Polaris Vinyl Playset

Assembly Manual

Polaris Vinyl Playset

Assembly Manual

Thank you for your purchase of this playset .

This manual is designed to simplify the assembly process, however we recommend having an experienced carpenter involved in the project. Please read through the entire manual before starting!

Take a deep breath and get at it; the satisfaction and enjoyment of this hideout is only a few minutes away.

Have fun!

You have purchased a product that consists of bulky pieces. With your purchase, you assume full responsibility to have the necessary manpower a vailable to assemble the product . We reccomend at least two able-bodied men for this assembly. You also agree that any damage that happens to the product during the entire construction process is your responsibility, and neither the seller, nor the manufacturer, will be held liable for any such damage.

Tools Required for Job

One 4' Step

Ladder

25’ Tape

Measure

9/16th Wrench

Cordless Drill

& 1/2" drill bit

#2 Square

Drive Tip

(included)

T30 Star

Drive Tip

(included)

Parts List

6WHS :

Polaris Vinyl Playset Assembly Manual

6WHS 2:

Unpack and identify parts.

6WHS 3:

Place two 2x6x 56" and two 2x6x 73 1/2" on a smooth, flat surface to begin. Notice floor joist hangers.

6WHS 4:

Thread 6 1/8" bolts into T-nuts on four corners. Fasten two 4x4x 74" (with caps up) on one side as shown. Fasten two 4x4x 54" on opposite side. Predrilled hole configuration is very important on all

4x4's. Hand tighten acorn nuts at this point. Be sure to always place washer between vinyl and acorn nut.

4

6WHS 5 :

Polaris Vinyl Playset Assembly Manual

6WHS 6 :

Continue fastening 2x6's to 4x4's using 6 7/8" bolts.

Tighten nuts at this point. Over-tightening acorn nuts can cause the head to pop off.

6WHS 7 : 6WHS 8 :

Install three floor joists. Fasten joists to hangers using 1 3/4 " washer head screws. Measure to ensure that tower is square at this point.

5

6WHS 9 :

Concord 1 1 10 Assembly Manual

6WHS 10 :

Lay out floor boards. Notice the two shorter ones between posts and narrow one in the center. Center floorboards.

Fasten using 1 1/2" screws.

6WHS 11 : 6WHS 12 :

Place three 2x6x 56" in these positions. The holes on these 2x6's are offset. Notice the pattern; leftlow, right-high. The side with no 2x6 is the side with the taller 4x4's. This side will receive the 7' deck.

Start 6 7/8" bolts in 2x6's.

6

6WHS 13 :

Polaris Vinyl Playset Assembly Manual

6WHS 14 :

Place bracket on corners and fasten with acorn nuts, using washers between metal and acorn nut.

Fasten "lips" on corner brackets with 1 3/4" screws.

6WHS 15 : 6WHS 16 :

App earance of the set at this point. Use template provided to fasten poly slats to this side only of tower. Fasten using 1 3/4" washer head screws.

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6WHS 17 :

Polaris Vinyl Playset Assembly Manual

6WHS 1 8 :

You are now ready to assemble the "legs" for the tower.

Be sure T-nuts are on the inside.

Fasten 2x6 using 3" lag screws.

6WHS 1 9 : 6WHS 20 :

Fasten brace into leg using 3" lag screws. Repeat steps 17-19 for second leg.

You are now ready to fasten the "leg" onto the assembled platform.

8

6WHS 21 :

Polaris Vinyl Playset Assembly Manual

6WHS 22 :

6WHS 23 : 6WHS 24 :

Notice T-nuts

9

6WHS 25 :

Polaris Vinyl Playset Assembly Manual

6WHS 26 :

Fasten using 4 3/8" bolts, washer and acorn nut. Fasten on long point using 4" lag screw.

6WHS 27 :

6WHS 28 :

Repeat fastening steps on second "leg." Appearance of the tower at this point.

10

Polaris Vinyl Playset Assembly Manual

You are now ready to install the cargo net, rock wall, and step ladder panels.

These are interchangeable at all locations on the "legs."

Decide where you want these positioned prior to fastening.

11

6WHS 29 :

Polaris Vinyl Playset Assembly Manual

6WHS 30 :

Fasten underneath using three 3" lag screws per leg .

Fasten top plate of each panel into 2x6 floor framing using 1 1/2" screws.

6WHS 31 : 6WHS 32 :

Also fasten at this point with 3" lag screws. Use four 3" lag screws at this fastening point as well.

1 2

6WHS 33 :

Polaris Vinyl Playset Assembly Manual

6WHS 34 :

Use three 3" lag screws to fasten ladder to leg.

6WHS 35 :

You are now ready to begin framing for 7' platform.

Fasten 2x6x 56" using 6 7/8" bolts. Notice on this

2x6 that the hole pattern switches to "left-high, right-low."

6WHS 36 :

Use template provided to fasten poly slats to tower.

Fasten 2x6x 56" with joist hangers using 6 7/8" bolts. Only finger tighten.

1 3

6WHS 37:

Polaris Vinyl Playset Assembly Manual

6WHS 3 8 :

Fasten 4x4x128" to 2x6 using 6 7/8" bolts.

Repeat on opposite corner.

6WHS 3 9 :

You are now ready to fasten the 2x6x 56" using

6 7/8" bolts.

6WHS 40 :

Fasten 2x6x 56" to bottom of 128" posts using 6 7/8" bolts. This 2x6 will have a cap on both ends.

All nuts should be tightened at this point.

Fasten 57 3/4" floor boards to tower using 1 1/2" screws. Use two 47 3/4" floor boards between outside posts.

1 4

6WHS 41 :

Polaris Vinyl Playset Assembly Manual

6WHS 42 :

You are now ready to finish the railing on the 7' deck. Notice in the photo the panel with the slats already fastened.

Fasten slats to 2x6 using template provided. This can be done after the 2x6 is fastened to the tower or before. Slat spacing is critical and is based on what component is being added to that specific panel.

6WHS 43 :

Note: Your slat spacing and opening locations may vary based on what components you purchased with your playset. Refer to page s 31-3 5 for assembly instructions for your components. Components can be installed anytime after the towers are complete.

Using 6 7/8" bolts, fasten three 2x6 x 56" to tower.

Two of these 2x6's will have caps on one end. This end should be towards the 5' deck. Finger tighten nuts.

1 5

6WHS 44 :

Polaris Vinyl Playset Assembly Manual

6WHS 45 :

To complete the 7' framing, fasten 2x6x 56" on inside of 4x4's.

Be sure all lips on metal corner brackets are fastened, top and bottom, using 1 3/4" washer head screws.

6WHS 46 : 6WHS 47 :

Finish fastening slats with template provided. Tower should look like this at this point. Once again, check that all the bolts and nuts are properly installed and tightened.

1 6

6WHS 4 8 :

Polaris Vinyl Playset Assembly Manual

6WHS 4 9 :

Fasten the small step ladder between the two decks using 1 1/2" screws.

6WHS 50 :

You are now ready to install the slide. Before installing the slide, locate the 2x6x 66 1/4" that you have not yet used. This will go beside the slide.

Fasten this 2x6 to inside of tower leg opposite of the step ladder, cargo net, or rock wall (which ever one will be beside the slide).

The purpose of this 2x6 is to provide support. Use three 3" lags to fasten.

1 7

6WHS 5 1 :

Polaris Vinyl Playset Assembly Manual

6WHS 5 2 :

Attach slide using 1 3/4" washer .

6WHS 5 3 :

Attach tire swing swivel under the lowest deck using 3" lags.

Then attach tire swing to the swivel.

1 8

Attach step ladder handle to the right of step ladder using 1 1/2" lags .

Attach at the top and the bottom.

The next step is to install the roof.

Instructions for tarp roof can be found on pages 19-22.

6WHS 1 :

Tarp Roof Assembly Instructions

6WHS 2 :

Begin by fastening 2x4x 104" to 4x4's as shown .

Measure to be sure it is centered properly. Fasten using 3" lags.

Fasten 2x4x 104" to this side as well.

6WHS 3 : 6WHS 4 :

Fasten 2x4 bracket to end of both 2x4 x 51"s as shown, using six 1 3/4" washer screw s.

Then fasten bracket with 2x4 attached to horizontal

2x4x 104" using 1 3/4" washer screws.

Repeat this step on opposite side.

1 9

6WHS 5 :

Tarp Roof Assembly Instructions

6WHS 6 :

2x4x 61" with caps on both ends can be fastened now or before previous step.

There will be a cover identified as "Concord upper deck."

6WHS 7 : 6WHS 8 :

Fasten as shown using 3" lag. Notice the positioning of poly strip. Fasten one side first, then unroll tarp over the top and fasten on opposite side.

Be sure to pull the tarp tight before fastening on second side.

20

Begin framing for tarp on lower deck. Fasten bracket shown to tower using 1 3/4" screws. Measure.

6WHS 9 :

Tarp Roof Assembly Instructions

6WHS 10 :

Then insert 2x4x28" into bracket and fasten on top and bottom side using 1 3/4" screws.

Fasten using two 3" lags.

Fasten on e on opposite side as well.

6WHS 1 1 :

6WHS 1 2 :

Fasten 2x4x 104 " to front of tower. Make sure it is centered properly.

Fasten bracket to 2x4x51" as shown in step 3. Then fasten to horizontal 2x4x104".

Make sure it is centered properly.

21

6WHS 13 :

Tarp Roof Assembly Instructions

6WHS 1 4 :

Fasten 2x4x61" to top of 2x4x51".

6WHS 1 5 :

Measure to find fastening point on this 2x4. Predrill hole then fasten using 3" lag.

6WHS 1 6 :

Identify tarp package marked "Concord lower deck."

Then fasten on e side, unroll, and fasten on opposite side.

Your completed tarp roof assembly should appear like this.

The next step is to install the swing frame.

Instructions for swing frame can be found on pages 2 3 -2 7 .

Instructions for the climbing set can be found on pages

2 8-30 .

22

Step 1 :

Swing

Frame

Assembly

Step 2 :

You are now ready to assemble the swing frame.

Begin by identifying the swing beam.

The end of the beam without caps gets fastened to the tower.

Fasten swing bearings to swing beam using lags provided in bearing packs.

Step 3 : Step 4:

If you purchased a plastic glider, your next step is to install the glider bracket. This bracket needs to be fastened to the opposite side of the swing beam as the swing bearings. It can be placed at any swing position.

Pre-drill four 1/2" holes, then fasten using four lag screws provided.

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Step 5 :

Swing

Frame

Assembly

Step 6 :

Finish fastening using the 1 3/4" washer head screws provided.

Rotate the swing beam 180 degrees so that the swing bearings are turned up. Fasten the swing beam receiver bracket to the swing beam using two 4 7/8" bolts provided. This bracket needs to be fastened to the end of the swing beam without the caps. Thread acorn nut onto bolt as far as you can, then back off several turns. Use washers between the acorn nut and the metal bracket.

Tighten nuts.

Step 8 :

Step 7 :

With swing beam in same position, attach beam strap to swing beam using two 4 7/8" bolts provided. Only finger tighten at this point. Note that this end of the beam should have caps on it. This bracket is fastened

36" from the end of the 14' beam. Use pre-drilled holes.

24

Identify end post and place between beam strap. Fasten using two 4 7/8" bolts provided. You are now ready to tighten all four bolts on beam strap.

If your setup location is level, the end post will need to be shortened approximately 1' (cut off bottom end).

Step 9 :

Swing

Frame

Assembly

Step 10 :

Fasten corner brace to swing beam and end post. Be sure end post is plumb. Attach using six 1 3/4" washer head screws.

Step 11 :

Lift swing beam into position. One person should be up in the tower. The other person should continue to hold the end post steady.

Note: your set may not appear exactly as pictured at this point.

Step 12 :

Push bracket against 2x6 vinyl then fasten first with two lags provided.

Next predrill 7/16" holes and fasten with two 2 3/4" bolts provided, using acorn nuts and washers.

25

Step 13 :

Swing

Frame

Assembly

Step 14 :

Swing beam receiver properly fastened.

Step 15 :

Identify ground runner and fasten to end post using

6 1/2" bolts. Thread acorn nut onto rod as far as you can, then back off several turns. Be sure to place washer between acorn nut and vinyl.

Step 16 :

Identify end post braces. Fasten the short angle to the ground runner that was installed on previous step.

Use 4 /18" bolts provided.

Align brace with end post then fasten long angle to end post using 3/8" x 4" lags provided. This should be predrilled using 1/4" drill bit.

26

Swing

Frame

Assembly

Step 17 :

Your completed swing frame should appear like this.

The next step is to install the climbing set.

Those instructions are found on pages 28-30.

27

Step

1

:

Climbing Set Assembly

Step

2

:

You are now ready to assemble climbing beam. To begin, identify the main components ; o ne top ladder, one ground runner 2x4, and two brace 2x4's , and one end ladder.

One one end, fasten two brackets as shown, using four 2 5/8" bolts (this is an upside down position).

Step 3 : Step 4 :

On opposite end, fasten end ladder to top ladder using four 4 1/8" bolts. Tighten using a 9/16" deep socket and a 9 1/6" open end wrench. Keep in mind that over-tightening can damage the acorn nut.

Flip ladder into upright position and place at desired location on playset.

2 8

Step 5 :

Climbing Set Assembly

Step 6 :

Fasten flange on bracket to 2x6 using two 3" lags. Be sure inside flange is tight against inside of 2x6.

Pre-drill 7/16" hole through hole on inside flange and through 2x6.

Step 7 : Step 8 :

Finish fastening top ladder to tower using two 2 5/8" bolts. Tighten immediately.

Fasten ground runner 2x4 to end ladder using two 6

1/8" bolts. Tighten immediately.

2 9

Step 9 :

Climbing Set Assembly

Step 10 :

Fasten short angle of brace 2x4 to ground runner using two 4 1/8" bolts. Tighten immediately.

Fasten long angle to end ladder using 4" lag. Predrilling is recommended.

Your climbing ladder assembly is now complete.

Now is a good time to go over the entire set and be sure all bolts and nuts are properly installed and tightened.

The next step is to install any components you may have purchased. Assembly instructions for the components can be found on pages 3 1 -3 5 .

30

Tic-tac-toe panel:

6WHS 1 :

Component Assembly Instructions

6WHS 2 :

With your tic-tac-toe panel, you will receive a

2x6x 18 1/2" .

Fasten one end of the tic-tac-toe to 2x6, centered, using four 1 /3/4" washer head screws.

Fasten opposite end to tower at any desired location, using four 1 3/4" washer head screws.

6WHS 3 : 6WHS 4 :

Fasten 2x6x 18 1/2" to poly slats on railing using four

1 3/4" washer head screws.

Completed install should look similar to this.

31

Hammock Swing :

6WHS 1 :

Component Assembly Instructions

6WHS 2 :

Begin by identifying these parts: swivel, extra chain, two snap hooks, and hammock.

Note: you will only need the extra chain and hook if you install this on a position of the swing beam instead of under the deck.

6WHS 3 :

Install the swivel using two lags provided.

Then attach one end of chain to the snap hook.

Finish the installation by attaching the snap hook to the swivel.

6WHS 4 :

If you are install ing under the deck it should look similar to this.

32

If you are installing on the swing frame, it should look similar to this

Component Assembly Instructions

Framing for peek-a-boo panel , tornado tube, tunnel express, and sidewinder slides :

6WHS 1 : 6WHS 2 :

Fasten small angle brackets to 2x4x 26" using 1 3/4" washer head screws.

There should be two like this one pictured when you have completed this step.

6WHS 3 :

6WHS 4 :

Fasten with 1 3/4" screws at desired location according to the components you purchased with your set. Fasten one on opposite side as well to create a frame.

Spacing between 2x4's should be 2 9 1/2".

Fasten flange to frame using 1 3/4" washer screws for peek-a-boo panel.

33

Component Assembly Instructions

Tornado tube, Tunnel Express, and Sidewinder slide Assembly

:

Step 1 : Step 2 :

To fasten the slide to the tower, first fasten L brackets to outside of two 2x 4 x26" using 1 3/4" screws provided.

Then place 2x 4 's at desired location on tower and fasten using 1 3/4" screws. Space between vertical

2x 4 's should be 2 9 1/2 ".

Step 3 :

34

Assemble slide and fasten slide to tower using hardware and instructions provided with slide.

Component Assembly Instructions

Super Spiral Slide Assembly:

6WHS 1 : 6WHS 2 :

After assembling slide according to instructions given in the box the slide came in, lift slide into place where you have already framed for the slide to be. This will take two able-bodied men.

One person hold slide steady while other person goes up into the tower to fasten slide.

6WHS 3 : 6WHS 4 :

Fasten the slide to the upper deck using the lags provided in the hardware pack that comes with the slide.

Fasten top of slide to top 2x6 of upper deck as well.

35