Gorilla Playsets Encore Assembly Manual

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.com

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. KEEP THEM IN A SAFE

PLACE WHERE YOU CAN REFER TO THEM AS NEEDED . CHECK FOR REVISED INSTRUC-

TIONS AT:

www.gorillaplaysets.com/manuals

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.).

Gorilla warrants all remaining products, including but not limited to its Breckenridge Playhouse™, Free Standing

Swing Set, Free Standing Tire Swing, SeeSaw, Children’s Picnic Table with Umbrella, Play -ZeeBo™ and spring riders to be free from defects in workmanship and materials, under normal use and conditions, for a period of 1 year.

Cosmetic imperfections and natural tendencies of wood such as peeling, splintering, warping, seasonal checking or cracking, knots or knot holes, etc. are normal characteristics of all outdoor wooden play equipment and are not covered by this warranty.

Wood rot or decay that develops because the product was installed in an area with poor drainage is not covered under this warranty. Lumber that has been damaged by wood boring bees, or conditions that develop as a result of faulty or improper installation of the product, are not covered by this warranty. Fading of stain, discoloration or mold on any wood part or accessory is not covered by this warranty. Cracks in plastic components, surface rust on hardware and chips on powder coated materials are not considered defects in material as long as they do not affect the functionality or structural integrity of the part or component.

It is the owner’s responsibility to maintain the swing set.

This includes but is not limited to re-staining and resealing the lumber as needed and regular inspection to be sure all hardware is tight.

Instructions for proper maintenance can be found on Gorilla ’s website. Imperfections or conditions that develop because of a failure to properly maintain the swing set are not covered by this warranty.

Gorilla will repair or, at its discretion, replace any above ground part within the stated warranty period that is defective in workmanship or materials. This decision is subject to verification of the defect, which, at Gorilla ’s discretion, may be accomplished by submitting photographs or by delivery of the defective part to Gorilla Playsets

• 190 Etowah Industrial Ct. • Canton, GA 30114 • 1 -800-882-0272 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase. In addition, within the first 30 days from the date of purchase, Gorilla will replace any parts discovered to be missing from or damaged in the original packaging.

This warranty is valid only if the product is used for the purpose for which it was designed and installed at a residential, single-family dwelling. This warranty is void if the product is used in a commercial, institutional or multi-family setting. This warranty does not cover normal wear and tear or (a) products that have been damaged by acts of God and/or nature, negligence, misuse or accident; (b) products that have been modified or repaired by unauthorized persons; (c) the cost of labor; or (d) the cost of shipping any replacement product or part.

GORILLA DISCLAIMS ALL OTHER REPRESENTATIONS AND WARRANTIES OF ANY KIND, EXPRESSED, IMPLIED,

STATUTORY OR OTHERWISE, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE. GORILLA WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty is non-transferable and does not extend to the owners of the product subsequent to the original purchaser. Some states do not allow limitations on implied warranties or exclusion of incidental or consequential damages, so these restrictions may not be applicable to you. This warranty gives you specific legal rights. You may also have other rights which vary from state to state.

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. Gorilla recommends you follow all tool manufacturers’ safety guidelines. Always wear eye protection and safety gloves to prevent injury. In several phases of construction two people may be required for lifting and securing of lumber.

While the play set is being constructed, please keep children off the equipment until the project is complete. Bolts and screw heads should be checked regularly for tightness.

The ground ladder, rope ladder, slide, swings and other areas where children spend a majority of their playtime should be checked more frequently.

Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used.

WEIGHT LIMITS FOR GORILLA PLAYSETS

• FORT PLATFORMS: 800 LBS. TOTAL WEIGHT

• SWING BELT: 225 LBS.

• GLIDER SWINGS: 70 LBS. PER CHILD. UP TO 140 LBS. TOTAL WEIGHT.

• TRAPEZE: 125 LBS.

• FULL BUCKET SWING/ HALF BUCKET SWING: 50 LBS.

• HEAVY DUTY TODDLER BUCKET SWING: 85 LBS.

• INFANT SWING: 35 LBS.

• TIRE SWING: 125 LBS. TOTAL WEIGHT

• ROPE LADDER: 75 LBS.

• ROCK WALL: 150 LBS.

• CLIMBING RAMP: 150 LBS.

• MONKEY BARS: 175 LBS.

• ALL SLIDES: 150 LBS.

Gorilla recommends that the weight limits for all components must not be exceeded.

Failure to adhere to these and other safety guidelines could result in damage to the play set and injury to the users.

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

ƵŶůŝŬĞůǇĞǀĞŶƚƚŚĂƚǇŽƵǁŝůůŶĞĞĚ ƚŽ ĐŽŶƚĂĐƚ ƵƐ ĂďŽƵƚ ĐŽǀĞƌĞĚ ƌĞƉĂŝƌƐ͕ ǁĞ ŵƵƐƚ ŚĂǀĞ Ă ǀĂůŝĚ tĂƌƌĂŶƚǇZĞŐŝƐƚƌĂƟŽŶŽŶĮůĞ͘

WARRANTY REGISTRATION

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ƉŚŽŶĞ

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Purchase

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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.

Cosmetic defects that do not affect the structural integrity of the product, or natural defects of wood such as warping, checking or any other physical properties of wood that do not present a safety hazard, are not covered by this warranty. Defects that develop because the product is exposed to extreme climate conditions or woodboring insects are not covered by this warranty.

Defects that develop as a result of faulty or improper installation of the product are also not covered by this warranty.

Most cracks are not warrantable , however if you believe that the integrity of your play set is compromised by this natural occurrence, please follow the warranty claim procedure found at www.gorillaplaysets.com. Click on the “Customer Care” tab on the left hand side of the page, then click on “Warranty Claim” and follow the directions.

KEEPING YOUR PLAYSET LIKE NEW

LUBRICATE:

• Spray swing hangers with Pam, Mazola or olive oil to stop squeaking.

• Do not use petroleum based products such as WD-40 or motor oil.

• To speed up the slide wipe center of slide ONLY with wax paper every 2 - 3 weeks.

TIGHTEN:

• Check and tighten hex/carriage bolts within first 60 days and then twice annually.

• Check lag screws for tightness before each season and then once during the season for tightness. Tighten lag screws as required.

SEAL:

• Apply an oil based sealer or preservative within 90 days, then every 2 - 3 years. You may need to power wash the unit before sealer application on year two.

INSECTS:

• To repel yellow jackets and wasps, using a cloth, coat all interior 90 degree corners with liquid dish soap underneath the play set deck. This will make wasps sick when they attempt to build a nest. Avoid using insecticides.

Model: 1701

(BOXES: 1700-1, 1700-2, 1701

& SLIDE BOX)

REV: 3.6.2013

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...............................................Pages 14-15

Hardware, Lumber and Accessory Checklists.………………………………....Pages 16-30

Arranging Corner Posts and adding T-Nuts to Corner Posts..………...…............ Step 1-2

Framing Fort……………………………………..…………………………..……..... Steps 3-9

Mounting Fort Side Supports…....……………….…………...….............................. Step 10

Rock Wall Assembly...................…………………...…..……..……...….…….... Steps 11-15

Adding Deck Boards, Stringer and Front Face Board.................................... Steps 16-18

Swing Beam Plate, Swing Hangers and Swing Beam Mount/Trap Arm......... Steps 19-21

Ladder Assembly and Installation…………………..……........…..................... Steps 22-23

Swing Beam Assembly...........……...……………………….….........……......... Steps 24-28

Center Posts, Window Supports/Windows…………………………………...... Steps 29-30

Tarp Boards, Panel Slats.…………………………......….…............................. Steps 31-32

Tic Tac Toe Assembly/Installation…………………………….....……................. Step 33-34

Sunburst and Crown Installation……………………………….…….....................… Step 35

Tarp, Climbing Rope, Wave Slide, Steering Wheel…..................................... Steps 36-39

Flag Kits, Name Plate, Hanging Swings/Trapeze, Ground Stakes …...…..... Steps 40-43

Safety Handles ..................................................................................................... Step 44

PLEASE READ OWNER’S MANUAL CAREFULLY

BEFORE STARTING ASSEMBLY!

2

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.

• This play set is designed for the use of 4 occupants who have a combined weight not exceeding 800 pounds on the elevated floor, 3 occupants who have a combined weight of 425 pounds on the swing area, for a total Unit capacity of 7 occupants who have a combined weight of 1225. (This weight does not include any picnic table area(s).)

• On-site adult supervision is required.

• Teach children not to walk close to, in front of, behind, or between moving swings or other moving playground equipment.

• Teach children to sit in and never stand on swings

• Teach children not to twist the chains and ropes and not to loop them over the swing beam, since this may reduce the strength of the chain or rope.

• Teach children not to jump from swings or other playground equipment in motion.

• Teach children not to push empty seats. The seat may hit them and cause serious injury.

• Teach children to sit in the center of the swings with their full weight on the seats.

• Teach children not to use the equipment in a manner other than intended.

• Teach children to always go down slides feet first. Never slide headfirst.

• Teach children to look before they slide to make sure no one is at the bottom.

• Teach children to never run up a slide, as this increases their chances of falling.

• The parents should have the children dress appropriately with well-fitting shoes. Loose clothing such as scarves and ponchos should not be worn. Always take off, tie up or tuck in cords and drawstrings on children’s clothing. These things can get caught on playground equipment and strangle a child.

• Teach children not to climb when the equipment is wet.

• Teach children to never jump from a fort deck. They should always use the ladder, ramp or slide.

• Teach children to never crawl or walk across the top of monkey bars.

• Teach children to never crawl on top of a fort roof.

• Verify that any suspended climbing ropes, chains, or cables are secured at both ends and that they cannot be looped around an adult hand.

• Teach children not to attach items to the playground equipment that are not specifically designed for use with the equipment, such as, but not limited to, jump ropes, clothesline, pet leashes, cables and chain as they may cause a strangulation hazard.

• Teach children to never wrap their legs around swing chain.

• Teach children to never slide down the swing chain.

• Teach children to remove their bike or other sports helmet before playing on the playgound equipment.

• Teach children to NEVER look at the sun or other bright light through any accessory such as but not limited to a telescope, periscope or binoculars.

WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to insure it has been properly installed and the swing beam legs are anchored.

3

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.

• Deterioration and corrosion on structural components, which connect to the ground.

• Missing or damaged equipment components, such as handholds, guardrails, swing seats.

• Check all nuts and bolts twice monthly during the usage season and tighten as required.

(But not so tight that you crack the wood) We recommend you check the swing beam and hardware often due to wood expansion and contraction. It is particularly important that this procedure be followed at the beginning of each season.

• Remove plastic swing seats and take indoors or do not use when the temperature drops below

32°F. Reinstall swings and other swing equipment at the beginning of the usage season.

• Oil all metallic moving parts monthly during the usage period.

• Check all coverings for bolts and sharp edges twice monthly during usage season to be certain they are in place. Replace when necessary. It is especially important to do this at the beginning of each new season.

• Check swing seats, ropes, cables and chains monthly during usage season for evidence of deterioration. Replacement should be made of any swing seat that has developed cracks in the plastic seats. Ropes, cables and chains should be removed and replaced if excessive wear is found. Contact us for warranted replacement parts.

• For rusted areas on metallic members such as monkey bars, hand supports brackets, etc.; sand and repaint, using a non lead-based paint meeting the requirements of Title 16 C.F.R. Part

1303. These requirements are available at: http://www.cpsc.gov/

• Inspect wood parts monthly. The grain of the wood sometimes will lift in the dry season causing splinters to appear. Light sanding may be necessary to maintain a safe playing environment. If you are treating your play set with stain regularly, it will help prevent severe checking/splitting and other weather damage.

• Once or twice a year, depending on your climate conditions, you must apply some type of protection (sealant) to the wood of your unit. Prior to the application of sealant, lightly sand any

“rough” spots on your set. Please note this is a requirement of your warranty.

• Creating and maintaining the play set on a level location is very important. As your children play, your play set will slowly dig its way into the soil, and it is very important that it settles evenly. Make sure the play set is level and true once each year or at the beginning of each play season.

• Twice a month during the usage season rake the playground protective surfacing materials to prevent compaction and maintain appropriate depths. Replace the protective surfacing materials as required.

• Disposal Instructions: When the play set is no longer desired, it should be disassembled and disposed of in such away that no unreasonable hazards will exist at the time the play set is discarded.

4

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.

Certain manufactured synthetic surfaces also are acceptable; however, test data on shock absorbing performance should be requested from the manufacturer.

Asphalt and concrete are unacceptable. They do not have any shock absorbing properties. Similarly, grass and turf should not be used. Their ability to absorb shock during a fall can be reduced considerably through wear and environmental conditions.

Certain loose-fill surfacing materials are acceptable. Surfacing materials are acceptable, such as the types and depths shown in the table.

Fall Heights and Materials

Type Of Material 6 in. depth

Double-Shredded bark mulch 6’ Fall Height

Wood Chips

Fine Sand

6’ Fall Height

5’ Fall Height

Shredded Tires*

Fine Gravel

10-12’ Fall Height

6’ Fall Height

9 in. depth 12 in. depth

10’ Fall Height 11’ Fall Height

7’ Fall Height

5’ Fall Height

12’ Fall Height

9’ Fall Height

N/A

7’ Fall Height

N/A

10’ Fall Height

*This data is from tests conducted by independent testing laboratories on a 6-inch depth of uncompressed shredded tire samples produced by four manufacturers. The tests reported critical heights, which varied from 10 feet to greater than 12 feet. It is recommended that persons seeking to install shredded tires as a protective surface request test data from the supplier showing the critical height of the material when it was tested in accordance with ASTM F1292.

It should be recognized that all injuries due to falls cannot be prevented no matter what surfacing material is used.

5

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. The fall zone in front and back of the swing should extend out a minimum distance of twice the height of the swing as measured from the ground to the top of the swing support structure.

LEVELING YOUR FORT DURING ASSEMBLY

• Complete the steps which will be the basic frame of the fort. {i.e. four corner posts with base (sand box boards) and deck supports}

• Position in the most level area chosen for the play set, keeping in mind the location and size of the swing beam, ladder, slides, etc. that extend off the fort.

• Once the frame is in the final position, check for vertical and horizontal levelness to determine which side(s) will need to be dug into the ground to level the play set.

• With a shovel, score the ground around the outside edges of the sandbox boards on the ‘high’ side of the fort. This is the area that will be dug in. Make sure to score deep enough; the scored lines will be your digging template.

• Push the frame off and away from the scored area, far enough to dig and remove dirt to reach the appropriate depth.

• Dig a channel along the scored line(s) for the base of the fort (corner post and sandbox boards) to rest into. Dig the channel(s) to the same level depth. The bottom of the channel(s) should be level to each other so your frame doesn’t teeter or rock because the channel(s) are uneven.

• Once you have removed enough grass and dirt, slide/push the frame into the channel(s). Place a level on the vertical and horizontal boards of the frame to determine if enough soil, or too much, was removed.

• Repeat this process until the basic frame is plumb and level and in its final position before completing the rest of the assembly.

• Measure to make sure fort is square.

Important: if you require a channel depth of more than 6”, then we recommend you have your play set area professionally graded before completing assembly.

Example Play area:

Side View of

Playset Frame

(Grade is the

Slanted Line)

The diagonal measure ments should be the same from corner post to corner post. If not, adjust corner posts so that the distance is equal.

= Area to be scored and channeled for levelness

6

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. Keep all hardware and metal parts separate from wooden pieces.

• After everything is laid out, check carefully to ensure all parts are present. Make sure there are no broken boards.

• Find an area to sort your hardware. It is best to open the hardware on a solid surface so that you do not lose any pieces in the grass. This will save time and familiarize you with all the different pieces in the hardware bag.

• Important note: Wood has some natural defects such as knots, surface cracks, etc…

We reject parts that are structurally defective. We use a high quality lumber in our structures; however, you should inspect each part for splinters or rough spots and sand them smooth to prevent injury.

• After familiarizing yourself with all of the components, read all instructions thoroughly.

Reading instructions after you have studied the parts will help you understand the installation process, and help to eliminate unnecessary mistakes.

• Pay close attention to the diameter and length of each bolt and screw.

• Never tighten hardware completely at first. It helps to have some adjustment for bolt alignment while you are attaching parts together. After everything is square, tighten each joint.

• After the main unit is assembled it is critical that the floor is level and square. If the main frame is not level, the walls and floor will be out of square.

• After you complete installation, make sure every bolt, screw, and nut is tight, and every board is secure. Wood will expand and contract with the seasons.

• Place the set on level ground, not less than 6 feet from any structure or obstruction such as a fence, garage, house, overhanging branches, laundry lines, or electrical wires.

7

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.

In the procedures you will be instructed to attach the boards with the holes offset up or with the holes offset down. This refers to which side of the board the hole/holes should be closer to. Offset holes up= hole/holes will be closer to the top of the board. Offset holes down= hole/holes will be closer to the bottom of the board. Note: some parts do not have offset holes, but instead the holes are on center. Therefore there will not be any reference on how to offset these parts.

EXAMPLE OF OFFSET HOLES UP

EXAMPLE OF OFFSET HOLES DOWN

Counter-sunk holes - Many of the parts that will be used have counter-sunk holes. A counter-sunk hole is one that surrounds one side of a through hole, but does not extend through the wood it’s self. When using a counter-sunk hole the bolt will be inserted through the through hole and either the head of the bolt and washer or nut and washer will occupy the counter sunk hole.

Counter-Sunk Hole

Through Hole

Lag Screws - Lag screws are used in the construction of our play sets to enhance the structural integrity of the unit. There will not be predrilled holes in the post for lag screw installation. Lag screws are self-tapping, though if you are using a manual socket wrench it may be advantageous to pre-drill a hole first. Instructions for this are provided on a separate page in the front of the manual. Be sure to tighten the lags completely when driving them in by hand. Power tools such as a heavy duty impact driver or large power drill should have enough torque to drive in the lag screws, but make sure not to over tighten as this can cause the threads to “strip out” in the post.

8

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

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 the T-nut inserted and installed flush to the wood.

Flush (Correct)

This picture shows an end view of the T-nut installed flush to the wood.

WARNING: DO NOT EMBED THE TOP

OF THE T-NUT INTO THE

FACE OF THE WOOD

Cross Section end view, you are looking at an X-ray view of the post and T-nut. The barrel of the T-nut is in the corner post the line is the face of the wood.

9

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. THE TEETH PENETRATE INTO THE

CORNER POST WOOD TO PREVENT THE T-NUT FROM SPINNING WHEN YOU TIGHTEN THE

HEX HEAD BOLT.

SHOWN BELOW YOU WILL SEE THE T-NUT IS HAMMERED INTO THE CORNER POST ON THE

BACK SIDE. THE BOARD IS BEING ATTACHED ON THE FRONT SIDE OF THE CORNER POST.

CORNER POST

BOARD YOU ARE

ATTACHING TO

CORNER POST.

CORNER POST

WASHER

T-NUT

A

BOARD YOU

ARE ATTACHING

TO CORNER POST.

HEX HEAD BOLT

WASHER

CROSS SECTION VIEW

OF BOARD, CORNER

POST AND FASTENERS.

T-NUT

FLANGE

IS HERE.

BACK SIDE OF

CORNER POST

FRONT SIDE OF

CORNER POST

HEX HEAD BOLT

THREADS ON

INSIDE OF

BARREL .

BARREL

SHAPED

END GOES

INTO HOLE IN

CORNER POST.

TEETH

T-NUT DETAILS

FLANGE

SHAPED END

WITH TEETH

DETAIL A

SCALE 2 : 1

10

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 1-

1/2" for the thickness. We "remill" that lumber to 1-3/8" thick.

• The 4 is the width of the board. "Nominal Lumber" at a home center will measure 3-

1/2" for the width. We "remill" that lumber to 3-3/8" wide.

Note: sometimes the width will be smaller than 3-3/8" because:

A) We need the width of the part to fit into a certain area of the play set.

B) We need the designation to be simple.

•

•

•

The 3600 is the length of the board. It means the board is 36 inches long. If the code were 3625 then the board is 36-1/4" in length.

The "BPB" abbreviation stands for "Bottom Panel Board". The wood part bill of materials in the instructions has a description which will match the abbreviation closely.

In the event that there is no tag on a wood part measure the part then:

A)Use the measurements and compare them to the wood list at the front of the instructions to identify it.

B)Look at the holes on the wood part and compare them to the pictures in the wood list.

C)Look to see if the holes are centered or if they are offset up or offset down.

This should help you identify any parts that have missing tags. In the event that you cannot identify a board please email us for assistance.

36" LENGTH

1 38 "

THICKNESS

3 38 " WIDTH

TAG

11

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. Each diameter will require a different size drill bit. When installing lag screws DO NOT OVERTIGHTEN.

LAG SCREW DIAMETER

5/16" DIAMETER

3/8" DIAMETER

DRILL BIT SIZE

9/64"

11/64"

Example: 3/8" diameter x 3-1/2" lag screw

This would be like the 2 x 4 board installation shown below. Place the board into position. Spot Drill through the holes in the 2 x 4 board into the corner posts with an 11/64" drill bit. Remove the 2 x 4 board. Continue to drill the holes to a total depth of 2-5/16" as shown at the right. Install the 2 x 4 board.

Example 5/16" diameter x 3-1/2" lag screw

This would be like the 2 x 4 board installation shown below. Place the board into position. Spot Drill through the holes in the 2 x 4 board into the corner posts with an 9/64" drill bit. Remove the 2 x 4 board. Continue to drill the holes to a total depth of 2-5/16" as shown at the right. Install the 2 x 4 board.

2 x 4 board

Corner Post

"

Example 3/8" diameter x 5" lag screw

This would be like the 4 x 4 board installation shown below. Place the board into position. Spot drill through the holes in the 4 x 4 board into the corner posts with an 11/64" drill bit. Remove the

4 x 4 board. Continue to drill the holes to a total depth of 2-13/16" as shown at the right. Install the 4 x 4 board.

4 x 4 board

Corner Post

Corner Post

Corner post

2 x 4 board

4 x 4 board

4

15

16

"

12

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.

MAXIMUM SWING BEAM LOAD IS 425 LBS.

150 LBS MAX

SWINGING WEIGHT

125 LBS MAX

SWINGING WEIGHT

150 LBS MAX

SWINGING WEIGHT

THIS END

OF SWING

BEAM IS

ATTACHED

TO PLAY SET.

TRAPEZE BAR

SWING BELT SWING BELT

13

REV A: 8/29/2012

Height - 10' - 3

1

16"

SITE PLAN:

14'-6

6'-5

1

8

"

Swing Belts (2) 3'-11

3

8

"

13'-10"

Ladder

Playset height: 10 feet - 3 inches

Swing Beam height: 7 feet - 2-1/2 inches

Deck height: 4 feet

Approximate assembly time: 5-7 hours

(6) foot unobstructed safety perimeter around playset recommended

14

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 Slide

___ (10) Rock Wall Grips (assorted colors)

___ (1) Telescope

___ (2) Safety Handle

___ (2) Flag Kit

___ (1) Tarp

___ (1) Name Plate

___ (4) Ground Stake

___ (1) Tic Tac Toe

___ (1) Steering Wheel

___ (1) Crown

___ (2) Window

Fort Hardware: see following pages

Swing Beam Hardware: see following pages

Wood Components: see following pages

15

#14 X 1-1/4"

PAN HEAD SCREW

QTY: 8

#8 X 1-1/4"

WOOD SCREW

QTY: 6

#8 X 1-1/2"

WOOD SCREW

QTY: 8

#8 X 1-3/4"

WOOD SCREW

QTY: 20

#8 X 2"

WOOD SCREW

QTY: 161

#8 X 2-1/2"

WOOD SCREW

QTY: 28

#8 X 3"

WOOD SCREW

QTY: 14

1700/1701 HARDWARE

PAGE: 1 OF 2

REV A: 10/29/2012 JH

9

8

7

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" WASHER

QTY: 8

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.

16

1700/1701 HARDWARE

PAGE: 2 OF 2

REV A: 10/29/2012 JH

5/16" X 3-1/2"

HEX LAG

SCREW

QTY: 4

3/8 X 3-1/2"

HEX LAG SCREW

QTY: 12

9

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 VIEWS SHOWN

ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.

17

PICTURE DESCRIPTION QTY.

2 X 4 X 17"

LADDER STEP

2-4-1700-LS

4

2 X 4 X 29"

REAR CENTER

POST

2-4-2900-RCP

1

2 X 4 X 47"

STRINGER

2-4-4700-S

1

2 X 4 X 47-1/2"

FRONT FACE

BOARD

2-4-4750-FFB

1

2 X 4 X 47-1/2"

FORT SIDE

SUPPORT

2-4-4750-FSS

2

2 X 4 X 47-1/2"

PANEL AND

DECK

SUPPORT

2-4-4750-PDS

2 X 4 X 47-1/2"

ROCK WALL

ROPE

SUPPORT

2-4-4750-RWRS

7

1

18

PICTURE DESCRIPTION

2 X 4 X 50"

END TARP

BOARD

2-4-5000-ETB

QTY.

2

2 X 4 X 57"

LADDER LEFT

SIDE

2-4-5700-LLS

1

2 X 4 X 57"

LADDER RIGHT

SIDE

2-4-5700-LRS

1

2 X 4 X 58"

CROSS

MEMBER

2-4-5800-CM

1

2 X 4 X 73-3/4"

FRONT CENTER

POST

2-4-7375-FCP

1

2 X 4 X 83"

BACK TARP

SUPPORT BOARD

2-4-8300-BTSB

1

2 X 4 X 83"

FRONT TARP

SUPPORT BOARD

2-4-8300-FTSB

1

19


2 X 6 X 47-1/2"

ARCH FACE

BOARD

2-6-4750-AFB

1

2 X 6 X 47-1/2"

END

SANDBOX

BOARD

2-6-4750-ESB

1

2 X 6 X 50"

ARCH ROCK

WALL CENTER

SUPPORT

2-6-5000-ARWCS

1

2 X 6 X 53-1/2"

ROCK WALL

SUPPORT

2-6-5350-RWS

2

2 X 6 X 53-15/16"

ARCH ROCK

WALL SIDE

SUPPORT

2-6-5392-ARWSS

2

2 X 6 X 75"

LEFT SIDE

SANDBOX

BOARD

2-6-7500-LSSB

2 X 6 X 75"

RIGHT SIDE

SANDBOX

BOARD

2-6-7500-RSSB

1

1

20


2 X 6 X 95-1/2"

END SANDBOX

BOARD

2-6-9550-ESB

1

4 X 4 X 47-1/2"

SWING BEAM

MOUNT

4-4-4750-SBM

1

4 X 4 X 89-1/2"

TRAP ARM

4-4-8950-TA

1

4 X 4 X 96"

CORNER POST 1

4-4-9600-CP1

1

4 X 4 X 96"

CORNER POST 2

4-4-9600-CP2

1

4 X 4 X 96"

CORNER POST 3

4-4-9600-CP3

1

4 X 4 X 96"

CORNER POST 4

4-4-9600-CP4

1

21


4 X 4 X 96"

SWING LEG

4-4-9600-SL

2

4 X 6 X 96"

SWING BEAM

4-4-9600-SB

1

5/4 X 3 X 11-1/2"

WINDOW PANEL

BOARD

125-3-1150-WPB

4

5/4 X 3 X 17-1/2"

TIC TAC TOE

MOUNT

125-3-1750-TTTM

2

5/4 X 4 X 18-1/2"

LADDER BACK

125-4-1850-LB

1

5/4 X 4 X 20"

WINDOW PANEL

BOARD

125-4-2000-WPB

4

5/4 X 4 X 40-1/2"

DECK SPACER

125-4-4050-DS

2

22


5/4 X 6 X 13-5/8"

SUN

125-6-1363-OS

2

5/4 X 6 X 47-1/2"

BOTTOM ROCK

WALL BOARD

125-6-4750-BRWB

1

5/4 X 6 X 47-1/2"

DECK BOARD

125-6-4750-DB

7

5/4 X 6 X 47-1/2"

ROCK WALL

BOARD

125-6-4750-RWB

9

5/4 X 3 X 28-1/2"

PANEL SLAT

125-3-2850-PS

14

5/4 X 4 X 10"

WAVE SUN

RAY

125-4-1000-WSR

8

2 X 4 X 47-1/2"

CENTER TARP

BOARD

2-4-4750-CTB

1

23


WAVE SLIDE

03-0010

1

SWING

W/CHAINS

04-0002

TRAPEZE

BAR

W/CHAINS

04-0006

2

1

24


SWING

PLATE

11-5002

1

1700/1701

CLIMBING

ROCK

07-0008

10

A-FRAME

SWING LEG

BRACKET

11-5010

1

HARDWARE BOX

INSTRUCTIONS

1

EA.

25


IRON

DUCTILE

SWING

HANGER

11-4012

6

90 GREEN

BRACKET

11-5013

2

SPRING

CLIP

11-4003

6

26


10' ROPE

1

TARP

1

FLAG KIT

09-1014

2

GROUND

STAKE

07-0016

4

27


TELESCOPE

07-0001

1

STEERING

WHEEL

07-0004

1

SAFETY

HANDLE

07-0005

2

28

PICTURE

(NOT SHOWN)

DESCRIPTION QTY.

TIC TAC TOE

(UNASSEMBLED)

07-0010

1

WINDOW

07-0013

2

CROWN

07-0019

NAME

PLATE

1

1

29

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. IF YOU PREFER THE SWINGBEAM ON THE RIGHT SIDE, REVERSE THE ORIENTATION OF THE CORNER

POSTS IN THIS STEP.

LEFT SIDE WILL

HAVE EXTRA HOLES

AT THESE LOCATIONS

4 X 4 X 96"

CORNER POST

REAR CORNER

POSTS WILL HAVE

AN EXTRA HOLE

AT THIS

LOCATION

CORNER POST #2

FRONT OF PLAY SET

CORNER POST #3

CORNER POST #1

CORNER POST #4

30

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.

T-NUT

NO T-NUTS IN THESE HOLES

NO T-NUTS

IN THESE HOLES

CORNER POST #2

CORNER POST #3

CORNER POST #1

CORNER POST #4

31

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.

2 X 4 X 47-1/2"

ROCK WALL

ROPE SUPPORT

(OFFSET UP)

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

2 X 6 X 47-1/2"

END SANDBOX BOARD

(OFFSET UP)

32

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.

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

2 X 6 X 95-1/2"

END SANDBOX

BOARD

33

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.

2 X 6 X 75"

SIDE SANDBOX BOARD

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

34

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.

5/16" WASHER

5/16 X 4-1/2" HEX BOLT

2 X 4 X 83"

TARP SUPPORT

BOARD

(OFFSET DOWN)

35

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.

2: THE 2 X 4 X 47-1/2" DECK SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES

ABOVE THE SANDBOX BOARD AND THE GROUND SUPPORT BOARD ON THE INSIDE OF THE LEFT AND RIGHT SIDE

CORNER POSTS WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS. THE HOLES SHOULD BE OFFSET DOWN ON

BOTH DECK SUPPORT BOARDS.

2 X 6 X 47-1/2"

ARCH FACE BOARD

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

5/16" X 3-1/2"

LAG SCREW

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

5/16" WASHER

2 X 4 X 47-1/2"

DECK SUPPORT

(OFFSET DOWN)

FRONT OF PLAYSET

36

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.

5/16 X 4-1/2"

HEX BOLT

5/16" WASHER

2 X 4 X 47-1/2

"

REAR PANEL

SUPPORT BOARD

(OFFSET DOWN)

REAR OF PLAYSET

37

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.

5/16" WASHER

5/16" X 4-1/2"

HEX BOLT

2 X 4 X 47-1/2"

PANEL BOARD

(OFFSET UP)

5/16" WASHER

5/16" X 3-1/2"

LAG SCREW

2 X 4 X 47-1/2"

PANEL BOARD

(SAFETY BOARD)

24"

38

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. SEE DETAIL A AND DETAIL B.

3: ENSURE THAT THE TWO FORT SIDE SUPPORTS ARE ATTACHED PROPERLY TO THE END SANDBOX BOARD BEFORE

SECURING THEM TO THE CORNER POSTS. USE A #8 X 2-1/2" WOOD SCREW IN THE TOP HOLE OF THE SUPPORT,

THEN USE A 3" WOOD SCREW IN THE BOTTOM HOLE OF THE SUPPORT. SEE DETAIL B.

DETAIL A

T-NUT

(INSTALL FIRST)

5/16" WASHER

5/16" X 2-1/2" HEX BOLT

ANGLED END OF FORT SIDE SUPPORT.

#8 X 2-1/2" WOOD SCREW

#8 X 3" WOOD SCREW

DETAIL B

2 X 4 X 47-1/2"

FORT SIDE

SUPPORT

B

2 X 4 X 47-1/2"

FORT SIDE

SUPPORT

A END SANDBOX BOARD

39

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. THE ANGLED END OF EACH ROCK WALL SUPPORT SHOULD REST FLUSH

AGAINST THE CORNER POST.

3: ENSURE THAT THE TWO ROCKWALL SUPPORTS ARE ATTACHED PROPERLY TO THE SIDE SANDBOX BOARDS

BEFORE SECURING THEM TO THE CORNER POSTS. USE A #8 X 2-1/2" WOOD SCREW IN THE TOP HOLE AND A

#8 X 3" WOOD SCREW IN THE BOTTOM HOLE OF THE ROCK WALL SUPPORT.

#8 X 2-1/2"

WOOD SCREW

#8 X 3"

WOOD SCREW

2 X 6 X 53-1/2"

ROCK WALL SUPPORT

5/16" WASHER

5/16" X 2-1/2" HEX BOLT

T-NUT

40

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.

3: SECOND, FASTEN THE SECOND #8 X 3" WOOD SCREW THROUGH THE ARCH ROCK WALL SIDE SUPPORT

BOTTOM HOLE INTO THE ROCK WALL SUPPORT. MAKE SURE THAT THIS BOARD IS ALIGNED WITH THE ROCK WALL

SUPPORT.

4: THIRD, FASTEN #8 X 3" WOOD SCREW THROUGH THE ROCK WALL SUPPORT INTO THE ARCH ROCK WALL

SUPPORT. MAKE SURE BOTH BOARDS ARE FLUSH ON THE SIDES AND WHERE THEY MEET.

#8 X 3" WOOD SCREW

(1ST)

ROCK

WALL

SUPPORTS

#8 X 3"

WOOD SCREW

(3RD)

2 X 6 X 54"

ARCH ROCK WALL

SIDE SUPPORT

#8 X 3"

WOOD SCREW

(2ND)

41

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. SECURE WITH #8 X 2" WOOD SCREWS.

3: PLACE THE ARCH ROCK WALL CENTER SUPPORT BEHIND THE ROCK WALL BOARDS AND CENTER IT UNDER THE

SMALL HOLES. FASTEN THE ARCH ROCK WALL CENTER SUPPORT TO THE ROCK WALL BOARDS WITH #8 X 2"

WOOD SCREWS.

TOP

ARCH ROCK WALL

CENTER SUPPORT

44"

BOTTOM 5/4" X 6 X 47-1/2"

ROCK WALL BOARD

#8 X 2" WOOD SCREW

ARCH ROCK WALL SIDE SUPPORT

ARCH ROCK WALL CENTER

SUPPORT

5/4" X 6 X 47-1/2"

BOTTOM ROCK WALL BOARD

MAKE SURE ROCK WALL CENTER

SUPPORT IS NOT BLOCKING THIS HOLE

42

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.

ROCK WALL BOARD

#8 X 2"

WOOD SCREWS

BOTTOM

ROCK WALL BOARD

43

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.

#14 X 1-1/4"

PANHEAD

SCREW

DETAIL A

1/4" WASHER

ROCK

A

ROCKS

44

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.

2: SEVEN 5/4" X 6 X 47-1/2" DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS WITH ONE END FLUSH TO THE

TOP MOST ROCK WALL BOARD.

3: SPACE THE DECK BOARDS EVENLY ACROSS THE DECK SUPPORTS BETWEEN THE DECK SPACERS. SECURE WITH #8

X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS.

#8 X 2" WOOD SCREWS

5/4 X 4 X 40-3/8"

DECK SPACER

(2)

DECK SPACER SHOULD NOT PROTRUDE BEYOND FRONT OF FRONT CORNER POSTS.

REAR CORNER POSTS

TOP MOST

ROCK WALL

BOARD

5/4" X 6 X 47-1/2"

DECK BOARDS (7)

FRONT CORNER POSTS

45

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.

#8 X 2" WOOD SCREWS

END OF STRINGER IS FLUSH

TO THE SIDE OF DECK SPACER

2 X 4 X 47"

STRINGER

46

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.

#8 X 2-1/2" WOOD SCREWS

2 X 4 X 47-1/2"

FRONT FACE BOARD

DECK SPACER

FLUSH TO THE TOP OF THE DECK SPACER

STRINGER IS

BEHIND THE

SCREWS

HERE.

#8 X 2-1/2"

WOOD

SCREWS

47

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.

4: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER.

3/8" X 3-1/2" CARRIAGE BOLT

SWING BEAM PLATE

MIDDLE HOLE EMPTY

4 X 4 X 47-1/2"

SWING BEAM MOUNT

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

48

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. USE 3/8" X 5" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE TRAP ARM, AND

3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM. PLACE BOLT CAPS OVER ANY EXPOSED THREADS AFTER

SECURING.

3/8" X 7" CARRIAGE BOLT

TORQUE WASHER

IRON DUCTILE

SWING HANGER

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

4 X 6 X 96"

SWING BEAM


TORQUE WASHER

4 X 4 X 89-1/2"

TRAP ARM

IRON DUCTILE

SWING HANGER

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

49

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. PLACE THE CARRIAGE BOLT INTO THE TORQUE WASHER, THEN INTO THE HOLE OF THE CORNER POST AND

SET WITH A HAMMER, USE 3/8" WASHERS AND 3/8" LOCK NUTS TO SECURE THE SWING BEAM MOUNT FROM THE

OUTSIDE. PLACE BOLT CAPS OVER THE EXPOSED THREADS AFTER SECURING.

3: THE 4 X 4 X 89-1/2" TRAP ARM WILL ATTACH TO THE UNIT IN THE SAME MANNER AS THE SWING BEAM MOUNT. THE

TRAP ARM WILL MOUNT ACROSS FROM THE SWING BEAM MOUNT ABOVE THE ROCK WALL.

THE HOLE ABOVE WHERE THE SWING BEAM MOUNT

ATTACHES IS TO BE USED ONLY ON UNEVEN (UPHILL)

GROUND. IF INSTALLING ON A RELATIVELY LEVEL

SURFACE, THIS HOLE WILL NOT BE USED.

TORQUE WASHER


BOLT COVER

3/8" LOCK NUT

3/8" WASHER

SWING BEAM MOUNT


4 X 4 X 89-1/2"

TRAP ARM

BOLT COVER

3/8" LOCK NUT

3/8" WASHER

50

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.

5: CAREFULLY TURN THE LADDER OVER AND FINISH THE OTHER SIDE WITH TWO 2" WOOD SCREWS PER STEP.

6: INSTALL TWO 90 GREEN BRACKETS USING 5/16" X 1-1/2" BOLTS AND 5/16" WASHERS.

7: INSTALL THE 5/4" X 4 X 18-1/2" LADDER BACK ABOVE THE OPENING OF THE TOP CHANNELS WITH ONE 2" WOOD

SCREW PER SIDE.

90 GREEN BRACKET

T-NUT

5/16" WASHER

5/16" X 1-1/2" HEX BOLT

2" WOOD SCREW

5/4" X 4 X 18-1/2"

LADDER BACK

2 X 4 X 17"

LADDER STEP

2" WOOD SCREW

2 X 4 X 57"

LADDER SIDE RIGHT

2 X 4 X 57"

LADDER SIDE LEFT

2" WOOD SCREW

51

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.

A

90 GREEN BRACKET

5/16" WASHER

5/16" X 1-1/2" HEX BOLT

2 X 4

GO UNDER DECK

AND INSERT T-NUTS

IN THE HOLES.

3/4"

52

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.

SWING LEG BRACKET

3/8" X 3-1/2" LAG SCREW

3/8" WASHER

4 X 4 X 96" SWING LEG

SWING LEGS FLUSH

TO TOP OF SWING

LEG BRACKET

53

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.


TORQUE WASHER

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

3/8" X 3-1/2"

LAG SCREW

54

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. PLACE A GREEN

BOLT CAP OVER EXPOSED THREADS AFTER SECURING.

4: DRILL AN 11/64" HOLE THROUGH THE HOLE IN THE SWING BEAM PLATE 3-1/2" INTO THE SWING BEAM. FASTEN

THE SWING BEAM TO THE SWING BEAM PLATE FROM UNDERNEATH WITH A 3/8" X 3-1/2" LAG SCREW AND 3/8"

WASHER.

SWING BEAM

3/8" WASHER

3/8" X 3-1/2"

LAG SCREW


TORQUE WASHER

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

55

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.

56

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.

2 X 4 X 58"

SWING LEG

CROSS MEMBER

3/8" X 3-1/2"

LAG SCREWS

3/8" WASHER

57

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.

3: SQUARE THE REAR CENTER POST TO THE REAR TARP SUPPORT BOARD. DRIVE TWO #8 X 2-1/2" SCREWS

THROUGH THE REAR CENTER POST INTO THE REAR TARP SUPPORT BOARD.

2 X 4 X 29"

REAR CENTER POST


T-NUT

2 X 4 X 73-1/2"

FRONT CENTER POST

5/16" WASHER

5/16" X 2-1/2" HEX BOLT

5/16" WASHER

5/16" X 2-1/2" HEX BOLT

#8 X 2-1/2" WOOD SCREWS

#8 X 2-1/2"

WOOD SCREWS

(GO UP ON

DECK AND

DRIVE THESE

FROM THE INSIDE

GOING OUT.)

58

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.

3: GO TO THE OUTSIDE FRONT OF THE PLAYSET AND INSTALL THE WINDOWS WITH #8 X 1-1/2" WOOD SCREWS.

4: ATTACH THE 5/4 X 3 X 11-1/2" HORIZONTAL WINDOW SUPPORTS AT THE BOTTOM WITH #8 X 2" WOOD SCREWS.

5: ATTACH THE 5/4 X 3 X 11-1/2" HORIZONTAL WINDOW SUPPORTS AT THE TOP WITH #8 X 2" WOOD SCREWS.

5/4 X 4 X 20" WINDOW PANEL BOARD

(VERTICAL WINDOW SUPPORTS)

1-1/2"

11-1/2" 11-1/2"

#8 X 2"

WOOD

SCREW

FRONT CENTER POST

WINDOWS

NOTE: THE 1" WIDE

FRAME SECTION IS TOP

5/4 X 3 X 11-1/2"

WINDOW PANEL

BOARD

(HORIZONTAL

WINDOW

SUPPORTS)

FRONT OF PLAY SET

WINDOW-

ATTACH

WITH

1-1/2"

WOOD SCREWS OUTSIDE FRONT OF PLAYSET

59

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.

2: THE TWO 2 X 4 X 50" END TARP BOARDS WILL SECURE ON THE ENDS OF THE TARP SUPPORTS WITH TWO #8 X 2-1/2"

WOOD SCREWS PER SIDE

2 X 4 X 47-1/2"

CENTER TARP BOARD

#8 X 2-1/2"

WOOD SCREWS

2 X 4 X 50"

END TARP BOARD

CENTER POSTS

TARP SUPPORTS

60

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.

3: ON LEFT SIDE OF THE FORT (SWING BEAM SIDE) BEGIN WITH THE TWO OUTER SLAT BOARDS, THEY ARE SPACED

2-1/2" FROM THE CORNER POSTS. ATTACH EACH PANEL SLAT WITH #8 X 2" WOOD SCREWS.

4: THE INNER BOARDS ARE SPACED 2-7/8" FROM EACH OTHER FOR A TOTAL OF SEVEN SLATS ON THE LEFT SIDE

(SWING BEAM SIDE). ATTACH EACH PANEL SLAT WITH #8 X 2" WOOD SCREWS.

5/4 X 3 X 28-1/2"

PANEL SLAT

(13 PIECES USED IN THIS STEP.

1 EXTRA IS LEFTOVER.)

SW

ING

BE

AM

SID

E

OUTE

R SLA

TS

REA

R O

F PLA

Y SET

#8 X 2"

WOOD

SCREW

REAR OF PLAY SET SWING BEAM SIDE

1-7/8"

2"

2"

2-1/2"

2-7/8"

OUTER SLATS

CORNER POSTS

OUTER SLATS

CORNER POSTS

61

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.

5/4 X 3 X 17-1/2"

TIC TAC TOE MOUNT

GREEN BRACKET

5/4 X 3 X 17-1/2"

TIC TAC TOE MOUNT

62

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.

63

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.

5: REPEAT SUBSTEPS 2 TO 4 FOR THE OTHER SIDE.

6: PLACE THE CROWN ON TOP OF THE FRONT WOOD SUN AND SECURE IT WITH TWO #8 X 1-1/4" WOOD

SCREWS.

CENTER POST

55°


5/4 X 4 X 10"

WAVE SUN RAY

#8 X 2" WOOD SCREW

5/4 X 6 X 13-5/8"

SUN

CROWN

#8 X 1-1/4"

WOOD SCREW

1/4" GAP

64

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. PLACE ONE 1-1/4" PAN

HEAD SCREW WITH A 1/4" WASHER INTO THE GROMMET. FASTEN FRONT RIGHT GROMMET TO THE TARP BOARD.

3: GO TO THE FRONT LEFT SIDE CORNER AND PULL THE TARP TIGHT. INSERT A SCREW AND WASHER INTO THE

GROMMET AND FASTEN IT TO THE TARP BOARD.

4: NOW THE NEXT RIGHT SIDE GROMMET WILL RECEIVE A SCREW/WASHER, THEN THE SAME GROMMET ON THE

OPPOSITE SIDE (LEFT SIDE).

5: ESSENTIALLY, WHAT YOU ARE DOING IS ALTERNATING FROM SIDE TO SIDE, FROM THE FRONT OF THE FORT

MOVING BACK, TO KEEP THE TARP TIGHT AND WRINKLE-FREE.

TARP

#14 X 1-1/4

PAN HEAD SCREW

WITH 1/4" WASHER

65

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. IF THE ROPE WRAPS AROUND YOUR HAND IT IS TOO

LOOSE. UNTIE THE TOP KNOT AND RETIE THE ROPE UNTIL IT NO LONGER WRAPS AROUND YOUR HAND.

THE KNOT BEHIND THIS HOLE

ROPE

THE KNOT BEHIND THIS HOLE

66

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. **DO NOT OVER TIGHTEN**

#8 X 1-1/4"

WOOD SCREW

**DO NOT OVER TIGHTEN**

WAVE SLIDE

67

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.

STEERING WHEEL CAP

INCLUDED HARDWARE

STEERING WHEEL

STEERING WHEEL INSERT

68

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.

DETAIL A

A

69

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.

ATTACH NAME PLATE HERE

WITH TWO #8 X 1-1/4" WOOD SCREWS

70

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.

**WARNING: DO NOT HANG SWING BELTS FROM TRAPEZE ARM**

TRAPEZE ARM

SWING BEAM

A

TRAPEZE

BAR

WITH CHAINS

SWING BELT

WITH CHAINS

SWING HANGER LOOP

SPRING CLIP

DETAIL A

SCALE 1 : 10

CHAIN FROM SWING BELT

SWING BELT

WITH CHAINS

71

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.

4: HAMMER A GROUND STAKE ON THE INSIDE OF EACH CORNER POST NEAR THE ROCK WALL. 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.

5: SECURE EACH STAKE TO THE CORNER POSTS WITH THE SCREWS PROVIDED WITH THE STAKES.

SWING LEG

SCREW THAT

COMES WITH

GROUND STAKE

GROUND STAKE

DETAIL A

SCALE 1 : 8

GROUND STAKES

CORNER

POSTS A

SWING LEGS

WOOD SCREW

THAT COMES

WITH GROUND

STAKE

B

GROUND STAKE

CORNER POST

DETAIL B

SCALE 1 : 8

72

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.

FRONT CENTER POST

#14 X 1-1/4" PAN HEAD SCREW AND 1/4" FLAT WASHER

INCLUDED WITH SAFETY HANDLES.

SAFETY HANDLES

CORNER POST

73

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