORWARD.
STEP 37: REAR PANEL SLATS 1: FIND FOUR 1 X 6 X 51" REAR PANEL SLATS AND TWO 1 X 4 X 51" REAR PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3. INSTALL THE PANEL SLATS AS SHOWN BELOW. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 1-1/2" WOOD SCREWS IN THE PRE-DRILLED HOLES. 5: ONCE THE PANEL SLATS ARE INSTALLED DRILL TWO HOLES IN THE MIDDLE OF EACH SLAT AND ATTACH TO THE REAR TOP PANEL BOARD WITH 1-1/2" WOOD SCREWS. ROOF PANELS REMOVED FOR CLARITY.
STEP 38: FINAL REAR PANEL BOARDS 1: FIND TWO 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS AND TWO 1 X 6 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS 3/4" FROM THE BOTTOM END AND 4" FROM THE TOP END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT. 3: INSTALL THE BOTTOM WINDOW SUPPORT BOARDS 5/16" OFF THE DECK AND SPACE THEM EQUALLY IN THE OPENING. ATTACH THE BOARDS WITH 1-1/2" WOOD SCREWS.
STEP 39: WINDOW SUPPORTS 1: FIND THE SIX 1 X 6 X 4-1/2" BOTTOM WINDOW SUPPORTS. PRE-DRILL THREE 1/8" HOLES IN THE BOTTOM OF EACH SUPPORT AS SHOWN IN THE DIAGRAM. 2: PLACE TWO SUPPORTS IN EACH OF THE TWO OPENINGS IN THE FRONT OF THE FORT, AND THE FINAL TWO SUPPORTS IN THE OPENING AT THE REAR OF THE FORT. THE SUPPORTS SHOULD BE FLUSH WITH THE BOTTOM OF THE CENTER MOUNTED 1 X 6 X 26" FRONT PANEL SLATS AS SHOWN BELOW. 3: ATTACH EACH SUPPORT USING THREE 1-1/2" WOOD SCREWS. ROOF PANELS REMOVED FOR CLARITY.
STEP 40: INSTALL WINDOWS 1: FIND FOUR WINDOW PANELS AND FOUR SUN PIECES. PLACE EACH WINDOW IN THE OPENING WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. TEST FIT THE SUN PIECES ABOVE THE WINDOW FRAME (THESE WILL BE INSTALLED LATER). 2: ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS. ROOF PANELS REMOVED FOR CLARITY.
STEP 41: INSTALL PANEL SLATS AND SUN PIECES 1: FIND EIGHT 1 X 6 X 14-1/4" FRONT PANEL SLATS AND EIGHT SUN PIECES. 2: PRE-DRILL EACH SLAT WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOW BELOW. 3: ATTACH THE PANEL SLATS AS SHOWN BELOW WITH THE BOTTOM OF THE SLAT RESTING UPON THE INSIDE FLANGE OF THE WINDOW FRAME. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 1-1/2" WOOD SCREWS IN THE PRE-DRILLED HOLES. 5: ATTACH FOUR MORE PANEL SLATS ON THE REAR SIDE.
STEP 42: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. DISREGARD STEPS 6 & 7. 2: CENTER THE TIC TAC TOE PANEL BETWEEN THE SUPPORTS ON THE SIDE WALL AND ATTACH WITH EIGHT 1" WOOD SCREWS PROVIDED IN THE TIC TAC TOE BOX.
STEP 43: SUNBURST 1: PRE-DRILL TWO 1/8" HOLES IN EACH SUN. THE HOLES WILL BE DRILLED NEAR THE OUTER EDGE ON EACH SIDE GOING STRAIGHT DOWN. 2: CENTER SUN ON THE PANEL BOARD AND ATTACH USING TWO 2" WOOD SCREWS. 3: REPEAT FOR OTHER SIDE OF FORT.
STEP 44: SUNBURST 1: LOCATE TWO 5/4 X 2 X 23" LARGE RAYS, TWO 5/4 X 2 X 16" SMALL RAYS AND TWO 5/4 X 2 X 18" SMALL RAYS. 2: PRE-DRILL ALL SMALL RAYS AT 3/4" ON CENTER FROM EACH END WITH A 1/8" DRILL BIT. PRE-DRILL ALL LARGE RAYS 3/4" ON CENTER FROM THE BOTTOM END WITH A 1/8" DRILL BIT. PRE-DRILL THE TOP END 3/4" FROM THE TOP END AND 1/2" FROM THE SIDE WITH A 1/8" DRILL BIT. (SEE DETAIL A) THIS IS NECESSARY TO AVOID HITTING THE JOINT WHERE THE ROOF SUPPORTS MEET.
STEP 45: SUNBURST 1: INSTALL SUNBURST SCREENS AS SHOWN BELOW, SO THAT IT IS FLUSH TO THE ROOF SUPPORTS. FASTEN EACH SCREEN WITH SIX 1-1/4" PAN HEAD SCREWS INTO THE GROMMETS IN THE SCREEN.
STEP 46: PANEL SUPPORT 1: MEASURE 17-3/4" FROM THE BOTTOM OF THE SANDBOX BOARD ON THE FRONT FACE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. LINE UP THE TOP OF THE 2 X 4 X 78" PANEL SUPPORT WITH THE MARKS. ATTACH THE 2 X 4 X 78" PANEL SUPPORT WITH "OFFSET HOLES UP" TO THE CORNER POSTS WITH 3/8" X 31/2" LAG SCREWS AND 3/8" WASHERS. NOTE: ROCK WALL OMITTED FOR CLARITY.
STEP 47: SAFETY BOARD 1: MEASURE 17-3/4" FROM BOTTOM OF THE SANDBOX BOARD ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. 2: ALIGN THE TOP OF THE SAFETY PANEL BOARD WITH THE MARKS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH "OFFSET HOLES DOWN" TO THE CORNER POSTS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 48: PICNIC TABLE 1: PLACE EACH OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORTS 15" OVER FROM THE CORNER POSTS. (SEE REAR VIEW) 2: MAKE SURE THE PICNIC TABLE VERTICAL SUPPORTS ARE SQUARE TO THE SANDBOX BOARDS. ATTACH THEM TO THE SANDBOX BOARDS FROM THE INSIDE USING TWO 2-1/2" WOOD SCREWS. ATTACH THE PICNIC TABLE VERTICAL SUPPORT (ON FRONT OF THE PLAYSET) TO THE 2 X 4 X 78" PANEL BOARD USING THREE 2-1/2" SCREWS. 3: NEXT FIND THE 2 X 4 X 31" BENCH SUPPORT BOARD.
STEP 49: PICNIC TABLE 1: FIND TWO 2 X 4 X 15" PICNIC TABLE SUPPORTS. 2: ATTACH EACH PICNIC TABLE SUPPORT TO THE TOP OF THE PICNIC TABLE VERTICAL SUPPORT AND TO THE CORNER POSTS. 3: ATTACH EACH PICNIC TABLE SUPPORT TO THE PICNIC TABLE VERTICAL SUPPORT AND THE CORNER POST USING SIX 2-1/2" WOOD SCREWS. NOTE: ROCK WALL REMOVED FOR CLARITY.
STEP 50: PICNIC TABLE 1: FIND SEVEN 2 X 4 X 51" PICNIC TABLE SEATS AND PICNIC TABLE TOP BOARDS. 2: ATTACH EACH BOARD WITH FOUR 2-1/2" WOOD SCREWS AS SHOWN BELOW TO CREATE THE PICNIC TABLE SEATS AND TOP. NOTE: LADDER AND ROCK WALL REMOVED FOR CLARITY.
STEP 51: BOTTOM PANEL SLATS 1: FIND FIFTEEN 1 X 6 X 17" PANEL SLATS. 2: PRE-DRILL SLATS WITH TWO EQUALLY SPACED HOLES 1" FROM EACH END WITH A 1/8" DRILL BIT. 3: ATTACH PANEL SLATS ALONG THE SAFETY BOARD AND PANEL BOARD EQUALLY SPACED. 4: ATTACH EACH PANEL SLAT USING FOUR 1-1/ 2" WOOD SCREWS. NOTE: ROCK WALL AND LADDER REMOVED FOR CLARITY. PANEL BOARD SAFETY BOARD 1-1/2" WOOD SCREW 1 X 6 X 17" PANEL SLAT (CENTERED BETWEEN POST AND SUPPORT.
STEP 52: ARCHED SIDE TOP BOARDS 1: PLACE THE 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD UP AGAINST THE TOP OF THE CORNER POSTS ON THE SIDE OF THE FORT. 2: ATTACH THE ARCHED SIDE TOP BOARD WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3: ATTACH ANOTHER ARCHED SIDE TOP BOARD ON THE OPPOSITE SIDE OF FORT.
STEP53: CHIMNEY/DORMER 1: USE THE INSTRUCTIONS PROVIDED TO ASSEMBLE AND INSTALL THE CHIMNEY AND DORMERS. TIP: WHEN INSTALLING THE ROOF BOARDS ONLY INSTALL A FEW ROOF BOARDS THEN ASSEMBLE AND INSTALL THE CHIMNEY. AFTERWARDS INSTALL MORE ROOF BOARDS THEN ASSEMBLE ANDINSTALL THE DORMER. FINALLY INSTALL THE REMAINING ROOF BOARDS AND ROOF FINISHER. ON THE OTHER SIDE OF THE ROOF THERE IS ONLY A DORMER. FOR THAT SIDE INSTALL SOME ROOF BOARDS FIRST. THEN ASSEMBLE AND INSTALL THE DORMER.
STEP 54: INSTALLING THE CLIMBING ROPE 1:DRILL A 7/8" HOLE THROUGH THE FRONT TOP 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 FRONT TOP PANEL BOARD. 3: YOU CAN TIE A FEW (NO MORE THAN THREE) KNOTS IN THE ROPE TO AID IN CLIMBING APPROXIMATELY 18" APART BEFORE TYING THE KNOT BEHIND THE BOTTOM ROCK WALL BOARD. 4: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD.
1: FIND THE PLASTIC FLAG KIT. STEP 55: PLASTIC FLAGS 2: ATTACH THE FLAGS TO THE FRONT CORNER POSTS AS SHOWN BELOW. 3: ATTACH EACH FLAG TO THE CORNER POST THROUGH THE PRE-DRILLED HOLES USING 1/2" PHILLIPS HEAD WOOD SCREWS PROVIDED WITH THE FLAG KIT.
STEP 56: MOUNTING TELESCOPE 1: PLACE THE TELESCOPE ASSEMBLY ON THE ROPE LADDER SUPPORT ABOVE THE TIC TAC TOE PANEL. USING THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE ROUND TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT. 2: PLACE THE TELESCOPE STAND INTO THE SLOT OF THE TELESCOPE BRACKET. 3: PLACE THE REMAINING ROUND TELESCOPE BRACKET ACROSS FROM THE FIRST BRACKET. FASTEN THE ROUND TELESCOPE BRACKET WITH 1-1/4" WOOD SCREWS TO THE ROPE LADDER SUPPORT.
STEP 57: 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 SWING BEAM. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN. 3: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL.
STEP 58: ATTACHING THE SAFETY HANDLES 1: LOCATE TWO SAFETY HANDLES PROVIDED WITH YOUR PLAYSET. 2: LOCATE THE HARDWARE PROVIDED IN THE BAG WITH THE HANDLES. **DO NOT USE THE SCREWS PROVIDED IN THE BAG WITH THE HANDLES** 3: LOCATE FOUR #14 X 1" LONG PAN HEAD SCREWS IN YOUR MAIN HARDWARE PACKAGE. USE THE 1/4" FLAT WASHERS PROVIDED IN THE BAG WITH THE HANDLES. 4: PLACE THE HANDLES 1" AWAY FROM THE EDGE OF EACH PANEL SLAT ABOVE THE LADDER AT THE REAR OF THE PLAY SET.
STEP 59: 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 60: ROPE LADDER ASSEMBLY 1: DRILL THREE 1/8" PILOT HOLES 2" DEEP INTO THE BOTTOM OF THE ROPE LADDER SUPPORT. (SEE DIMENSIONS BELOW) 2: SCREW THE EYEBOLT LAG SCREWS INTO THE HOLES AT THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIGHTEN.
STEP 61: ROPE LADDER ASSEMBLY 1: PLACE THE HOOKS ON THE END OF THE ROPE LADDER ASSEMBLY THROUGH THE EYE OF THE EYEBOLT LAGS. 2: THREAD THE BOTTOM ROPE ENDS OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE A SECURE KNOT IN THE END OF EACH ROPE.
PART II CLATTER BRIDGE WITH TARP FOR WOODBRIDGE PLAY SET 95
5/16" X 3-1/2" HEX LAG SCREW QTY: 34 3/8 X 5" HEX LAG SCREW QTY: 4 NOTE: THIS SHEET IS A COMBINATION OF 11-1920 AND 11-0026 HARDWARE.
PICTURE NOTE: THIS LIST IS A COMBINATION OF THE 106 AND 802 WOOD KITS. DESCRIPTION QTY.
PICTURE DESCRIPTION 2 X 4 X 29" BRIDGE DECK BOARD 5/4 X 2-5/8" X 28-1/2" PANEL SLAT 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 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE TOWER OF THE CLATTER BRIDGE.
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK 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: LAY THE 2 X 6 X 36-3/4" 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 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK 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: LAY THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS.
STEP 4: DRILLING CHAIN HOLES 1: LOCATE TWO 2 X 4 X 36-3/4" BOTTOM PANEL/DECK SUPPORT BOARDS. 2: PLACE ONE OF THE BOARDS WITH THE COUNTERSUNK HOLES FACING UP OVER A SCRAP 2 X 4 BOARD. THE SCRAP BOARD WILL HELP PREVENT THE PADDLE BIT FROM SPLINTERING OUT THE BACK SIDE OF THE BOARD. 3: MEASURE AND MAKE A MARK AT THE LOCATIONS SHOWN BELOW. 4: DRILL A 1" DIAMETER HOLE WITH A PADDLE BIT AT EACH LOCATION THROUGH THE BOARD. 5: REPEAT SUBSTEPS 2 TO 4 FOR THE SECOND BOARD.
STEP 5: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 36-3/4" DECK SUPPORTS TO THE HOLES AT 54-1/2" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST. D C LEFT SIDE FRAME RIGHT SIDE FRAME B A 2 X 4 X 36-3/4" DECK SUPPORT (WITH HOLES YOU DRILLED) 2 X 4 X 36-3/4" DECK SUPPORT 5/16" WASHER 5/16 X 4-1/2" HEX BOLT 2 X 6 BOTTOM PANEL BOARD NOT SHOWN FOR CLARITY.
STEP 6: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD 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: PLACE THE 2 X 4 X 36-3/4" TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS.
STEP 7: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD 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: PLACE THE 2 X 4 X 36-3/4" TOP PANEL BOARD ON THE REAR OF THE CORNER POSTS.
STEP 8: LAG SCREWS 1: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. TO SQUARE AND LEVEL THE DECK OF THE TOWER TO THE DECK OF THE FORT PLACE A DECK BOARD ACROSS THE 2 X 4'S. THEN PLACE A 2 X 4 X 66" BRIDGE RAIL ON TOP OF THE DECK BOARD AND ON TOP OF THE FORT DECK. PLACE A LEVEL ON TOP OF THE 66" BRIDGE RAIL, THEN MAKE THE DECKS LEVEL TO ONE ANOTHER.
STEP 9: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK SPACERS AND DECKBOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 3 4" 2X 3 18" 1 48" 3 14" 3 14" 1 48" 1 48" 3 4" 1 8" 4X 5/4 X 4 X 29-3/8" DECK SPACER 1 8" 5/4 X 6 X 36-11/16" DECK BOARD 2: PLACE THE 5/4 X 4 X 29-3/8" DECK SPACERS BETWEEN THE CORNER POSTS.
STEP 10: FRONT FACE BOARD 1: PLACE THE 5/4 X 6 X 36-11/16" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 3: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 11: DECK 1: INSTALL THE 5/4 X 6 X 36-11/16" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 5/16") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS.
STEP 12: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH HOLES YOU DRILLED) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 2: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
STEP 13: PANEL SLATS 1: FIND FIVE 5/4 X 3 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: INSTALL THE FIRST PANEL SLAT 2-1/2" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8" APART AS SHOWN IN THE PICTURE AT THE BOTTOM LEFT BELOW. 4: ATTACH THE PANEL SLATS WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES TO THE RIGHT SIDE OF THE TOWER. 1" D 1" 2X 2" WOOD SCREW.
STEP 14: BRIDGE RAILS 1: PLACE THE TOP SURFACE OF THE UPPER TWO 2 X 4 X 66" BRIDGE RAILS 5-1/2" BENEATH THE TOP SURFACE OF THE TOP PANEL BOARD. THE COUNTERSUNK HOLE IN THE END OF THE BRIDGE RAIL SHOULD FACE THE INSIDE. FASTEN THE BRIDGE RAIL TO THE CORNER POST WITH 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2: MEASURE 16" FROM THE TOP OF EACH BRIDGE RAIL AND MAKE A PENCIL MARK ON THE INSIDE OF THE CORNER POSTS. 3: PLACE THE BOTTOM OF EACH LOWER 2 X 4 X 66" BRIDGE RAIL ON THE MARK ON THE CORNER POST.
STEP 15: BRIDGE RAILS TO PLAY SET 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER CORNER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 31/2" LAG SCREWS AND 5/16" WASHERS. 3: MAKE THE BOTTOM OF EACH LOWER BRIDGE RAIL 16" FROM THE TOP OF THE TOP BRIDGE RAIL. 4: ATTACH EACH LOWER BRIDGE RAIL TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 16: BRIDGE RAIL SLATS 1. PRE-DRILL THE 5/4 X 3 X 16" BRIDGE RAIL SLATS ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2. PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS. 3. ATTACH THE REMAINING SLATS TO THE UNIT WITH 3" SPACING BETWEEN THE SLATS.
STEP 17: BRIDGE DECK AND CHAIN ASSEMBLY 1: FIND FIFTEEN 2 X 4 X 29" BRIDGE DECK BOARDS AND INSERT T-NUTS INTO THE PRE-DRILLED HOLES. USE A HAMMER TO SEAT THE T-NUTS INTO THE BOARDS. T-NUT 2 X 4 X 29" BRIDGE DECK BOARD T-NUT FLANGE 2: FLIP ALL 15 BRIDGE DECK BOARDS OVER SO THAT THE FLANGE OF THE T-NUT IS FACING DOWN. LAY THE BRIDGE DECK BOARDS OUT ON A FLAT SURFACE AS SHOWN BELOW.
STEP 18: BRIDGE DECK AND CHAIN ASSEMBLY 1: LOCATE TWO 96" CHAIN SECTIONS THAT SHIPPED WITH THE CLATTER BRIDGE. 2: PLACE THE CHAINS OVER THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW. 3: LINE UP THE 18TH LINK IN THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES.
STEP 19: BRIDGE DECK AND CHAIN ASSEMBLY 1: PLACE A 5/16" WASHER BETWEEN THE 18TH CHAIN LINK AND THE BRIDGE DECK BOARD. 2: PLACE A 5/16" X 1-3/4" HEX BOLT WITH 5/16" WASHER THROUGH THE 18TH CHAIN LINK, THEN THROUGH THE 5/16" WASHER, THEN THROUGH THE HOLE IN THE BRIDGE DECK BOARD AND SCREW IT INTO THE T-NUT. TIGHTEN THE BOLT BUT NOT SO TIGHT THAT YOU CRACK THE WOOD. 3: COUNT OVER 4 CHAIN LINKS FROM THE LAST HEX BOLT. AT THIS CHAIN LINK PLACE A 5/16" WASHER BETWEEN THE CHAIN LINK AND THE BRIDGE DECK BOARD.
STEP 20: BRIDGE DECK/CHAIN INSTALLATION 1: LAY THE BRIDGE DECK/CHAINS ASSEMBLY BETWEEN THE PLAY SET AND THE TOWER WITH THE CHAINS FACING THE GROUND. THREAD THE CHAIN ENDS IN THE BRIDGE DECK ASSEMBLY THROUGH THE HOLES IN THE BOTTOM PANEL BOARD AND DECK SUPPORT BOARD ON THE TOWER. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE BOTTOM PANEL BOARD ON THE TOWER. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP.
STEP 21: LAG POSTS 1: LOCATE TWO 4 X 4 X 32" LAG POSTS. 2: PLACE THE LAG POSTS ON THE INSIDE OF CORNER POSTS A AND B AS SHOWN. THE COUNTERSUNK HOLE THAT IS 4" FROM THE END SHOULD BE AT THE TOP. 3: ATTACH EACH LAG POST TO THE CORNER POST WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS.
STEP 22: VERTICAL TARP SUPPORTS 1: PLACE THE 2 X 4 X 33" VERTICAL TARP SUPPORTS ON THE INSIDE OF THE TOP PANEL BOARDS. THE END OF EACH VERTICAL TARP SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE TOP PANEL BOARD. CENTER EACH VERTICAL TARP SUPPORT WITH THE CENTER OF THE TOP PANEL BOARD. SQUARE EACH VERTICAL TARP SUPPORT TO THE TOP PANEL BOARD. 2: ATTACH THE VERTICAL TARP SUPPORTS TO THE TOP PANEL BOARDS WITH 2-1/2" WOOD SCREWS.
STEP 23: TARP BOARDS 1: LOCATE THREE 2 X 4 X 36-3/4" TARP BOARDS. 2: PLACE ONE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE END OF THE TARP BOARD SHOULD BE FLUSH WITH THE SIDES OF THE VERTICAL TARPS SUPPORTS. 3: ATTACH THE TARP BOARD TO THE VERTICAL TARP SUPPORTS WITH 2-1/2" WOOD SCREWS. 4: PLACE ONE TARP BOARD ON TOP OF THE CORNER POSTS. THE TARP BOARD SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. 5: ATTACH THE TARP BOARD TO THE TOP OF THE CORNER POSTS WITH 2-1/2" WOOD SCREWS.
STEP 24: CLATTER BRIDGE TARP 1: LOCATE THE 34-1/4" X 57-1/2" CLATTER BRIDGE TARP. 2: PLACE THE TARP OVER THE TOP OF THE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. 3: THE TARP WILL OVERLAP THE SIDE OF THE TARP BOARDS ON TOP OF THE CORNER POSTS. 4: ATTACH THE TARP THROUGH THE GROMMETS TO THE TARP BOARDS WITH #14 X 1-1/4" PAN HEAD SCREWS AND 1/4" FLAT WASHERS.
STEP 25: BOARD REMOVAL 1: REMOVE THE 2 X 4 AT THE TOP LEFT AS SHOWN BELOW. 2: REMOVE THE 2 X 6 AT THE MIDDLE LEFT AS SHOWN BELOW. 3: USE A 5/16" X 3-1/2" HEX BOLT AND A 5/16" WASHER TO FILL THE FOUR HOLES WHERE THE 2 X 4 AND 2 X 6 WERE ATTACHED. REMOVE THIS 2 X 4. SET IT ASIDE FOR FUTURE USE. REMOVE THIS 2 X 6. SET IT ASIDE FOR FUTURE USE. USE A 5/16" X 3-1/2" HEX BOLT AND A 5/16" WASHER TO FILL THE FOURHOLES WHERE THE 2 X 4 AND 2 X 6 WERE ATTACHED.
STEP 26: DRILLING RADICAL RIDE ENTRY PLATE 1: LOCATE THE RADICAL RIDE ENTRY PLATE IN THE RADICAL RIDE SLIDE BOX. 2: DRILL FOUR HOLES WHERE INDICATED BELOW WITH A 3/8" DRILL BIT. 3: THE BOTTOM TWO MOUNTING HOLES SHOWN BELOW ARE NOT USED WHEN MOUNTING THE FACE PLATE TO THE LAG POSTS. TOP SURFACE - THIS WILL BE EVEN WITH THE TOP OF THE LAG POSTS WHEN YOU INSTALL THE RADICAL RIDE SLIDE. HOLES USED FOR MOUNTING ENTRY PLATE TO LAG POSTS AFTER SLIDE IS ASSEMBLED. 5 8" 3 8 " TYP.
STEP 27: ATTACHING RADICAL RIDE SLIDE 1: ASSEMBLE THE RADICAL RIDE 5 TUBE SLIDE FOLLOWING THE DIRECTIONS THAT CAME WITH THE SLIDE. WHEN YOU GET TO STEP 3 IN THE RADICAL RIDE 5 INSTRUCTIONS **STOP** AND USE THIS STEP INSTEAD TO MOUNT THE ENTRY PLATE AND ENTRY ASSEMBLY TO THE CLATTER BRIDGE TOWER. 2: ATTACH THE ENTRY PLATE AND ENTRY SECTIONS TOGETHER AT THE MIDDLE HOLE AS SHOWN BELOW ON EACH SIDE. USE A 5/16" X 3/4" HEX BOLT, TWO 5/16" WASHERS AND A LOCK NUT FOR THIS.
STEP 28: ATTACHING 2 X 4 AND 2 X 6 PANEL BOARDS 1: LOCATE THE 2 X 4 X 36-3/4" TOP PANEL BOARD AND THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD THAT YOU REMOVED IN STEP 25. 2: PLACE THE BOTTOM OF THE 2 X 4 FLUSH TO THE TOP OF THE ENTRY PLATE. ATTACH THE 2 X 4 TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 3: PLACE THE TOP OF THE 2 X 6 OFFSET UP AGAINST THE BOTTOM OF THE ENTRY PLATE. ATTACH THE 2 X 6 TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 29: ATTACHING WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING OF THE CLATTER BRIDGE TOWER AS SHOWN WITH THE LIP OF THE SLIDE RESTING ON TOP OF THE DECK BOARDS.
STEP 30: FINAL PANEL SLAT 1: LOCATE THE 5/4 X 2-5/8" X 25" PANEL SLAT. 2: THIS SLAT WILL GO INSIDE THE PLAY SET ON TOP OF THE DECK ON THE LEFT HAND SIDE. IT WILL BE FLUSH AGAINST THE BRIDGE RAILS AS SHOWN IN DETAIL A BELOW. 3: ATTACH THE PANEL SLAT TO THE INSIDE OF THE 2 X 6 X 70 FRONT FACE BOARD AND INSIDE OF THE 2 X 6 X 70 TOP PANEL BOARD WITH TWO 2" WOOD SCREWS.
STEP 31: NAME PLATE 1: ATTACH THE Gorilla NAME PLATE CENTERED ON THE FRONT OF YOUR SWING BEAM WITH TWO 2-1/2" WOOD SCREWS.
WARRANTY REGISTRATION - WOODBRIDGE Gorilla Playsets manufactures the finest quality products that are designed for outstanding strength and durability. We back our products with an unparalleled warranty. In the unlikely event that you will need to contact us about covered repairs, we must have a valid Warranty Registration on file.
