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Big Backyard MONTERREY PLAY SYSTEM F23265 Installation And Operating Instructions Manual

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MONTERREY PLAY SYSTEM - F23265
INSTALLATION AND OPERATING INSTRUCTIONS
26' 5"
11' 1"
25' 7"
13' 7"
8 - 10 Hrs
Two person
assembly
3403265
WARNING
and give them to any future owner of this play system. Manufacturer contact information provided below.
OBSTACLE FREE SAFETY ZONE - 26' 6" x 25'7" area requires Protective Surfacing. See page 3.
MAXIMUM VERTICAL FALL HEIGHT - 6'5"
CAPACITY - 8 Users Maximum, Ages 3 to 10; Weight Limit 110 lbs. (49.9 kg) per child.
RESIDENTIAL HOME USE ONLY. Not intended for public areas such as schools, churches, nurseries, day cares or parks.
Solowave Design
375 Sligo Rd. West, PO Box 10
Mount Forest, ON Canada N0G 2L1
General Inquiries:
8:00am - 4:30pm EST
Toll Free: 1-877-966-3738
support@solowavedesign.com
To reduce the risk of serious injury or death, you must read and
follow these instructions. Keep and refer to these instructions often

Table of Contents

Warnings and Safe Play Instructions. . . . . . . . . . . . . . . pg. 2
Protective Surfacing Guidelines. . . . . . . . . . . . . . . . . . . pg. 3
Instructions for Proper Maintenance . . . . . . . . . . . . . . . pg. 4
About Our Wood - Limited Warranty . . . . . . . . . . . . . . pg. 5
Keys to Assembly Success . . . . . . . . . . . . . . . . . . . . . . pg. 6
Metric Conversion Sheets . . . . . . . . . . . . . . . . . . . . . pg. 7,8
Part ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 9
Installation of I.D./Warning Plaque . . . . . . . . . . . .Final Step
Rev 05/22/2012

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Summary of Contents for Big Backyard MONTERREY PLAY SYSTEM F23265

  • Page 1: Table Of Contents

    MONTERREY PLAY SYSTEM – F23265 INSTALLATION AND OPERATING INSTRUCTIONS WARNING To reduce the risk of serious injury or death, you must read and 26' 5" follow these instructions. Keep and refer to these instructions often 11' 1" and give them to any future owner of this play system. Manufacturer contact information provided below. OBSTACLE FREE SAFETY ZONE - 26’...

  • Page 2: Warnings And Safe Play Instructions

    Warnings and Safe Play Instructions CONTINUOUS ADULT SUPERVISION REQUIRED. Most serious injuries and deaths on playground equipment have occurred while children were unsupervised! Our products are designed to meet mandatory and voluntary safety standards. Complying with all warnings and recommendations in these instructions will reduce the risk of serious or fatal injury to children using this play system.

  • Page 3: Protective Surfacing Guidelines

    support@solowavedesign.com...

  • Page 4: Instructions For Proper Maintenance

    support@solowavedesign.com...

  • Page 5: About Our Wood - Limited Warranty

    support@solowavedesign.com...

  • Page 6: Keys To Assembly Success

    Keys to Assembly Success Tools Required Shovel Measuring Drill (1/8” Safety Hammer Ratchet 1/2”, Level #2 & #3 Phillips Square Step Tape 3/16” Bit) Glasses 7/16” & 9/16” or Robertson Ruler Ladder Part Identification Key 1234 Post 2 x 4 x 83” On each page, you will find the parts and quantities required to complete the assembly step illustrated on that page.

  • Page 7: Metric Conversion Sheets

    support@solowavedesign.com...
  • Page 8 support@solowavedesign.com...

  • Page 9: Part Id

    Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size Nominal Size 26pc. - 0517 Cedar Roofing (3/8 x 3-1/2 x 48") - Box 2 - 3630517 ⅜" x 3½" ⅝" x 3½" ½"...
  • Page 10 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size Nominal Size 2pc. - 1853 Cedar Gap Board (1 x 5 x 38-3/4") - Box 2 - 3631853 ⅝" x 4½" 1" x 5" ⅝"...
  • Page 11 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Nominal Size Actual Size 2pc. - 0516 Bottom Arch (1 x 6 x 24") - Box 2 - 3640516 1" x 6" ⅝" x 5⅜" "...
  • Page 12 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size Nominal Size 1pc. - 4919 SW Rail Block (2 x 4 x 5-3/8") - Box 2 - 3644919 1⅜" x 3⅜" 2" x 4" 1½"...
  • Page 13 Hardware Identification (Actual Size) 1/4 x 1-1/2" 4pc. LS1 - Lag Screw - (9262212) 1/4 x 3" 10pc. LS3 - Lag Screw - (9262230) Hex Bolt 1/4 x 1-1/2" 1pc. H1 - - (9277212) Hex Bolt 1/4 x 2" 20pc. H2 - - (9277220) Hex Bolt 1/4 x 2-1/2"...
  • Page 14 Hardware Identification (Actual Size) Hex Bolt 5/16 x 1" 4pc. G2 - - (9277310) Hex Bolt 5/16 x 1-1/2" 4pc. G1 - - (9277312) Hex Bolt 5/16 x 2" 2pc. G8 - - (9277320) Hex Bolt 5/16 x 4" 5pc. G4 - - (9277340) Hex Bolt 5/16 x 4-1/2"...
  • Page 15 Hardware Identification (Actual Size) 38pc. TN1 - 1/4" T - Nut (9285200) 44pc. FW3 - #8 Flat Washer - (9251500) 18pc. LW2 - 5/16" Lock Washer - (9253300) 17pc. FW0 - 3/16" Flat Washer - (9251100) 43pc. LW1 - 1/4" Lock Washer - (9253200) 18pc.
  • Page 16 Swing Hanger Bolt Thru. (6 pk) 1X 3201103 (4 Pk) Corner Brace Set 1X 3200184 Triangle Plate (4pk) Green 1X 3320356 Big Backyard I.D Plaque w hardware 1X 3320215 Phone Assembly 2X 3320401 Flower Box Set (Green) 1X 3750255 Canopy Set...
  • Page 17 Step 1: Inventory Parts - Read This Before Starting Assembly STOP STOP STOP STOP T his is the time for you to inventory all your hardware, wood and accessories, referencing the parts identification sheets. This will assist you with your assembly. • T he wood pieces will have the four digit key number stamped on the ends of the boards. The wood pieces are referenced throughout the instructions with this number. • Please refer to Page 6 for proper hardware assembly. • E ach step indicates which bolts and/or screws you will need for assembly, as well as any flat washers, lock washers, t-nuts or lock nuts. I f there are any missing or damaged pieces or you need assistance with assembly please contact the Consumer Relations Department directly. Call us before going back to the store. 1-877-966-3738 support@solowavedesign.com R ead the assembly manual completely, paying special attention to ANSI warnings; C. notes; and safety/maintenance information on pages 1 - 6. B efore you discard your cartons fill out the form below. D. • T he carton I.D. stamp is located on the end of each carton. The tracking number is located on the Big Backyard ID Plaque (3320356).
  • Page 18 Step 2: Rock Wall Assembly Fig. 2.1 0630 0630 Note: The holes in the rock boards 0606 0630 0349 0631 must orient to the 0631 top of the boards. 7-3/4” Approx Note: Gaps between boards 2-1/4”, not to exceed 2-3/8” A: Lay 2 (0349) Rock Rails down, side by side with angled edges facing down. (fig. 2.1) B: Place (0606) CE Access Board on the bottom of each (0349) Rock Rail as shown in fig. 2.1. Make sure (0606) CE Access Board is flush to the outside and bottom edges of each (0349). Attach using 4 (S2) #8 x 1-1/2” Wood...
  • Page 19 Step 3: Swing Beam Assembly Warning: For your child’s safety, Fig. 3.4 orientate the swing hangers as shown to ensure your swing will have proper swing motion when installed. Failure to do so could result in premature failure of the swing hanger or swing chain.
  • Page 20 Step 4: Swing End Assembly A: Attach 2 (1863) SW Posts to (1856) SW Upright using 2 (G4) 5/16 x 4” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 4.1) Fig. 4.1 5/16” Lock Washer 1863 1856 1862 5/16” Flat Washer 5/16” T-Nut 5/16” 5/16” Flat T-Nut Washer 5/16” Lock Washer 1863 B: Attach (1862) SW Support to both (1863) SW Posts and (1856) SW Upright using 3 (G5) 5/16 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 4.1) Wood Parts Hardware 5/16 x 4” Hex Bolt SW Post 2 x 4 x 86-11/16” 1863 (5/16”...
  • Page 21 Step 5: Attach Swing End to Swing Beam A: Place (4919) SW Rail Block in the centre between (1826) Front Beam and (1825) Back Beam and attach with 1 (H8) 1/4 x 4-1/4” Hex Bolt (with lock washer, flat washer and t-nut). (fig. 5.1 & 5.2) 1826 Fig. 5.1 Fig. 5.2 1/4” Lock Washer 1826 1825 4919 1/4” Flat Washer 1825 1/4” T-Nut B: Attach Swing Beam Assembly to the side of the Swing End Assembly with the overhang (fig. 5.3 & 5.4) using 1 (G5) 5/16 x 4-1/2” Hex Bolt (with lock washer, flat washer and t-nut) in the top hole of Triangle Plate and 1 (G8) 5/16 x 2” Hex Bolt (with 2 flat washers and lock nut) in the bottom hole of Triangle Plate. (fig. 5.4) Make sure Swing End Assembly flares out at an angle. (fig. 5.3) 1826 5/16” Lock 5/16” Flat Fig. 5.4 Washer Washer Fig. 5.3 Side with overhang 1825 5/16”...
  • Page 22 Step 6: Roof Assembly Part 1 A: Attach 1 (0863) Roof Support to another at the peak using 1 (S4) #8 x 3” Wood Screw. Do this twice so you have 2 Roof Support Assemblies. (fig. 6.1 & 6.2) B: Attach 1 (0501) Joist to another at the peak using 1 (S4) #8 x 3” Wood Screw. (fig. 6.1) C: Place the Roof Supports and Roof Joist Assemblies in the pattern shown in fig. 6.1 Step * ** Fig. 6.1 Fig. 6.2 0863 0863 0501 0863 Wood Parts Hardware Roof Support 2 x 3 x 43-1/2” #8 x 3” Wood Screws 0863 Joist 2 x 2 x 43-1/2” 0501 support@solowavedesign.com...
  • Page 23 Step 6: Roof Assembly Part 2 D: Starting at the top of the Roof Support Assembly and working down attach 3 (0517) Cedar Roofing on one side of the (0863) Roof Supports and (0501) Joists with 3 (S0) #8 x 7/8” Truss Screws per board. (fig. 6.3 and 6.5) Be sure to overlap the Cedar Roofing as shown in fig. 6.4. E: Repeat Step A for the other side of the Roof Support Assembly. F: Drill a hole 1-1/4” above the factory drilled holes in 2 (0517) Cedar Roofing. Attach 1 (0517) Cedar Roofing at the bottom of the Roof Support Assembly on each side, making sure they are flush to each (0863) Roof Support with 3 (S0) #8 x 7/8” Truss Screws. (fig.6.3 and 6.5) * ** G: Evenly space and attach the remaining (0517) Cedar Roofing, leaving no gaps, with 3 (S0) #8 x 7/8” Truss Screws per board. There should be 13 (0517) Cedar Roofing per side. (fig. 6.3) Fig. 6.3 x 39 per side Step * ** Fig. 6.5 0517 0863 0863 0501 1-1/4” Flush to edge Fig. 6.4 Overlap cedar roofing Roof Supports removed for clarity Wood Parts Hardware 78 x...
  • Page 24 Step 7: Side Wall Assembly A: On the ground lay flat two (1500) Posts then attach (1874) Side Ground with 4 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut); (1501) Floor End using 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut) in the bottom holes, noticing hole locations; and (1864) SL Roof Side with 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut) as shown in fig. 7.1. Note: Pre-drill all holes using a 1/8” drill bit before installing the lag screws. B: Make sure assembly is square and then fasten (1501) Floor End to (1500) Posts in the top holes using 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer). (fig. 7.1) Fig. 7.1 1864 1500 1500 1501 1/4” flat washer 1874 Notice the hole locations of (1501) Floor End 1/4” T-Nut 1/4” Flat...
  • Page 25 Step 8: Swing Wall Assembly A: Attach (1872) Ground using 4 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut); (1501) Floor End (in the bottom holes), (1502) Wall Support and (1865) SW Roof Side using 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut) for each board to two (1500) Posts. (fig. 8.1) Note: Keep all bolts loose. B: Place (1861) SW Mount across (1501) Floor End, (1502) Wall Support and (1865) SW Roof Side then attach using 3 (G4) 5/16 x 4” Hex Bolts (with lock washer, flat washer and t-nut) as shown in fig. 8.1. Notice the side hole locations are towards the top of the board. Note: Pre-drill all holes using a 1/8” drill bit before installing the lag screws. C: Make sure assembly is square and then fasten (1501) Floor End to (1500) Posts in the top holes using 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer). (fig. 8.2) Tighten all (H2) 1/4 x 2” Hex Bolts. 1865 5/16” t-nut Fig.
  • Page 26 Step 9: Back Wall Assembly A: On the back side of the assembly, attach (0799) Floor Back to both (1500) Posts using 2 (H5) 1/4 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut) The bolt on the Side Wall should be installed from the inside of the assembly. (fig. 9.1) The middle bolt hole should be towards the bottom. B: Attach (1855) Divider to (0799) Floor Back with 1 (H1) 1/4 x 1-1/2” Hex Bolt (with lock washer, flat washer and t-nut). (fig. 9.1). C: Attach (1855) Divider to (0358) Top Front Back using 1 (PB2) 1/4 x 1-1/4” Pan Bolt (with lock washer, flat washer and t-nut). (fig. 9.1) D: Make sure (0358) Top Front Back is level and then attach to both (1500) Posts using 4 (S7) #12 x 2” Pan Screws (with 3/16” flat washers). (fig. 9.1) Note: Pre-drill all holes using a 1/8” drill bit before installing the lag screws. E: Attach (0351) Front Back to the bottom of (1500) Posts with 2 (LS3) 1/4 x 3” Lag Screws (with flat washer) in the top (pre-drilled) holes and 2 (S7) #12 x 2” Pan Screws (with 3/16” flat washers) in the bottom holes as shown in fig. 9.1. 1/4” lock 1/4” flat washer washer 0358 Front Fig. 9.1 1500 1/4” t-nut with 3/16”...
  • Page 27 Step 10: Front Wall Assembly A: On the front side of the assembly, attach (0799) Floor Back to both (1500) Posts using 2 (H5) 1/4 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 10.1) The middle bolt hole should be towards the bottom. Note: Pre-drill all holes using a 1/8” drill bit before installing the lag screws. B: Attach (1883) Front Ground to the bottom of (1500) Posts with 2 (LS3) 1/4 x 3” Lag Screws (with flat washer) in the top (pre-drilled) holes and 2 (S7) #12 x 2” Pan Screws (with 3/16” flat washers) in the bottom holes as shown in fig. 10.1. C: Attach (1885) Centre Post to (0799) Floor Back with 1 (H5) 1/4 x 4-1/2” Hex Bolt (with lock washer, flat washer and t-nut); to (1883) Front Ground with 1 (H4) 1/4 x 4” Hex Bolt (with lock washer, flat washer and t-nut); and to (1559) Top Front with 1 (H4) 1/4 x 4” Hex Bolt (with lock washer, flat washer and t-nut). (fig. 10.1). D: Make sure (1559) Top Front is level and then attach to both (1500) Posts using 4 (S7) #12 x 2” Pan Screws (with 3/16” flat washers). (fig. 10.1) 1865 1/4” flat 1/4” lock 1559 washer washer Flush Fig. 10.1 1864 1/4”...
  • Page 28 Step 11: Attach Gussets Note: Pre-drill all holes using a 1/8” drill bit before installing the lag screws. A: Make sure the assembly is square before proceeding. B: Attach (0403) Gusset to (1500) Post on the front Swing Wall side using 1 (LS3) 1/4 x 3” Lag Screw (with flat washer). The other end of the gusset should be tight against (0799) Floor Back. (fig. 11.1) C: Attach the other end of (0403) Gusset to (0799) Floor Back with 1 (LS3) 1/4 x 3” Lag Screw (with flat washer) 0403 Gusset as shown in fig. 11.1. 0367 Floor Gusset 1/4 x 3" Lag Screw D: Measure 2” down from the top of (1501) Floor End, place 1 (0367) Floor Gusset against each (1500) Post on #8 x 1-1/2" Wood Screw the Swing Wall and attach to posts using 1 (LS3) 1/4 x 3” Lag Screw (with flat washer) per post. The other end of the gusset should be tight against (1501) Floor End. (fig. 11.1 and 11.2) E: Attach the other end of each (0367) Floor Gusset to (1501) Floor End with 2 (S2) #8 x 1-1/2” Wood Screws as shown in fig. 11.1.
  • Page 29 Step 12: Attach Lower Diagonals Pre-drill all holes using a 1/8” drill bit before installing the lag screws. A: Attach 1 (0369) Lower Diagonal to each end of (1872) Ground with 1 (H2) 1/4 x 2” Hex Bolt (with flat washer, lock washer and t-nut) per side. (fig. 12.1) Make sure to keep the bolts loose. B: Through the pre-drilled holes attach (0369) Lower Diagonals to each (1500) Post using 1 (LS3) 1/4 x 3” Lag Screw (with flat washer) per diagonal. (fig. 12.1) Tighten the Hex Bolts from Step A. Fig. 12.1 1/4” flat washe 1500 0369 0369 1/4” t-nut...
  • Page 30 Step 13: Floor Frame Assembly A: Remove the middle and bottom bolts in (1861) SW Mount. Do not discard these bolts, you will re-install them after the (0790) Floor Joist is attached. (fig. 13.1) B: From inside of the assembly, measure 2” down from the top of each (1501) Floor End (fig. 13.2) and then attach (0790) Floor Joist to each board in the top pilot holes with 2 (S4) #8 x 3” Wood Screws per end. (fig.13.2) C: Reinstall the bolts in (1861) SW Mount and tighten all three bolts. (fig. 13.1) D: On the back of the assembly attach (0795) Side Joist to the inside of (0799) Floor Back with 2 (H3) 1/4 x 2-1/2” Hex Bolts (with lock washer, flat washer and t-nut) in the outside holes and 2 (S7) #12 x 2” Pan Screws in the inside holes as shown in fig. 13.1. Fig. 13.1 1501 1861 2" Back Fig. 13.2 0790 Outside View 1/4” lock washer 1/4” flat washer 0799 1501 E: On the front of the assembly attach one (1882) Short Joist on 0799 each side of (1885) Centre Post, 1882 1/4” 0795 0790 to the inside of (0799) Floor t-nut Back with 1 (H3) 1/4 x 2-1/2”...
  • Page 31 Step 14: Attach Gap and Floor Boards A: Place one (1853) Cedar Gap Board at each end of the assembly; two (1881) CE Centre Gap Board in the middle so the gaps in the boards fit around the (1885) Centre Post; and six (1851) Cedar Floor Boards in between the Gap and Centre Boards. Make sure all boards are evenly spaced. (fig. 14.1) B: Attach all boards to (0795) Side Joist, (0790) Floor Joist and (1882) Short Joists with 5 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 14.1) Fig. 14.1 S2 x 5 per board 1853 0795 (hidden under floor boards) 1851 0790 (hidden under floor boards) Evenly spaced 1881 1882 (hidden under floor boards) 1885 Wood Parts Hardware Cedar Gap Board 1 x 5 x 38-3/4” 50 x #8 x 1-1/2”...
  • Page 32 Step 15: Swing Side Wall Assembly A: In between both (1500) Posts on Swing Wall side attach six (1503) Wall Boards to (1501) Floor End and (1502) Wall Support using 4 (S0) #8 x 7/8” Truss Screws per board. Make sure the bottom of the boards are tight against the floor boards and bevelled edges are facing out and are at the top of the boards. The distance between boards should be evenly spaced, not exceeding 1-13/16”. (fig. 15.1 and 15.2) Note: Gaps between boards evenly spaced, not to exceed 1-13/16” Bevelled edges towards top and facing out Fig. 15.1 1861 Fig. 15.2 1500 1502 x 24 1503 1500 1501 Hardware Wood Parts 24 x #8 x 7/8”...
  • Page 33 Step 16: Chalk Wall Frame Assembly A: On the back of the assembly, attach (0726) Panel Frame to (1500) Post using 2 (S2) #8 x 1-1/2” Wood Screws. The top of (0726) Panel Frame is tight to the bottom of (0358) Top Front Back. (fig. 16.1) B: Place (0705) Cedar Wall tight to the bottom of (0726) Panel Frame and attach to (1500) Post using 2 (S2) #8 x 1-1/2” Wood Screws. The bevelled edge faces the inside of the assembly, against (1855) Divider. (fig. 16.2) 0358 Fig. 16.1 1855 1500 Fig. 16.2 Inside Fort View 0726 1855 0705 0705 Bevelled edge facing inside of assembly 0799 Back Wood Parts Hardware Panel Frame1 x 2 x 25-1/2” #8 x 1-1/2” Wood Screw 0726 Cedar Wall 1 x 4 x 23-1/2”...
  • Page 34 Step 17: Attach Chalk Wall/Tarp to Fort A: On the back of the assembly, loosen the top bolt in (1855) Divider and place the Chalk Wall Tarp in between (1855) Divider and (0358) Top Front Back. (fig. 17.1) B: Attach Chalk Wall Tarp to (0358) Top Front Back, (0726) Panel Frame, (0705) Cedar Wall and (1855) Divider using 12 (S5) #8 x 1/2” Pan Screws (with #8 flat washer) as shown in fig. 17.1. The 2 screws on (1855) Divider are attached from the inside of the assembly. (fig. 17.1) C: Tighten the top bolt in (1855) Divider. D: Make sure (0705) Cedar Wall is level and then attach to (1855) Divider using 2 (S1) #8 x 1-1/8” Wood Screws. (fig. 17.1) with #8 flat washer 0358 Fig. 17.1 1500 0726 (Hidden by tarp) S5 x 10 with #8 flat washer 0705 1855 Back Hardware Other Parts 12 x #8 x 1/2” Pan Screw (#8 flat washer) 1 x Chalk Wall Tarp #8 x 1-1/8”...
  • Page 35 Step 18: Slide and Front Wall Frame Assembly A: On the Side Wall side of the assembly, attach (1851) Cedar Floor Board to both (1500) Posts, tight to the top of (1501) Floor End, using 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 18.1) B: On the Front side of the assembly, attach (1239) Picket to (1500) Post and (1885) Centre Post, tight to the top of (0799) Floor Back, using 2 (S2) #8 x 1-1/2” Wood Screws. (fig. 18.1) C: Tight to the top of (1239) Picket, attach (1880) CE Wall Board to (1500) Post and (1885) Centre Post using 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 18.1) Fig. 18.1 1880 1851 1501 0799 1239 1500 1885 Front Side Wall 1500 Wood Parts Hardware Cedar Floor Board 1 x 5 x 38-3/4” 10 x #8 x 1-1/2”...
  • Page 36 Step 19: Cafe Canopy Assembly A: Feed Cafe Frame A through the pockets of the Cafe Canopy on the long side. The end with the screw holes should be on the inside of the canopy. (fig. 19.1) B: Feed Cafe Frame B through the pockets of the shorter side of the Cafe Canopy. The end with the screw holes should line up with the screw holes on Cafe Frame A. (fig. 19.1) C: Attach both frames together with 2 (MB1) #12 x 1/2” Machine Bolt (with #12 lock nut). (fig. 19.2 and 19.3) Fig. 19.1 Cafe Canopy Notice Hole Locations Cafe Frame A Cafe Frame B Fig. 19.2 Feed canopy frame A & B through the pockets of the canopy #12 Lock Nuts Fig. 19.3 Hardware Other Parts #12 x 1/2” Machine Bolt (#12 lock nut) 1 x Cafe Canopy 1 x Cafe Frame A 1 x Cafe Frame B...
  • Page 37 Step 20: Attach Cafe Canopy to Fort Part 1 C: The distance from the bottom of Cafe A: Remove the (S2) #8 B: Place the Cafe Canopy on the fort so Frame B to the bottom of (1239) Picket x 1-1/2” Wood Screw on Cafe Frame A (longer side) is on the Side should be 7/16”. (fig. 20.3) the (1885) Centre Post Wall side and Cafe Frame B (shorter side) side of the (1239) Picket. is on the Front side of the fort. (fig. 20.1) (fig. 20.2) Cafe Frame B Fig. 20.3 1885 Fig. 20.2 1239 7/16” Side view Front of Fort 1239 Cafe Frame A Remove from previous step Fig. 20.4 Front 3-9/16” 1501 Fig. 20.1 1885 D: The distance from the bottom of Cafe Frame A to the bottom of (1501)
  • Page 38 EXTRA IMAGES!!!!!! Step 20: Attach Cafe Canopy to Fort Part 2 Pre-drill holes using a 1/8” drill bit before installing the (S6) #12 x 1” and (S7) #12 x 2” Pan Screws. E: Attach Cafe Frame A to (1501) Floor End with 2 (S6) #12 x 1” Pan Screws (fig. 20.5 and 20.6) and Cafe Frame B to (1239) Picket with 1 (S7) #12 x 2” Pan Screws. (fig. 20.7) F: Attach Cafe Canopy to top of (1851) Cedar Floor Board with 5 (S5) #8 x 1/2” Pan Screws (with #8 flat washers) and to (1880) Fig. 20.1 1239 CE Wall Board with 3 (S5) #8 x 1/2” Pan Screws (with #8 flat washer). Make sure...
  • Page 39 Step 21: Side Wall Window Assembly Part 1 A: Tight to the bottom of (1864) SL Roof Side, with the arch facing down, attach (1884) Side Top to both (1500) Posts with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 21.1) B: Tight to the top of the (1851) Cedar Floor Board, which the Cafe Canopy is attached to, attach 2 more (1851) Cedar Floor Boards to both (1500) Posts with 4 (S2) #8 x 1-1/2” Wood Screws per board. The boards should be tight to each other. (fig. 21.1) Fig. 21.1 1864 x 12 1884 1851 1500 1851 Hidden behind Cafe Canopy 1500 Wood Parts Hardware Cedar Floor Board 1 x 5 x 38-3/4” 12 x #8 x 1-1/2” Wood Screw 1851 Side Top 1 x 5 x 38-1/4”...
  • Page 40 Step 21: Side Wall Window Assembly Part 2 C: Measure 4-1/2” from the top of (1864) SL Roof Side and tight to both (1500) Posts attach 2 (0702) CE Wall Boards, with bevelled edges facing out and at the top of the boards, to (1884) Side Top and the middle (1851) Cedar Floor Board using 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 21.2 and 21.3) D: Tight to each (0702) CE Wall Boards attach 2 more boards, with bevelled edges facing out and at the top of the boards, to (1884) Side Top and the middle (1851) Cedar Floor Board using 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 21.2) Fig. 21.3 1500 1864 Fig. 21.2 4-1/2” 1500 x 16 1884 0702 1884 Bevelled edges 0702 towards top and facing out 1500 1864 1851 Wood Parts Hardware CE Wall Boards 1 x 6 x 23-1/2” 0702 16 x #8 x 1-1/8”...
  • Page 41 Step 22: Front Wall Window Assembly A: Tight to the top of the (1880) CE Wall Board, which the Cafe Canopy is attached to, attach 2 more (1880) CE Wall Boards to (1500) Post and (1885) Centre Post with 4 (S2) #8 x 1-1/2” Wood Screws per board. The boards should be tight to each other. (fig. 22.1) B: Measure 1” from the top of (1559) Top Front and tight to both (1885) Centre Post and (1500) Post attach 2 (1880) CE Wall Boards, with bevelled edges facing out and at the top of the boards, to (1559) Top Front and the middle (1880) CE Wall Board using 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 22.2) Fig. 22.2 Fig. 22.1 Bevelled edges towards top and facing out 1880 1559 1500 1885 1880 1880 1880 1880 Hidden behind Cafe Canopy 1885 1500 Hardware Wood Parts CE Wall Board 1 x 5 x 23-1/2” #8 x 1-1/2”...
  • Page 42 Step 23: Attach Ground Stakes MOVE FORT TO FINAL LOCATION. FINAL LOCATION MUST BE LEVEL GROUND Warning! To prevent tipping and avoid potential injury, stakes must be driven 10-1/2” into ground. Digging or driving stakes can be dangerous if you do not check first for underground wiring, cables or gas lines. A: Drive 2 (0318) Ground Stakes 10-1/2” into the ground at both ends of (1872) Ground into each (0369) Lower Diagonal as shown in fig. 23.1. Attach using 2 (S3) #8 x 2-1/2” Wood Screws per ground stake.
  • Page 43 Step 24: Roof Frame Assembly A: Attach 1 (0357) Tarp Front Back to each end of (1864) SL Roof Side and (1865) SW Roof Side, making sure the pilot holes are centred on the end of each Roof Side, with 4 (S2) #8 x 1-1/2” Wood Screws per (0357) Tarp Front Back. (fig. 24.1 and 24.2) B: At all 4 corners centre and attach 1 Corner Brace using 3 (S5) #8 x 1/2” Pan Screw per brace as shown in fig. 24.1 and 24.3. Corner Brace Fig. 24.1 Fig. 24.3 Corner Brace 1865 0357 0357 0357 Fig. 24.2 1864 1864 Hardware Other Parts Wood Parts #8 x 1-1/2” Wood Screw 4 x Corner Brace Tarp Front Back 1 x 4 x 47-3/4” 0357 12 x #8 x 1/2”...
  • Page 44 Step 25: Attach Roof to Fort A: With two helpers place the Roof Assembly, from Step 6, on the fort as shown in fig. 25.1. The roof should be centred on the assembly and (0863) Roof Supports should be flush to the inside of the fort and resting on (1865) SW Roof Side and (1864) SL Roof Side. The (0501) Joists should fit tight to the inside of each (0357) Tarp Front Back. B: Attach 1 (0514) Roof Brace to each (0863) Roof Support so it is tight against the angled edge of the Roof Supports using 2 (S2) #8 x 1-1/2” Wood Screws per brace. (fig. 25.2 & 25.3) C: Attach each (0514) Roof Brace to (1865) SW Roof Side and (1864) SL Roof Side using 2 (S1) #8 x 1-1/8” Wood Screws per brace. (fig. 25.2 & 25.3) D: Predrill and attach (0357) Tarp Front Back to (0501) Joists using 1 (S2) #8 x 1-1/2” Wood Screw per side. (fig. 25.1) Fig. 25.1 Fig. 25.3 0863 0514 0501 1865 0863 0357 1865 0863 1864 0501 1865 0357 0514 1864 Fig. 25.2 Hardware Wood Parts Roof Brace 1 x 6 x 13”...
  • Page 45 Step 26: Attach Roof Arches A: From inside the Roof Assembly, on each opening, place 1 (0515) Top tight to the top of each (0863) Roof Support using 4 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 26.1 & 26.2) B: Tight to the bottom of each (0515) Top attach 1 (0516) Bottom Arch to each (0863) Roof Support using 4 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 26.1 & 26.2) Fig. 26.2 Fig. 26.1 Inside Fort View 0863 0863 0516 0515 Hardware Wood Parts Top 1 x 6 x 13-1/2” 16 x #8 x 1-1/2” Wood Screw 0515 Bottom Arch 1 x 6 x 24” 0516 support@solowavedesign.com...
  • Page 46 Step 27: Attach Wall Canopy A: Loosen the 4 bolts indicated in fig. 27.1 then tuck the Wall Canopy between the posts and (1872) Ground, down to the top of the bolts. B: Measure 19” up from the top of (1872) Ground and attach (1658) Safety Rail to both (1500) Posts with 4 (S2) #8 x 1-1/2” Wood Screws. (1658) Safety Rail should overlap the Wall Canopy by 1”. (fig. 27.1 and 27.2) C: From the outside of the assembly and 1/2” in from the edge of the canopy attach Wall Canopy to both (1500) Posts with 2 (S5) #8 x 1/2” Pan Screws (with #8 flat washer) per post. (fig. 27.1) D: From the inside of the assembly and 1/2” in from the edge of the canopy attach Wall Canopy to both (1658) Safety Rail and (1872) Ground with 3 (S5) #8 x 1/2” Pan Screws (with #8 flat washer) per board. (fig. 27.1) E: Tighen the previously loosened bolts. Fig. 27.1 x 6 with #8 flat washer 1658 1500 1500 Fig. 27.2 S2 x 4 1872 Wall Canopy with #8 flat washer Loosen these bolts Hardware Wood Parts Other Parts 1 x Wall Canopy Safety Rail 1 x 4 x 38-1/2” 10 x #8 x 1/2”...
  • Page 47 Step 28: Short and Long Table Top Assemblies A: Place (1887) Long Table Top on (1868) Table Support so the end with the shorter notch is flush to one end of (1868) Table Support. Also, the notched out edge of (1887) Long Table Top is flush to the face of (1868) Table Support as shown in fig. 28.1. Attach boards together using 5 (S7) #12 x 2” Pan Screws through (1868) Table Support. B: Place (1886) Short Table Top on (1888) Front Table Support so the bevelled end is flush to the end of (1888) Front Table Support as shown in fig. 28.2, noticing the hole orientation. Also, the notched out edge of (1886) Short Table Top is flush to the face of (1888) Front Table Support. (fig. 28.2). Attach boards together using 3 (S7) #12 x 2” Pan Screws through (1888) Front Table Support. Longer Notch Fig. 28.1 1887 Flush Shorter Notch notched out Flush edge to face notched out edge to face 1868 Flush notched out Flush to edges edges to face Bevelled End 1886 Fig. 28.2 1888 Flush to edges Notice hole orientation Wood Parts Hardware Long Table Top 5/4 x 4 x 41-1/4”...
  • Page 48 Step 29: Attach Wrap Around Canopy A: Loosen the bolts attaching (1883) Front Ground to (1885) Centre Post and (1500) Post and the bolts attaching (1874) Side Ground to both (1500) Posts then tuck the Wall Canopy between the posts and ground boards, down to the top of the bolts. (fig. 29.1) B: From the outside of the assembly and 1/2” in from the edge of the canopy attach Wrap Around Canopy to (1885) Centre Post and the (1500) Post at the end of the canopy with 2 (S5) #8 x 1/2” Pan Screws (with #8 flat washer) per post. (fig. 29.1 and 29.2) C: From the inside of the assembly and 1/2” up from the edge of the canopy attach Wrap Around Canopy to (1883) Front Ground with 2 (S5) #8 x 1/2” Pan Screws (with #8 flat washer) and to (1874) Side Ground with 3 (S5) #8 x 1/2” Pan Screws (with #8 flat washer). (fig. 29.1 and 29.2) D: Tighten the previously loosened bolts. Fig. 29.1 1500 Fig. 29.2 1883 1500 1883 x 4 with #8 1885 flat washer with #8 flat washer 1874 Hardware Other Parts 1 x Wrap Around Canopy #8 x 1/2” Pan Screw (#8 flat washer) support@solowavedesign.com...
  • Page 49 Step 30: Attach Table Top Assemblies to Fort A: Place Long Table Top assembly notches tight against both (1500) Posts, so it overlaps the Wrap Around Canopy by 1”. Attach assembly through (1868) Table Support to each post using 2 (S3) #8 x 2-1/2” Wood Screws per post. Make sure the screws are attached to the posts at the top edge of the tarp. (fig. 30.1 and 30.2) B: Place Short Table Top assembly tight to the bottom of Long Table Top assembly at (1500) Post and against (1885) Centre Post. Attach assembly through (1888) Front Table Support to each post using 1 (S3) #8 x 2-1/2” Wood Screws per post. (fig. 30.1 and 30.2) Fig. 30.1 1500 1887 1886 1868 1888 1885 Fig. 30.2 1500 Hardware #8 x 2-1/2” Wood Screw support@solowavedesign.com...
  • Page 50 Step 31: Attach Wrap Around Canopy to Table Supports A: From the inside of the assembly and 1/2” down from the edge of the canopy attach Wrap Around Canopy to (1888) Front Table Support with 2 (S5) #8 x 1/2” Pan Screws (with #8 flat washer) and to (1868) Table Support with 3 (S5) #8 x 1/2” Pan Screws (with #8 flat washer). (fig. 31.1) Fig. 31.1 1868 1888 with #8 flat washer Hardware #8 x 1/2” Pan Screw (#8 flat washer) support@solowavedesign.com...
  • Page 51 Step 32: Attach Components to Fort Part 1 Note: Pre-drill all holes using a 1/8” drill bit before installing the (S7) #12 x 2” Pan Screws. A: Place Slide centred between (1885) Centre Post and (1500) Post. (fig. 32.1 and 32.2) B: Attach slide to fort through the (0799) Floor Back using 3 (S7) #12 x 2” Pan Screws. (fig. 32.2) C: On the front of the assembly attach the Flower Box, centred, to the top (1880) CE Wall Board with 2 (S5) #8 x 1/2” Pan Screws as shown in fig. 32.1 and 32.3. Fig. 32.1 Fig. 32.2 1500 0799 Flower Box Slide 1880 Fig. 32.3 Flower Box Hardware Other Parts...
  • Page 52 Step 32: Attach Components to Fort Part 2 D: At the corner of the Wrap Around Canopy, on (1500) Post, attach the Phone Holder with 2 (S6) #12 x 1” Pan Screws. (fig. 32.4 and 32.5) E: Attach one end of the Phone Cord to the Phone Holder and the other end to the base of the Phone. (fig. 32.5) F: Place Phone in the Phone Holder. Fig. 32.4 Fig. 32.5 1500 Phone 1500 Phone Holder Phone Cord Hardware Other Parts #12 x 1” Pan Screw 1 x Phone Assembly support@solowavedesign.com...
  • Page 53 Step 33: Attach Rock Rail to Fort Note: Pre-drill all holes using a 1/8” drill bit before installing the (S15) wood screws. A: Place Rock Wall Assembly from Step 2 centred on and flush to top of (0799) Floor Back (fig. 33.1 and 33.3). Attach (0349) Rock Rails to (0799) Floor Back using 4 (S15) #8 x 1-3/4” Wood Screws as shown in fig. 33.2. B: Attach (0606) CE Access Board to top of Rock Wall Assembly, flush to top of (0349) Rock Rail using 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 33.4) Fig. 33.1 Fig. 33.3 Flush Fig. 33.2 0799 0349 Flush 0349 0606 Fig. 33.4 Hardware Wood Parts CE Access Board 1 x 6 x 19-3/4”...
  • Page 54 Step 34: Stool Seat Assembly A: Using the hardware provided with the Stool Seat Assembly attach 1 Seat to 1 Seat Support and then create a second seat as in fig. 34.1. B: Keeping the Cross Brace tight to the Seat Assemblies, fasten the Cross Brace to each of the Seat Assemblies using the hardware provided. (fig. 34.2) 1/4-20 x 1” Machine Screw Fig. 34.1 1/4” Flat washer Seat Spacer Seat Support 1/4-20 Lock Nut Fig. 34.2 Cross Brace 1/4-20 x 1-1/4” Machine Screw Other Parts 1 x Stool Set (with hardware) support@solowavedesign.com...
  • Page 55 Step 35: Attach Stool Seat and Flower Box to Fort A: Attach the Stool Seat Assembly to (1874) Side Ground using 2 (G2) 5/16 x 1” Hex Bolt (with lock washer, flat washer and t-nut) per Seat Assembly. (fig. 35.1 and 35.2) B: Attach a Flower Box, centred under the window on (1851) Cedar Floor Board with 2 (S5) #8 x 1/2” Pan Screws as shown in fig. 35.1 and 35.3. Fig. 35.3 Fig. 35.1 1851 1851 Fig. 35.2 5/16” T- Nut (not shown) 1874 5/16” Flat Washer 5/16” Lock Washer Hardware Other Parts #8 x 1/2” Pan Screw 1 x Flower Box 5/16 x 1”...
  • Page 56 Step 36: Attach Swing Assembly to Fort A: Attach Swing Assembly from Step 5 to (1861) SW Mount with 1 (G5) 5/16 x 4-1/2” Hex Bolt (with lock washer, flat washer and t-nut) and 1 (G8) 5/16 x 2” Hex Bolt (with 2 flat washers and 1 lock nut) as shown in fig. 36.1 and 36.2. 1861 5/16” Flat Fig. 36.2 Washers 5/16” T-Nut 5/16” Lock Washer 5/16” Lock Nut Fig. 36.1 5/16” Flat Washers Hardware 5/16 x 2” Hex Bolt (5/16” flat washer x 2, 5/16” lock nut) 5/16 x 4-1/2” Hex Bolt (5/16”...
  • Page 57 Step 37: Attach Swing Ground Stakes A: Drive one (0318) Ground Stake 10-1/2” into the ground at each (1863) SW Post and attach with 2 (S3) #8 x 2-1/2” Wood Screws per ground stake. (fig. 37.1 and 37.2) Warning! To prevent tipping and avoid potential injury, stakes must be driven 10-1/2” into ground. Digging or driving stakes can be dangerous if you do not check first for underground wiring, cables or gas lines. Fig.
  • Page 58 Step 38: Attach Glider and Swings If Bolt protrudes Warning! Check entire play centre for beyond T-Nut bolts protruding beyond T-Nuts. Use extra washers to eliminate this condition. Use an extra Flat W asher A: Attach 2 Belt Swings and Acro Swing to the Bolt-Thru Swing Hangers. (fig. 39.1) Fig. 39.1 Acro Swing Belt Swings Other Parts 2 x Belt Swings...
  • Page 59 Final Step: Attach I.D. Plaque ATTACH THIS WARNING & I.D. PLAQUE TO A PROMINENT LOCATION ON YOUR PLAY EQUIPMENT! (Fort or Swing Post) This provides warnings concerning safety and important contact information. A Tracking Number is provided to allow you to get critical information or order replacement parts for this specific model Attach with screws provided to a location...
  • Page 60 NOTES NOTES support@solowavedesign.com...
  • Page 61 NOTES NOTES support@solowavedesign.com...
  • Page 62 NOTES NOTES support@solowavedesign.com...
  • Page 63 NOTES NOTES support@solowavedesign.com...
  • Page 64 MAIL TO: Fill out your registration card online at Solowave Design www.bigbackyard.com/ownerslounge 375 Sligo Road W. Mount Forest, Ontario, Canada Big Backyard would like to say Thank You for N0G 2L1 your time and feedback. Attention: Customer Service REVISION: 12/01/09...