Gorilla Playsets Congo Outing II Assembly Manual
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Gorilla Playsets Congo Outing II Assembly Manual

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Congo Outing II
ASSEMBLY MANUAL
Copyright © 2009 Gorilla Playsets
All Rights Reserved
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA 30114
(800) 882-0272
14/SEP/2009 – Version 1.3.0

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  • Page 1 Congo Outing II ASSEMBLY MANUAL Copyright © 2009 Gorilla Playsets All Rights Reserved Gorilla Playsets 190 Etowah Industrial Court Canton, GA 30114 (800) 882-0272 14/SEP/2009 – Version 1.3.0...
  • Page 2 STOP…PLEASE READ!! IF YOU HAVE MISSING OR DAMAGED PARTS OR NEED ASSISTANCE ASSEMBLING, PLEASE CALL gorilla playsets MANUFACTURING DIRECT. (800) 882-0272 FACTORY HOURS – MON.–FRI., 8AM-5PM EST DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECT. THE RETAILER DOES NOT STOCK COMPONENTS.
  • Page 3 Congo Outing II TABLE OF CONTENTS Warranty and Safety Guidelines…………………………………………….….……..4-10 Kit Contents and Tool List…………..………………………………………………. 11-15 Hardware and Lumber Checklist...…………………………………………………. 16-26 Adding T-Nuts to Corner Posts...…………………………………..………...… steps 1-2 Framing Fort……………………………………..…………………………..…… steps 3-7 Mounting Deck Supports…………………………..……………….…………...… step 8 Attaching Ground Braces………………………………...…..……..……...….…… step 9 Attaching Deck Spacers and Ladder Assembly..……………………..……...
  • Page 4 Yet you’ll appreciate how quick and easy construction really is! Our playset kits are designed for children ages 3 to 11. gorilla playsets® believes every child should have a playset and with our kits they can! You can rest assured your new playset is safe, durable and designed to hold up to the elements.
  • Page 5 This decision is subject to verification of the defect upon delivery of the defective part to gorilla playsets®...
  • Page 6 • ROCK WALL: 150 LBS. • ALL SLIDES: 125 LBS. Gorilla Playsets recommends that the weight limits for all components must not be exceeded. Failure to adhere to these and other safety guidelines could result in damage to the playset and injury to the users.
  • Page 7 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 8 Ropes, cables and chains should be removed and replaced if excessive wear is found. Contact Gorilla Playsets for warranted replacement parts.
  • Page 9 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) Handbook for Public Playground Safety offers from its . The guide can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
  • Page 10 LEVELING YOUR FORT DURING ASSEMBLY • Complete the steps which will be the basic frame of the fort {i.e. four corner posts with base (sand box boards) and deck supports} • Position in the most level area chosen for the playset, keeping in mind the location and size of the swing beam, ladder, slides, etc.
  • Page 11 Congo Outing II KIT CONTENTS COMPONENTS Description Check List (Swings, Slides, Accessories) Swingbelts w/ Chains __________ 8ft. Wave Slide __________ Congo Outing II Assembly Manual __________ Rockwall Grips (assorted colors) __________ Trapeze Swing __________ Description (Fort Hardware) see following pages Description...
  • Page 12 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 17’ SWING BELTS (2) ROCK WALL TRAPEZE ARM (1) 12’ LADDER WAVE SLIDE Playset height: 10’6” Approximate assembly time: 8-12 Hours { 6 foot unobstructed safety perimeter around playset recommended }...
  • Page 13 Helpful Installation Hints • Depending on your experience, assembly of Gorilla playsets can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts. Therefore, we recommend you set aside a full two days for assembly.
  • Page 14 General Info To Review Before Installation This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your playset. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board.
  • Page 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 #8 X 1-1/4" WOOD SCREW QTY: 2 #8 X 2" WOOD SCREW QTY: 144 #8 X 2-1/2" WOOD SCREW QTY: 25 #14 X 1-1/4" #8 X 3" PAN HEAD SCREW WOOD SCREW QTY: 44 QTY: 4 1/4" WASHER QTY: 44 3/8"...
  • Page 17 3/8 X 3-1/2" HEX LAG SCREW QTY: 12 #2 SQUARE DRIVE TIP QTY: 1 GREEN PLASTIC 3/8 x 9" 3/8 x 6-1/2" 3/8 x 3-1/2" BOLT CAP CARIAGE BOLT CARIAGE BOLT CARIAGE BOLT QTY: 19 QTY: 1 QTY: 16 QTY: 2 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 18 PICTURE DESCRIPTION QTY. 2 X 4 X 83" TARP SUPPORT BOARD (LEFT AND RIGHT SIDE) 2 X 4 X 73 " FRONT CENTER POST 2 X 4 X 58" SWING LEG CROSS-MEMBER 2 X 4 X 57" LADDER SIDE (1 LEFT, 1 RIGHT) 2 X 4 X 53 "...
  • Page 19 PICTURE DESCRIPTION QTY. 2 X 4 X 47 " FORT SIDE SUPPORT 2 X 4 X 47 " TOP PANEL BOARD 2 X 4 X 47 " CENTER TARP BOARD 2 X 4 X 47 " FRONT FACE BOARD 2 X 4 X 47" CENTER STRINGER 2 X 4 X 29"...
  • Page 20 PICTURE DESCRIPTION QTY. 2 X 6 X 95 " GROUND SUPPORT BOARD 2 X 6 X 75" SIDE SANDBOX BOARD (1 LEFT, 1 RIGHT) 2 X 6 X 47 " SANDBOX BOARD X 6 X 47 " ROCK WALL BOARD X 6 X 47 "...
  • Page 21 PICTURE DESCRIPTION QTY. X 3 X 28 " PANEL SLAT X 4 X 18 " LADDER BACK 4 X 4 X 96" SWING LEG 4 X 4 X 96" CORNER POST 1 4 X 4 X 96" CORNER POST 2 4 X 4 X 96"...
  • Page 22 PICTURE DESCRIPTION QTY. 4 X 4 X 47 " SWING BEAM SUPPORT 4 X 6 X 96" SWING BEAM 2 X 2 X 18" GROUND STAKE 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 23 PICTURE DESCRIPTION QTY. 8' WAVE SLIDE SWINGS W/CHAINS TRAPEZE W/CHAINS...
  • Page 24 PICTURE DESCRIPTION QTY. SWING PLATE CLIMBING ROCKS A-FRAME SWING BRACKET HARDWARE NOT SHOWN INSTRUCTIONS...
  • Page 25 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS " X 1 " GREEN BRACKET SPRING CLAMP...
  • Page 26 PICTURE DESCRIPTION QTY. 10' ROPE TARP...
  • Page 27 STEP 1: CORNER POST LAYOUT 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: LAY OUT EACH OF THE 4 X 4 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET.
  • Page 28 STEP 2: INSERTING T-NUTS INTO CORNER POSTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
  • Page 29 STEP 3: ATTACHING SANDBOX AND TOP PANEL BOARD 1: THE 2 X 6 X 47 " SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHT SIDE CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. 2: THE 2 X 4 X 47 "...
  • Page 30 STEP 4: ATTACHING GROUND SUPPORT BOARD 1: THE 2 X 6 X 95 " GROUND SUPPORT BOARD (WITH SIX PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE LEFT SIDE CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. " WASHER "...
  • Page 31 STEP 5: ATTACHING THE SIDE SANDBOX BOARDS 1: THE 2 X 6 X 75" SIDE SANDBOX BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE FRONT AND REAR CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. 2: THE STRUCTURE SHOULD BE ABLE TO STAND ON ITS OWN, WITHOUT ANY SUPPORT, AT THIS STAGE.
  • Page 32 STEP 6: ATTACHING TARP SUPPORT BOARDS 1: THE 2 X 4 X 83" TARP SUPPORT BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACH TO THE TOP OF THE FRONT AND REAR CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. 2: OFFSET HOLES SHOULD BE POINTED DOWN ON BOTH BOARDS. 3: THE SHORTEST END FROM THE COUNTER-SUNK HOLES WILL POINT TOWARD THE SWING BEAM SIDE OF THE FORT.
  • Page 33 STEP 7: ATTACHING REAR PANEL SUPPORT BOARD 1: THE 2 X 4 X 47 " REAR PANEL SUPPORT BOARD (WITH TWO PRE-DRILLED HOLES) ATTACHES TO THE SET OF HOLES BELOW THE TARP SUPPORT BOARD ON THE BACK SIDE OF THE FORT WITH 4 "...
  • Page 34 STEP 8: ATTACHING DECK SUPPORTS 1: THE 2 X 4 X 47 " DECK SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES ABOVE THE SANDBOX BOARD AND THE GROUND SUPPORT BOARDON THE INSIDE OF THE LEFT AND RIGHT SIDE OF THE CORNER POSTS WITH 4 "...
  • Page 35 STEP 9: ATTACHING FORT SIDE SUPPORTS 1: LAY THE 2 X 4 X 47 " FORT SIDE SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTATED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PACE A T-NUT IN THE PRE-DRILLED HOLE ON EACH END AND SECURE WITH A HAMMER.
  • Page 36 STEP 10: ATTACHING DECK SPACERS, PANEL AND FACE BOARDS 1: THE ORDER IN WHICH THESE BOARDS ARE INSTALLED IS VERY IMPORTANT, FOLLOW THE STEPS CAREFULLY. 2: FIRST, WITH OFFSET HOLES DOWN, SECURE THE 2 X 4 X 47 " BACK PANEL BOARD TO THE CORNER POSTS WITH 4 "...
  • Page 37 STEP 11: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57" LADDER SIDE ON A FLAT SURFACE WITH CHANNELS FACING DOWN. PLACE THE BARREL OF A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE, AND SECURE WITH A HAMMER. REPEAT THIS STEP FOR THE OTHER LADDER SIDE.
  • Page 38 STEP 12: ATTACHING THE LADDER 1: THE LADDER ATTACHES TO THE RIGHT FRONT SIDE, FLUSH TO THE INSIDE EDGE OF THE CORNER POST. 2: MAKE SURE THE LADDER IS LEVEL AND MARK THE POSITION OF THE BRACKET HOLES ON THE 2 X 4. 3: DRILL "...
  • Page 39 STEP 13: ATTACHING THE ROCK WALL SUPPORTS 1: LAY THE 2 X 4 X 53 " ROCK WALL SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTATED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PACE A T-NUT IN THE PRE-DRILLED HOLE ON EACH END AND SECURE WITH A HAMMER.
  • Page 40 STEP 14: ATTACHING THE ROCK WALL BOARDS 1: BEGIN WITH THE UPPER MOST X 6 X 47 " ROCK WALL BOARD AND SECURE TO THE ROCK WALL SUPPORT WITH TWO 2" WOOD SCREWS PER SIDE. THE ROUNDED EDGE OF THE ROCK WALL BOARD SHOULD BE AGAINST THE CORNER POSTS BEFORE ATTACHING.
  • Page 41 STEP 15: ATTACHING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. 2: THE ROCKS INCLUDED WITH YOUR PLAYSET MAY VARY, IN ANY CASE, THE 1 " PANHEAD SCREWS WILL BE USED TO ATTACH THE ROCKS.
  • Page 42 STEP 16: ATTACHING THE DECK BOARDS 1: SEVEN X 6 X 47 " DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS, FLUSH TO THE TOP ROCK WALL BOARD. 2: SPACE EVENLY ACROSS THE SUPPORTS. 3: SECURE WITH FOUR 2" WOOD SCREWS, TWO PER SIDE. 2"...
  • Page 43 STEP 17: PANEL SUPPORTS 1: THE BOTTOM 2 X 4 X 47 " PANEL SUPPORT BOARD SHOULD HAVE THE HOLES OFFSET UPWARD. USE 4 " HEX BOLTS AND " WASHERS TO SECURE THE BOARDS TO THE CORNER POSTS. 2: THE TOP 2 X 4 X 47 "...
  • Page 44 STEP 18: PANEL/WALL SLATS 1. BEGIN ON THE BACK WALL OF THE FORT WITH TWO PANEL SLATS ( X 3 X 28 "). THEY ARE SPACED APPROX. 3" FROM THE CORNER POSTS. 2. THE INNNER BOARDS OF THE BACK SIDE ARE THEN SPACED 2 "...
  • Page 45 STEP 19: SWING BEAM SUPPORT 1: THE 4 X 4 X 47 " SWING BEAM SUPPORT HAS COUNTER-SUNK HOLES IN THE CENTER, AND ON THE ENDS. INSTALL THE SWING BEAM SUPPORT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES AT THE CENTER FACE DOWN.
  • Page 46 STEP 20: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT ON THE OUTSIDE HOLES USING 3 " CARRIAGE BOLTS WITH "...
  • Page 47 STEP 22: 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 6 " CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND "...
  • Page 48 STEP 23: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE FORT AND SWING LEGS. MAKE SURE THE IRON DUCTILES ARE FACING DOWN.
  • Page 49 STEP 24: SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM LEG BRACKET USING 6 " CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND " LOCK NUTS WITH " WASHERS UNDERNEATH. 2: USE A "...
  • Page 50 STEP 25: SWING BEAM TO 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 HOLES AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLES ON THE SWING BEAM PLATE.
  • Page 51 STEP 26: 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 52 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 SECURE TO THE SWING LEGS WITH 3 " LAG SCREWS AND " WASHERS.
  • Page 53 STEP 28: ATTACHING CENTER POSTS 1: THE 2 X 4 X 73 " AND 2 X 4 X 29" CENTER POSTS WILL ATTACH TO THE TARP SUPPORT BOARDS WITH 2 " HEX BOLTS, " WASHERS, AND T-NUTS. 2: THE FRONT CENTER POST WILL SECURE AT THE BOTTOM TO THE DECK SPACER, FROM UNDERNEATH, WITH TWO "...
  • Page 54 STEP 21: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 96" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3 " LAG SCREWS AND "...
  • Page 55 STEP 29: TARP BOARDS 1: THE 2 X 4 X 47 " CENTER TARP BOARD WILL SECURE ON TOP OF THE CENTER POSTS WITH TWO 2 " WOOD SCREWS PER SIDE. 2: THE TWO 2 X 4 X 50" TARP BOARDS WILL SECURE ON THE ENDS OF THE TARP SUPPORTS WITH TWO 2 "...
  • Page 56 STEP 30: SLIDE 1: LAY SLIDE ON DECK WITH LIP EXTENDING ONTO/OVER DECK SPACER 2: SECURE THE SLIDE TO THE DECK SPACER WITH TWO 1 " WOOD SCREWS APPROXIMATE LOCATION OF 1 " WOOD SCREWS...
  • Page 57 STEP 31: HANGING THE 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 58 STEP 32: TARP 1: LAY TARP ACROSS TARP BOARDS, MAKE SURE HEM SIDE IS DOWN. 2: CENTER TARP ON BOARDS AND BEGIN WITH THE FRONT RIGHT SIDE CORNERPLACE ONE 1 " PANHEAD SCREW INTO THE GROMMET. 3: PULL THE TARP TIGHT AND SCREW IN THE LEFT FRONT SIDE CORNER. 4: NOW THE NEXT RIGHT SIDE GROMMET WILL RECEIVE A SCREW, THEN THE SAME GROMMET ON THE OPPOSITE SIDE (LEFT SIDE).
  • Page 59 STEP 33: SAFETY BOARD 1: PLACE THE 2 X 4 X 47 " SAFETY BOARD ACROSS THE FRONT CORNER AND CENTER POSTS. 2: SECURE THE SAFETY BOARD TO THE CORNER POSTS WITH 4 " HEX BOLTS AND " WASHERS. 3: USE A 2 "...
  • Page 60 STEP 34: CENTER STRINGERS 1: PLACE THE 2 X 4 X 47" CENTER STRINGERS UNDERNEATH THE DECK AND ROCK WALL BOARDS. 2: FASTEN THE CENTER STRINGERS TO THE DECK AND ROCK WALL BOARDS FROM THE OUTSIDE WITH 2" WOOD SCREWS. ONE SCREW PER BOARD. NOTE: THE CENTER STRINGERS WILL MOUNT PERPENDICULAR TO THE DIRECTION OF THE DECK AND ROCK WALL BOARDS.
  • Page 61 STEP 35: 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. 2: THREAD THE OTHER END OF THE ROPE THROUGH THE HOLE IN THE BOTTOM ROCK WALL BOARD. PULL THE ROPE TIGHT AND TIE A SECURE KNOT BEHIND THE BOTTOM ROCK WALL BOARD.
  • Page 62 _______________________________________________________________________ _______________________________________________________________________ _______________________________________________ Thank you for registering with gorilla playsets™! The information you provided will be kept confidential and will ONLY be used to better serve our customers. Remove this page from the manual and mail to the address below.

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