Leisure Time Products Sky Fort 6009 Assembly Instructions Manual

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Model

#6009

Assembly Requires

Two Moderately Skilled People

20 - 24 Hours.

If you need assistance with parts or have assembly questions, please call Customer Service

Please read the entire instruction manual carefully before proceeding with the assembly or use of

your new gym set. SAVE THIS MANUAL for future reference in the event that you need to contact us

Leisure Time Products, Inc., provides a 5-year pro-rated limited warranty. See page 60 of this manual for details.

We take great care to design our products with your child's safety in mind. However, only with careful supervision and

proper safety instructions, can you be assured of safe play time on any product designed for children.

LEISURE TIME PRODUCTS INC.

800-765-4138

for assistance or replacement part information and ordering.

YOUR WARRANTY

Accessories available at

Accessory Items On Back Cover

samsclub.com

For Residential Use Only

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Summary of Contents for Leisure Time Products Sky Fort 6009

Page 1 YOUR WARRANTY Leisure Time Products, Inc., provides a 5-year pro-rated limited warranty. See page 60 of this manual for details. We take great care to design our products with your child's safety in mind. However, only with careful supervision and proper safety instructions, can you be assured of safe play time on any product designed for children.
Page 2 Ground stakes: Metal stakes are occurs, it becomes difficult to correct, and provided and are to be installed as Leisure Time Products, Inc. cannot assume outlined in the assembly manual. responsibility for any failure from incorrect Cementing is required if you have loose installation.
Page 3 At this time and always, review the "safety and general information - cautions for use" sections with each child using the play product. Page 2 - SAFETY & ASSEMBLY INFO © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 4 • Wear proper clothing and safety equipment (safety glasses, boots and gloves) while assembling your gym set. ALTHOUGH LEISURE TIME PRODUCTS, INC. READY-TO-ASSEMBLE PLAYSET IS STAINED AT OUR FACTORY. A WATER PROTECTANT IS REQUIRED AT LEAST ONCE A YEAR. THE WOODEN PARTS FOR YOUR PLAYSET ARE MADE FROM...
Page 5: Safety & Assembly
A FALL ON TO A HARD SURFACE COULD RESULT IN SERIOUS INJURY Any edging used to contain the ground must be beyond the safe play area. (Ex. Landscape timbers or railroad ties) Page 4 - SAFETY & ASSEMBLY © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 6 SAFE PLAY AREA DIAGRAMS 28’ - 8” Page 5 - SAFETY & ASSEMBLY © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 7: Using The Hardware
USING THE HARDWARE LEISURE TIME PRODUCTS, INC. GYM SETS USE A FEW STANDARD CONNECTIONS. BECOMING FAMILIAR WITH THESE CONNECTIONS WILL SIMPLIFY ASSEMBLY AND INSURE A SAFER PLAY PRODUCT FOR YOUR CHILDREN. How to use Hex Head Bolts and Spike T-Nuts...
Page 10 1.375 x 3.375 x 50.5 [3.49 x 8.57 x 128.27] E6 - Porch Leg - 2 Hole - 2 Required 1.375 x 3.375 x 50.5 [3.49 x 8.57 x 128.27] Page 9 - WOODEN PARTS A1 to E6 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 11 .9375 x 5.375 x 50.375 [2.38 x 13.65 x 127.95] H9 - Window Board - 5 Holes - 4 Required .9375 x 5.375 x 45.25 [2.38 x 13.65 x 114.94] Page 10 - WOODEN PARTS E7 to H9 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 12 .9375 x 3.375 x 24.5 [2.38 x 8.57 x 62.23] K16R - Porch Roof Rafter - 1 Holes - 2 Required .9375 x 3.375 x 24.5 [2.38 x 8.57 x 62.23] Page 11 - WOODEN PARTS H10 to K16R © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 13 .625 x 3.375 x 50.5 [1.59 x 8.57 x 128.27] P11 - Gable Board - 2 Holes - 1 Required .625 x 3.375 x 46.75 [1.59 x 8.57 x 118.75] Page 12 - WOODEN PARTS K17 to P11 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 14 .625 x 3.375 x 16 [1.59 x 8.57 x 40.64] P30 - Gable Window Board - 1 Hole - 2 Required .625 x 3.375 x 13 [1.59 x 8.57 x 33.02] Page 13 - WOODEN PARTS P12 to P30 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 16 .625 x 4 x 35.5 [1.59 x 10.16 x 90.17] SD1 - Club House Wall Board - 4 Holes - 1 Required .625 x 3 x 27 [1.59 x 7.62 x 68.58] Page 15 - WOODEN PARTS R1 to SD1 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 17 5/16 X 1 1/2" HEAD 3/8 X 8" BOLT ZHB1 3/4 BOLT ZHB2 HEAD 5/16 X 1 3/4" HEAD 5/16 X 2" BOLT BOLT HEAD HEAD BOLT BOLT Page 16 - HEX HEAD BOLTS © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 18: Screws & Washers
Page 18 and take special care to note the sizes given in each step. See page 5 for proper installation instructions. Page 17 - SCREWS & WASHERS © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 19 ZFW8X27 ..... . . Fender Washer (8 x 27mm)......5 Page 18 - FASTENER DETAIL LIST © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 20: Additional Items
QUICK LINK SWING HANGER ADDITIONAL ITEMS 1 - ASSEMBLY MANUAL 1 - HARDWARE KIT 1 - 50226 - 10 FT. SLIDE 8 - Y41 GROUND STAKES Page 19 - MISC. PARTS © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 21 Spike T-Nut Lock Washer Hex Head Bolt Flat Attach H10 Floor Rail to B3 legs with Washer 5/16 X 3 ¾” Hex Bolts, Lock Washers, Flat Washers and Spike T-Nuts. Page 20 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 22 Bottom Floor Rail to B3 and B2 legs with 5/16 X 2 ½” lag screws, Lock Washers and flat washers. Note: remember to pilot drill legs with 3/16” drill bit. Left Back Page 21 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 23 Lock Washers, and Flat Washers through H10’s and H11 floor rails into deck braces. 2” Note: remember to use 3/16” bit to pilot drill. 2” 2 1/2” 2 1/2” Page 22 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 24 1" Phillips Truss Head Bolts 5/16" Lock Washers, Flat Washers and 1/4" Barrel Nuts as shown. Attach O5 Sand Box Seats to bottom rails with 1 ½” Wood Screws. Page 23 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 25 K12L and K12R and attach to B3 Legs with 5/16 X 2” Lag Screws, Lock Washers and Flat Washers. K12R Note: pilot drill with 3/16” bit. 11 1/2” K12L Page 24 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 26 Lock Washers and Flat Washers. Flush with top of P3 and Level across B3 legs. Note: pilot drill with 3/16” bit. Note: Picnic Seats are removed from this drawing to show you position only in this diagram. Page 25 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 27 Now attach four P12 Picnic Table Top to K18 and K3 with 1 ½” Wood Screws. To finish Table Top attach P29 Table Top Support under and in center of table with 1 1/8” Wood Screws. Per diagram 1 1/2” 1 1/8” Page 26 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 28 Bolts, Lock Washers, Flat Washers, and Spike T-Nuts in upper holes. Use 5/16 X 2 ½” Lag Screws, Lock Washers and Flat Washers in bottom holes. Note: pilot drill with 3/16” bit. Page 27 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 29 BARREL Y30-40G Step 28 Attach K7 Back Clubhouse Rail to B5 Post with 5/16 X 3 ¾” Hex Bolt, Lock Washer, Flat Washer and Spike T-Nut through upper hole. Page 28 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 30 5/16" TOOTH SPIKE TEE LOCK WASHER Attach B6 Clubhouse Corner (front-right) to K19 Wall Rail with 5/16 x 3 ¾” Hex bolt, Lock Washer, Flat Washer, and Spike T-Nut. Page 29 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 31 Step 34 Attach K2 Roof Support Rails to B5 and B7 and to B4 and B6 with 5/16 X 3 ¾” Hex Bolt, Lock Washer, Flat Washer and Spike T-Nuts. Page 30 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 32 Washer to B5 Post. (Note: Hole in P22 at 1 ½” from edge towards Floor.) Note: pilot drill with 3/16” bit. Holes are closer to bottom of board (1 1/2”) Page 31 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 33 B5 and B4 flush with K2 roof support Rails with 5/16 X 2” Lag Screws, Lock Washers and Flat Washers. Note: pilot drill with 3/16” bit. 1/4 X 3/4" 1/4" PHILLIPS BARREL TRUSS HEAD HEAD BOLT Page 32 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 34 5/16” x 1 ½” Lag Screw, Lock Washer and Flat Washer. BOLT Note: pilot drill with FLAT WASHER 3/16” bit. FLOOR FLAT WASHER LOCK WASHER BARREL Y30-40G Inside Page 33 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 35 Attach two P25 Clubhouse Wall Board to K2, K7 against B7 Post with 1 1/8” Wood Screws. Step 48 Attach six P24 Wall Boards to K7 and P22 with 1 1/8” Wood Screws Page 34 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 36 P10 Wall Boards against B6 Corner Post and attach with 1 1/8” wood Screws. Attach two P32 Wall Boards flush with top of P10’s to K5 Rail with 1 1/8” Wood Screws. Page 35 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 37 WOOD SCREW Attach two P21, then one Q4 and two more P21 with 1 1/8” 5/16" SPIKE TEE Wood Screws (Note: These holes will be used in later step.) Page 36 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 38 Back diagram). Left Step 55 1” 2 3/4” Wood Screws Repeat procedure on left side Bay Window. Per 1” Wood Screws diagram. Note: H9 is 2 3/4” from posts Page 37 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 39 1 ½” Wood Screws. This will hold roof rafters #8 X 1-1/2" in place. WOOD SCREW 5/16" 5/16 X 2 1/2" INTERNAL 5/16" TOOTH HEAD SPIKE TEE LOCK BOLT WASHER Front Back Page 38 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 40 Attach Gable Boards to inside of E8 Rafters on front of clubhouse starting with P4 then P7, P11, P13, P18 and Q6 with 1 1/8” Wood Screws on front side. (Note: Pilot drill holes on top). Page 39 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 41 Attach P8 Soffit Cap on top of H8 Rail with 1 ½” Wood Screws flush with inside of H8. #8 X 1-1/8" WOOD SCREW #8 X 1-1/2" WOOD SCREW #8 X 3/4 " WASHER HEAD SCREW Page 40 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 42 Left from boring through.) On left side push Q3 support and secure same way (per diagram). Attach Y30-40G to Q3's at Peak with ¾” Washer Head Screws. Right Left Page 41 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 43 INTERNAL 5/16 X 1 1/2" 5/16" TOOTH SPIKE TEE LOCK SCREW WASHER Attach Four P24 Wall Boards to K19 and P2 with 1 1/8” Wood Screws 2 5/8” apart. Page 42 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 44 Washer, and Spike T-Nut. Level Roof and fasten Back Rafter Assembly to K5 Rail on right side with 5/16” X 1 ½” Lag Screw, Lock Washer, and Flat Washer per diagram. Page 43 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 45 Rail in center and drill 3/8” hole through Rail and to the top of first step pilot drill K17’s Fasten Ladder to Floor Rail with 5/16” X 2 ½” Lag Screws , Lock Washers and Flat Washers. Page 44 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 46 Use 1/4” x 1” Phillips Truss Head Bolt with 5/16” Lock Washer. Then place 5/16” Flat Washer on Barrel Nut and attach Rock to each board. 3 1/2” overhang Note: Pilot drill with 3/16” bit. Page 45 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 47 Screws, Lock Washers and Flat Washers. 5/16" #8 X 2" INTERNAL WOOD TOOTH SCREW LOCK Attach P35 End Ladder Back to E1 End WASHER Ladder Rail with 2” Wood Screws Page 46 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 48 Using Y30-40G holes as guide, mark Wall Rail K1 and drill 3/8” holes. Attach to Rail with 5/16” X 1 ¼” Hex Bolts, Lock Washers, Flat Washers, and Y30-40G Spike T-Nuts per diagram. Page 47 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 49 5/16” X 4” Hex Bolts, Flat Washers, Flat Washers, and 5/16” Lock Nuts. Attach Angle Brace Assembly to Beam Assembly (per diagram) Note: Ground board to inside, per diagram. 4” Hex Bolts Y1-105G Page 48 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 50 Note: Clean debris from holes 3/8” Spike T-Nuts inserted in Beam. " INTERNAL TOOTH LOCK WASHER 3/8" FLAT WASHER 5/16 X 5 3/4" HEAD BOLT 3/8" 3/8 X 8" SPIKE TEE HEAD BOLT Page 49 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 51: Metal Bracket
Level Crow's Nest Floor Rails and attach E14's to A1 Beam with 5/16” X 2 ½” Lag Screws, Lock Washers and Flat Washers. Now finish tightening Hex Bolts. Note: Pilot drill with 3/16” bit. Page 50 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 52 Attach four F1 Crow's Nest Wall Supports to E9 Rails using 5/16” X 2 ½” Hex Bolts, Lock Washers, Flat Washers into 5/16” Spike T-Nuts inserted in earlier step. Page 51 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 53 Screws, Lock Washers, and Flat Washers. Measure down 2 ½” per diagram and attach another P23 to F1 Supports with 5/16” X 1 ½” Lag Screws, Lock Washers, and Flat Washers. Page 52 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 54 S t e p s t o t h e E 5 Clubhouse Wall Boards with 5/16” X 1 ½” Hex Y35-24.75G Bolts, Lock Washers, and Flat Washers into 5/16” Spike T-Nuts placed in E5 Rail in earlier step. Page 53 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 55 K13 Wall Rail with 3/8” drill bit to fasten 5/16" FLAT WASHER Y10-16.5G Metal Grip with ¾” Phillips Truss Head bolt, Lock Washer, Flat Washer, and Barrel Nut. Page 54 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 56 Assemble glider (Per diagram) and attach below Crows Nest to swing hangers. Tighten the quick link with a wrench. The quick link must be tightened so that it cannot be opened by hand. Page 55 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 57 Step bolts through Slide and 5/16” Lock Washers and flat washers on Barrel Nuts on bottom of floor boards. 1/4 X 1" STEP BOLT 5/16" INTERNAL 1/4" TOOTH BARREL 5/16" LOCK HEAD FLAT WASHER WASHER BOLT SLIDE WOOD FLOOR FLAT WASHER LOCK WASHER 5/16" BARREL NUT Page 56 © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 58: Maintenance
MAINTENANCE REQUIRED PERIODIC MAINTENANCE All outdoor wooden products, including Leisure Time Products, Inc products, require routine inspection and regular maintenance. After installation, a follow-up inspection should take place after one week and twice a month thereafter for the remaining life of your play products. Maintenance should be performed at any time it is deemed necessary.
Page 59 However, if rocks or roots surface under the base support pieces, these protrusions must be removed or the play product relocated to another area in order to eliminate rocking. Page 58 - MAINTENANCE © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 60 Question: Who can I hire to assemble my playset? Answer: We do not suggest assemblers. Please refer to your yellow pages or ask for a recommendation from where you purchased your playset. Page 59 - MAINTENANCE © Copyright Leisure Time Products Inc. Sky Fort 09-0112...
Page 61: Warranty
PLEASE READ THIS BOOKLET COMPLETELY BEFORE BEGINNING THE ASSEMBLY PROCESS. THIS MANUAL HAS BEEN PREPARED TO HELP YOU AND YOUR FAMILY ACHIEVE FULL BENEFIT FROM YOUR LEISURE TIME PRODUCTS INC. BACKYARD PLAYSET. IT CONTAINS HELPFUL INFORMATION CONCERNING ASSEMBLY PREPARATION, INSTALLATION PROCEDURE, REQUIRED MAINTENANCE, REPLACEMENT PARTS, AND SHOULD THE SITUATION OCCUR, THE PROCEDURE FOR FILING A WARRANTY CLAIM.
Page 62: Replacement Parts
These accessories are Available a samsclub.com Sub-Floor Add-on Kit Sand Box Cover Replacement Parts & Other Accessory Items • Yellow Plastic Hand Grips • Belt Swing Steering Wheel Tic-Tac-Toe Play Activity • Trapeze Bar Add-On • Two Seat Glider • Picnic Table Add-on Kit •...

Leisure Time Products Sky Fort 6009 Assembly Instructions Manual

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