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Gorilla Playsets Riverview 801N User Manual

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Riverview
Model: 801N
(BOXES: 801N-1, 801N-2,
1513, RV, 120 & Slide Box
Copyright © 2015 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
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Summary of Contents for Gorilla Playsets Riverview 801N

  • Page 1 ™ ™ playsets playsets ™ ™ play sets play sets Riverview Model: 801N (BOXES: 801N-1, 801N-2, 1513, RV, 120 & Slide Box Copyright © 2015 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com...
  • 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 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 - RIVERVIEW - 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 strength and durability. OPTION 1 (678) 880-3329...
  • 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: 801N (BOXES: 801N-1, 801N-2, 1513, RV, 120 & Slide Box) REV: 3.17.2015...
  • Page 10 TABLE OF CONTENTS Safety Guidelines………………………………………..…......…....Pages 3-6 Le eling Fort General Information and De nitions..........Pages Ho to Install T Nuts Board Identi cation Predrill Lag Scre Directions and Swing Beam Loading..........…………………......Pages 9-13 Site Plan, Required Tool List and Kit Contents............Pages 14-15 Hard are Lum er and Accessory Chec lists............
  • Page 11 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 12 Safety and Maintenance Tips for Your New Play Set: (continued) Playgrounds should e inspected on a regular asis. If any of the follo ing conditions are noted they should e remo ed corrected or repaired immediately to pre ent in uries. •...
  • Page 13 Play Set Surfacing Recommendations: Belo are some of the recommendations that the U.S. Consumer Product Safety Commission CPSC offers from its Hand oo for Pu lic Playground Safety. The guide can e do nloaded in full at .cpsc.go /cpscpu /pu s/325.pdf 1.
  • Page 14 2. Fall Zones A fall one co ered ith a protecti e surfacing material is essential under and around e uipment here a child might fall. This area should e free of other e uipment and o stacles onto hich a child might fall. Stationary clim ing e uipment and slides should ha e a fall one e tending a Minimum of in all directions from the perimeter of the e uipment.
  • Page 15 General Info to Review Before Installation • Depending on your e perience assem ly of the playset can ta e as little as hours up to 24 hours depending on si e after in entory of parts therefore e recommend you set aside a full two days for assembly.
  • Page 16 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 e ill refer to parts ith offset holes. This refers to the orientation of the holes on the oard. An offset hole is one that is closer to one side than it is the other or in other ords it is not centered on the oard.
  • Page 17 Common Installation Practice Installing T-nuts When installing T nuts into the ood use a smooth faced hammer to set the face of the T nut ush into the ood. Corner Post T-nut Insert the arrel of the T nut into the predrilled hole.
  • Page 18 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 19 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 20 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 21 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 22 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 10'-1 8 " 5'10" Ladder 3'-1 16 " 2 " Swing Belts (2) 9'10 " 3'11 2 " Trape e Bar (1) 3'2"...
  • Page 23 REQUIRED TOOL LIST: Standard or Cordless Drill / Phillips Bit 2 s uare it pro ided Drill Bits 1/8 3/8 / 4 11/ 4 and a 7/8 Paddle style it. Wrench and Soc et Deep Well Soc et Deep Well Soc et Wrench and Soc et ___ Level ___ Tape Measure...
  • Page 24 5/16" X 3-1/2" 3/8 X 3-1/2" 11-0072 HEX LAG HEX LAG SCREW SCREW QTY: 24 QTY: 26 801N HARDWARE SHEET 1 OF 2 9/19/2014 JH #2 SQUARE DRIVE BIT QTY: 1 PLASTIC 3/8 x 9" 3/8 x 7" 3/8 x 3-1/2" 3/8 x 6-1/2"...
  • Page 25 11-0072 #8 X 1" 801N HARDWARE WOOD SCREW QTY: 8 SHEET 2 OF 2 #8 X 1-1/4" 9/19/2014 JH WOOD SCREW QTY: 24 #14 X 1-1/4" #8 X 1-1/2" PAN HEAD SCREW WOOD SCREW QTY: 16 QTY: 394 #8 X 2" WOOD SCREW QTY: 200 #8 X 2-1/2"...
  • Page 26 PICTURE DESCRIPTION QTY. 1 X 4 X 25" PANEL SLAT 1-4-2500-PS 1 X 4 X 26" FRONT PANEL SLAT 1-4-2600-FPS 1 X 4 X 51" REAR PANEL SLAT 1-4-5100-RPS 1 X 5 X 25" PANEL SLAT 1-5-2500-PS 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55"...
  • Page 27 PICTURE DESCRIPTION QTY. 1 X 6 X 14-1/4" FRONT PANEL SLAT 1-6-1425-FPS 1 X 6 X 16" TIC TAC TOE SUPPORT 1-6-1600-TTTS 1 X 6 X 17" PANEL SLAT 1-6-1700-PS 1 X 6 X 26" FRONT PANEL SLAT 1-6-2600-FPS 1 X 6 X 27-3/4" PANEL SLAT 1-6-2775-PS 1 X 6 X 29-1/2"...
  • Page 28 PICTURE DESCRIPTION QTY. 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 55" ROOF PEAK 1-6-5500-RP 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 15" PICNIC TABLE SUPPORT 2-4-1500-PTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 18"...
  • Page 29 PICTURE DESCRIPTION QTY. 2 X 4 X 23" BENCH SUPPORT 2-4-2300-BS 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 51" PICNIC TABLE SEATS AND TOP 2-4-5100-PTST 2 X 4 X 51-1/8" ROOF SUPPORT LEFT LEFT AND RIGHT 2-4-5113-RSL 2-4-5113-RSR RIGHT...
  • Page 30 PICTURE DESCRIPTION QTY. 2 X 4 X 70" CENTER DECK SUPPORT 2-4-7000-CDS 2 X 4 X 70" DECK SUPPORT 2-4-7000-DS 2 X 4 X 70" PANEL SUPPORT 2-4-7000-PS 2 X 6 X 13-5/8" 2-6-1363-S 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD 2-6-4750-ASTB 2 X 6 X 47-1/2"...
  • Page 31 PICTURE DESCRIPTION QTY. 2 X 6 X 67-1/4" SUNBURST BOARD 2-6-6725-SB 2 X 6 X 70" FRONT FACE BOARD 2-6-7000-FFB 2 X 6 X 70" FRONT TOP PANEL BOARD 2-6-7000-FTPB 2 X 6 X 70" REAR FACE BOARD 2-6-7000-RFB 2 X 6 X 70" REAR TOP PANEL BOARD 2-6-7000-RPTB...
  • Page 32 PICTURE DESCRIPTION QTY. 4 X 4 X 47-1/2" SWING BEAM MOUNT 4-4-4750-SBM 4 X 4 X 78" ROPE LADDER SUPPORT 4-4-7800-RLS 5/4 X 2 X 16" SMALL RAY 125-2-1600-SR 5/4 X 2 X 18" SMALL RAY 125-2-1800-SR 5/4 X 2 X 23" LARGE RAY 125-2-2300-LR 5/4 X 3 X 18-3/4"...
  • Page 33 PICTURE DESCRIPTION QTY. 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB 5/4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 4 X 4 X 108" PLASTIC COATED CORNER POST 4 X 4 X 108" PLASTIC COATED SWING LEG 4 X 6 X 120" PLASTIC COATED SWING BEAM 2 X 4 X 24"...
  • Page 34 Charleston - Accessories PICTURE DESCRIPTION QTY. WAVE SLIDE 03-0013 ROPE SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 35 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A PACK ROCKS OF 5 ROCKS) A-FRAME SWING BRACKET 11-5010 801N HARDWARE NOT SHOWN 11-0072...
  • Page 36 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 10' ROPE (ROCK WALL)
  • Page 37 PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 GROUND STAKES (PAIR) 07-0016 SAFETY HANDLES (PAIR) 07-0005...
  • Page 38 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY 1513 BOX UNASSEMBLED DORMER 1513 BOX BOXED TIC-TAC-TOE SPINNER PANEL 07-0010 FLAG KIT 09-1014...
  • Page 39 PICTURE DESCRIPTION QTY. CROWN CROWN 07-0019 WINDOW PANEL WINDOW PANEL 07-0013 STEERING WHEEL 07-0004 SUNBURST SCREEN 06-2001...
  • Page 40 STEP 1: ATTACHING THE T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE PLAY SET PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DISASSEMBLE THEN REASSEMBLE TO MAKE YOUR CORRECTIONS. MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS.
  • Page 41 STEP 2: 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 78" ROPE LADDER RUNNER ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 42 STEP 3: ASSEMBLING THE RIGHT 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" END SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 43 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"...
  • Page 44 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET 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 45 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR CORNER POSTS. THE HOLES IN THE SANDBOX BOARD ARE OFFSET UP. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHER TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 46 STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS.
  • Page 47 STEP 6B: ANGLE SUPPORTS 1: FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 48 STEP 7: 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 40-1/4" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/8" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 49 STEP 8: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: USE THE HOLE IN THE CENTER OF THE DECK SPACER AS A GUIDE TO DRAW A LINE ON THE OUTSIDE OF THE BOTTOM PANEL BOARD ON EACH SIDE OF THE PLAY SET.
  • Page 50 STEP 9: 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 DOWN AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16"...
  • Page 51 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. 2: START WITH A 5/4 X 6 X 47-1/2"...
  • Page 52 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 53 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 54 STEP 13: ROCK WALL 1: FASTEN THE 90 BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME. GREEN BRACKET 5/16" WASHER 5/16"...
  • Page 55 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND THIRTY 1/4" WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH THREE WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
  • Page 56 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT SIDE - RIGHT OF THE PLAY SET AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 BRACKETS AS A TEMPLATE;...
  • Page 57 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 58 STEP 17: LADDER TO PLAY SET 1: THE LADDER WILL ATTACH TO THE REAR OF THE PLAY SET. PLACE THE LADDER AGAINST THE BOTTOM PANEL BOARD CENTERED IN THE NOTCHED OUT AREA. 2: THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE BOTTOM PANEL BOARD.
  • Page 59 STEP 18: FRONT PANEL SLATS 1: FIND TWO 1 X 4 X 25" FRONT PANEL SLATS AND ONE 1 X 5 X 25" FRONT PANEL SLAT. 2: PREDRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3: INSTALL THE PANEL SLATS AS SHOWN ON THE FIGURE BELOW WITH THE 1 X 5 X 25"...
  • Page 60 STEP 19: SIDE PANEL SLATS 1: FIND ELEVEN 1 X 6 X 27-3/4" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END WITH TWO EQUALLY SPACED HOLES WITH A 1/8" DRILL BIT. 3. INSTALL THE PANEL SLATS AS SHOWN LEAVING 1/4" GAP BETWEEN EACH PANEL SLAT OR A 1/4" GAP BETWEEN THE CORNER POST AND PANEL SLAT.
  • Page 61 STEP 20: TIC TAC TOE SUPPORT 1:FIND THE TWO 1 X 6 X 16" TIC TAC TOE SUPPORT SLATS. 2: PRE-DRILL THE SLATS 2" FROM EACH END, AND 4" OVER FROM THE FIRST HOLE AS SHOWN ON THE DIAGRAM USING A 1/8" DRILL BIT. 3: INSTALL THE SLATS IN THE GAP LEFT FROM THE PREVIOUS INSTALLATION LEAVING A 3/4"...
  • Page 62 STEP 21: 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 ON THE TOP, AND 3/8"...
  • Page 63 STEP 22: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWING BEAM. 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 64 STEP 23: 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 65 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"...
  • Page 66 STEP 25: 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 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 67 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 68 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 THE 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.
  • Page 69 STEP 28: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" 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 70 STEP 29: ROOF SUPPORT 1: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE FORT WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. NOTE: THE ROOF PEAK SUPPORTS (TRIANGLES) SHOULD FACE OUT. ROOF PEAK SUPPORT ROOF PEAK SUPPORT FACES OUT FACES OUT 2 X 4 X 51-1/8"...
  • Page 71 STEP 30: ROOF 1: PLACE THE 1 X 5 X 55" 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 72 STEP 31: 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 EIGHT 1-1/4" WOOD SCREWS. 55" ROOF PEAK...
  • Page 73 STEP 32: ROOF 1: PLACE THE 1 X 6 X 55" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE 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" WOOD SCREWS. 3: PLACE A 1 X 5 X 55"...
  • Page 74 STEP 33: SUNBURST BOARD 1: FIND TWO 2 X 6 X 56-1/2" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS.
  • Page 75 STEP 34: BOTTOM SUNBURST BOARD 1: FIND TWO 2 X 6 X 67-1/4" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS.
  • Page 76 STEP 35: FRONT TOP PANEL SLATS 1: FIND SIX 1 X 6 X 26" AND TWO 1 X 4 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT THE DIMENSIONS SHOWN ON THE DIAGRAM.
  • Page 77 STEP 36: REAR PANEL SLATS 1: FIND FOUR 1 X 6 X 51" REAR PANEL SLATS AND TWO 1 X 4 X 51" REAR PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3.
  • Page 78 STEP 37: FINAL REAR PANEL BOARDS 1: FIND TWO 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS AND TWO 1 X 6 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS 3/4" FROM THE BOTTOM END AND 4" FROM THE TOP END WITH TWO HOLES EQUALLY SPACED WITH A 1/8"...
  • Page 79 STEP 38: WINDOW SUPPORTS 1: FIND THE SIX 1 X 6 X 4-1/2" BOTTOM WINDOW SUPPORTS. PRE-DRILL THREE 1/8" HOLES IN THE BOTTOM OF EACH SUPPORT AS SHOWN IN THE DIAGRAM. 2: PLACE TWO SUPPORTS IN EACH OF THE TWO OPENINGS IN THE FRONT OF THE FORT, AND THE FINAL TWO SUPPORTS IN THE OPENING AT THE REAR OF THE FORT.
  • Page 80 STEP 39: INSTALL WINDOWS 1: FIND FOUR WINDOW PANELS AND FOUR SUN PIECES. PLACE EACH WINDOW IN THE OPENING WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. TEST FIT THE SUN PIECES ABOVE THE WINDOW FRAME (THESE WILL BE INSTALLED LATER).
  • Page 81 STEP 40: INSTALL PANEL SLATS AND SUN PIECES 1: FIND EIGHT 1 X 6 X 14-1/4" FRONT PANEL SLATS AND EIGHT SUN PIECES. 2: PRE-DRILL EACH SLAT WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOW BELOW. 3: ATTACH THE PANEL SLATS AS SHOWN BELOW WITH THE BOTTOM OF THE SLAT RESTING UPON THE INSIDE FLANGE OF THE WINDOW FRAME.
  • Page 82 STEP 41: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. DISREGARD STEPS 6 & 7. 2: CENTER THE TIC TAC TOE PANEL BETWEEN THE SUPPORTS ON THE SIDE WALL AND ATTACH WITH EIGHT 1" WOOD SCREWS PROVIDED IN THE TIC TAC TOE BOX.
  • Page 83 STEP 42: SUNBURST 1: PRE-DRILL TWO 1/8" HOLES IN EACH SUN. THE HOLES WILL BE DRILLED NEAR THE OUTER EDGE ON EACH SIDE GOING STRAIGHT DOWN. 2: CENTER SUN ON THE PANEL BOARD AND ATTACH USING TWO 2" WOOD SCREWS. 3: REPEAT FOR OTHER SIDE OF FORT.
  • Page 84 STEP 43: SUNBURST 1: LOCATE TWO 5/4 X 2 X 23" LARGE RAYS, TWO 5/4 X 2 X 16" SMALL RAYS AND TWO 5/4 X 2 X 18" SMALL RAYS. 2: PRE-DRILL ALL SMALL RAYS AT 3/4" ON CENTER FROM EACH END WITH A 1/8" DRILL BIT. PRE-DRILL ALL LARGE RAYS 3/4"...
  • Page 85 STEP 44: SUNBURST 1: INSTALL SUNBURST SCREENS AS SHOWN BELOW, SO THAT IT IS FLUSH TO THE ROOF SUPPORTS. FASTEN EACH SCREEN WITH SIX 1-1/4" PAN HEAD SCREWS INTO THE GROMMETS IN THE SCREEN.
  • Page 86 STEP 45: PANEL SUPPORT 1: MEASURE 17-3/4" FROM THE BOTTOM OF THE SANDBOX BOARD ON THE FRONT FACE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. LINE UP THE TOP OF THE 2 X 4 X 70" PANEL SUPPORT WITH THE MARKS.
  • Page 87 STEP 46: SAFETY BOARD 1: MEASURE 17-3/4" FROM BOTTOM OF THE SANDBOX BOARD ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. 2: ALIGN THE TOP OF THE SAFETY PANEL BOARD WITH THE MARKS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH "OFFSET HOLES DOWN"...
  • Page 88 STEP 47: PICNIC TABLE 1: PLACE EACH OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORTS 15" OVER FROM THE CORNER POSTS. (SEE REAR VIEW) 2: MAKE SURE THE PICNIC TABLE VERTICAL SUPPORTS ARE SQUARE TO THE SANDBOX BOARDS. ATTACH THEM TO THE SANDBOX BOARDS FROM THE INSIDE USING TWO 2-1/2"...
  • Page 89 STEP 48: PICNIC TABLE 1: FIND TWO 2 X 4 X 15" PICNIC TABLE SUPPORTS. 2: ATTACH EACH PICNIC TABLE SUPPORT TO THE TOP OF THE PICNIC TABLE VERTICAL SUPPORT AND TO THE CORNER POSTS. 3: ATTACH EACH PICNIC TABLE SUPPORT TO THE PICNIC TABLE VERTICAL SUPPORT AND THE CORNER POST USING SIX 2-1/2"...
  • Page 90 STEP 49: PICNIC TABLE 1: FIND FIVE 2 X 4 X 51" PICNIC TABLE SEATS AND PICNIC TABLE TOP BOARDS. 2: ATTACH EACH BOARD WITH FOUR 2-1/2" WOOD SCREWS AS SHOWN BELOW TO CREATE THE PICNIC TABLE SEATS AND TOP. NOTE: LADDER AND ROCK WALL REMOVED FOR CLARITY.
  • Page 91 STEP 50: BOTTOM PANEL SLATS 1: FIND TWENTY 1 X 6 X 17" PANEL SLATS AND TWO 1 X 6 X 30" PANEL SLATS. 2: PRE-DRILL SLATS WITH TWO EQUALLY SPACED HOLES 1" FROM EACH END WITH A 1/8" DRILL BIT. 3: ATTACH PANEL SLATS ALONG THE SAFETY BOARDS AND PANEL BOARD EQUALLY SPACED.
  • Page 92 STEP 51: ARCHED SIDE TOP BOARDS 1: PLACE THE 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD UP AGAINST THE TOP OF THE CORNER POSTS ON THE SIDE OF THE FORT. 2: ATTACH THE ARCHED SIDE TOP BOARD WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3: ATTACH ANOTHER ARCHED SIDE TOP BOARD ON THE OPPOSITE SIDE OF FORT.
  • Page 93 STEP52: CHIMNEY/DORMER 1: USE THE INSTRUCTIONS IN THE APPENDIX AT THE BACK OF THIS MANUAL TO ASSEMBLE THE CHIMNEY AND DORMERS. 2: INSTALL THE CHIMNEY AND DORMERS AS SHOWN BELOW. USE THE HARDWARE SHOWN IN THE CHIMNEY AND DORMERS INSTRUCTIONS TO INSTALL THEM. CHIMNEY DORMER DORMER...
  • Page 94 STEP 53: 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 BOARDS. 2: THE FLARED END OF THE SLIDE WILL REST ON THE BOTTOM PANEL BOARD. 3: ATTACH THE SLIDE TO THE DECK WITH FOUR 1-1/4"...
  • Page 95 STEP 54: INSTALLING THE CLIMBING ROPE 1:DRILL A 7/8" HOLE THROUGH THE FRONT TOP PANEL BOARD (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. TIP: PLACE A SCRAP 2 X 4 OR 4 X 4 BLOCK BEHIND THE BACK SIDE OF WHERE THE HOLE IS GOING TO BE DRILLED. THIS SHOULD HELP TO PREVENT SPLITOUT ON THE BACK SIDE.
  • Page 96 STEP 55: PLASTIC FLAGS 1: FIND THE PLASTIC FLAG KIT. 2: ATTACH THE FLAGS TO THE FRONT CORNER POSTS AS SHOWN BELOW. 3: ATTACH EACH FLAG TO THE CORNER POST THROUGH THE PRE-DRILLED HOLES USING 1/2" PHILLIPS HEAD WOOD SCREWS PROVIDED WITH THE FLAG KIT. PLASTIC FLAG KIT PLASTIC FLAG KIT...
  • Page 97 STEP 56: MOUNTING TELESCOPE 1: PLACE THE TELESCOPE ASSEMBLY ON THE ROPE LADDER SUPPORT ABOVE THE TIC TAC TOE PANEL. USING THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE ROUND TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT. 2: PLACE THE TELESCOPE STAND INTO THE SLOT OF THE TELESCOPE BRACKET.
  • Page 98 STEP 57: 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 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.
  • Page 99 STEP 58: ATTACHING THE SAFETY HANDLES 1: LOCATE TWO SAFETY HANDLES PROVIDED WITH YOUR PLAYSET. 2: LOCATE THE HARDWARE PROVIDED IN THE BAG WITH THE HANDLES. **DO NOT USE THE SCREWS PROVIDED IN THE BAG WITH THE HANDLES** 3: LOCATE FOUR #14 X 1" LONG PAN HEAD SCREWS IN YOUR MAIN HARDWARE PACKAGE. USE THE 1/4" FLAT WASHERS PROVIDED IN THE BAG WITH THE HANDLES.
  • Page 100 STEP 59: 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 BY CLIPPING CHAINS ON HIGHER OR LOWER LINKS. TRAPEZE BAR W/CHAINS SWING BELT...
  • Page 101 STEP 60: ROPE LADDER VIEW OF COMPLETED ROPE LADDER ASSEMBLY. THE NEXT STEP SHOWS YOU HOW TO ASSEMBLE THIS. THESE BEAD SHAPES REPRESENT KNOTS THAT YOU WILL TIE...
  • Page 102 STEP 61: ROPE LADDER 1: FIND THREE ROPE LADDER ROPES. MAKE A KNOT IN THE END OF EACH ROPE AND THREAD THE FREE END THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT. PULL EACH ROPE TAUGHT. 2: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 6 INCHES AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 6 INCHES BELOW THE ROPE LADDER SUPPORT.
  • Page 103 STEP 62: CROWN 1: PLACE THE CROWN OVER THE WOOD SUN PIECE ON THE FRONT OF THE PLAY SET. 2: ATTACH THE CROWN TO THE SUN WITH TWO #8 X 1-1/2" WOOD SCREWS. #8 X 1-1/2" WOOD SCREWS CROWN...
  • Page 104 STEP 63: GROUND STAKES 1: HAMMER GROUND STAKES INTO THE GROUND AT AN ANGLE BESIDE THE SWING LEGS AS SHOWN BELOW. 2: FASTEN EACH GROUND STAKE TO THE SWING LEG WITH THE #8 X 2" SCREW PROVIDED. DETAIL A SCALE 1 : 9 GROUND STAKE 2"...
  • Page 105 STEP 64: NAME PLATE 1: PLACE THE MANUFACTURER'S NAME PLATE CENTERED ON THE SWING BEAM. 2: FASTEN THE NAME PLATE TO THE SWING BEAM WITH TWO #8 X 1-1/2" WOOD SCREWS. PLACE NAME PLATE HERE AND SECURE WITH SCREWS.
  • Page 106 APPENDIX...
  • Page 107 #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 108 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
  • Page 109 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
  • Page 110 PICTURE DESCRIPTION QTY. DORMER ROOF PEAK ASSEMBLY DORMER RIGHT SIDE ASSEMBLY DORMER SUNRAY ASSEMBLY...
  • Page 111 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 112 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 113 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 114 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 115 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 116 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.