Gorilla Playsets Chateau Assembly Manual
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Gorilla Playsets Chateau Assembly Manual

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Chateau
ASSEMBLY MANUAL
Copyright © 2010 Gorilla Playsets
All Rights Reserved
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA 30114
(800) 882-0272
17/FEB/2010 – Version 2.5.3

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  • Page 1 Chateau ASSEMBLY MANUAL Copyright © 2010 Gorilla Playsets All Rights Reserved Gorilla Playsets 190 Etowah Industrial Court Canton, GA 30114 (800) 882-0272 17/FEB/2010 – Version 2.5.3...
  • Page 2 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.
  • Page 3 STOP…PLEASE READ!! IF YOU HAVE MISSING OR DAMAGED PARTS OR NEED ASSISTANCE ASSEMBLING, PLEASE CALL Gorilla Playsets MANUFACTURING DIRECT. (800) 882-0272 FACTORY HOURS – MON.–FRI., 8AM-5PM EST DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECT. THE RETAILER DOES NOT STOCK COMPONENTS.
  • Page 4 Blue Ridge Chateau TABLE OF CONTENTS Warranty and Safety Guidelines………………………….……………………….pg 4-11 Kit Contents and Tool List…………..……………………….……………………pg 11-29 Framing the play set...………………………………………...……………..….steps 1 - 6 Constructing deck and lower panel boards………………………………….steps 7 - 10 Constructing rock - wall and securing to fort…………………………..…..steps 11 - 15 Constructing and attaching ladder………..….……..………….………….steps 16 - 17...
  • Page 5 Our play set kits are designed for children ages 3 to 11. Gorilla Playsets® believes every child should have a play set and with our kits they can! You can rest assured your new play set is safe, durable and designed to hold up to the elements.
  • Page 6 Limited Manufacturers Warranty ® Gorilla Playsets (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions at its original installation, for 10 years for structural wood components and for one year for all other components (e.g., hardware, plastics, tarps, rope ladder, etc.).
  • Page 7 WEIGHT LIMITS FOR GORILLA PLAYSETS • FORT PLATFORMS: 800 LBS. TOTAL WEIGHT • SWING BELTS: 175 LBS. • GLIDER SWINGS: 70 LBS. PER CHILD • TRAPEZE: 125 LBS. • FULL BUCKET SWING: 50 LBS. • TODDLER BUCKET SWING: 50 LBS.
  • Page 8 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. •...
  • Page 9 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 •...
  • Page 10 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) Handbook for Public Playground Safety offers from its . 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.
  • Page 11 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.
  • Page 12 Check List (Swings, Slides, Accessories) Swingbelts w/ Chains __________ Telescope __________ Rope Ladder __________ 10ft. Wave Slide __________ The Chateau Assembly Manual __________ Rockwall Grips (assorted colors) __________ Trapeze Swing __________ Unassembled dormer __________ Unassembled chimney __________ Safety handles (pair)
  • Page 13 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 19’ ROPE LADDER SWING BELTS (2) TRAPEZE ARM (1) LADDER 15’ ROCK WALL WAVE SLIDE Playset height: 11’ Approximate assembly time: 6-8 Hours { 6 foot unobstructed safety perimeter around playset recommended }...
  • Page 14 Helpful Installation Hints • Depending on your experience, assembly of Gorilla Playsets can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly.
  • Page 15 General Info To Review Before Installation 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.
  • Page 16 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.

  • Page 17: Table Of Contents

    #8 X 1-1/2" WOOD SCREW QTY: 140 #8 X 2" WOOD SCREW QTY: 227 #8 X 2-1/2" WOOD SCREW QTY: 48 #8 X 3" WOOD SCREW QTY: 8 #14 X 1-1/4" PAN HEAD SCREW QTY: 4 3/8" LOCK NUT 5/16" TEE NUT QTY: 19 QTY: 38 1/2"...
  • Page 18 5/16 X 4" 5/16 X 3-1/2" 3/8 X 3-1/2" EYEBOLT LAG HEX LAG SCREW HEX LAG SCREW QTY: 3 QTY: 22 QTY: 12 #2 SQUARE DRILL BIT QTY: 1 PLASTIC 3/8 x 9" 3/8 x 3-1/2" 3/8 x 7" 3/8 x 6-1/2" BOLT CAP CARIAGE BOLT CARIAGE BOLT...
  • Page 19 PICTURE DESCRIPTION QTY. 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-AS 2 X 4 X 14" BOTTOM PANEL BOARD 2-4-1400-BPB 2 X 4 X 15" PICNIC TABLE TOP SUPPORT 2-4-1500-PTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 23"...
  • Page 20 PICTURE DESCRIPTION QTY. 2 X 4 X 51" LEFT ROOF SUPPORT (1 HOLE OFFSET) RIGHT 2-4-5100-RSL 2-4-5100-RSR 2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON CENTER) 2-4-5800-CM 2 X 4 X 66" LEFT LADDER SIDE 2-4-6600-LLS 2-4-6600-LRS RIGHT 2 X 4 X 66"...
  • Page 21 PICTURE DESCRIPTION QTY. 2 X 4 X 78" ROPE LADDER SUPPORT (2 HOLES ON CENTER) 2-4-7800-RLS 2 X 6 X 16" HALF SUN 2-6-1600-S 2 X 6 X 47 " BOTTOM PANEL AND SANDBOX BOARD (4 HOLES OFFSET) 2-6-4750-ESPB 2 X 6 X 70" FRONT FACE BOARD (4 HOLES OFFSET)
  • Page 22 PICTURE DESCRIPTION QTY. X 10" SMALL RAY 125-2-1000-SR X 16" LARGE RAY 125-2-1600-LR X 42" SUN SUPPORT 125-3-4200-SS X 28 " PANEL SLAT 125-3-2850-PS X 4 X 40 " DECK SPACER 125-4-4025-DS X 3 X 18 " LADDER BACK 125-3-1875-LB X 3 X 23 "...
  • Page 23 PICTURE DESCRIPTION QTY. X 6 X 10" ROOF TOP SUPPORT 125-6-1000-RPS X 6 X 23 " BOTTOM ROCK WALL BOARD 125-6-2387-BRW X 6 X 23 " ROCK WALL BOARD 125-6-2387-RWB X 6 X 47 " DECK BOARD 125-6-4737-DB X 6 X 51" PICNIC TABLE TOP AND SEATS 125-6-5100-PTST...
  • Page 24 PICTURE DESCRIPTION QTY. 1 X 4 X 47 " GROOVE-ONLY ROOF STARTER 1-4-4750-RS 1 X 6 X 47 " TONGUE-AND- GROOVE ROOF BOARD 1-6-4750-RB PLASTIC COATED 4 X 4 X 108" SWING BEAM SL-1 PLASTIC COATED 4 X 4 X 96" CORNER POST 101-CP PLASTIC COATED...
  • Page 25 PICTURE DESCRIPTION QTY. EXTREME WAVE SLIDE ROPE LADDER ASSEMBLY SWINGS W/CHAINS TRAPEZE W/CHAINS...
  • Page 26 PICTURE DESCRIPTION QTY. SWING PLATE CLIMBING ROCKS A-FRAME SWING BRACKET HARDWARE NOT SHOWN INSTRUCTIONS...
  • Page 27 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS TELESCOPE 10' ROPE...
  • Page 28 PICTURE DESCRIPTION QTY. 90 GREEN BRACKET SPRING CLAMP SAFETY HANDLES (PAIR)
  • Page 29 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY UNASSEMBLED DORMER FLAG KIT...
  • Page 30 STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 96"...

  • Page 31: Washer

    STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.

  • Page 32: Hex Bolt

    STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 33 STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT 5/16"...
  • Page 34 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD SHOULD FACE UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 35 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 36 STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 5/16"...
  • Page 37 STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-1/2" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/4" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 38 STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE.
  • Page 39 STEP 10: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 5/4 X 6 X 47-1/2"...
  • Page 40 STEP 11: ROCK WALL 1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER. T-NUT 2 X 4 X 66"...
  • Page 41 STEP 12: ROCK WALL 1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2"...
  • Page 42 STEP 13: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME. GREEN BRACKET 5/16"...
  • Page 43 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
  • Page 44 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. THE BOTTOM OF THE GREEN BRACKETS SHOULD BE APPROXIMATELY 3/4"...
  • Page 45 STEP 16: LADDER 2 X 4 X 66" 1: FIND TWO 2 X 4 X 66" LADDER SIDES. LADDER SIDE 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH T-NUT OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
  • Page 46 STEP 17: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE BOTTOM PANEL BOARD.
  • Page 47 STEP 18: PANEL SLATS 1: FIND TWENTY-SEVEN 5/4 X 2-5/8 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2"...
  • Page 48 STEP 19: ROOF SUPPORTS 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 51" ROOF SUPPORTS TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE. 2: CONNECT THE ENDS WITH A 2"...
  • Page 49 STEP 20: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS WITH 1/2" WASHERS ON TOP, AND 3/8"...
  • Page 50 STEP 21: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 51 STEP 22: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. SWING LEGS FLUSH TO TOP OF SWING LEG BRACKET...
  • Page 52 STEP 23: REST SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT. 2: LINE UP THE PRE-DRILLED HOLES, AND REST THE SWING BEAM ON TOP OF THE FORT AND THE SWING BEAM LEGS.
  • Page 53 STEP 24: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2"...
  • Page 54 STEP 25: MOUNT SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS.. 2: LINE UP THE PILOT HOLES AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLES ON THE SWING BEAM PLATE.
  • Page 55 STEP 26: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE).
  • Page 56 STEP 27: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS. 3/8 X 3-1/2"...
  • Page 57 STEP 28: ROOF PEAK SUPPORT 1: PRE-DRILL HOLES IN THE TWO 5/4 X 10" ROOF PEAK SUPPORTS TO THE PATTERN SHOWN BELOW. 5/4 X 10" ROOF PEAK SUPPORT 2: PLACE THE 5/4 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS.
  • Page 58 STEP 29: ROOF 1: PLACE THE 1 X 4 X 47-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 59 STEP 30: ROOF 1: PLACE THE 1 X 6 X 47-1/2" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 60 STEP 31: ROOF 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH 1-1/2" WOOD SCREWS. 1-1/2" WOOD SCREW 47-1/2" ROOF PEAK...
  • Page 61 STEP 32: SUNBURST 1: PRE-DRILL HOLES IN THE 2 X 6 X 16" SUN TO THE PATTERN SHOWN BELOW. 2 X 6 X 16" 4" 4" 2: PLACE THE 2 X 6 X 16" SUN CENTERED AGAINST THE 5/4 X 2-5/8 X 42" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2"...
  • Page 62 STEP 33: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP UNDERNEATH THE ROOF BOARDS, AND AGAINST THE ANGLED ROOF SUPPORTS. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP. 2: FASTEN THE SUN ASSEMBLY TO THE FORT WITH 2" WOOD SCREWS FROM THE OUTSIDE INTO THE ROOF SUPPORTS. 3: REPEAT ON THE OPPOSITE SIDE OF THE FORT.
  • Page 63 STEP 34: SUNBURST 1: PREDRILL ALL SUNRAYS AT 3/4" ON CENTER FROM EACH END. 2: CENTER THE 5/4 X 1-1/2 X 16" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS AND FASTEN WITH TWO 1-1/2" SCREWS. 3: EQUALLY SPACE THE SMALL RAYS ABOUT THE HALF SUN (THREE ON EACH SIDE OF LARGE RAY) AND MARK THE POSITION OF THE SMALL SUNRAYS WITH A PENCIL.
  • Page 64 STEP 35: HANGING THE SWINGS 1: START BY ATTACHING ONE SPRING CLIP TO EACH IRON DUCTILE ON THE SWING BEAM. 2: ATTACH ONE CHAIN PER ACCESSORY TO EACH SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED SPRING CLIP SWING CHAIN...
  • Page 65 STEP 36: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 66 STEP 37: PICNIC TABLE 1: PLACE THE 2 X 4 X 15" PICNIC TABLE SUPPORT ON TOP OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORT AND POSITION THE BOARDS AT A RIGHT ANGLE. 2: ENSURE THAT THE PICNIC TABLE SUPPORT AND THE PICNIC TABLE VERTICAL SUPPORT ARE SQUARE AND FASTEN THE PICNIC TABLE SUPPORT TO THE VERTICAL SUPPORT WITH THREE 2 1/2"...
  • Page 67 STEP 38: PICNIC TABLE 1: MEASURE 18” FROM THE GROUND UP AND MARK THIS POINT ON THE CORNER POST. 2: ATTACH THE BENCH SUPPORT TO THE OUTSIDE OF THE CORNER POST SO THAT THE TOP IS AT 18” FROM THE GROUND.
  • Page 68 STEP 39: PICNIC TABLE 1: ATTACH THE PICNIC TABLE SEAT ON THE SEAT SUPPORTS WITH TWO 2” WOOD SCREWS IN EACH END. 2: ATTACH THE PICNIC TABLE TOPS TO THE TABLE SUPPORTS WITH TWO 2” WOOD SCREWS IN EACH END. ROCK WALL REMOVED FOR ASSEMBLY CLARIFICATION 2"...
  • Page 69 STEP 40: ROPE LADDER ASSEMBLY 1: DRILL THREE 1/8" PILOT HOLES 2" DEEP INTO THE BOTTOM OF THE ROPE LADDER SUPPORT (SEE DIMENSIONS BELOW). 2: PLACE THE EYEBOLT LAGS INTO THE HOLES AT THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIGHTEN. 5-1/2"...
  • Page 70 STEP 41: ROPE LADDER ASSEMBLY 1: PLACE THE HOOKS ON THE END OF THE ROPE LADDER ASSEMBLY THROUGH THE EYE OF THE EYBOLT LAG. 2: THREAD THE BOTTOM OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE A SECURE KNOT.
  • Page 71 STEP 42: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: THE FLARED END OF THE SLIDE WILL REST ON THE BOTTOM PANEL BOARD. 3: ATTACH THE SLIDE TO THE DECK WITH 1-1/4"...
  • Page 72 STEP 43: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE FRONT TOP PANEL BOARD, BETWEEN THE TWO PANEL SLATS. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4"...
  • Page 73 STEP 44: INSTALLING CLIMBING ROPES 1: DRILL A 7/8" HOLE THROUGH THE END PANEL BOARD (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE END PANEL BOARD. 3: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD.
  • Page 74 STEP 45: TIC-TAC-TOE PANEL 1: FOLLOW THE INSTRUCTIONS PROVIDED WITH THE TIC-TAC-TOE PANEL. AFTER THE PANEL IS ASSEMBLED, CENTER THE TIC-TAC-TOE PANEL BETWEEN THE PANEL SLATS ON THE BACK WALL, AND ATTACH WITH 2" WOOD SCREWS.
  • Page 75 STEP 46: CHIMNEY AND DORMERS USE THE INSTRUCTIONS PROVIDED TO ASSEMBLE AND INSTALL THE CHIMNEY AND DORMERS.
  • Page 76 STEP 47: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES ON THE UNIT AS SHOWN BELOW AND ATTACH WITH THE PROVIDED HARDWARE.
  • Page 77 STEP 48: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT AND BACK OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS THROUGH THE DECK INTO THE TOP OF THE BRACE, AND ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORTS TO THE CORNER POSTS.
  • Page 78 STEP 49: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS ON TOP OF THE BRACE, AND ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORTS TO THE CORNER POSTS.
  • Page 79 STEP 50: FLAG KITS 1: PLACE THE FLAG KIT IN THE DESIRED LOCATION ON THE FORT AND ATTACH WITH THE HARDWARE PROVIDED. THE RECOMMENDED LOCATION IS ON THE CORNER POSTS AT THE FRONT OF THE FORT.
  • Page 80 _______________________________________________________________________ _______________________________________________________________________ _______________________________________________ Thank you for registering with gorilla playsets™! The information you provided will be kept confidential and will ONLY be used to better serve our customers. Remove this page from the manual and mail to the address below.

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