™ playsets ™ playsets Encore Model: 1701 (BOXES: 1700-1, 1700-2, 1701 & SLIDE BOX) Copyright © 2013 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 - 2013 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 - ENCORE Gorilla Playsets manufactures ƚŚĞ ĮŶĞƐƚ ƋƵĂůŝƚLJ ƉƌŽĚƵĐƚƐ ƚŚĂƚ ĂƌĞ ĚĞƐŝŐŶĞĚ ĨŽƌ ŽƵƚƐƚĂŶĚŝŶŐ ƐƚƌĞŶŐƚŚ ĂŶĚ ĚƵƌĂďŝůŝƚLJ͘ tĞ ďĂĐŬ ŽƵƌ ƉƌŽĚƵĐƚƐ ǁŝƚŚ ĂŶ ƵŶƉĂƌĂůůĞůĞĚ ǁĂƌƌĂŶƚLJ͘ /Ŷ ƚŚĞ ƵŶůŝŬĞůLJ ĞǀĞŶƚ ƚŚĂƚ LJŽƵ ǁŝůů ŶĞĞĚ ƚŽ ĐŽŶƚĂĐƚ ƵƐ ĂďŽƵƚ ĐŽǀĞƌĞĚ ƌĞƉĂŝƌƐ͕ ǁĞ ŵƵƐƚ ŚĂǀĞ Ă ǀĂůŝĚ tĂƌƌĂŶƚLJ ZĞŐŝƐƚƌĂƟŽŶ ŽŶ ĮůĞ͘ 3 EASY WAYS TO REGISTER KWd/KE ϭ &Ădž ƚŚŝƐ ĐŽŵƉůĞƚĞĚ ĨŽƌŵ ƚŽ͗ (678) 880-3329 OR DĂŝů ƚŚŝƐ ĐŽŵƉůĞƚĞĚ ĨŽƌŵ ƚŽ͗ Gorilla Playsets ϭϵϬ ƚŽǁĂŚ /ŶĚƵƐƚƌŝĂ
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.
Model: 1701 (BOXES: 1700-1, 1700-2, 1701 & SLIDE BOX) REV: 3.6.
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 into place. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" • The 2 is the thickness of the board. "Nominal Lumber" at a home center will measure 11/2" for the thickness. We "remill" that lumber to 1-3/8" thick. • The 4 is the width of the board.
PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole. Pay attention to the DIAMETER of the lag screw you are installing. Your playset may come with two different diameter lag screws.
SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs. Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs. 2) The maximum allowable swinging weight at the Trapeze position is 125 lbs. 3) The MAXIMUM SWING BEAM LOAD IS 425 lbs.
Please familiarize yourself with the manual, parts/components and general 1700 SERIES - TARP ROOF construction Encore/Cartecayprocess 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 w/Chains ___ (1) Wave
1700/1701 HARDWARE #8 X 1-1/4" WOOD SCREW QTY: 6 PAGE: 1 OF 2 REV A: 10/29/2012 JH #8 X 1-1/2" WOOD SCREW QTY: 8 #14 X 1-1/4" PAN HEAD SCREW QTY: 8 #8 X 1-3/4" WOOD SCREW QTY: 20 9 8 #8 X 2" WOOD SCREW QTY: 161 7 #8 X 2-1/2" WOOD SCREW QTY: 28 #8 X 3" WOOD SCREW QTY: 14 6 5/16" TEE NUT QTY: 44 3/8" LOCK NUT QTY: 21 5 4 3/8" WASHER QTY: 33 3 TORQUE WASHER QTY: 19 2 5/16" WASHER QTY: 48 1 5/16 X 4-1/2" HEX BOLT QTY: 34 5/16 X 2-1/2" HEX BOLT QTY: 6 5/16 X 1-1/2" HEX BOLT QTY: 4 1/4" WASHE
1700/1701 HARDWARE 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 4 PAGE: 2 OF 2 9 REV A: 10/29/2012 JH 8 7 6 5 4 3 #2 SQUARE DRIVE TIP QTY: 1 2 1 3/8 x 9" CARRIAGE BOLT QTY: 1 3/8" x 7" CARRIAGE BOLT QTY: 8 3/8 x 6-1/2" CARRIAGE BOLT QTY: 6 3/8 x 5" CARRIAGE BOLT QTY: 4 3/8 x 3-1/2" CARRIAGE BOLT QTY: 2 PLASTIC BOLT CAP QTY: 21 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
PICTURE DESCRIPTION 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 29" REAR CENTER POST 2-4-2900-RCP QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION WAVE SLIDE 03-0010 SWING W/CHAINS 04-0002 TRAPEZE BAR W/CHAINS 04-0006 QTY.
PICTURE DESCRIPTION QTY. SWING PLATE 1 11-5002 CLIMBING ROCK 07-0008 A-FRAME SWING LEG BRACKET 11-5010 1700/1701 HARDWARE BOX INSTRUCTIONS 10 1 1 EA.
PICTURE DESCRIPTION IRON DUCTILE SWING HANGER QTY.
PICTURE DESCRIPTION 10' ROPE QTY.
PICTURE DESCRIPTION QTY.
PICTURE DESCRIPTION QTY.
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 4 X 4 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 POSTS IN THE CORRECT DIRECTION. NOTE: THE LADDER SIDE IS CONSIDERED THE FRONT OF THE PLAYSET WITH THE SWING BEAM EXTENDING OFF TO THE LEFT SIDE.
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 FIRS. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
STEP 3: END SANDBOX BOARD/ROPE SUPPORT 1: THE 2 X 6 X 47-1/2" END SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHT SIDE CORNER POSTS, OFFSET HOLES UP, WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 2: THE 2 X 4 X 47-1/2" ROCK WALL ROPE SUPPORT ( WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE TOP SET OF HOLES ON THE RIGHT SIDE OF THE CORNER POSTS, OFFSET HOLES UP, WITH 5/16 X 4-1/2" 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 SIX PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE LEFT SIDE CORNER POSTS WITH 4-1/2" 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) ATTACH TO THE BOTTOM OF THE FRONT AND REAR CORNER POSTS WITH 5/16 X 4-1/2" 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 TARP SUPPORT BOARDS 1: THE 2 X 4 X 83" TARP SUPPORT BOARDS (WITH THE PRE-DRILLED HOLES) ATTACH TO THE TOP OF THE FRONT AND REAR CORNER POSTS WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 2: THE OUTER COUNTER-SUNK HOLES SHOULD BE OFFSET DOWN ON BOTH BOARDS. 3: THE SHORTEST END FROM THE COUNTER-SUNK HOLE WILL POINT TOWARD THE SWING BEAM SIDE OF THE FORT.
STEP 7: ATTACHING ARCH FACE BOARD AND DECK SUPPORT 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 TARP SUPPORT BOARD. ATTACH THE TOP HOLES OF THE ARCH FACE BOARD USING 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS. ATTACH THE BOTTOM HOLES OF THE ARCH FACE BOARD USING 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS.
STEP 8: ATTACHING REAR PANEL SUPPORT BOARDS 1: THE 2 X 4 X 47-1/2" REAR PANEL SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES BELOW THE TARP SUPPORT BOARD ON THE REAR OF THE FORT WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. THE HOLES SHOULD BE OFFSET DOWN.
STEP 9: ATTACHING PANEL SUPPORTS AND SAFETY BOARD 1: THE 2 X 4 X 47-1/2" PANEL SUPPORT BOARDS SHOULD BE PLACED WITH HOLES OFFSET UP AGAINST THE LEFT SIDE CORNER POSTS. USE 5/16" X 4-1/2" 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 10: 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 EACH END AND SECURE WITH HAMMER. SEE DETAIL A. 2: THE 2 X 4 X 47-1/2" FORT SIDE SUPPORT (WITH ANGLED END) ATTACHES TO THE HOLE 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 POSTS.
STEP 11: 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 PRE-DRILLED 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 SIDE SANDBOX BOARD. ATTACH EACH ROCK WALL SUPPORT TO THE SIDE SANDBOX BOARD WITH 2-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 12: 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 A #8 X 3" WOOD SCREW THROUGH 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.
STEP 13: ATTACHING THE ROCK WALL CENTER SUPPORT 1: BEGIN WITH THE 5/4 X 6 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 6 X 47-1/2" BOTTOM ROCK WALL BOARD WITH ONE HOLE WILL MOUNT AT THE BOTTOM WITH THE 7/8" HOLE TOWARDS THE BOTTOM. THIS BOARD WILL BE AT 44" FROM THE TOP ROCK WALL BOARD AND FLUSH TO THE ROCK WALL SIDE SUPPORTS.
STEP 14: ATTACHING THE ROCK WALL BOARDS 1: MOUNT THE REMAINING ROCK WALL BOARDS TO THE ROCK WALL SUPPORTS FROM TOP TO BOTTOM WITH #8 X 2" WOOD SCREWS. 2: WHEN YOU GET TO THE LAST ROCK WALL BOARD MAKE SURE THE GAP BETWEEN THIS BOARD AND THE BOTTOM ROCK WALL BOARD IS NO BIGGER THAN 1/4". IF NECESSARY UNSCREW THE BOTTOM ROCK WALL BOARD AND SHIFT THE TOP FLUSH TO THE LAST ROCK WALL BOARD.
STEP 15: ATTACHING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL OFFSET PATTERN SHOWN BELOW. A DIFFERENT PATTERN MAY BE USED IF YOU WISH. 2: THE ROCKS INCLUDED WITH YOUR PLAYSET MAY VARY IN COLOR. USE THE #14 X 1-1/4" PANHEAD SCREWS AND 1/4" WASHERS INCLUDED WITH THE ROCKS TO ATTACH THE ROCKS TO THE ROCK WALL BOARDS.
STEP 16: ATTACHING THE DECK BOARDS AND DECK SPACERS 1: THE 5/4" X 4 X 40-3/8" DECK SPACERS MOUNT BETWEEN THE REAR CORNER POSTS AND BETWEEN THE FRONT CORNER POSTS. THE REAR SPACER SHOULD BE FLUSH TO THE INSIDE OF THE REAR POSTS. THE FRONT SPACER SHOULD NOT PROTRUDE BEYOND THE FRONT OF THE FRONT CORNER POSTS. DRIVE #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS.
STEP 17: ATTACHING THE 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 HOLES AT THE CENTER OF THE DECK BOARDS AS A GUIDE. MAKE SURE THE END OF THE STRINGER IS FLUSH WITH THE SIDE OF THE DECK SPACER AT THE FRONT OF THE PLAY SET. 3: ATTACH THE STRINGER TO THE DECK BOARDS/DECK SPACERS WITH #8 X 2" WOOD SCREWS.
STEP 18: ATTACHING THE FRONT FACE BOARD 1: THE EDGE OF THE 2 X 4 X 47-1/2" FRONT FACE BOARD WILL BE FLUSH TO THE TOP OF THE DECK SPACER. SECURE THE FRONT FACE BOARD TO THE CORNER POSTS WITH THREE #8 X 2-1/2" WOOD SCREWS PER SIDE. 2: INSTALL TWO 2-1/2" WOOD SCREWS THROUGH THE CENTER OF THE FRONT FACE BOARD INTO THE STRINGER AS SHOWN BELOW. 2 X 4 X 47-1/2" FRONT FACE BOARD #8 X 2-1/2" WOOD SCREWS DECK SPACER FLUSH TO THE TOP OF THE DECK SPACER STRINGER IS BEHIND THE SCREWS HERE.
STEP 19: 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 OUTER HOLES USING 3/8" X 3-1/2" CARRIAGE BOLTS AND 3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
STEP 20: 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 SWING HANGER TO THE SWING BEAM USING 3/8" X 7" 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 AFTER SECURING. 3: FASTEN IRON DUCTILE SWING HANGERS TO THE TRAP ARM IN THE SAME MANNER THAT YOU FASTENED THEM TO THE SWING BEAM.
STEP 21: ATTACHING THE SWING BEAM MOUNT AND TRAP ARM 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.
STEP 22: 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 CHANELS 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 DRIVE TWO 2" WOOD SCREWS THROUGH THE LADDER SIDE INTO EACH STEP.
STEP 23: 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: GO UNDER THE DECK AND INSERT T-NUTS IN THE HOLES. 5: ATTACH THE 90 GREEN BRACKET TO THE 2 X 4 WITH 5/16" X 1-1/2" HEX BOLTS AND 5/16" WASHERS.
STEP 24: ATTACHING SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 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 AT EACH SWING LEG BRACKET HOLE. 3: 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 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" HOLE THROUGH THE MIDDLE HOLE IN THE SWING LEG BRACKET INTO THE SWING BEAM 3-1/2" DEEP. DRIVE A 3/8" X 3-1/2" LAG SCREW WITH 3/8" WASHER INTO 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 THE LEGS. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM MOUNT USING A 3/8" X 9" CARRIAGE BOLT WITH TORQUE WASHER ON TOP AND A 3/8" WASHER AND 3/8" LOCK NUT ON THE BOTTOM.
STEP 27: 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 28: SWING LEG CROSS MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS MEMBER AGAINST THE SWING BEAM LEGS WITH THE HOLES CENTERED ON THE LEGS. 2: LEVEL THE SWING LEG CROSS MEMBER, AND MAKE MARKS WITH A PENCIL INSIDE THE HOLES ONTO THE SWING LEGS. DRILL 11/64" HOLES 2-1/2" DEEP AT THE MARKS. 3: ATTACH THE SWING LEG CROSS MEMBER TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
STEP 29: ATTACHING CENTER POSTS 1: FIRST ATTACH THE 2 X 4 X 73-1/2" FRONT CENTER POST AND 2 X 4 X 29" REAR CENTER POST TO THE TARP SUPPORT BOARDS WITH 5/16" X 2-1/2" HEX BOLTS, 5/16" WASHERS, AND T-NUTS. 2: SQUARE THE THE FRONT CENTER POST TO THE DECK. ATTACH THE BOTTOM OF THE FRONT CENTER POST TO THE DECK SPACER FROM UNDERNEATH WITH TWO #8 X 2-1/2" WOOD SCREWS. ATTACH THE FRONT CENTER POST TO THE ARCH FACE BOARD ON THE INSIDE USING TWO #8 X 2-1/2" WOOD SCREWS.
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 FRONT CENTER POST ON BOTH SIDES WITH #8 X 2" WOOD SCREWS. 2: ATTACH THE 5/4 X 4 X 20" VERTICAL WINDOW SUPPORTS NEXT TO THE CORNER POSTS ON BOTH SIDES WITH #8 X 2" WOOD SCREWS.
STEP 31: TARP BOARDS (TARP ROOF) 1: THE 2 X 4 X 47-1/2" CENTER TARP BOARD WILL SECURE ON TOP OF THE CENTER POSTS WITH TWO #8 X 2-1/2" WOOD SCREWS PER SIDE.
STEP 32: PANEL SLATS 1: BEGIN ON THE REAR WALL OF THE FORT WITH THE TWO OUTER SLAT BOARDS (5/4 X 3 X 28-1/2" PANEL SLAT). THEY ARE SPACED 1-7/8" FROM THE CORNER POSTS. ATTACH EACH PANEL SLAT WITH #8 X 2" WOOD SCREWS. 2: THE INNER BOARDS ON THE REAR ARE THEN SPACED 2" FROM EACH OTHER FOR A TOTAL OF SIX SLATS ON THE REAR OF THE PLAY SET. ATTACH EACH PANEL SLAT WITH #8 X 2" WOOD SCREWS.
STEP 33: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. ASSEMBLE THE TIC TAC TOE ACCORDING TO THE INSTRUCTIONS IN THE BOX. IGNORE STEPS 6 AND 7 IN THE INSTRUCTIONS. 2: LOCATE THE 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. DRILL A 1/8" HOLE IN EACH END OF THE MOUNT AS SHOWN BELOW. 3: FASTEN THE TIC TAC TOE MOUNTS TO THE GREEN TIC TAC TOE BRACKETS WITH THE SCREWS PROVIDED IN THE TIC TAC TOE BOX.
STEP 34: MOUNTING TIC TAC TOE PANEL 1: PLACE THE TIC TAC TOE PANEL ASSEMBLY FROM THE PREVIOUS STEP ONTO THE BACK WALL. THE BOTTOM OF THE LOWER TIC TAC TOE MOUNT SHOULD BE 4" ABOVE THE DECK. 2: ATTACH EACH TIC TAC TOE MOUNT TO THE PANEL SLATS WITH #8 X 1-3/4 WOOD SCREWS. #8 X 1-3/4" WOOD SCREW TIC TAC TOE MOUNT BOARD PANEL SLAT THE BOTTOM OF THIS BOARD SHOULD BE 4" ABOVE THE DECK.
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 IT WITH TWO #8 X 2" WOOD SCREWS. 2: ALL THE 5/4 X 4 X 10" WAVE SUN RAY PIECES GET INSTALLED ON THE INSIDE SURFACE OF THE WOODEN SUN. 3: INSTALL THE TOP WAVE SUN RAYS ABOUT 55 FROM THE CENTER POST AND SECURE WITH #8 X 1-3/4" WOOD SCREWS. 4: PLACE THE BOTTOM WAVE SUN RAY BELOW THE TOP WAVE SUN RAY LEAVING A 1/4" GAP IN BETWEEN.
STEP 36: TARP NOTE: IT IS EASIER TO INSTALL THE PAN HEAD SCREWS/WASHERS SHOWN BELOW IF 1/8" PILOT HOLES ARE DRILLED INTO THE TARP BOARDS AT THE TARP GROMMET LOCATIONS. USE CAUTION IF DRILLING PILOT HOLES INTO THE TARP BOARDS SINCE DRILLING THE HOLES TOO DEEP THROUGH THE TARP BOARD WILL DAMAGE THE TARP ON THE OUTSIDE. 1: LAY TARP ACROSS TARP BOARDS, MAKE SURE HEM SIDE IS WRAPPED AROUND TO THE INSIDE OF THE TARP BOARD. 2: CENTER THE TARP ON BOARDS AND BEGIN WITH THE FRONT RIGHT SIDE CORNER.
STEP 37: CLIMBING ROPE 1: THREAD ONE END OF THE 10' ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE A SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN THE 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 38: INSTALLING THE WAVE SLIDE 1: PLACE THE WAVE SLIDE IN THE OPENING AT THE FRONT OF THE FORT. LAY THE WAVE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE WAVE SLIDE TO THE DECK WITH 1-1/4" PAN HEAD SCREWS.
STEP 39: 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: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL.
STEP 40: 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 41: NAME PLATE 1: ATTACH THE NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO #8 X 1-1/4" WOOD SCREWS.
STEP 42: HANGING SWINGS 1: LOCATE TWO SWING BELTS 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. 4: LOCATE ONE TRAPEZE BAR WITH CHAINS ATTACHED. 5: SNAP A SPRING CLIP THROUGH THE SWING HANGER LOOP ON THE TRAPEZE ARM. 6: SNAP A CHAIN ONTO EACH SPRING CLIP. ADJUST THE TRAPEZE BAR UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS.
STEP 43: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: HAMMER EACH GROUND STAKE IN AT AN ANGLE SIMILAR TO WHAT IS SHOWN. USE CAUTION WHEN HAMMERING SO THAT YOU DO NOT MAR THE WOOD. LEAVE THE TOP PORTION OF THE GROUND STAKE ABOVE THE GROUND FAR ENOUGH SO THAT YOU CAN STILL GET THE SCREW INTO THE HOLE AT THE TOP OF THE STAKE. 3: SECURE EACH STAKE TO THE SWING LEGS WITH THE SCREWS PROVIDED WITH THE STAKES.
STEP 44: 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.
