PlayNation Play Systems Colossal Kingdom Deluxe Manual
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PlayNation Play Systems Colossal Kingdom Deluxe Manual

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Colossal Kingdom Deluxe
Copyright © 2014 PlayNation Play Systems, Inc.
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.playnation.com
Latest Revision: 12/19/2014

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  • Page 1 Colossal Kingdom Deluxe Copyright © 2014 PlayNation Play Systems, Inc. All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.playnation.com Latest Revision: 12/19/2014...
  • 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 use our “Quick Response Center”...
  • Page 3 PLAYNATION WARRANTY MANUFACTURER'S LIMITED LIFETIME WARRANTY PlayNation Play Systems, Inc. warrants its Lifetime™ series of swing sets to be free from defects in workmanship and materials, under normal use and conditions, for the lifetime of the product for above ground structural wood components and for two years for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.) except PlayNation's Super Scoop Slides™...
  • Page 4 PLAYNATION WARRANTY In addition, within the first 30 days from the date of purchase, PlayNation will replace any parts discovered to be missing from or damaged in the original packaging. This warranty is valid only if the product is used for the purpose for which it was designed and installed at a residential, single-family dwelling.

  • Page 5: Important Safety Guidelines

    IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set.
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 7 WARRANTY REGISTRATION PlayNation manufactures the 3 EASY WAYS TO REGISTER finest quality products that Mail this completed form to: are designed for outstanding Fax this completed form to: PlayNation Playsets strength and durability. OPTION 1 (800) 880-3300 190 Etowah Industrial Court back our products with an Canton, GA 30114 unparalleled warranty.
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 9 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 10 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 11 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 12 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 13 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 14 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 15 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 16 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 17: 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 18: 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 19: 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 20 STEP 1: LADDER AND ROPE LADDER RUNNERS 1: PLACE THE 4 X 4 X 84" LADDER RUNNER FLUSH WITH THE BOTTOM OF THE LADDER ASSEMBLY, TO THE INSIDE OF THE LADDER. ALLOW THE LADDER RUNNER TO EXTEND EQUALLY PAST THE LADDER RAILS.
  • Page 21 STEP 2: ANGLE BRACES 1: PLACE THE 4 X 4 X 16" ANGLE BRACES FLUSH TO THE SIDES OF THE LADDER AND ROCK WALL ASSEMBLIES WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS. 3/8 X 5" LAG SCREW 3/8" WASHER...
  • Page 22 STEP 3: MAIN DECK BEAMS 1: PLACE THE 4 X 6 X 124" MAIN DECK BEAMS FLUSH TO THE OUTSIDE OF THE LADDER AND ROCK WALL ASSEMBLIES, LINING UP THE PILOT HOLES AT EACH END TO THE COUNTER-SUNK HOLES ON THE LADDER AND ROCK WALL SIDES. 2: FIND FOUR 6-1/2"...
  • Page 23 STEP 4: FAT FREDDIES 1: PLACE THE 4 X 6 X 15" FAT FREDDIESAT THE ENDS OF THE MAIN BEAMS. NOTE THAT THERE ARE TWO FOR THE LEFT SIDE AND TWO FOR THE RIGHT. 2: THE NOTCHES IN THE FAT FREDDIES WILL FIT WITH THE LADDER AND ROCK WALL ASSEMBLIES WHEN THEY ARE SCISSORED OUT.
  • Page 24 STEP 5: DECK 1: PLACE THE DECK PANELS ON TOP OF THE MAIN BEAMS, ALLOWING THE 2 X 4 DECK STREAMERS TO FIT INSIDE OF THE MAIN BEAMS. 2: FASTEN THE DECK PANELS TO THE MAIN BEAMS WITH ONE 2-1/2" WOOD SCREW ON BOTH SIDES OF EACH BOARD.
  • Page 25 STEP 6: TIRE SWIVEL 1: REST THE TIRE SWIVEL ON TOP OF THE DECK AND, USING THE HOLES IN THE TIRE SWIVEL AS A GUIDE, MARK THE LOCATION OF THE HOLES. 2: DRILL 3/8" HOLES IN THE BRDGE DECK WHERE THE MARKS WERE MADE. 3: FASTEN THE TIRE SWIVEL TO THE DECK WITH 4"...
  • Page 26 STEP 7: UPRIGHTS 1: LINE UP THE PILOT HOLES OF THE 4 X 4 X 42” CORNER UPRIGHTS WITH THE HOLES AT EACH END OF THE MAIN FLOOR BEAMS. 2: FASTEN THE CORNER UPRIGHTS TO THE MAIN FLOOR BEAMS USING 6-1/2” CARRIAGE BOLTS WITH TORQUE WASHERS FROM THE OUTSIDE, AND 3/8”...

  • Page 27: Step 8: Side Rails

    STEP 8: SIDE RAILS 1: PLACE THE 4 X 4 X 124" SWING BEAM SIDE RAIL FLUSH TO THE CORNER UPRIGHTS, LINING UP THE PILOT HOLES. MAKE SURE THAT THE SIDE WITH THREE CLOSELY PATTERNED COUNTER-SUNK HOLES IS FACING DOWN. 2: ATTACH THE SWING BEAM SIDE RAIL TO THE CORNER AND CENTER UPRIGHTS USING 6-1/2"...
  • Page 28 STEP 9: ROPE LADDER SUPPORT 1: PLACE THE 4 X 6 X 115" ROPE LADDER SUPPORT TO THE CORNER UPRIGHTS ON THE SAME SIDE THAT THE ROPE LADDER RUNNER WAS INSTALLED, LINING UP THE PILOT HOLES. 2: FASTEN THE ROPE LADDER SUPPORT TO THE CORNER UPRIGHTS USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS FROM THE INSIDE OF THE FORT, AND 3/8"...
  • Page 29 STEP 10: TRAPEZE ARM 1: PLACE THE 4 X 6 X 115" TRAPEZE ARM AGAINST THE CORNER UPRIGHTS ON THE OPPOSITE SIDE OF THE ROPE LADDER SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE TRAPEZE ARM TO THE CORNER UPRIGHTS USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS FROM THE INSIDE OF THE FORT, AND 3/8"...

  • Page 30: Step 11: Wall Panels

    STEP 11: WALL PANELS 1: FIND THE TWO LARGE WALL PANELS AND ONE SLIDE WALL PANEL. 2: THE TOPS OF THE WALL PANELS WILL MOUNT FLUSH TO THE TOP OF THE SIDE RAILS BETWEEN THE CENTER AND CORNER UPRIGHTS WITH 3/8 X 5" LAG SCREWS WITH 3/8" WASHERS. 3: FINISH ATTACHING THE WALL PANELS TO THE UNIT WITH 3/8 X 5"...
  • Page 31 STEP 12: ROOF SUPPORTS 1: FIND FOUR 4 X 4 X 84" ROOF SUPPORTS. THERE ARE TWO FOR THE LEFT SIDE AND TWO FOR THE RIGHT. IT WILL BE HELPFUL TO HAVE AN ASSISTANT HOLD THE ROOF SUPPORT WHILE YOU FASTEN IT TO THE FORT. PREDRILLING A 1/4" HOLE PARTIALLY IN THE BOARDS RECEIVING LAG SCREW WILL, A) MAKE DRIVING IN THE LAG SCREWS EASIER BY HAND AND B) PREVENT POSSIBLE SPLITS IN THE BOARDS.
  • Page 32 STEP 13: ROOF STARTER ASSEMBLY 1: PLACE THE ROOF STARTER ASSEMBLY CENTERED ON TOP OF THE ROOF SUPPORTS. 2: ATTACH THE ROOF CAP/ROOF STARTER ASSEMBLY TO THE ROOF SUPPORTS WITH FOUR 1-1/2" WOOD SCREWS. ROOF CAP/ROOF STARTER ASSEMBLY FASTEN HERE WITH 1-1/2"...
  • Page 33 STEP 14: ROOF 1: FIND THIRTY-TWO 1 X 6 X 72" TONGUE-IN-GROOVE ROOF BOARDS, TWO 1 X 4 X 72" TONGUE-ONLY ROOF FINISHERS, AND TWO 5/4 X 4 X 65" ROOF END CAPS. 2: PLACE THE 1 X 6 X 72" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS.
  • Page 34 STEP 15: SUNBURST 1: FIND TWO 5/4 X 3 X 51" SUN SUPPORTS. 2: PLACE THE SUN SUPPORTS ON THE OUTSIDE OF THE FORT, AGAINST THE ROOF SUPPORTS AND CENTER UPRIGHT. THE ANGLED ENDS OF THE SUN SUPPORT WILL REST UNDERNEATH THE ROOF BOARDS. 3: BEFORE ATTACHING TO THE FORT, MAKE SURE THE SUN SUPPORT IS LEVEL.
  • Page 35 STEP 16: SUNBURST 1: FIND TWO 2 X 6 X 16" SUNS. 2: PLACE THE SUN ON THE OUTSIDE OF THE SUN SUPPORT, CENTERED TO THE CENTER UPRIGHT. 3: ATTACH THE SUN TO THE SUN SUPPORT WITH 2-1/2" WOOD SCREWS 2 X 6 X 16"...
  • Page 36 STEP 17: SUNBURST 1: FIND FOUR 5/4 X 2 X 14" LARGE RAYS, AND FOUR 5/4 X 2 X 13" SMALL RAYS. 2: PLACE THE LARGE RAYS BETWEEN THE CENTER UPRIGHT AND SUN AT AN ANGLE THAT ALLOWS THEM TO TOUCH THE ROOF PEAK AND NOT EXTEND PAST THE CENTER OF THE SUN.
  • Page 37 STEP 18: ROOF STRINGERS 1: FIND TWO 5/4 X 4 X 85" ROOF STRINGERS. 2: CENTER THE ROOF STRINGERS FROM INSIDE THE FORT ON THE ROOF BOARDS. 3: ATTACH THE ROOF STRINGER TO THE ROOF BOARDS WITH 1-1/2" WOOD SCREWS, USING TWO SCREWS PER ROOF BOARD.
  • Page 38 STEP 19: ANGLE SUPPORTS 1: FIND FOUR 4 X 4 X 16" ANGLE SUPPORTS. THERE ARE TWO FOR THE LEFT SIDE AND TWO FOR THE RIGHT. 2: POSITION THE ANGLE SUPPORTS SO THAT THE ANGLED END WILL REST FLUSH AGAINST THE CORNER UPRIGHTS, AND THE COUNTER-SUNK HOLES WILL BE FACING TOWARDS THE OUTSIDE OF THE UNIT.
  • Page 39 STEP 20: CLIMBING ROCKS 1: FIND FIFTEEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. TWO PAN HEAD SCREWS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW.

  • Page 40: Step 21: Rope Ladder

    STEP 21: ROPE LADDER 1: THREAD THE ROPE THROUGH THE HOLES IN THE ROPE LADDER SUPPORT FROM THE BOTTOM THROUGH THE TOP. FORM A SECURE KNOT AT THE TOP OF THE ROPE LADDER SUPPORT. 2: THREAD THE ROPE THROUGH THE HOLES IN THE ROPE LADDER RUNNER FROM THE FRONTSIDE OF THE ROPE LADDER RUNNER, THROUGH THE BACK SIDE.

  • Page 41: Step 22: Swing Beam Plate

    STEP 22: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SIDE RAIL, LINING UP PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SIDE RAIL ON THE OUTSIDE HOLES USING 3-1/2" CARRIAGE BOLTS WITH 1/2"...
  • Page 42 STEP 23: SWING BEAM 1: BOLT SWING BEAM BLOCK SUPPORTS TOGETHER WITH 7" CARRIAGE BOLTS AND 1/2" WASHERS THROUGH THE 90 ANGLE BRACKETS. 2: USE 3/8" WASHERS AND 3/8" LOCK NUTS ON BOTTOM SIDE OF BLOCK. 3: USE BOLT CAPS TO COVER ANY EXPOSED THREADS 7"...
  • Page 43 STEP 24: SWING BEAM 1: PLACE SWING BEAM BLOCK ASSEMBLY ON THE GROUND. 2: PLACE THE 4 X 6 X 132" SWING BEAM LEGS BESIDE THE BEAM BLOCK WITH THE COUNTER-SUNK HOLES FACING OUT. 3: HOLD IN PLACE AND SLIDE 12" CARRIAGE BOLT WITH 1/2" WASHER THROUGH THE 45 ANGLE BRACE, 4 X 6 LEG, SWING BEAM BLOCK ASSEMBLY, 4 X 6 LEG, AND 45 ANGLE BRACE.
  • Page 44 STEP 25: SWING BEAM 1: PLACE SWING BEAM BETWEEN 90 SWING BEAM BRACES. 2: FASTEN THE SWING BEAM TO THE SWING LEGS FROM THE TOP OF THE SWING BEAM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS. USE 3/8" LOCK NUTS WITH 3/8" WASHERS ON THE 45 ANGLE BRACES. 3: PLACE BOLT CAPS OVER ANY EXPOSED THREADS.
  • Page 45 STEP 26: SWING BEAM 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 46 STEP 27: MOUNT SWING BEAM TO FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: PICK UP THE SWING BEAM AND LEG ASSEMBLY. AS YOU LIFT THE BEAM, THE LEGS WILL SCISSOR CLOSER KEEP CHILDREN AWAY DURING THIS STEP. AS THE LEGS CLOSE, THEY CREATE A PINCH TOGETHER.
  • Page 47 STEP 28: SWING BEAM LEGS 1: USE THE SWING BEAM LEGS TO LEVEL THE SWING BEAM. 2: FASTEN THE SWING BEAM LEGS TO THE SWING BLOCK ASSEMBLY WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS. 3: TIGHTEN THE 12" CARRIAGE BOLT THAT WAS INSTALLED EARLIER. YOU MAY NEED TO USE LOCKING PLIERS TO HOLD THE CARRIAGE BOLT IN PLACE WHEN INSTALLING.
  • Page 48 STEP 29: SWING BEAM CROSS MEMBER 1: PLACE THE 4 X 6 X 70" SWING LEG CROSS MEMBER ON THE SWING BEAM LEGS AND LEVEL. FASTEN 4 X 6 CROSS MEMBER TO 4 X 6 LEGS WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS. 4 X 6 X 70"...
  • Page 49 STEP 30: TRAPEZE ARM IRON DUCTILE 1: LINE UP THE HOLES OF THE IRON DUCTILE WITH THE HOLES IN THE END OF THE TRAPEZE ARM. 2: FASTEN THE DUCTILE TO THE TRAPEZE ARM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8"...

  • Page 50: Step 31: Hanging The Swings

    STEP 31: HANGING THE SWINGS 1: PLACE THE SPRING CLIPS ON THE CHAINS OF THE SWINGS, PUNCHING BAG , AND TIRE SWING. 2: HANG THE SWINGS AND PUNCHING BAG BY THE SWING CLIPS FROM THE DUCTILES ON THE SWING BEAM AND TRAPEZE BAR.
  • Page 51 STEP 32: SLIDE 1: LOOK ON THE BOTTOM OF THE SLIDE. YOU WILL NOTICE THAT ONE END HAS A SMALL NOTCH. REST THIS ON THE DECK AND PUSH THE SLIDE AS FAR BACK ON THE DECK AS THE NOTCH WILL ALLOW. 2: CENTER THE SLIDE IN THE OPENING BETWEEN THE CENTER UPRIGHT AND THE SLIDE WALL PANEL AND ATTACH WITH 1-1/4"...
  • Page 52 STEP 33: ENTRY PANELS 1: PLACE THE ENTRY PANELS AT THE OPENINGS ON THE LADDER AND ROCK WALL SIDES OF THE FORT. 2: THE ENDS OF THE PANELS WILL REST FLUSH AGAINST THE CORNER UPRIGHTS, WITH THE COUNTER-SUNK HOLES FACING TOWARDS THE INSIDE OF THE UNIT. 3: USE 3/8 X 5"...

  • Page 53: Step 34: Safety Handles

    STEP 34: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES ABOVE THE BASE OF THE ENTRY PANELS, CENTERED ON THE PANEL SLATS. 2: ATTACH THE SAFETY HANDLES TO THE PANEL SLATS OF THE ENTRY PANELS WITH 1-1/4" PAN HEAD SCREWS. SAFETY HANDLES...

  • Page 54: Step 35: Steering Wheel

    STEP 35: 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 FRONT CENTER UPRIGHT. 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 55 STEP 36: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS ONTO THE SIDE RAIL, JUST ABOVE THE SLIDE. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4"...
  • Page 56 STEP 37: DINNER BELL 1: CENTER THE BASE OF THE DINNER BELL ON THE ROPE LADDER SUPPORT AND ATTACH WITH PROVIDED SCREWS. 2: ASSEMBLE THE BELL AND TIGHTEN TO THE BASE WITH THE PROVIDED NUT...
  • Page 57 STEP 38: 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 58 STEP 39: 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. 1-1/4" WOOD SCREW DORMER ROOF PEAK...
  • Page 59 STEP 40: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE 2" WOOD SCREWS TO FASTEN THE DORMERS TO THE ROOF. USE 2" WOOD SCREWS IN THESE LOCATIONS (EACH SIDE)

  • Page 60: Step 41: Monkey Bar Assembly

    STEP 41: MONKEY BAR ASSEMBLY 1: PLACE THE MONKEY BAR ASSEMBLY IN THE MIDDLE HOLES OF THE LADDER ASSEMBLY. 2: POSITION THE MONKEY BAR PLATE BETWEEN THE MONKEY BAR ASSEMBLY AND THE LADDER ASSEMBLY AND LINE THE PLATE HOLES UP WITH THE TWO MIDDLE HOLES OF THE LADDER ASSEMBLY. 3: SEE BELOW FOR EXACT PLACEMENT OF THE 6-1/2", AND 3-1/2"...

  • Page 61: Step 42: Corner Posts

    STEP 42: CORNER POSTS 1: FIND FOUR 4 X 4 X 54" CORNER POSTS. THE ORIENTATION OF THE POSTS ARE IMPORTANT IN THIS STEP. THE SINGLE COUNTER-SUNK HOLE AT THE TOP OF THE POSTS MUST FACE TOWARD EACH OTHER. 2: THE CORNER POSTS WILL ATTACH IN THE PRE-DRILLED HOLES WITH THE BOTTOM COUNTER-SUNK HOLE OF THE CORNER POSTS LINING UP WITH THE TWO HOLES IN THE MONKEY BAR ASSEMBLY CLOSEST TO THE LADDER ASSEMBLY.
  • Page 62 STEP 43: ATTACHING MONKEY BAR ASSEMBLY TO FORT 1: TAKE THE MONKEY BAR ASSEMBLY CREATED IN THE PREVIOUS STEP AND MOVE IT TO THE OPENING ON THE OPPOSITE SIDE OF THE SWING BEAM. MAKE SURE THAT THE FACE OF THE RUNG ASSEMBLY IS FLUSH WITH THE CORNER AND CENTER UPRIGHTS.
  • Page 63 STEP 44: MONKEY BAR SUPPORTS 1: FIND THE TWO 4 X 4 X 25-1/2" MONKEY BAR SUPPORTS. THERE WILL BE ONE FOR THE LEFT SIDE, AND ONE FOR THE RIGHT. 2: PLACE THE MONKEY BAR SUPPORTS ON THEIR APPROPRIATE SIDES, FLUSH TO THE BOTTOM OF THE MONKEY BAR ASSEMBLY, AND AGAINST THE CENTER AND CORNER UPRIGHTS.
  • Page 64 STEP 45: SKY LOFT ENTRY PANEL 1: FIND THE SKY LOFT ENTRY PANEL. THE ENTRY PANEL WILL MOUNT TO THE UNIT FLUSH TO THE TOP OF THE TOP RAIL. 2: ATTACH THE ENTRY PANEL TO THE MAIN SUPPORT BEAM AND TOP RAIL WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS.
  • Page 65 STEP 46: SKY LOFT DECK 1: FIND NINE 5/4 X 5-1/2 X 43" DECK BOARDS, ONE 5/4 X 2-1/4 X 43" DECK SPACER, AND THREE 5/4 X 3-1/4 X 35-3/4" DECK SPACERS. 2: THE DECK BOARDS WILL FASTEN TO THE MONKEY BAR ASSEMBLY WITH TWO 2" WOOD SCREWS PER SIDE. 3: SEE THE PICTURE BELOW FOR LOCATIONS.
  • Page 66 STEP 47: SKY LOFT WALL PANELS 1: FIND TWO SIDE WALL PANELS AND ONE REAR WALL PANEL. THERE IS A LEFT AND RIGHT SIDE WALL PANEL. 2: PLACE THE SIDE WALL PANELS ON THE UNIT SO THAT THE COUNTER-SUNK HOLES ARE CENTERED ALONG THE CORNER POSTS, AND THE PANEL SLATS REST ON THE DECK.
  • Page 67 STEP 48: LAG SCREWS 1: AFTER THE PANELS HAVE BEEN INSTALLED ON THE UNIT, GO BACK AND USE 3/8 X 5" LAG SCREWS WITH 3/8" WASHERS IN THE TOP HOLES OF THE CORNER POSTS. MAKE SURE THE POSTS ARE SQUARE BEFORE DRIVING THE LAG SCREWS.
  • Page 68 STEP 49: ROOF SUPPORTS 1: FIND THE FOUR 2 X 4 X 36" ROOF SUPPORTS. THE ROOF SUPPORTS WILL MOUNT ON THE OPPOSITE SIDE OF THE COUNTER-SUNK HOLES IN THE CORNER POSTS. 2: FROM THE OUTSIDE OF THE ROOF SUPPORTS, USE A 4-1/2" CARRIAGE BOLT WITH A TORQUE WASHER. THE CARRIAGE BOLT/TORQUE WASHER WILL GO THROUGH THE HOLE IN THE ROOF SUPPORT, INTO THE HOLE OF THE CORNER POST.
  • Page 69 STEP 50: ROOF PEAK SUPPORTS 1: FIND THE TWO 5/4 X 6 X 10" ROOF PEAK SUPPORTS. THE ROOF PEAK SUPPORTS WILL MOUNT TO THE ROOF SUPPORTS SO THAT THE PEAK OF THE ROOF IS FLUSH TO THE PEAK OF THE ROOF PEAK SUPPORTS. 2: USE THREE 2"...
  • Page 70 STEP 51: ROOF STARTERS 1: FIND ONE 1 X 4 X 55" GROOVE ONLY ROOF STARTER, AND ONE 1 X 5 X 55" GROOVE ONLY ROOF STARTER. CENTER THE BOARDS ACROSS THE ROOF SUPPORTS, AND POSITION THEM SO THAT THE 1 X 5 X 55" ROOF STARTER OVERLAPS THE 1 X 4 X 55"...
  • Page 71 STEP 52: ROOF 1: FIND TWELVE 1 X 6 X 55" TONGUE AND GROOVE ROOF BOARDS, AND TWO 1 X 4 X 55" TONGUE ONLY ROOF FINISHERS. CENTER THE BOARDS ACROSS THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF EACH BOARD.

  • Page 72: Step 53: Roof End Caps

    STEP 53: ROOF END CAPS 1: FIND TWO 5/4 X 4 X 50-3/8" END CAPS. THE END CAPS WILL MOUNT AT THE ENDS OF THE ROOF SUPPORT. 2: ATTACH THE END CAPS TO THE ROOF SUPPORTS WITH TWO 2" WOOD SCREWS PER SIDE. 5/4 X 4 X 50-3/8"...
  • Page 73 STEP 54: SUN ASSEMBLY 1: FIND THE SUN ASSEMBLY. THE SUN ASSEMBLY WILL MOUNT UNDERNEATH THE ROOF SUPPORTS, AGAINST THE CORNER POSTS, WITH THE ANGLED ENDS FLUSH TO THE BOTTOM OF THE ROOF SUPPORTS. MAKE SURE THAT THE SIDE OF THE SUN THAT IS FLUSH TO THE SUN SUPPORT IS FACING TOWARDS THE INSIDE OF THE FORT. 2: ATTACH THE SUN ASSEMBLY TO THE CORNER POSTS WITH TWO 2"...
  • Page 74 STEP 55: LARGE SUNRAY 1: FIND THE 5/4 X 2 X 20" LARGE SUNRAY. THE LARGE SUNRAY WILL MOUNT IN THE CENTER OF THE SUN ASSEMBLY FROM INSIDE THE FORT. 2: ATTACH THE LARGE SUNRAY TO THE SUN ASSEMBLY AND ROOF SUPPORTS WITH ONE 2" WOOD SCREW PER SIDE. 5/4 X 2 X 20"...
  • Page 75 STEP 56: SUNRAYS 1: FIND TWO 5/4 X 2 X 15-1/2" MEDIUM SUNRAYS, AND TWO 5/4 X 2 X 13" SMALL SUNRAYS. THE SUNRAYS WILL MOUNT INSIDE THE FORT TO THE PATTERN SHOWN IN THE BOTTOM VIEW. EXACT PLACEMENT IS NOT NECESSARY AS LONG AS ONE SIDE IS THE SAME AS THE OTHER.
  • Page 76 STEP 57: TIC TAC TOE 1: LOCATE THE GREEN DOWELS AND MATCH THEM AS FOLLOWS: ONE THREADED STUD END, AND ONE THREADED INSERT. 2: SCREW THE STUDS INTO THE INSERTS UNTIL TIGHT. 3: REPEAT STEPS 1 AND 2 WITH THE REMAINING TWO SETS 4: LOCATE ONE OF THE GREEN BRACKETS AND PLACE THE DOWELS IN AS SHOWN.
  • Page 77 STEP 58: TIC TAC TOE 1: LOCATE THE TIC-TAC- TOE TUMBLERS AND PLACE ONE ON EACH DOWEL ABOVE THE COLLARS. 2: CONTINUE PLACING COLLARS AND TUMBLERS ON THE DOWELS UNTIL NONE REMAIN. 3: LOCATE THE GREEN BRACKET AND PLACE ON TOP OF ASSEMBLY. LINE UP THE HOLES IN THE BRACKET WITH THE DOWELS ON THE UNIT.
  • Page 78 STEP 59: TIC-TAC-TOE PANEL 1: CENTER THE 1-3/4 X 1-1/2 X 10-3/4" BLOCK BETWEEN THE PANEL SLATS ON THE REAR WALL PANEL OF THE SKY LOFT, 4" FROM THE DECK, AND ATTACH WITH 2" WOOD SCREWS. 2: PLACE THE TIC-TAC-TOE PANEL ON THE PREVIOUSLY INSTALLED BOARD, AND THEN PLACE THE OTHER 1-3/4 X 1-1/2 X 10-3/4"...
  • Page 79 STEP 60: 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 80 STEP 61: 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 81 STEP 62: 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.
  • Page 82 STEP 63: FLAG KIT *NEW* PLEASE NOTE THAT IN 2010 WE CHANGED OVER TO NEW FLAGS. ALSO IN 2010 WE DECREASED THE FLAG COUNT FROM 3 TO 2. YOU MAY MOUNT THE FLAGS EITHER ON THE FRONT OF THE SWING BEAM OR ON THE FRONT OF THE FORT AT THE END OF THE SIDE RAILS.

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