Gorilla Playsets 1500CWR Manual
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Gorilla Playsets 1500CWR Manual

Boxes: 1501, 1512, 1528, 1529, extreme tube slide box, x1, 120 & slide box
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play sets
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Malibu Extreme
Model: 1500CWR
(BOXES: 1501, 1512, 1528,
1529, Extreme Tube Slide Box,
Copyright © 2015 Gorilla Playsets
190 Etowah Industrial Court
www.gorillaplaysets.com
playsets
playsets
X1, 120 & Slide Box)
All Rights Reserved
Canton, GA 30114
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  • Page 1 ™ ™ play sets play sets Malibu Extreme Model: 1500CWR (BOXES: 1501, 1512, 1528, 1529, Extreme Tube Slide Box, X1, 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: Important 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 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 190 Etowah Industrial Court...
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 7: Important - Please Read

    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: Important Documents

    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: 1500CWR (BOXES: 1501, 1512, 1528, 1529, Extreme Tube Slide Box, X1, 120 & Slide Box) REV: 3.26.2015...
  • 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 ..Pages 1 35 Adding T-Nuts to Corner Posts...…………………………………..………...…...
  • 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

    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-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 MAXIMUM SWING BEAM LOAD IS 425 LBS.
  • Page 22 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 20'-10 8 " 10'-1 8 " 4'-11 8 " 5'-10" Ladder 3'-1 8 " 2'-8" Swing Belt (2) 3'-11 2 " Trape e 1 14'-4 "...

  • Page 23: Required Tool List

    REQUIRED TOOL LIST: Standard or Cordless Drill / Phillips Bit 2 s uare it pro ided Drill Bits 1/8 3/1 / 4 11/ 4 . Wrench and Soc et Deep Well Soc et Deep Well Soc et Wrench and Soc et ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill)
  • Page 24 1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" #8 X 1-3/4" PAN HEAD SCREW WOOD SCREW QTY: 4 QTY: 4 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 #8 X 3"...
  • Page 25 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 1501 HARDWARE PAGE: 2 OF 2 REV A: 9/10/2014 JH #2 SQUARE DRIVE BIT QTY: 1 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" 3/8 x 9"...
  • Page 26 1512 HARDWARE PAGE: 1 OF 1 REV A 1/16/2014 J.H. #8 X 2" WOOD SCREW QTY: 35 #8 X 2-1/2" WOOD SCREW QTY: 6 #8 X 3" WOOD SCREW QTY: 3 5/16" TEE NUT QTY: 10 5/16 X 4-1/2" 5/16" X 3-1/2" HEX BOLT LAG SCREW QTY: 10...
  • Page 27 1528 HARDWARE #8 X 1" PAGE 1 OF 1 WOOD SCREW QTY: 2 1/16/2015 SO. #8 X 1-1/4" WOOD SCREW QTY: 25 #8 X 1-1/2" WOOD SCREW QTY: 110 #8 X 2" WOOD SCREW QTY: 25 #8 X 2-1/2" WOOD SCREW QTY: 12 #2 SQUARE DRIVE BIT...
  • Page 28 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 14-3/4" PICNIC TABLE TOP SUPPORT 2-4-1475-PTTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 21-1/2" END PANEL BOARD 2-4-2150-EPB...

  • Page 29: Description Qty

    PICTURE DESCRIPTION QTY. 2 X 4 X 28-9/16" CENTER POST FRONT/REAR 2-4-2856-CPFR 2 X 4 X 32-1/2" PICNIC TABLE 2-4-3250-PTL 2 X 4 X 35.15" ROOF SUPPORT LEFT (1 HOLE OFFSET) 2-4-3515-RSL 2-4-3515-RSR RIGHT 2 X 4 X 47 " BOTTOM PANEL/ SAFETY BOARD (2 HOLES OFFSET)
  • Page 30 PICTURE DESCRIPTION QTY. 2 X 4 X 70" DECK SUPPORT (2 HOLES ON CENTER) 2-4-7000-DS 2 X 4 X 70" REAR TOP PANEL BOARD (2 HOLES OFFSET/ 1 CENTERED) 2-4-7000-RTPB 2 X 4 X 69-3/4" ROOF FINISHER SUPPORT (2 HOLES ON CENTER) 2-4-6975-RFS 2 X 4 X 70"...
  • Page 31 PICTURE DESCRIPTION QTY. 2 X 6 X 70" BOTTOM PANEL AND SANDBOX BOARD (4 HOLES OFFSET) 2-6-7000-SB 2 X 6 X 70" FRONT TOP PANEL BOARD (4 HOLES OFFSET, 1 CENTER) 2-6-7000-FTPB 2 X 6 X 70" REAR FACE BOARD (4 HOLES OFFSET) 2-6-7000-RFB 2 X 6 X 79-1/2"...
  • Page 32 PICTURE DESCRIPTION QTY. X 13 " PICNIC TABLE SLAT 125-3-1325-PTS X 17 " TIC TAC TOE MOUNT 125-3-1750-TTTM X 28 " PANEL SLAT 125-3-2825-PS X 33" PANEL SLAT 125-3-3300-PS X 4 X 14 " DECK SPACER 125-4-1450-DS X 4 X 22 "...
  • Page 33 PICTURE DESCRIPTION QTY. X 3 X 23 " ROCK WALL CAP 125-3-2387-RWC X 4 X 40 " DECK SPACER 125-4-4038-DS X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS X 5 X 10.81" ROOF PANEL PEAK SUPPORT 125-5-1081-RPPS X 6 X 22" SANDBOX SEAT 125-6-2200-SS X 6 X 23...
  • Page 34 PICTURE DESCRIPTION QTY. X 6 X 43" PICNIC TABLE TOP AND SEATS 125-6-4300-PTTS X 6 X 47 " DECK BOARD 125-6-4737-DB 1 X 2 X 32" ROOF BATTEN 1-2-3200-RB 1 X 4 X 8-3/4" WALL PANEL BOARD 1-4-0875-WPB 1 X 4 X 12-1/4" WALL PANEL BOARD 1-4-1225-WPB...
  • Page 35 PICTURE DESCRIPTION QTY. 1 X 4 X 29.29" LEFT TONGUE-ONLY ROOF FINISHER FRONT 1-4-2929-RFF RIGHT 1 X 4 X 76-7/8" GROOVE-ONLY ROOF STARTER REAR 1-4-7688-RSR 1 X 4 X 76-7/8" GROOVE-ONLY ROOF STARTER FRONT 1-4-7688-RSF 1 X 4 X 76-7/8" TONGUE-ONLY ROOF FINISHER REAR...
  • Page 36 PICTURE DESCRIPTION QTY. PLASTIC COATED 4 X 6 X 120" SWING BEAM SB-3-0 4 X 4 X 40" END WALL SLIDE MOUNT 4-4-4000-EWSM 2 X 4 X 29-1/4" SLIDE HEADER BOARD 2-4-2925-SHB COUNT AND ORGANIZE YOUR LUMBER INTO LIKE STACKS (2 X 4, 2 X 6, 4 X 4, 4 X 6, ETC.). THIS WILL HELP IN IDENTIFYING COMPONENTS AND REDUCE YOUR BUILDING TIME...
  • Page 37 PICTURE DESCRIPTION QTY. WAVE SLIDE 03-0013 ROPE LADDER ROPES SWINGS W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 38 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A PACK ROCKS OF 5) A-FRAME SWING BRACKET 11-5010 HARDWARE HARDWARE BOXES: 1501,1528,1512 BOXES...
  • Page 39 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 ROCK WALL ROPE...
  • Page 40 PICTURE DESCRIPTION QTY. 90 GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...

  • Page 41: Solar Wall Light

    PICTURE DESCRIPTION QTY. FRONT PLASTIC ARCH 07-0027-G PLASTIC SUNBURST 07-0028-G DORMER WINDOW 07-0029-G SOLAR WALL LIGHT 09-2003...
  • Page 42 PICTURE DESCRIPTION QTY. MANUFACTURER (NOT SHOWN) LOGO PLATE GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004 UNASSEMBLED DORMER (1529 BOX) UNASSEMBLED CHIMNEY (1529 BOX OR SLIDE BOX)
  • Page 43 PICTURE DESCRIPTION QTY. EXTREME TUBE SLIDE 03-0014...

  • Page 44: Step 1: Attaching T-Nuts To The Corner Posts

    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 108"...
  • Page 45 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 79-1/2" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2"...
  • Page 46 STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: 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. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2"...

  • Page 47: Step 4: Deck Supports

    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.

  • Page 48: Step 5: Front Frame Assembly

    STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS AT THE BOTTOM. THE HOLES IN THE SANDBOX BOARD MUST 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 49: Step 6: Rear Frame Assembly

    STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST 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 50 STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE THREE 2 X 6 BOARDS AT DECK HEIGHT AND THE ROPE LADDER SUPPORT AT THIS TIME. SQUARE EACH OF THESE THREE BOARDS TO THE POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS.
  • Page 51 STEP 6B: ANGLE SUPPORTS 1: TWO 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT SIDE OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.

  • Page 52: Lag Screw

    STEP 7: BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 47-1/2" 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 53 ! ATTENTION ! IN THE FOLLOWING THREE STEPS YOU WILL BEGIN THE INSTALLATION OF THE DECK SPACERS AND DECK BOARDS. IF YOU HAVE DIFFICULTY GETTING THE DECK BOARDS/DECK SPACERS TO FIT BETWEEN THE FRONT FACE BOARD AND REAR FACE BOARD DO THE FOLLOWING: 1: LOOSEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET.
  • Page 54 STEP 8: DECK SPACER AND DECK BOARD 1: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER BETWEEN THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. FASTEN THE DECK SPACER TO THE DECK SUPPORTS WITH FOUR 2" WOOD SCREWS. 2: PLACE THE 5/4 X 6 X 47-3/8"...
  • Page 55 STEP 9: END WALL SLIDE MOUNT POST 1: FIND THE 4 X 4 X 40" END WALL SLIDE MOUNT POST. 2: MEASURE 26" INCHES FROM THE FRONT OF THE FRONT RIGHT CORNER POST AND MARK THE MEASUREMENT ON THE INSIDE OF THE 2 X 6 X 79-1/2" ROPE LADDER SUPPORT. MEASURE DOWN 2" FROM THE TOP OF THE ROPE LADDER SUPPORT AND MARK THE MEASUREMENT ON THE INSIDE.

  • Page 56: Top View

    STEP 10: DECK SUPPORTS 1: PLACE TWO 2 X 4 X 70" DECK SUPPORTS UNDER THE DECK BOARD/DECK SPACER AND BESIDE THE POST. HAVE AN ASSISTANT HOLD UP THE END OF THE DECK SUPPORT ON THE LEFT END. THE LEFT END SHOULD BE FLUSH AGAINST THE 2 X 6 BOTTOM PANEL BOARD.
  • Page 57 STEP 10A: 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. THE HOLES AT 22-1/8" & 17-3/8" ONLY NEED TO BE DRILLED ONCE.

  • Page 58: Step 11: Rock Wall

    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 59 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 60 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 61 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
  • Page 62 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8”...
  • Page 63 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 T-NUT SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE...
  • Page 64 STEP 17: LADDER TO FORT 1: CENTER THE LADDER IN THE OPENING OF THE REAR FACE BOARD ON THE REAR OF THE FORT AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE REAR ENTRY BOARD. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8”...
  • Page 65 STEP 18: CENTER POST FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF EACH 2 X 4 X 28-9/16" CENTER POST FRONT/REAR. 2: PLACE THE CENTER POST INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET. LINE UP THE HOLES IN THE CENTER POSTS WITH THE HOLES IN THE RAILINGS. 3: FASTEN THE CENTER POSTS TO THE RAILINGS WITH 5/16"...

  • Page 66: Step 19: Panel Slats

    STEP 19: PANEL SLATS 1: FIND THIRTEEN 5/4 X 2-5/8 X 28-1/4" 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 67: Step 20: Swing Beam Plate

    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 ON TOP, AND 3/8" LOCK NUTS WITH 3/8"...
  • Page 68 STEP 21: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWINGBEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 7"...
  • Page 69 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 70 STEP 23: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE TOP OF THE FORT RAILINGS.THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM.
  • Page 71 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 72 STEP 25: MOUNT SWING BEAM ON FORT *AN EXTRA PERSON IS REQUIRED 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 HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
  • Page 73 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 74 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 75 STEP 28: ROOF SUPPORTS 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 35.15" 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 2-1/2"...

  • Page 76: Step 29: Roof Peak Support

    STEP 29: ROOF PEAK SUPPORT 1: PLACE THE 5/4 X 6 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 2" WOOD SCREWS.
  • Page 77 STEP 30: ROOF STARTER REAR 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER REAR AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER SHOULD BE PLACED FLUSHED TO THE PEAK OF THE ROOF SUPPORT.
  • Page 78 STEP 31: ROOF REAR SECTION AND CHIMNEY 1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR. THIS SIDE OF THE ROOF GETS SEVEN ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 79 STEP 32: ROOF FRONT SECTION 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPPING THE ROOF STARTER REAR. THE HOLES IN THE ROOF STARTER FRONT SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER FRONT SHOULD BE PLACED FLUSH TO THE TOP EDGE OF THE ROOF STARTER REAR.
  • Page 80 STEP 33: DORMERS 1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE DORMERS. AFTER INSTALLING THE SEVENTH ROOF BOARD NSTALL THE DORMER MOUNTING BLOCK 9-3/4" FROM THE SIDE EDGE OF THE ROOF TO THE SIDE EDGE OF THE DORMER MOUNTING BLOCK, AND 15" FROM THE BOTTOM OF THE SEVENTH ROOF BOARD TO THE TOP EDGE OF THE DORMER MOUNTING BLOCK.
  • Page 81 STEP 34: FRONT GABLE ASSEMBLY 1: FIND ONE 5 X 11 X 46.97" ROOF PANEL LEFT ASSEMBLY, ONE 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY, ONE 5/4 X 5 X 10.81 ROOF PANEL PEAK SUPPORT AND A FRONT PLASTIC ARCH. 2: PLACE THE ROOF PANEL ASSEMBLIES ON A FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP, ALIGN THE ANGLED ENDS OF THE ROOF PANEL ASSEMBLIES FLUSH AT THE PEAK AND LEAVING A GAP AT THE BOTTOM OF THE SEAM, THIS PROVIDES YOU FREEDOM FOR ADJUSTABILITY.
  • Page 82 STEP 35: ATTACHING THE FRONT GABLE 1: MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE TOP PANEL BOARD, MAKE SURE THE GABLE ASSEMBLY IS FLUSH AGAINST THE FRONT CORNER POSTS. THE GABLE ROOF PEAK SHOULD BE RESTING ON TOP OF THE ROOF FRONT SECTION.
  • Page 83 STEP 36: WALL PANEL SUPPORTS 1: PLACE THE 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE AND THE OPPOSITE END WITH THE COUNTERSUNK HOLE FLUSH AGAINST THE LEFT FRONT CORNER POST. MAKE SURE THE ANGLED END OF THE WALL PANEL SUPPORT IS FLUSH TO THE INSIDE OF THE GABLE ASSEMBLY.
  • Page 84 STEP 37: ROOF FINISHERS FRONT 1: PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE. PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT ANGLED END ON TOP OF THE GABLE ASSEMBLY RIGHT SIDE. FIT THE TONGUE END INTO THE GROOVE OF THE ROOF BOARD ABOVE THEM.
  • Page 85 STEP 38: ROOF BATTEN 1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE ROOF PANEL, CENTERED BETWEEN THE ROOF SUPPORTS, FLUSH THE BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD, MAKE SURE IT IS PARALLEL TO THE ROOF SUPPORTS.

  • Page 86: Step 39: Wall Panel Boards

    STEP 39: WALL PANEL BOARDS 1: START MOUNTING THE 1 X 4 X 19.31" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT. THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE FRONT LEFT CORNER POST.

  • Page 87: Step 40: Plastic Sunburst

    STEP 40: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF, THE PLASTIC SUNBEAM MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2"...

  • Page 88: Step 41: Hanging The Swings

    STEP 41: 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 89: Step 42: Safety Board

    STEP 42: 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 90: Step 43: Picnic Table

    STEP 43: PICNIC TABLE 1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS. 2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4"...
  • Page 91 STEP 44: PICNIC TABLE 1: MEASURE 26-3/8” FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8" 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3"...

  • Page 92: Wood Screws

    STEP 45: PICNIC TABLE 1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS. 2: CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS. 3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS. 5/4 X 6 X 43"...

  • Page 93: Step 46: Rope Ladder

    STEP 46: 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 14" AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 14 INCHES BELOW THE ROPE LADDER SUPPORT.
  • Page 94 STEP 47: EXTREME TUBE SLIDE 1: ASSEMBLE THE EXTREME TUBE SLIDE (SEE INSTRUCTIONS ENCLOSED IN EXTREME TUBE SLIDE BOX.) 2: USE STEP 47A TO ATTACH THE SLIDE TO THE PLAY SET. PLACE A PLASTIC "T-SHAPED" PLUG IN THE HOLE IN THE CORNER POST HERE BEFORE MOUNTING THE SLIDE TO THE PLAY SET IN THE NEXT STEP.
  • Page 95 STEP 47A: ATTACHING THE SLIDE TO THE FORT 1: ATTACH SLIDE ENTRY ASSEMBLY TO THE CORNER POST AND CENTER POST OF THE FORT WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" FENDER WASHERS. 2: DO NOT ATTACH THE BOTTOM RIGHT HOLE OF THE SLIDE ENTRY PLATE AT THIS TIME. 5/16"...
  • Page 96 STEP 47B: SLIDE PANEL 1: FIND THE 2 X 4 X 21-1/2" END PANEL BOARD, AND THE 2 X 6 X 21-1/2" END PANEL BOARD. 2: PLACE THE 2 X 6 X 21-1/2" BOTTOM PANEL BOARD AGAINST THE CORNER POST WITH OFFSET HOLES DOWN, AND MOUNT THE BOTTOM RIGHT HOLE WITH A 5/16 X 4-1/2"...
  • Page 97 STEP 47C: ATTACHING SLIDE HEADER BOARD 1: PLACE THE 2 X 4 X 29-1/4" SLIDE HEADER BOARD BETWEEN THE SLIDE AND THE ROPE LADDER SUPPORT. ATTACH SLIDE HEADER BOARD TO POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2 X 4 X 29-1/4"...
  • Page 98 STEP 48: ANGLE SUPPORTS ON TUBE SLIDE SIDE 1: TWO 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE RIGHT SIDE (TUBE SLIDE SIDE). 2: FOR THE ANGLE SUPPORT AT THE RIGHT REAR USE TWO 2-1/2" WOOD SCREWS THROUGH THE TOP OF THE BRACE INTO THE 2 X 6 X 21-1/2"...
  • Page 99 STEP 49: WAVE 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: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK WITH 1-1/4"...
  • Page 100 STEP 50: INSTALLING THE ROCK WALL ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE FRONT TOP PANEL BOARD. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.

  • Page 101: Step 51: Safety Handles

    STEP 51: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL CENTER POST OR CORNER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
  • Page 102 STEP 52: 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 SLIDE SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET.
  • Page 103 STEP 53: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 3: LOCATE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS.
  • Page 104 STEP 54: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE PLAY SET ON THE INSIDE. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS.

  • Page 105: Step 55: Sandbox Seats And Name Plate

    STEP 55: SANDBOX SEATS AND NAME PLATE 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET.

  • Page 106: Step 56: Solar Wall Lights

    STEP 56: SOLAR WALL LIGHTS 1: WITH A PENCIL MAKE A CENTER MARK ON THE OUTSIDE FACE OF THE 1 X 4 X 19.31 WALL PANEL BOARD, MEASURE 4-7/8" HORIZONTALLY FROM THE OUTSIDE EDGE OF THE CORNER POST TOWARDS THE CENTER OF THE WALL PANEL BOARD AND 2-3/8" FROM THE BOTTOM EDGE OF THE WALL PANEL SUPPORT TOWARDS THE CENTER OF THE WALL PANEL BOARD AS SHOWN IN THE DIAGRAM BELLOW.

  • Page 107: Step 57: Steering Wheel

    STEP 57: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK. 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2"...

  • Page 108: Step 58: Ground Stakes

    STEP 58: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. 2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #8 X 2" WOOD SCREW PROVIDED WITH THE GROUND STAKE. #8 X 2"...
  • Page 109 Leftover Parts List 1500CW/CWR/CT Play Sets Our 1500 series play sets are modular and include parts to construct many different models. Some of these parts included with your play set will not be used because they are for a different model. The list below includes parts for your play set that will be leftover when construction is completed.
  • Page 110 APPENDIX...
  • Page 111 1529 HARDWARE #8 X 1-1/4" PAGE 1 OF 1 WOOD SCREW QTY: 22 1/16/2015 S.O. #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 #2 SQUARE DRIVE BIT...
  • Page 112 PICTURE DESCRIPTION QTY. DORMER SUNRAY ASSEMBLY 2-10-1355-DS DORMER ROOF PANEL ASSEMBLY 2-13-1828-DRPA DORMER SIDE RIGHT ASSEMBLY 2-17-1850-DSRA DORMER SIDE LEFT ASSEMBLY 2-17-1850-DSLA DORMER MOUNT 2-3-1150-DM CHIMNEY FRONT ASSEMBLY 2-8-1500-CFA CHIMNEY RIGHT SIDE ASSEMBLY 2-10-1500-CRS...
  • Page 113 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY 2-10-1500-CLS CHIMNEY REAR ASSEMBLY 2-8-0700-CRA CHIMNEY MOUNTING BLOCK 2-3-0675-CMB...
  • Page 114 STEP 1: DORMER SUNRAYS AND SIDES 1: FIND ONE DORMER SIDE LEFT ASSEMBLY AND ONE DORMER SIDE RIGHT ASSEMBLY. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY. ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW.
  • Page 115 STEP 2: DORMER WINDOW 1: MOUNT THE DORMER WINDOW IN THE FRONT OF THE DORMER, THE WINDOW SHOULD FIT IN BETWEEN THE DORMER SIDES AND THE DORMER SUNRAY. THE BACK FACE OF THE WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS. 2: MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DORMER WINDOW AND FASTEN WITH #8 X 1-1/2"...
  • Page 116 STEP 3: DORMER ROOF PANELS 1: FIND TWO DORMER ROOF PANEL ASSEMBLIES. 2: PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY ASSEMBLIES, THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK, MAKE SURE THE PRE-DRILLED HOLES ON THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES.
  • Page 117 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 118 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 119 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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