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Summary of Contents for PLAYSTAR VARSITY GOLD
- Page 1 ® ® Safety Guide & Assembly Instructions Featured Components Featured Components (purchase separately) (purchase separately) PS 7668 PS 7668 PS 7958 PS 7690 PS 7958 PS 8870 PS 8876 PS 8850 PS 8876 PS 8814 PS 8814 Featured Components Featured Components (purchase separately) (purchase separately) PS 7766...
- Page 2 • Thoroughly read all safety instructions before Testing and Materials (ASTM) Home Playground beginning. Safety Standard. In order for PlayStar to comply with the ASTM Standard, we cannot recommend • Children must remain clear of construction site until anyone above these limits.
- Page 3 SAFETY INSTALLATION: 2. Only one child, for each single planned 4. Dress children appropriately and do not seat or single planned activity should allow them to wear inappropriate items, 1. Follow the instructions provided, do not be allowed on this set at one time, with such as but not limited to, loose fitting alter its design in any way.
- Page 4 COMPONENTS INCLUDED (not actual size) Swing Assembly Sturdy Frame Brkts. Hangers (4) Tool Kit (1) Left-hand (1) Right-hand (2) Corner Rings (2) Swing Seat (1) Brackets (12 Sturdy Frame Brace (1) Quick-Link Connectors (4) Discovery Telescope (1) Climbing Rocks (4) Tarp Roof (1) Drill Template (1) Gym Ring Chains (2)
- Page 5 BOARDS INCLUDED Before starting to assemble your playset, make sure all boards and hardware are identified and stacked by size. This will improve your assembly time. All boards are identified by “nominal” dimensions. The “actual” width and thickness of boards will vary.
- Page 6 BOARDS INCLUDED All boards are identified by “nominal” dimensions. The “actual” width and thickness of boards will vary. During assembly process, hide the marked end of the board to the inside so it is not visible on your completed playset. Note: These boards require some basic drilling that is best...
- Page 7 PLEASE NOTE: Letters represent pattern not position Note: When the PlayStar logo is showing, the three tabs on the bottom will position the template square with any two edges. When the arrow is...
- Page 8 PLEASE NOTE Patterns (Letters represent pattern not position) can be created anywhere along the board by turning the template over (arrow side up) and sliding it to the desired position. Use the shaded holes for that pattern. 2" x 6" 1"...
- Page 9 ATTACHING CORNER BRACKETS There are several steps in the assembly of your playset when you will be asked to attach “corner brackets”. Please review these diagrams to understand where to place the brackets, how to attach them, and what hardware to use. POSITIONING THE BRACKETS: The “corner bracket”...
- Page 10 TOWER ASSEMBLY Items for STEP 1: (2) 2" x 4" x 88" boards (4) 2" x 4" x 38³ ₄" boards (16) #8 x 2¹⁄₂" deck screws 75¹⁄₄" 47" 31¹⁄₄" On a flat work surface, lay out two 2" x 4" x 88" 90˚...
- Page 11 Items for STEP 3: Stand tower frames on their sides as shown. (6) 2" x 4" x 46³ ₄" boards Attach six 2" x 4" x 46³⁄₄" boards at the dimensions shown. Make sure the assembly remains square while (36) #8 x 2¹⁄₂" deck screws securing with #8 x 2¹⁄₂"...
- Page 12 Items for STEP 4: (8) Corner Brackets (32) #8 x 1¹ ₄" deck screws (8) ³ ₈" x 3¹ ₂" hex bolts (6) ³ ₈" x 2" hex bolts (2) ³ ₈" x 1¹ ₂" lag screws (30) ³ ₈" washers (14) ³...
- Page 13 Items for STEP 5: (1) 2" x 4" x 46³⁄₄" board (4) #8 x 2¹ ₂" deck screws Predrill the 2" x 4" x 38³ ₄" boards at the dimension shown. Center the 2" x 4" x 46³⁄₄" board behind the holes and flush with the top of the 2"...
- Page 14 Items for STEP 7: (2) 2" x 4" x 88" boards (20) #8 x 2¹⁄₂" deck screws Attach two 2" x 4" x 88" boards at dimensions shown. Secure with #8 x 2¹⁄₂" deck screws. 21¹⁄₂" 21¹⁄₂" 7 & 8 F AGES ATTERNS...
- Page 15 Items for STEP 8: (2) 2" x 4" x 46³ ₄" boards (8) #8 x 2¹ ₂" deck screws Attach two pre-drilled 2" x 4" x 46³ ₄" boards at the dimensions shown. Center boards on tower, there should be a 4" overhang on each end of the boards.
- Page 16 Items for STEP 9: Attach two pre-drilled 2" x 4" x 31¹⁄₂" boards at dimensions shown. Center boards on tower, there should an overhang on each end of (2) 2" x 4" x 31¹⁄₂" boards the boards. Make sure the top and bottom of board is flush while (8) #8 x 2¹⁄₂"...
- Page 17 SWING BEAM ASSEMBLY Items for STEP 11: (6) 2" x 4" x 88" boards (48) #8 x 2¹ ₂" deck screws ¹ 13¹ " " Mark & Drill 3 Boards as shown ¹ 25¹ " " 37³ ₄" ³ ₄ ³...
- Page 18 Items for STEP 12: (3) Step 11 Assemblies (2) Right-hand Sturdy-frame Brackets (1) Left-hand Sturdy-frame Bracket (6) #8 x 1¹ ₄" deck screws (6) ³ ₈" x 3¹ ₂" hex bolts (12) ³ ₈" washers (6) ³ ₈" lock nuts Use the bracket as a drill guide and drill two ¹...
- Page 19 Items for STEP 13: (2) ³ ₈" x ³ ₄" hex bolts (2) ³ ₈" lock nuts Mate one right-hand bracket assembly to one left-hand bracket assembly as shown. Secure with two ³ ₈" x ³ ₄" hex bolts and ³ ₈" lock nuts through the two lower holes of brackets as shown (do not use flat washers).
- Page 20 Items for STEP 15: (1) 2" x 4" x 46³⁄₄" board (4) #8 x 2¹⁄₂" deck screws Position assembly as shown. Align the posts so that the outermost points measure 84³⁄₄" as shown. Attach 2" x 4" x 46³⁄₄" board at dimension shown.
- Page 21 Items for STEP 16: (2) corner brackets (8) #8 x 1¹ ₄" screws (2) ³ ₈" x 3¹ ₂" hex bolts (2) ³ ₈" x 2" hex bolts (8) ³ ₈" washers (4) ³ ₈" lock nuts Attach corner brackets. To complete the A-Frame Assembly, flip over as shown and position brackets so that the short side is against the 2"...
- Page 22 Swing Station Assembly Items for STEP 17: (1) 2" x 6" x 88" board (1) 2" x 6" x 35⁷ ₈" board (4) #8 x 1¹ ₄" deck screws Use brackets as a drill guide and drill ¹ ₈" holes Lay out the single post assembly and the A-Frame 1"...
- Page 23 Items for STEP 18: (1) 2" x 6" x 88" board (1) 2" x 6" x 35⁷ ₈" board (16) #8 x 2¹ ₂" deck screws Predrill the 2" x 6" x 88" and 2" x 6" x 35⁷ ₈" beam boards at the dimension shown. (See Pages 7 &...
- Page 24 Items for STEP 19: (5) ³ ₈" x 3¹ ₂" hex bolts (10) ³ ₈" washers Lift swing beam assembly and (5) ³ ₈" lock nuts support with saw horses. Note: If you do not have saw horses, rest beam From the bottom side of beam, use on ground and rotate A-frame and single the six ³...
- Page 25 Items for STEP 20: Mark the top beam board, on the bottom edge, at the dimensions shown, for swing hanger locations. (6) swing hangers (6) ³ ₈" x 3" lag screws NOTE: If you are installing the Air Rider, follow the installation (6) ³...
- Page 26 CONNECT TOWER AND SWING BEAM Items for STEP 21: On the post of tower assembly where the beam will be attached, measure and mark hole location (7" down and 1⁵ ₈" from edge) as shown. (Fig. 1) (1) ³ ₈" x 4¹ ₂" bolt (2) ³...
- Page 27 Items for STEP 22: Attach two 2" x 4" x 24¹⁄₄" boards as shown. The back of the (2) 2" x 4" x 24¹⁄₄" boards boards must be flush with the 2" x 4" x 88" boards and the top (6) #8 x 2¹...
- Page 28 Items for STEP 23: Position 2" x 6" x 12" board 1¹⁄₂" down from top of 2" x 4" x 24¹⁄₄" and (1) 2" x 6" x 12" board tight against 2" x 4" x 88" as shown. Secure with #8 x 2¹⁄₂" deck (4) #8 x 2¹...
- Page 29 Items for STEP 24: (1) 2" x 4" x 31¹⁄₂" board (4) #8 x 2¹ ₂" deck screws Attach one 2" x 4" x 31¹⁄₂" board at dimensions ¹⁄₂" overhang shown. Center board on tower, there should be an overhang on each end of the board. Make sure the top and bottom of board is flush while securing with #8 x 2¹⁄₂"...
- Page 30 Items for STEP 25: Attach thirteen pre-drilled and counter-sank 1" x 4" x 29¹ ₂" boards on the (13) 1" x 4" x 29¹ ₂" boards outside of tower at the approximate dimension shown. Equally space (52) #8 x 1¹ ₂" deck screws boards and secure with #8 x 1¹⁄₂"...
- Page 31 Items for STEP 26: Position 2" x 4" x 31¹⁄₂" board approximately 28" up from bottom of tower flush with the tower and swing beam posts as shown. Attach with #8 x 2¹ ₂" (1) 2" x 4" x 31¹⁄₂" board deck screws.
- Page 32 Items for STEP 27: (1) 2" x 4" x 13¹ ₈" board (1) 2" x 4" x 24¹ ₄" board (4) #8 x 2¹ ₂" deck screws Position 2" x 4" x 13¹ ₈" board approximately 28" up from bottom of tower flush with back of 2" x 4" x 88". Make sure board is level with 2"...
- Page 33 Items for STEP 28: Position 2" x 4" x 28" board at an angle so that the front corner is aligned with the top outside corner of the 2" x 4" x 13¹⁄₈" board and the back edge (1) 2" x 4" x 28" board is resting on the ground as shown.
- Page 34 Items for STEP 29: Position the back 2" x 4" x 31¹⁄₂" board tight against the 2" x 4" x 88" boards as shown. Center with equal ¹⁄₂" overhang on support boards. Attach with (3) 2" x 4" x 31¹⁄₂" boards #8 x 2¹⁄₂"...
- Page 35 Items for STEP 30: Position the front 2" x 4" x 31¹⁄₂" board with the mark made in Step 28 and flush with the end of 2" x 4" x 24¹⁄₄" support board. Center with equal (2) 2" x 4" x 31¹⁄₂" boards ¹⁄₂"...
- Page 36 Items for STEP 31: Attach the tarp roof. (1) Tarp roof Position end of tarp 1¹⁄₂" from the bottom edge of the (6) #14 x 1¹⁄₄" pan head screws board as shown and centered side to side. Pre-drill ¹⁄₈" holes 1" deep into the board. Secure with three #14 x 1¹⁄₄"...
- Page 37 Items for STEP 32: Position edge of tarp awning flush with the back 2" x 4" x 31¹⁄₂" board as shown and centered side to side. (1) Tarp Awning Pre-drill ¹⁄₈" holes 1" deep into the board. (6) #14 x 1¹⁄₄" pan head screws Secure with three #14 x 1¹⁄₄"...
- Page 38 STURDY-FRAME BRACE INSTALLATION Step 33: Remove the top ³⁄₈" x 3¹⁄₂" hex bolt, washers and lock nut from the post support as shown. (Save these parts because they will be used in the next step.) ³⁄₈" x 3¹⁄₂" hex bolt NOTE: It is easiest to remove this bolt by continuing to rotate in a counterclockwise direction.
- Page 39 STOP From this point, skip to the section specific of your design option. GO TO PAGE 65 GO TO PAGE 65 GO TO PAGE 52 GO TO PAGE 40...
- Page 40 STARTER DESIGN OPTION ONLY Position boards so the top corner is flush with the rear edge of the Items for STEP 36: 2" x 4" x 38³⁄₄" and the bottom of the 2" x 4" x 46³⁄₄" as shown. (2) 2" x 4" x 46³ ₄" boards (2) ³...
- Page 41 Items for STEP 37: Position 2" x 4" x 35⁷⁄₈" behind the 2" x 4" x 46³⁄₄" boards at 3¹⁄₄" (1) 2" x 4" x 35⁷ ₈" board from the top as shown. (4) #8 x 2¹ ₂" deck screws Secure each end of the board from behind with two #8 x 2¹⁄₂"...
- Page 42 Items for STEP 38: Position 2" x 4" x 46³⁄₄" board at 13¹⁄₈" as shown. (1) 2" x 4" x 46³ ₄" board (2) #8 x 2¹ ₂" deck screws Secure to 2" x 4" x 35⁷⁄₈" board from behind with two #8 x 2¹⁄₂" deck screws.
- Page 43 Items for STEP 39: Cut the template along the lines using scissors and punch out all four holes. (1) Printed Template Locate the top of the template at the dimensions shown. Make sure the short edge of the template is flush with the front side of the 2" x 4" x 46³⁄₄" board as shown.
- Page 44 THIS PAGE INTENTIONALLY LEFT BLANK...
- Page 45 Items for STEP 40: Align top surface of 2" x 4" x 13¹⁄₈" board with two marks to level (3) 2" x 4" x 13¹ ₈" boards step as shown. Make sure the top front corners of 2" x 4" x 13¹⁄₈" (12) #8 x 2¹...
- Page 46 Items for STEP 41: (1) 2" x 4" x 18⁵ ₈" board (4) #8 x 2¹ ₂" deck screws Position 2" x 4" x 18⁵⁄₈" on top of the 2" x 4" x 35⁷⁄₈" as shown. Secure from behind to each of the 2"...
- Page 47 Items for STEP 42: Center 2" x 4" x 46³⁄₄" board between the two (1) 2" x 4" x 46³ ₄" board adjacent 2" x 4" x 46³⁄₄" boards at approximately (2) #8 x 2¹ ₂" deck screws 8³⁄₄" from each other as shown. Secure to 2"...
- Page 48 Items for STEP 43: Attach two pre-drilled and counter-sank 1" x 4" x 21⁷ ₁₆" boards as shown. Secure each board with #8 x 1¹⁄₂" deck screws. Do not over (2) 1" x 4" x 21⁷ ₁₆" boards tighten the screws. (12) #8 x 1¹...
- Page 49 Items for STEP 44: Attach twelve pre-drilled and counter-sank 1" x 4" x 21⁷ ₁₆" boards in between the two boards you attached in the previous step. Start at the (12) 1" x 4" x 21⁷⁄₁₆" boards top and keep boards tight to each other. Secure with #8 x 1¹⁄₂" deck (72) #8 x 1¹...
- Page 50 Items for STEP 45: Position 2" x 4" x 31¹⁄₂" boards flush with the side, top and bottom of mounting boards as shown. Secure with #8 x 2¹ ₂" deck screws. (2) 2" x 4" x 31¹⁄₂" boards (12) #8 x 2¹ ₂" deck screws Flush Flush 7 &...
- Page 51 ANCHORING - STARTER DESIGN OPTION Items for Step 46: (6) Playset Anchors (6) ³ ₈" x 1¹ ₂" lag screws (6) ³ ₈" washers At locations shown, screw Playset Anchors into ground by hand (a long screwdriver will help). Use the anchor as a drill guide and drill a ¹⁄₄" hole 1"...
- Page 52 BRONZE DESIGN OPTION ONLY Items for STEP 36: Position 2" x 4" x 31¹⁄₂" boards flush with the side, top and bottom (2) 2" x 4" x 31¹⁄₂" boards of mounting boards as shown. Secure with #8 x 2¹ ₂" deck screws. (12) #8 x 2¹...
- Page 53 The Climbing Bar Kit (PS 7766) must be installed now. STOP Do Not follow the instructions included with the Climbing Bar Kit. LUMBER LIST and CUTTING GUIDE This design option requires Two (2) additional 2" x 4" x 8' boards (not included with this kit) and One (1) 2"...
- Page 54 CLIMBING BAR ASSEMBLY Attach triangle bracket onto 2" x 4" x 75³⁄₄" board. Items for step 37: (1) 2" x 4" x 75³⁄₄" board (cut previously) Lay bracket flat on the board. Slide bracket until (1) triangle bracket the stops on the underside are tight against the (2) #8 x 1¹⁄₄"...
- Page 55 Items for step 38: (1) 2" x 4" x 46³⁄₄" board (2) #8 x 1¹⁄₄" deck screws Attach 2" x 4" x 46³⁄₄" board. Lay the assembly from the previous step on the board. Slide assembly until the stops on the underside of bracket are tight against the board and the corner of the 2"...
- Page 56 Items for step 39: (1) ³⁄₈" x 3¹⁄₂" hex bolt (4) ³⁄₈" x 2" hex bolts (6) ³⁄₈" washers (5) ³⁄₈" lock nuts Secure assembly with ³ " hex bolts, ³ " washers and ³ " lock nuts as shown. NOTE: If you are bolting through one board, use a ³...
- Page 57 Items for step 40: (1) 2" x 4" x 75³⁄₄" board (1) triangle bracket (2) #8 x 1¹⁄₄" deck screws Attach triangle bracket onto 2" x 4" x 75³⁄₄" board. Lay bracket flat on the board. Slide bracket until the stops on the underside are tight against the board and the edge of the bracket is flush with the corner of the board as shown.
- Page 58 Items for step 41: (1) 2" x 4" x 46³⁄₄" board (2) #8 x 1¹⁄₄" deck screws Attach 2" x 4" x 46³⁄₄" board. Lay the assembly from the previous step on the board. Slide assembly until the stops on the underside of bracket are tight against the board and the corner of the 2"...
- Page 59 Items for step 42: (1) ³⁄₈" x 3¹⁄₂" hex bolt (4) ³⁄₈" x 2" hex bolts (6) ³⁄₈" washers (5) ³⁄₈" lock nuts Secure assembly with ³ " hex bolts, ³ " washers and ³ " lock nuts as shown as shown. NOTE: If you are bolting through one board, use a ³...
- Page 60 Items for step 43: Predrill the 2" x 4" x 75³⁄₄" boards at the dimension shown. (1) 2" x 4" x 18⁵⁄₈" board (4) climbing bars Center the 2" x 4" x 18⁵⁄₈" board behind the holes. Secure (4) #8 x 2¹⁄₂" deck screws with #8 x 2¹⁄₂"...
- Page 61 Items for step 44: Position 2" x 4" x 44¹⁄₂" board centered at the bottom of existing (1) 2" x 4" x 44¹⁄₂" board 2" x 4" x 18⁵⁄₈" board as shown. Attach with #8 x 1¹ ₂" deck (2) #8 x 1¹⁄₂" deck screws screws.
- Page 62 Items for step 46: Attach corner brackets. Position brackets so that the long sides are against (2) corner brackets the 2" x 4" x 46³⁄₄" board and the short side is flush (4) #8 x 1¹⁄₄" deck screws with the end of the board. (2) ³⁄₈"...
- Page 63 CONNECT TOWER & CLIMBING BAR ASSEMBLY Items for step 47: Lift Climbing Bar Assembly into an upright position at the 75¹⁄₄" dimension shown. (4) #8 x 1¹⁄₄" deck screws (2) ³⁄₈" x 3¹⁄₂" hex bolts Use the bracket as a drill guide and drill ¹ ₈" holes 1" deep (4) ³⁄₈"...
- Page 64 ANCHORING - BRONZE DESIGN OPTION Items for Step 48: At locations shown, screw Playset Anchors into ground by hand (a long (6) Playset Anchors screwdriver will help). Use the anchor as a drill guide and drill a ¹⁄₄" hole (6) ³ ₈" x 1¹ ₂" lag screws 1"...
- Page 65 SILVER & GOLD DESIGN OPTIONS ONLY Items for STEP 36: Attach two 2" x 4" x 31¹ ₂" boards at dimensions shown. Secure with #8 x 2¹⁄₂" deck screws. (2) 2" x 4" x 31¹ ₂" boards (12) #8 x 2¹ ₂" deck screws 6¹⁄₂"...
- Page 66 The Adventure Tunnel Kit (PS 8876) must be installed now. STOP Follow the building instructions included with the Adventure Tunnel Kit skipping Step 2 ONLY. Then continue with these instructions. Attach one pre-drilled and counter-sank 1" x 4" x 29¹ ₂" Items for STEP 37: board on the outside of tower at the approximate (1) 1"...
- Page 67 ANCHORING - SILVER DESIGN OPTION Items for Step 38: (6) Playset Anchors (6) ³ ₈" x 1¹ ₂" lag screws (6) ³ ₈" washers At locations shown, screw Playset Anchors into ground by hand (a long screwdriver will help). Use the anchor as a drill guide and drill a ¹⁄₄" hole 1"...
- Page 68 ANCHORING - GOLD DESIGN OPTION Items for Step 38: (7) Playset Anchors (7) ³ ₈" x 1¹ ₂" lag screws (7) ³ ₈" washers At locations shown, screw Playset Anchors into ground by hand (a long screwdriver will help). Use the anchor as a drill guide and drill a ¹⁄₄" hole 1"...
- Page 69 SLIDE – Mounting Instructions 1. Align slide at right angle (90˚) to 48" play deck. Lip of slide should rest on the play deck 1¹ ₂". Using the slide as a template, mark play deck through the three holes in the slide. Drill three ¹/₈" holes at marked location. GOLD DESIGN OPTION ONLY: If one or more pre-drilled holes for slide line up with a gap between the deck boards, then shift the slide slightly to one side or another to...
- Page 70 CLIMBING WALL – Assembly Instructions 1. Align top of Climbing Wall at right angle 90˚. Lip of 5. Reinstall Climbing Wall permanently, attaching it to climbing wall should rest on the play deck 1¹ ₂". Using play deck using #14 x 1¹ ₄" pan head screws provided. the Climbing Wall as a template, mark play deck 6.
- Page 71 COMPONENTS - Mounting Instructions SWING SEAT • GYM RINGS 1. Attach coated ends of chains onto play component using Quick-Link Connectors provided. Tighten securely with an adjustable wrench. Adjustment Zone 2. Hook uncoated ends of chain onto Swing Hangers provided. 3.
- Page 72 PlayStar, Incorporated, Janesville, WI 53547 © 2014 PlayStar, Inc. Reproduction of this document in part or whole is prohibited without the permission of PlayStar, Inc. Protected by one or more of the following United States or Foreign Patents: US D418,189; US D409,708; US D424,154; US D428,637; US 6,402,663; US D422,332; US D410,059;...
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