Gorilla Playsets Sun Palace Deluxe 723 Manual
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Gorilla Playsets Sun Palace Deluxe 723 Manual

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Sun Palace Deluxe
*51-0044-W*
51-0044-W
Model: 723
(BOXES: 701N-1, 701N-2, 703N,
705, 721-1, 721-2, 723, 725, Rad
Ride 7 Box & Slide Box)
Copyright © 2015 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
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  • Page 1 Sun Palace Deluxe Model: 723 (BOXES: 701N-1, 701N-2, 703N, 705, 721-1, 721-2, 723, 725, Rad Ride 7 Box & Slide Box) Copyright © 2015 Gorilla Playsets All Rights Reserved *51-0044-W* 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com 51-0044-W...
  • Page 2 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”...
  • Page 3 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.

  • Page 4: Safety Guidelines

    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.

  • Page 5: Warranty Registration

    Warranty registration - sun palace Deluxe - Gorilla Playsets manufactures ™ 3 Easy Ways To REgisTER the finest quality products that Mail this completed form to: are designed for outstanding Fax this completed form to: Gorilla Playsets option 1 strength and durability. We back...
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 7 IMPORTANT – PLEASE READ Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years.
  • Page 8 Please review these safety rules regularly with your children. WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to ensure it has been properly installed. Gorilla Playsets 190 Etowah Industrial Court Canton, GA. 30114...
  • Page 9 Model: 723 (BOXES: 701N-1, 701N-2, 703N, 705, 721-1, 721-2, 723, 725, Rad Ride 7 Box & Slide Box) REV: 3.10.2015...

  • Page 10: Table Of Contents

    TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 4-7 Leveling Fort, General Information and Definitions..........Pages 7-9 How to Install T-Nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 10-14 Site Plan, Required Tool List and Kit Contents..………………………..Pages 15-16 PART I Lower Level Hardware, Lumber and Accessory Checklists………………………………..Pages 18-31 Assembling the Ladder…………………………………..………...….....
  • Page 11 TABLE OF CONTENTS Part II Upper Level Hardware, Lumber and Accessory Checklists………………………………..Pages 83-98 Framing the Upper Level………………..…………………………..……....Steps 1-4 Connecting the levels with Deck Supports and leveling the Upper Level..…..Step 5 Corner Posts, Safety Bar, Center Post and Center Deck Supports....Steps 6-10 Deck Blocks/Deck Support, Center Post/Center Deck Support......
  • Page 12 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 13 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 14 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.
  • Page 15 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’...
  • Page 16 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. •...
  • Page 17 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.
  • Page 18 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 19 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.
  • Page 20 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" •...
  • Page 21 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.

  • Page 22: Swing Beam Loading

    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.
  • Page 23 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 24'-9 " 8'-1" 4'-0" 9'-0" Rope Ladder Ladder Rad Ride 7 Slide 4'-10 " Swing Belts (2) 4'-10 8 " 9'-9 "...
  • Page 24 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)

  • Page 25: Part I Lower Level

    PART I 701-703 LOWER LEVEL...
  • Page 26 11-0073 701N Hardware REV C 9/19/2014JH #8 X 2" Page 1 of 2 WOOD SCREW QTY: 125 #8 X 2-1/2" WOOD SCREW QTY: 92 #8 X 3" #14 X 1-1/4" WOOD SCREW PAN HEAD SCREW QTY: 4 QTY: 20 #10 X 3-1/2" WOOD SCREW QTY: 15 3/8"...
  • Page 27 11-0073 3/8" X 5" 3/8" X 3-1/2" 701 Hardware HEX LAG SCREW HEX LAG SCREW QTY: 14 REV C QTY: 37 9/19/2014JH Page 2 of 2 #2 SQUARE QTY: 1 3/8" x 7" 3/8" x 5-1/2" PLASTIC 3/8 x 9" 3/8"...
  • Page 28 #8 x 1-1/4" WOOD SCREW 11-0074 QTY: 8 703N Hardware REV C #8 x 1-1/2" 9/19/2014 JH WOOD SCREW Page 1 of 1 QTY: 165 #8 X 2" WOOD SCREW QTY: 52 3/8 X 3-1/2" HEX LAG SCREW QTY: 4 3/8"...
  • Page 29 PICTURE DESCRIPTION QTY. 2 X 2 X 10-5/8" TIC TAC TOE BOARD 2-2-1063-TTTB 2 X 4 X 24" ROPE LADDER STEP 2-4-2400-RLST 2 X 4 X 30-3/4" BOTTOM PANEL THIS ITEM WONT BOARD BE USED ON THIS PLAYSET 2-4-3075-BPB 2 X 4 X 54-1/2" TARP BOARD 2-4-5450-TB 2 X 4 X 58"...
  • Page 30 PICTURE DESCRIPTION QTY. 2 X 6 X 41-1/4" DECK SPACER 2-6-4125-DS 2 X 6 X 50-3/4" DECK BOARD 2-6-5075-DB 2 X 6 X 78-3/4" INNER FORT SUPPORT 2-6-7875-IFS 2 X 6 X 79-1/4" OUTER FORT SUPPORT 2-6-7925-OFS 4 X 4 X 16" ANGLE SUPPORT LEFT...
  • Page 31 PICTURE DESCRIPTION QTY. 4 X 4 X 70" TIRE SWING SUPPORT 4-4-7000-TSS 4 X 4 X 74" ROCK WALL BOTTOM SUPPORT 4-4-7400-RWBS 4 X 4 X 80-1/4" LADDER LEFT SIDE 4-4-8025-LLS 4 X 4 X 80-1/4" LADDER RIGHT SIDE 4-4-8025-LRS 4 X 4 X 80-1/4"...
  • Page 32 PICTURE DESCRIPTION QTY. 4 X 4 X 108" SWING LEG 4-4-10800-SL 4 X 4 X 120" SIDE RAIL 4-4-12000-SR 4 X 4 X 120" SWING BEAM SIDE RAIL 4-4-12000-SBSR 4 X 6 X 108" SWING BEAM 4-6-10800-SB 5/4 X 4 X 28-1/2" PANEL SLAT ONLY 6 ITEMS WILL BE USED...
  • Page 33 PICTURE DESCRIPTION QTY. 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55" ROOF STARTER 1-5-5500-RS 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 1 X 6 X 55" ROOF PEAK 1-6-5500-RP 2 X 6 X 16" 2-6-1600-S 2 X 6 X 80-1/4"...
  • Page 34 PICTURE DESCRIPTION QTY. 4 X 4 X 61-1/4" CORNER POST FRONT HAS AN EXTRA HOLE HERE. CORNER POST FRONT/REAR 4-4-6125-CPF 4-4-6125-CPR 5/4 X 6 X 12" ROOF TRIANGLE 125-6-1200-RT 5/4 X 2 X 13" SMALL RAY 125-2-1300-SR 5/4 X 2 X 14" MEDIUM RAY 125-2-1400-MR 5/4 X 2 X 17"...
  • Page 35 PICTURE DESCRIPTION QTY. FLAG KIT 09-1014 GROUND STAKES (PAIR) 07-0016-P TRAPEZE W/CHAINS 04-0006 SWING W/CHAINS 04-0002...
  • Page 36 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS 07-0008 is a ROCKS pkg of 5) A-FRAME SWING BRACKET 11-5010 HARDWARE BOXES 701N & 703N HARDWARE BOXES 11-0073 11-0074...
  • Page 37 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGER 11-4012 TELESCOPE 07-0001 10' ROPE ROPE LADDER ROPES...
  • Page 38 PICTURE DESCRIPTION QTY. TIRE SWING 04-0014 SPRING CLIP 11-4003 TIRE SWIVEL 11-4010 TIC TAC TOE PANEL 07-0010...
  • Page 39 PICTURE DESCRIPTION QTY. UNASSEMBLED DORMER UNASSEMBLED CHIMNEY 01-3005 (705 BOX) STEERING WHEEL 07-0004 LADDER RUNG 1-5/16" X 21-1/2" 11-5106 SAFETY HANDLE 08-0001...

  • Page 40: Assembling The Ladder

    STEP 1: ASSEMBLING THE LADDER 1: START WITH THE 4 X 4 X 80-1/4" LADDER SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE FIVE HOLES AND THE FIVE CHANNELS ON THE INSIDE TO FACE EACH OTHER, AND THE ANGLED ENDS SHOULD BE FACING THE SAME WAY.
  • Page 41 STEP 2: ATTACHING THE ROPE LADDER RUNNER 1: FIND THE 4 X 4 X 97" ROPE LADDER RUNNER. TAKE SPECIAL NOTE OF THE ROUNDED EDGE ON THE 7/8" HOLES ON THE END OF THE ROPE LADDER RUNNER. 2: LINE UP THE TWO 3/8" PILOT HOLES ON THE ROPE LADDER RUNNER TO THE COUNTER-SUNK HOLES ON THE LADDER SIDE PIECES.
  • Page 42 STEP 3: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE LADDER ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE LADDER ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE LADDER SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT. CENTER THE COUNTER-SUNK HOLES ON THEIR RESPECTIVE BOARDS BEFORE ATTACHING.

  • Page 43: Assembling The Rock Wall

    STEP 4: ASSEMBLING THE ROCK WALL 1: START WITH THE 4 X 4 X 80-1/4" ROCK WALL SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE ANGLED ENDS TO FACE THE SAME WAY. IT SHOULD ALSO BE NOTED THAT THERE ARE TWO 3/8" HOLES JUST BELOW THE ANGLED ENDS.
  • Page 44 STEP 5: ASSEMBLING THE ROCK WALL 1: MEASURE 67" FROM THE BOTTOM OF EACH OF THE ROCK WALL SIDES AND MARK THIS LOCATION. 2: BEFORE INSTALLING BOARDS, MAKE SURE THAT THE ROCK WALL SIDES ARE SQUARE TO THE ROCK WALL BOTTOM SUPPORT.
  • Page 45 STEP 6: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE ROCK WALL ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE ROCK WALL ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE ROCK WALL SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT.
  • Page 46 STEP 7: INSTALLING OUTER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 79-1/4" OUTER FORT SUPPORTS. THE EASIEST WAY TO DIFFERENTIATE THE OUTER SUPPORTS FROM THE INNER SUPPORTS IS TO LOOK FOR THE COUNTER-SUNK HOLES AT 12-1/4" FROM EACH END. THE TWO BOARDS WITH THE HOLES CLOSEST TO THE BOTTOM (LONGER) SIDE ARE THE OUTER FORT SUPPORTS, THE BOARDS WITH THE HOLES CLOSEST TO THE TOP (SHORTER) SIDE ARE THE INNER FORT SUPPORTS.
  • Page 47 STEP 8: INSTALLING INNER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 78-3/4" INNER FORT SUPPORTS. 2: LINE UP THE 3/8" HOLE CLOSEST TO THE BOTTOM WITH THE BOTTOM HOLE OF THE INNER FORT SUPPORT. 3: ATTACH THE INNER FORT SUPPORT TO THE LADDER ASSEMBLY WITH 5/16 X 4" HEX BOLTS AND 5/16" WASHERS. 4: REPEAT STEPS 2 AND 3 TO FASTEN THE INNER FORT SUPPORT TO THE ROCK WALL ASSEMBLY.
  • Page 48 STEP 9: INSTALLING T-NUTS ON CORNER POSTS 1: FIND FOUR 4 X 4 X 61-1/4" CORNER POSTS. FRONT CORNER POSTS HAVE AN EXTRA HOLE AT 30-1/2" FROM THE BOTTOM. 2: USING THE DIAGRAM BELOW, INSTALL T-NUTS INTO THE APPROPRIATE HOLES. PLACE T-NUTS INTO THE HOLES OF THE CORNER POST AND SET WITH A HAMMER.
  • Page 49 STEP 10: INSTALLING CORNER POSTS 1: TAKE THE CORNER POSTS WITH THE T-NUTS INSTALLED FROM THE PREVIOUS STEP AND ARRANGE THE POSTS IN THEIR PROPER ORIENTATION. (SHOWN BELOW WITH NUMBERS TO REFERENCE THE PREVIOUS STEP) 2: THE CORNER POSTS SHOULD BE ORIENTED WITH THE COUNTER-SUNK HOLES FACING TOWARD EACH OTHER ON BOTH SIDES.
  • Page 50 STEP 11: ATTACHING THE SWING BEAM PLATE TO THE SWING BEAM SIDE RAIL 1: FIND THE 4 X 4 X 120" SWING BEAM SIDE RAIL. NOTE THE DIFFERENCE BETWEEN THE SWING BEAM SIDE RAIL AND THE SIDE RAIL. THE SWING BEAM SIDE RAIL WILL HAVE THREE MORE COUNTER SUNK HOLES ON ONE SIDE THAN THE SIDE RAIL.
  • Page 51 STEP 12: ATTACHING THE SWING BEAM SIDE RAIL 1: FIND TWO TORQUE WASHERS. PLACE A 7" CARRIAGE BOLT INSIDE THE TORQUE WASHER. PLACE THE TORQUE WASHER/CARRIAGE BOLT ASSEMBLY INTO THE HOLES OF THE CORNER POST SO THAT THE HEAD OF THE CARRIAGE BOLT IS INSIDE OF THE FORT.
  • Page 52 STEP 13: ATTACHING THE SIDE RAIL 1: TAKE THE 4 X 4 X 120" SIDE RAIL AND LINE UP THE PILOT HOLES IN THE CORNER POSTS WITH THE HOLES IN THE SIDE RAIL. 2: FASTEN THE SIDE RAIL TO THE FORT WITH 5/16 X 6" HEX BOLTS AND 5/16" WASHERS INTO THE T-NUTS OF THE CORNER POSTS.
  • Page 53 STEP 14: ATTACHING THE ROPE LADDER SUPPORT AND THE ROCK WALL ROPE SUPPORT 1: FIND THE 4 X 4 X 88" ROPE LADDER SUPPORT AND LAY IT ON TOP OF THE SIDE RAIL AND THE SWING BEAM SIDE RAIL ON THE LADDER SIDE OF THE FORT. 2: LINE UP THE COUNTER-SUNK HOLES OF THE ROPE LADDER SUPPORT WITH THE HOLES IN THE CORNER POSTS AND ATTACH WITH 5/16 X 6"...
  • Page 54 STEP 15: INSTALLING LAG SCREWS 1: MAKE SURE THAT THE UNIT IS LEVEL AND SQUARE. 2: STARTING AT THE INNER AND OUTER FORT SUPPORTS, USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS IN THE EMPTY HOLES ON THE 2 X 6 PARTS TO SECURE THE BASE OF THE FORT. 3: THE UPPER PART OF THE FORT NEEDS TO BE SECURED WITH 3/8 X 5"...

  • Page 55: Installing Rock Wall Boards

    STEP 16: INSTALLING ROCK WALL BOARDS 1: FIND ELEVEN 5/4 X 6 X 48" ROCK WALL BOARDS. 2: LAY THE ROCK WALL BOARDS ACROSS THE ROCK WALL SIDES. 3: ATTACH THE ROCKS WITH TWO 2" WOOD SCREWS PER END. 4: THE FINAL BOARD WILL BE THE 5/4 X 6 X 48" BOTTOM ROCK WALL BOARD WITH ONE HOLE IN THE CENTER. IT WILL ATTACH IN THE SAME MANNER AS THE OTHER ROCK WALL BOARDS.
  • Page 56 STEP 17: INSTALLING TARP BOARDS 1: FIND TWO 2 X 4 X 54-1/2" TARP BOARDS. 2: CENTER THE BOARD ACROSS THE ENDS OF THE SWING BEAM SIDE RAIL AND THE SIDE RAIL. 3: ATTACH THE TARP BOARDS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 4: REPEAT THIS PROCESS ON THE OPPOSITE SIDE OF THE FORT.
  • Page 57 STEP 18: DECK 1: FIND NINE 2 X 6 X 50-3/4" DECK BOARDS. 2: LAY THE DECK BOARDS ACROSS THE INNER FORT SUPPORTS, BETWEEN THE BOTTOM AND REAR BOTTOM PANEL BOARDS, AND INSIDE THE AREA BETWEEN THE CORNER POSTS. 3: FIND FOUR 2 X 6 X 41-1/4" DECK SPACERS. 4: LAY TWO DECK SPACERS ACROSS THE INNER FORT SUPPORTS ON THE LADDER AND ROCK WALL SIDES OF THE FORT.
  • Page 58 STEP 19: INSTALLING THE BOTTOM PANEL BOARDS 1: FIND TWO 2 X 4 X 58" REAR BOTTOM PANEL BOARDS. 2: LAY ONE BOARD ACROSS THE DECK ON THE SWING BEAM SIDE OF THE FORT, CENTERED BETWEEN THE TWO CORNER POSTS (INSTALL OUTSIDE). 3: ATTACH THE REAR BOTTOM PANEL BOARD WITH 3/8 X 3-1/2"...
  • Page 59 STEP 20: CENTER POSTS 1: TAKE THE 4 X 4 X 29-1/2" CENTER POSTS, AND LINE UP THE HOLE IN THE POSTS WITH THE THROUGH HOLE IN THE SWING BEAM SIDE RAIL/SIDE RAIL. 2: WHEN THE CENTER POST IS LINED UP PROPERLY, INSTALL A 5/16" T-NUT INTO THE HOLE IN THE CENTER POSTS. 3: FASTEN THE CENTER POSTS TO THE FORT WITH 5/16 X 6"...
  • Page 60 STEP 21: ROOF SUPPORT ASSEMBLIES 1: IF YOUR ROOF PEAK SUPPORTS ARE NOT PREDRILLED THEN DRILL 1/8" HOLES IN THEM TO THE PATTERN SHOWN BELOW. 2: PLACE THE ENDS OF THE ROOF SUPPORTS TOGETHER AS SHOWN BELOW. THE HOLES SHOULD BE ABOUT 55"...
  • Page 61 STEP 21A: ROOF SUPPORTS 1: HAVE AN ASSISTANT HELP YOU LIFT THE ROOF SUPPORT ASSEMBLIES ON TOP OF THE SIDE RAIL OR SWING BEAM SIDE RAIL. DO THEM ONE AT A TIME. 2: PLACE A RULER OR BOARD ON TOP OF THE SIDE RAILS TO CHECK AND MAKE SURE THERE IS NO INTERFERENCE WITH THE END TARP BOARDS.
  • Page 62 STEP 22: PANEL SLATS 1: FIND SIX 5/4 X 4 X 28-1/2" PANEL SLATS, AND ARRANGE THEM SO THAT THEY ARE EVENLY SPACED ACROSS THE SWING BEAM SIDE OF THE FORT. 2: ATTACH THE PANEL SLATS WITH TWO 2" WOOD SCREWS PER END. 5/4 X 4 X 28-1/2"...
  • Page 63 STEP 23: CENTER DECK SUPPORTS 1: FIND THE 4 X 4 X 70" TIRE SWING SUPPORT, AND ARRANGE EVENLY UNDERNEATH THE DECK. 2: ATTACH THE TIRE SWING SUPPORT WITH A 3/8 X 5" LAG SCREW AND A 3/8" WASHER THROUGH THE LADDER CENTER.
  • Page 64 STEP 24: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWING BEAM. 2: FASTEN THE IRON DUCTILES TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS AND WASHERS ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
  • Page 65 STEP 25: 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 LEG BRACKET 3/8 X 3-1/2"...
  • Page 66 STEP 26: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE FORT AND POSITION THE LEGS UNDERNEATH THE END OF THE BEAM. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND SWING LEGS.
  • Page 67 STEP 27: ATTACHING SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM LEG BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS UNDERNEATH. 2: USE A 3/8 X 3-1/2"...
  • Page 68 STEP 28: ATTACHING THE SWING BEAM TO THE FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: AFTER THE LEGS ARE ATTACHED, HAVE ONE PERSON ON THE GROUND PICK UP THE SWING BEAM BY THE LEGS, AND ANOTHER PERSON PICK UP THE SWING BEAM FROM INSIDE THE FORT AND WALK OUT THE SWING BEAM. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
  • Page 69 STEP 29: LEVEL THE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
  • Page 70 STEP 30: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 70" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS-MEMBER, AND FASTEN TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 2 X 4 X 70"...
  • Page 71 STEP 31: TIRE SWING 1: GO UNDER THE DECK. PLACE THE TIRE SWING SWIVEL ON THE TIRE SWING SUPPORT. CENTER THE TIRE SWING SWIVEL BELOW THE MIDDLE DECK BOARD. 2: MARK THE LOCATION OF THE HOLES IN THE SWIVEL WITH A PENCIL, AND WITH A 3/8" DRILL BIT, DRILL HOLES THROUGH THE TIRE SWING SUPPORT AND MIDDLE DECK BOARD.
  • Page 72 STEP 32: INSTALLING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. 2: THE ROCKS INCLUDED IN YOUR PLAYSET MAY VARY, IN ANY CASE, THE 1-1/4" PAN HEAD SCREWS WITH WASHERS WILL BE USED TO ATTACH THE ROCKS.
  • Page 73 STEP 33: CLIMBING ROPE 1: THREAD ONE END OF THE ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE A SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN ROPE TO AID IN CLIMBING. SET KNOTS ACCORDING TO YOUR CHILD'S NEEDS.
  • Page 74 STEP 34: ROPE LADDER ASSEMBLY 1: FIND THE THREE ROPE LADDER ROPES OF EQUAL LENGTH. MEASURE 30" FROM ONE SIDE OF EACH PIECE OF ROPE AND MAKE A MARK AT THIS LOCATION. 2: TIE A KNOT ON THE OTHER SIDE OF THE ROPE THAT IS JUST ABOVE THE MARK THAT WAS MADE ON THE ROPE (SEE BELOW).

  • Page 75: Installing The Rope Ladder

    STEP 35: INSTALLING THE ROPE LADDER 1: UNROLL THE ROPE LADDER ASSEMBLY. LOOK FOR THE BOARD THAT HAS KNOTS TIED ABOVE AND BELOW THE ROPE LADDER STEP. THIS WILL BE THE TOP OF THE ROPE LADDER. 2: THREAD THE TOP OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER SUPPORT, AND TIE A SECURE KNOT.
  • Page 76 STEP 36: ROOF COMPONENTS 1: USING A 1/8" DRILL BIT, DRILL HOLES IN THE ROOF COMPONENTS TO THE DIMENSIONS SHOWN BELOW. Rounded Edge " 1 X 5 X 55" ROOF STARTER " " Groove Side 16 " Tongue Side " 1 X 6 X 55"...
  • Page 77 STEP 37: ROOF PEAK 1: PLACE THE 55" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH WOOD SCREWS. 55" ROOF PEAK #8 X 1-1/4" WOOD SCREW PREDRILL 1/8" HOLES HERE THROUGH THE ROOF PEAK ONLY.
  • Page 78 STEP 38: ROOF 1: PLACE THE 1 X 6 X 55" 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 FOURTEEN ROOF BOARDS. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED OVER THE ROOF SUPPORTS.
  • Page 79 STEP 39: SUNBURST 1: PLACE THE 2 X 6 X 16" SUN CENTERED AGAINST THE 5/4 X 3 X 53" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2" WOOD SCREWS. REPEAT THIS PROCESS FOR THE OTHER SIDE OF THE FORT. 2 X 6 X 16"...
  • Page 80 STEP 40: SUNBURST 1: PLACE THE ASSEMBLY MADE IN A PRIOR 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 81 STEP 41: SUNBURST 1: CENTER THE 5/4 X 2 X 17" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS. IF YOU HAVE A 703N ROOF KIT THEN THE HOLES IN THE LARGE RAY ARE PRE-DRILLED AND ARE OFFSET TO THE SIDE ON EACH END. PROCEED TO SUBSTEP 2 IF YOU HAVE THESE.

  • Page 82: Roof Stringers

    STEP 42: ROOF STRINGERS 1: PLACE 5/4 X 3 X 78" ROOF STRINGER AGAINST THE UNDERSIDE OF THE ROOF BOARDS IN THE CENTER. 2: ATTACH ROOF STRINGER TO ROOF BOARDS WITH ONE #8 X 1-1/2" WOOD SCREW PER ROOF BOARD. 3: REPEAT FOR OTHER SIDE OF ROOF.
  • Page 83 STEP 43: 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 REAR CENTER POST ON THE SWING BEAM SIDE. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN.
  • Page 84 STEP 44: SAFETY HANDLES 1: FIND FOUR SAFETY HANDLES. 2: PLACE A SAFETY HANDLE JUST ABOVE THE ROCK WALL OPENING ON EACH SIDE, AND INSTALL WITH 1-1/4" PANHEAD SCREWS AND WASHERS. 3: REPEAT THIS PROCESS FOR THE LADDER SIDE OF THE FORT. SAFETY HANDLE 1-1/4"...
  • Page 85 STEP 45: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. IGNORE STEP 6 & 7 IN THE INSTRUCTIONS. 2: ATTACH THE TWO 1-3/8" X 1-5/8" X 10-1/2"L TIC TAC TOE BOARDS TO THE GREEN PLASTIC BRACKETS WITH THE 1"L PHILLIPS HEAD SCREWS PROVIDED IN THE TIC TAC TOE BOX.
  • Page 86 STEP 46: HANGING SWINGS 1: CLIP EACH OF THE SPRING CLIPS ONTO THE IRON DUCTILE SWING HANGERS, THEN CLIP ONTO THE SWING CHAINS. 2: USE THE CLIPS TO ADJUST THE HEIGHT OF THE SWING BY CLIPPING ON HIGHER OR LOWER LINKS. 3: COUNT BACK THE SAME NUMBER OF LINKS ON THE OPPOSITE SIDE TO ENSURE THAT THE SWING IS LEVEL, AND ADJUST TO FIT YOUR NEEDS.
  • Page 87 STEP 47: HANGING THE TIRE SWING 1: HANG THREE SPRING CLIPS FROM THE TIRE SWIVEL. 2: HANG ONE OF THE CHAINS IN ONE OF THE SPRING CLIPS AT THE DESIRED HEIGHT. 3: CONTINUE THE PROCESS WITH THE REMAINING CHAINS, MAKING SURE THAT THE TIRE SWING IS LEVEL WHEN FINISHED.
  • Page 88 STEP 48: 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.
  • Page 89 STEP 49: NAMEPLATE 1: ATTACH THE MANUFACTURER NAMEPLATE CENTERED ON THE FRONT OF YOUR SWING BEAM WITH TWO 2" WOOD SCREWS. PLACE NAME PLATE HERE AND ATTACH.
  • Page 90 PART II 721-723 UPPER LEVEL...
  • Page 91 721 HARDWARE PAGE 1 OF 2 2/6/2015 S.O. 3/8" WASHER QTY: 28 TORQUE WASHER 5/16 X 2-1/2" 5/16 X 1-1/2" QTY: 2 HEX BOLT HEX BOLT QTY: 2 QTY: 4 5/16" WASHER QTY:85 1/4" WASHER QTY: 7 5/16" X 3-1/2" 3/8 X 4-1/2"...
  • Page 92 721 HARDWARE PAGE 2 OF 2 2/6/2015 S.O. #8 X 2" WOOD SCREW QTY: 207 BLACK PLUG QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 49 #8 X 3" 5/16" TEE NUT WOOD SCREW QTY: 47 QTY: 9 3/8" LOCK NUT QTY: 2 PLASTIC BOLT CAP...
  • Page 93 723 HARDWARE #8 X 1-1/4" PAGE 1 OF 1 WOOD SCREW QTY: 14 2/5/2015 S.O. #8 X 1-1/2" WOOD SCREW QTY: 140 #8 X 2" WOOD SCREW QTY: 35 #8 X 2-1/2" WOOD SCREW QTY: 8 #8 X 3" WOOD SCREW QTY: 4 5/16"...
  • Page 94 PICTURE DESCRIPTION QTY. 5/4 X 4 X 23.88" DECK SPACER 125-4-2388-DS 5/4 X 4 X 51.25" DECK SPACER 125-4-5125-DS 5/4 X 4 X 58.13" DECK FILLER 125-4-5813-DF 5/4 X 6 X 22" SANDBOX SEAT 125-6-2200-SS 5/4 X 6 X 26" PANEL SLAT 125-6-2600-PS 5/4 X 6 X 30.5"...
  • Page 95 PICTURE DESCRIPTION QTY. 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-AS 2 X 4 X 19.38" LADDER STEP 2-4-1938-LS 2 X 4 X 21.5" ANGLE SUPPORT 2-4-2150-AS 2 X 4 X 27.55" LADDER RIGHT SIDE 2-4-2755-LLS 2 X 4 X 27.55" LADDER LEFT SIDE 2-4-2755-LRS...
  • Page 96 PICTURE DESCRIPTION QTY. 2 X 4 X 49.19" CENTER DECK SUPPORT 2-4-4919-CDS 2 X 4 X 49.19" DECK SUPPORT 2-4-4919-DS 2 X 4 X 58" FILLER PANEL BOARD 2-4-5800-FPB 2 X 4 X 58.38" SAFETY BAR 2-4-5838-SB 2 X 4 X 58.38" SANDBOX SAFETY BAR 2-4-5838-SBSB...
  • Page 97 PICTURE DESCRIPTION QTY. 2 X 6 X 31" SANDBOX BOARD/ BOTTOM PANEL BOARD 2-6-3100-SBBPB 2 X 6 X 58.38" TOP PANEL BOARD 2-6-5838-TPB 2 X 6 X 58.38" SANDBOX BOARD 2-6-5838-SBB 4 X 4 X 10.13" CENTER POST 4-4-1013-CP 4 X 4 X 21.13" DECK BLOCK 4-4-2113-DB 4 X 4 X 23.88"...
  • Page 98 PICTURE DESCRIPTION QTY. 4 X 4 X 42.28" CENTER POST 4 X 4 X 4228-CP 4 X 4 X 45.68" CENTER POST 4-4-4568-CP 4 X 4 X 58.38" DECK SUPPORT 4-4-5838-DS 4 X 4 X 38.88" CENTER POST 4-4-3888-CP 4 X 4 X 117.84" MIDDLE POST 4-4-11784-MP 4 X 4 X 121.88"...
  • Page 99 PICTURE DESCRIPTION QTY. 2 X 4 X 58" FILLER PANEL BOARD 2-4-5800-FPB 2 X 4 X 58.38" TARP BOARD 2-4-5838-TB 4 X 4 X 24.38" FILLER POST 4-4-2438-FP...
  • Page 100 PICTURE DESCRIPTION QTY. 1 X 3 X 11.25" WINDOW TOP & BOTTOM BOARD 1-3-1125-WTBB 1 X 4 X 10.5" WALL PANEL BOARD 1-4-1050-WPB 1 X 4 X 14.25" WALL PANEL BOARD 1-4-1425-WPB 1 X 4 X 17.75" WALL PANEL BOARD 1-4-1775-WPB 1 X 4 X 21.38"...
  • Page 101 PICTURE DESCRIPTION QTY. 1 X 4 X 65.38" ROOF FINISHER 1-4-6538-RF 1 X 5 X 65.38" ROOF PEAK 1-5-6538-RP 1 X 6 X 65.38" ROOF BOARD 1-6-6538-RB 5/4 X 2 X 8" RUN RAY 125-2-0800-SR 5/4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS...
  • Page 102 PICTURE DESCRIPTION QTY. 2 X 4 X 50.77" ROOF SUPPORT RIGHT 2-4-5077-RSR 2 X 6 X 13.63" 2-6-1363-S...
  • Page 103 PICTURE DESCRIPTION QTY. UNASSEMBLED DORMER 725 BOX RIDE SLIDE 03-0002...
  • Page 104 PICTURE DESCRIPTION QTY. PUNCHING 09-0002 SUPER SCOOP 03-0007...
  • Page 105 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGER 11-4012 SPRING CLIP 11-4003 90 GREEN BRACKET 11-5013 SAFETY HANDLE (PAIR) 07-0005...
  • Page 106 PICTURE DESCRIPTION QTY. WINDOW 07-0013 CROWN 07-0019 HARDWARE 721 & 723 HARDWARE BOXES BOXES...
  • Page 107 STEP 1: ATTACHING T-NUTS TO THE 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 117.84"...
  • Page 108 STEP 2: ASSEMBLING THE UPPER LEVEL SIDE FRAME 1: LAY THE POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 31.00 SANDBOX BOARD ON TOP OF THE CORNER POST AT THE BOTTOM. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN.
  • Page 109 STEP 3: SANDBOX BOARDS AND TOP PANEL BOARD YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE FRONT AND BACK SIDE ASSEMBLIES. 2: ATTACH ONE 2 X 6 X 58.38" SANDBOX BOARD TO THE BOTTOM OF THE POSTS OF BOTH FRAME ASSEMBLIES ON EACH SIDE , THE HOLES IN THE SANDBOX BOARDS MUST BE OFFSET UP.
  • Page 110 STEP 4: UPPER LEVEL UNDER DECK SUPPORTS 1: PLACE THE 4 X 4 X 58.38" UNDER DECK SUPPORT DIRECTLY UNDERNEATH THE DECK SUPPORTS. ATTACH THE UNDER DECK SUPPORT TO THE MIDDLE POSTS AND CORNER POSTS WITH 3/8" X 5" LAG SCREWS AND 3/8" WASHERS AS SHOWN IN THE DIAGRAM BELOW.
  • Page 111 STEP 5: CONNECTING THE DECK SUPPORTS 1: PLACE THE 2 X 4 X 49.19 DECK SUPPORTS AGAINST THE UPPER LEVEL MIDDLE POSTS AND THE PLAYSET CORNER POSTS UNDERNEATH THE SIDE RAIL. USE 5/16" X 4-1/2" HEX BOLTS TO ATTACH THE DECK SUPPORTS TO THE T-NUTS INSTALLED ON THE CORNER POSTS. 2: PLACE THE UPPER LEVEL FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE.
  • Page 112 STEP 6: UPPER LEVEL CORNER POSTS 1: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 2: USING THE DIAGRAM BELOW, LAY OUT BOTH 4 X 4 X 38.88 CORNER POSTS IN A FLAT SURFACE. 3: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW.
  • Page 113 STEP 7: SAFETY BAR 1: LAY THE 2 X 4 X 58.38" SAFETY BAR ON A FLAT SURFACE, USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. THE BARREL OF THE T-NUTS SHOULD GO IN THE HOLE FIRST.
  • Page 114 STEP 8: CENTER POST 1: LAY THE 4 X 4 X 45.68" CENTER POST ON A FLAT SURFACE, USE A HAMMER TO SEAT THE T-NUT AFTER INSERTING IT INTO THE HOLE SHOWN IN THE DIAGRAM BELOW. THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE SAFETY BAR.
  • Page 115 STEP 9: CENTER DECK SUPPORTS 1: PLACE THE THE 4 X 4 X 10.13" CENTER POST AGAINST THE 4 X 4 X 58.38" DECK SUPPORT, MAKING SURE IT IS FLUSH ON THE BOTTOM AND EQUALLY SPACED BETWEEN THE TWO CORNER POSTS.
  • Page 116 STEP 10: CONNECTING THE CENTER DECK SUPPORT PLACE THE 2 X 4 X 49.19" CENTER DECK SUPPORT (OFFSET DOWN) AGAINST THE 4 X 4 X 10.13" CENTER POST. THE 10" END SHOWN BELOW SHOULD BE ON TOP OF THE DECK SUPPORT ON THE UPPER LEVEL.
  • Page 117 STEP 11: ATTACHING DECK BLOCKS AND DECK SUPPORT 1: INSERT THE 4 X 4 X 21.13" DECK BLOCKS IN BETWEEN THE 2 X 4 CENTER DECK SUPPORTS AND THE 2 X 4 DECK SUPPORTS, UNDERNEATH THE PLAY SET SIDE RAIL. MAKE SURE THE C-BORE HOLES ARE FACING DOWN AND FASTEN TO THE SIDE RAIL USING 3/8"...
  • Page 118 STEP 12: CENTER POST AND CENTER DECK SUPPORT 1: MOUNT THE 4 X 4 X 42.28" CENTER POST IN BETWEEN THE TWO 2 X 4 CENTER DECK SUPPORTS AGAINST THE SAFETY BAR AND THE 4 X 4 DECK SUPPORT. THE COUNTERSUNK HOLE (WITH NO ROUNDED EDGES) SHOULD BE AT THE TOP AND THE DEEP C-BORE HOLE (WITH ROUNDED EDGES) SHOULD BE AT THE BOTTOM.USE A 5/16"...
  • Page 119 STEP 13: IRON DUCTILE 1: LINE UP THE HOLES OF THE IRON DUCTILE WITH THE HOLES IN THE CENTER DECK SUPPORT, THE IRON DUCTILE WILL BE ON THE BOTTOM. 2: FASTEN THE IRON DUCTILE TO THE SWING BEAM USING 3/8" X 4-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8"...

  • Page 120: Top And Bottom Panel Boards

    STEP 14: TOP AND BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 70.00" TOP PANEL BOARD ON THE TOP LOWER HOLES ON THE CORNER POSTS. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE END HOLES OF THE TOP PANEL BOARD TO THE T-NUTS INSTALLED IN THE CORNER POSTS.

  • Page 121: Deck Filler, Deck Spacers And Deck Boards

    STEP 15: DECK FILLER, DECK SPACERS AND DECK BOARDS 1: CENTER THE 5/4 X 4 X 58.13" DECK FILLER ABOVE THE DECK SUPPORTS, FLAT AGAINST THE MIDDLE POSTS AND CENTER POST. FASTEN USING #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE MIDDLE POSTS AND CENTER POST AS SHOWN BELOW.

  • Page 122: Angle Supports

    STEP 16: ANGLE SUPPORTS 1: FIND SIX 2 X 4 X 18.00" ANGLE SUPPORTS AND MOUNT THEM UNDER THE DECK ON THE FRONT, REAR AND SIDES OF THE FORT. THE TOP OF THE ANGLE SUPPORTS SHOULD BE FLUSH OR LOWER THAN THE BOTTOM OF THE DECK BOARDS.

  • Page 123: Bottom And Top Panel Boards

    STEP 17: BOTTOM AND TOP PANEL BOARDS 1: PLACE THE 2 X 6 X 31.00" SANDBOX BOARD/BOTTOM PANEL BOARD (OFFSET HOLES UP)(1) AT THE MIDDLE OF THE CORNER POST AND BOTTOM OF CENTER POST. USE A 5/16" X 4-1/2" HEX BOLT AND A 5/16"...
  • Page 124 STEP 18: LADDER 1: FIND FOUR 2 X 4 X 27.55" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 2 X 4 X 27.55" LADDER SIDE 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
  • Page 125 STEP 19: LADDER TO FORT 1: PLACE THE LADDERS INTO POSITION ON TOP OF THE LOWER LEVEL DECK RESTING AGAINST THE DECK BLOCKS BELOW THE SIDE RAIL. ATTACH USING #14 X 1" PAN HEAD SCREWS AND 1/4" WASHERS THROUGH THE HOLES IN THE LADDER BRACKETS INTO THE DECK BLOCKS. 2: UNDERNEATH THE DECK ATTACH THE DECK BOARDS TO EACH LADDER SIDE WITH #8 X 2-1/2"...

  • Page 126: Center Posts And Bottom Panel Board

    STEP 20: CENTER POSTS AND BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 42.50" BOTTOM PANEL BOARD ABOVE THE ROPE LADDER SUPPORT, CENTERED BETWEEN THE CORNER POST AND THE MIDDLE POST. USE 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS TO ATTACH THE BOTTOM PANEL BOARD TO THE POSTS. 2: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 68.00"...

  • Page 127: Panel Slats

    STEP 21: PANEL SLATS 1: FIND SIX 5/4 X 6 X 30.50" PANEL SLATS. 2: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE TOP AND BOTTOM PANEL BOARDS WITH #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES.

  • Page 128: Panel Slats

    STEP 22: PANEL SLATS 1: FIND FOUR 5/4 X 6 X 30.50" PANEL SLATS AND PLACE THEM AT THE FRONT OF THE FORT AGAINST THE TOP AND BOTTOM PANEL BOARDS. ATTACH WITH #8 X 2" WOOD SCREWS. 2: FIND FOUR 5/4 X 6 X 26.00" PANEL SLATS AND PLACE THEM AT THE REAR OF THE FORT AGAINST THE TOP AND BOTTOM PANEL BOARD LOCATED ABOVE THE ROPE LADDER SUPPORT.

  • Page 129: Sandbox Seats And Safety Bar

    STEP 23: SANDBOX SEATS AND SAFETY BAR 1:l MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE MIDDLE POSTS. ATTACH THE 2 X 4 X 58.38"...
  • Page 130 STEP 24: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 50.77" ROOF SUPPORT LEFT, TWO 2 X 4 X 50.77" ROOF SUPPORT RIGHT AND TWO 5/4 X 5 X 10.00" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP.

  • Page 131: Roof Assembly

    STEP 25: ROOF SUPPORTS 1: INSERT T-NUTS INTO THE UPPER HOLES OF THE CORNER POSTS FROM THE INSIDE OF THE FORT AND SET WITH A HAMMER. 2: PLACE THE ROOF SUPPORT ASSEMBLY OUTSIDE THE FORT AGAINST THE CORNER POSTS. ATTACH USING 5/16" X 4-1/2" HEX BOLT AND 5/16" WASHERS INTO THE COUNTERSUNK HOLES OF THE ROOF SUPPORTS INTO THE T-NUTS INSTALLED IN THE CORNER POSTS.
  • Page 132 STEP 26: ROOF STARTERS 1: PLACE THE 1 X 4 X 65.38" 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 133 STEP 27: ROOF PEAK 1: PLACE THE 1 X 4 X 65.38" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS. 1 X 4 X 65.38" ROOF PEAK #8 X 1-1/4"...
  • Page 134 STEP 28: ROOF BOARDS, ROOF FINISHER AND DORMER 1: PLACE THE 1 X 6 X 65.38" ROOF BOARDS ON TOP OF THE RIGHT SIDE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. THIS SIDE GETS EIGHT ROOF BOARDS. FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH #8 X 1-1/2"...
  • Page 135 STEP 29: SUNBURST 1: PLACE THE 2 X 6 X 13.63" SUN CENTERED ON TOP OF THE 2 X 4 X 31.19" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH #8 X 3" WOOD SCREWS. REPEAT THIS PROCESS FOR THE OTHER SIDE OF THE FORT.

  • Page 136: Sunburst Assembly

    STEP 30: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP CENTERED UNDERNEATH THE ROOF SUPPORTS. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP. 2: FASTEN THE SUN ASSEMBLY TO THE FORT WITH #8 X 2-1/2" WOOD SCREWS FROM THE BOTTOM INTO THE ROOF SUPPORTS.
  • Page 137 STEP 31: SUNRAYS 1: EQUALLY SPACE THE 5/4 X 2 X 8.00" SUNRAYS ABOUT THE HALF SUN (THREE ON EACH SIDE OF THE CENTER POST) AND MARK THE POSITION OF THE SMALL SUNRAYS WITH A PENCIL. 2: SECURE THE SUNRAYS ONE AT A TIME TO THE HALF SUN AND THE ROOF SUPPORT BEAMS AND LINE THEM UP WITH THE MARK DRAWN.
  • Page 138 STEP 32: WALL PANEL BOARDS 1: FIND TWO 1 X 3 X 11.25" WINDOW TOP/BOTTOM BOARDS AND PLACE THEM AGAINST THE TOP PANEL BOARD AND SUN SUPPORT, FOLLOW THE DIMENSIONS OF THE DIAGRAM BELOW AND ATTACH USING #8 X 1-1/2" WOOD SCREWS. NOTE: THE PREDRILLED HOLES MUST BE OFFSET UP FOR THE TOP BOARDS AND OFFSET DOWN FOR THE BOTTOM BOARDS.
  • Page 139 STEP 33: PLASTIC WINDOWS AND PLASTIC CROWN 1: FIND TWO PLASTIC WINDOWS, PLACE EACH WINDOW IN THE OPENING BETWEEN THE WALL PANEL BOARDS AND THE CENTER POST. MAKE SURE THE 1" WIDE SECTION OF THE WINDOW FRAME IS POSITIONED AT THE TOP. ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS.
  • Page 140 STEP 34: WALL PANEL BOARDS 1: FIND ONE 1 X 4 X 21.38" WALL PANEL BOARD AND PLACE IT NEXT TO THE PREVIOUSLY INSTALLED WALL PANEL BOARD LEAVING APPROXIMATELY A 1/4" GAP IN BETWEEN. MAKE SURE THE ANGLED END IS POINTING UP FOLLOWING THE ROOF SUPPORT PITCH.
  • Page 141 STEP 35: ATTACHING THE RAD RIDE TO THE FORT 1: REMOVE LAGS AND WASHERS FROM THE WALL PANEL (CENTER POST ONLY). 2: ASSEMBLE THE RAD RIDE ACCORDING TO THE INSTRUCTIONS PROVIDED. SEE BELOW FOR PLACEMENT OF YOUR SLIDE. 3: ATTACH THE ENTRY OF THE SLIDE TO THE FORT CORNER END CENTER POST. REPLACE THE REMOVED LAGS AND WASHER, INSERT 5/16"...

  • Page 142: Attaching The Super Scoop Slide

    STEP 36: ATTACHING THE SUPER SCOOP SLIDE 1: PLACE THE SUPER SCOOP SLIDE IN THE OPENING OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH #14 X 3" PAN HEAD SCREWS. ***DO NOT OVER TIGHTEN*** #14 X 3"...
  • Page 143 STEP 37: PUNCHING BAG 1: THE PUNCHING BAG COMES WITH A SHORT SECTION OF CHAIN ATTACHED TO IT WITH AN "S"- HOOK. 2: ATTACH THE END OF THE CHAIN TO THE IRON DUCTILE WITH A SPRING CLIP. IRON DUCTILE SPRING CLIP SWING CHAIN PUNCHING BAG...
  • Page 144 STEP 38: 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 ON THE REAR SIDE TOP PANEL BOARD. 2: PLACE THE TELESCOPE STAND AND THE TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET.
  • Page 145 STEP 39: SAFETY HANDLES (UPPER LEVEL) 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLE UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE UPPER LEVEL CORNER POSTS AND CENTER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.

  • Page 146: Flag Kits

    STEP 40: FLAG KITS 1: INSTALL THE FLAG KITS IN THE DESIRED LOCATION ON YOUR PLAY SET. THE RECOMENDED LOCATION IS ON THE SIDE RAIL BETWEEN THE LOWER AND UPPER LEVEL. ATTACH THE FLAG KITS WITH THE HARDWARE PROVIDED. ATTACH WITH PHILLIPS PAN HEAD SCREWS PROVIDED WITH THE FLAGS.
  • Page 147 APPENDIX...
  • Page 148 #8 X 1-1/4" WOOD SCREW QTY: 22 #8 X 1-1/2" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 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.
  • Page 149 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
  • Page 150 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
  • Page 151 PICTURE DESCRIPTION QTY. DORMER ROOF PEAK ASSEMBLY DORMER RIGHT SIDE ASSEMBLY DORMER SUNRAY ASSEMBLY...
  • Page 152 STEP 1: DORMER 1: FIND TWO LEFT SIDE AND TWO RIGHT SIDE DORMER ROOF ASSEMBLIES. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE LEFT AND RIGHT ROOF ASSEMBLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW. 4: ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1-1/4"...
  • Page 153 STEP 2: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/4" WOOD SCREWS. DORMER ROOF PEAK...
  • Page 154 STEP 3: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE A 2" WOOD SCREW TO FASTEN THE DORMER PEAK TO THE ROOF. 3: USE 1-1/2" WOOD SCREWS TO FASTEN THE FACE OF THE DORMER TO THE ROOF. USE A 2"...
  • Page 155 STEP 4: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW. USE A 2" WOOD SCREW IN THIS LOCATION CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY.
  • Page 156 STEP 5: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS. USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE) USE 1-1/4" WOOD SCREWS IN THIS LOCATION (EACH SIDE)
  • Page 157 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.

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