Gorilla Playsets Wedgewood Manual
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Gorilla Playsets Wedgewood Manual

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Wedgewood
Model: 1600
(BOXES: 1600-1, 1600-2,
310 & SLIDE BOX)
Copyright © 2013 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
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Summary of Contents for Gorilla Playsets Wedgewood

  • Page 1 ™ ™ playsets playsets ™ ™ plays ets plays ets Wedgewood Model: 1600 (BOXES: 1600-1, 1600-2, 310 & SLIDE BOX) Copyright © 2013 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com...
  • 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 to use our “Quick Response Center”...
  • Page 3 GORILLA PLAYSETS WARRANTY - 2013 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
  • Page 4 Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used. WEIGHT LIMITS FOR GORILLA PLAYSETS • FORT PLATFORMS: 800 LBS. TOTAL WEIGHT • SWING BELT: 225 LBS.
  • Page 5 WARRANTY REGISTRATION - WEDGEWOOD - Gorilla Playsets manufactures 3 EASY WAYS TO REGISTER Gorilla Playsets (678) 880-3329 Where did you buy this product?: Date of Place of Purchase Purchase Name: Email: Street City State Please select 18-30 41-50 Excellent you rate the...
  • Page 6 IMPORTANT – PLEASE READ As fresh lumber acclimates to its new environment, the natural tendencies of the tree can show itself in the form of checks, or “cracks” in the lumber. In almost all cases this is normal and it will not affect the structural integrity of your play set.
  • Page 7 Model: 1600 (BOXES: 1600-1, 1600-2, 310 & SLIDE BOX) REV: 2.18.2013...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 3-6 Leveling Fort, General Information and Definitions…………………....Pages 6-8 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 9-13 Site Plan, Required Tool List and Kit Contents..........Pages 14-15 Hardware, Lumber and Accessory Checklists.………………………………..Pages 16-30 Assembling the Ladder....…………………………………..………...…..
  • 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 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-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 1600 Series ELLA'S CLUBHOUSE/WEDGEWOOD(Costco) HEIGHT: 11' - 4" Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 20'-4 8 " Rock Wall Wave Slide Swing Belts (2) 10'-6 4 "...
  • Page 21 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill)
  • Page 22 1600 HARDWARE PAGE 1 OF 2 REV A: 11/7/2012 JH #8 X 1-1/4" WOOD SCREW QTY: 6 #14 X 1-1/4" #8 X 1-1/2" PAN HEAD SCREW WOOD SCREW QTY: 12 QTY: 76 #8 X 2" WOOD SCREW QTY: 225 #8 X 2-1/2" WOOD SCREW QTY: 73 #8 X 3-1/2"...
  • Page 23 3/8 X 3-1/2" 3/8 X 5" HEX LAG SCREW HEX LAG SCREW QTY: 36 QTY: 10 1600 HARDWARE PAGE 2 OF 2 REV A: 11/7/2012 JH #2 SQUARE DRIVE BIT QTY: 1 PLASTIC 3/8 x 9" 3/8 x 6" 3/8 x 6-1/2" 3/8 x 3-1/2"...
  • Page 24 PICTURE DESCRIPTION QTY. 1 X 4 X 55" ROOF PEAK 1-4-5500-RP 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55" ROOF STARTER 1-5-5500-RS 2 X 4 X 10" PANEL BOARD 2-4-1000-PB 2 X 4 X 24"...
  • Page 25 PICTURE DESCRIPTION QTY. 2 X 4 X 39" ROOF SUPPORT RIGHT 2-4-3900-RSR 2 X 4 X 43-1/8" SUN BURST SUPPORT 2-4-4313-SBS 2 X 4 X 45" PANEL BOARD 2-4-4500-PB 2 X 4 X 47-7/8" PANEL BOARD 2-4-4788-PB 2 X 4 X 58" ROCK WALL CENTER SUPPORT...
  • Page 26 PICTURE DESCRIPTION QTY. 2 X 6 X 20-1/2" LADDER STEP 2-6-2050-LS 2 X 6 X 41-1/4" DECK SPACER 2-6-4125-DS 2 X 6 X 47-3/4" DECK BOARD 2-6-4775-DB 2 X 6 X 48" ROCK WALL ROPE SUPPORT 2-6-4800-RWRS 2 X 6 X 65-3/8" INNER FORT SUPPORT 2-6-6538-IFS...
  • Page 27 PICTURE DESCRIPTION QTY. 4 X 4 X 108" SWING LEG 4-4-10800-SL 4 X 4 X 16" ANGLE SUPPORT LEFT SIDE 4-4-1600-ASLS 4 X 4 X 16" ANGLE SUPPORT RIGHT SIDE 4-4-1600-ASRS 4 X 4 X 45" SWING MOUNT 4-4-4500-SM 4 X 4 X 56" TIRE SWING SUPPORT 4-4-5600-TSS...
  • Page 28 PICTURE DESCRIPTION QTY. 4 X 4 X 73" ROCK WALL BOTTOM SUPPORT 4-4-7300-RWBS 4 X 4 X 80-1/8" LADDER LEFT SIDE 4-4-8014-LLS 4 X 4 X 80-1/8" LADDER RIGHT SIDE 4-4-8014-LRS 4 X 4 X 80-1/8" ROCK WALL SIDE 4-4-8014-RWS 4 X 4 X 96"...
  • Page 29 PICTURE DESCRIPTION QTY. 5/4 X 3 X 11-3/8" WINDOW UNDER 125-3-1138-WU 5/4 X 3 X 12" SMALL SUN 125-3-1200-SSR 5/4 X 3 X 18" LARGE SUN 125-3-1800-LSR 5/4 X 4 X 22-3/4" WINDOW PANEL BOARD 125-4-2275-WPB 5/4 X 4 X 27-1/2" PANEL SLAT 125-4-2750-PS 5/4 X 6 X 4-1/2"...
  • Page 30 PICTURE DESCRIPTION QTY. 5/4 X 6 X 10-1/2" ROOF PEAK SUPPORT 125-6-1050-RPS 5/4 X 6 X 22-3/4" WINDOW PANEL BOARD 125-6-2275-WPB 5/4 X 6 X 48" BOTTOM ROCK WALL BOARD 125-6-4800-BRWB 5/4 X 6 X 48" ROCK WALL BOARD 125-6-4800-RWB...
  • Page 31 PICTURE DESCRIPTION QTY. WAVE SLIDE 1-5/16X 21- 1/2" LADDER RUNG 11-5106 SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 32 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A PACK OF 5 ROCKS) A-FRAME SWING BRACKET 11-5010 HARDWARE (NOT SHOWN) :1600 HARDWARE BOX INSTRUCTIONS...
  • Page 33 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGER 11-4012 TELESCOPE 07-0001 ROCK WALL ROPE ROPE LADDER ROPE...
  • Page 34 PICTURE DESCRIPTION QTY. TIRE SWING 04-0014 SPRING CLIP 11-4003 TIRE SWIVEL 11-4010...
  • Page 35 PICTURE DESCRIPTION QTY. DORMER (UNASSEMBLED) IN 310 BOX STEERING WHEEL 07-0004 CHIMNEY (UNASSEMBLED) IN 310 BOX SAFETY HANDLE 08-0001...
  • Page 36 DESCRIPTION PICTURE QTY. WINDOW 07-0013 TIC TAC TOE (UNASSEMBLED) 07-0010 FLAG KIT 09-1014 GROUND STAKE 07-0016 CROWN 07-0019 NAME (NOT SHOWN) PLATE...

  • Page 37: Assembling The Ladder

    STEP 1: ASSEMBLING THE LADDER 1: START WITH THE 4 X 4 X 80-1/4" LADDER SIDES. THE SIDES SHOULD BE POSITIONED IN MANNER THAT ALLOWS THE FIVE HOLE AND THE FIVE CHANNELS ON THE INSIDE TO FACE EACH OTHER, AND THE ANGLED ENDS SHOULD BE FACING THE SAME WAY.
  • Page 38 STEP 2: ATTACHING THE ROPE LADDER RUNNER 1: FIND THE 4 X 4 X 96" ROPE LADDER RUNNER. TAKE SPECIAL NOTE OF THE ROUNDED EDGE ON THE 7/8" HOLES ON THE END OF THE ROPE LADDER RUNNER. 2: LINE UP THE TWO 3/8" PILOT HOLES ON THE ROPE LADDER RUNNER TO THE COUNTER-SUNK HOLES ON THE LADDER SIDE PIECES.

  • Page 39: Safety Guidelines

    STEP 3: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE LADDER ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE LADDER ASSEMBLY SO THAT THE ANGLED ENDS RESTS AGAINST THE LADDER SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT. CENTER THE COUNTER-SUNK HOLES ON THEIR RESPECTIVE BOARDS BEFORE ATTACHING.

  • Page 40: Assembling The Rock Wall

    STEP 4: ASSEMBLING THE ROCK WALL 1: START WITH THE 4 X 4 X 80-1/8" ROCK WALL SIDES. THE SIDES SHOULD BE POSITIONED IN A MANNER THAT ALLOWS THE ANGLED ENDS TO FACE THE SAME WAY. IT SHOULD ALSO BE NOTED THAT THERE ARE TWO 3/8" HOLES JUST BELOW THE ANGLED ENDS.
  • Page 41 STEP 5: ASSEMBLING THE ROCK WALL 1: MEASURE 67" FROM THE BOTTOM OF EACH OF THE ROCK WALL SIDES AND MARK THIS LOCATION. 2: BEFORE INSTALLING BOARDS, MAKE SURE THAT THE ROCK WALL SIDES ARE SQUARE TO THE ROCK WALL BOTTOM SUPPORT, ONCE THE ROCK WALL SIDES ARE SQUARE, LAY THE 54 X 6 X 48"...

  • Page 42: Leveling Fort, General Information And Definitions

    STEP 6: INSTALLING ANGLE SUPPORTS 1: MAKE SURE THE ROCK WALL ASSEMBLY IS SQUARE. FIND TWO 4 X 4 X 16" ANGLE SUPPORTS. 2: PLACE THE ANGLE SUPPORTS ON THE ROCK WALL ASSEMBLY SO THAT THE ANGLED END RESTS AGAINST THE ROCK WALL SIDES, AND THE COUNTER-SUNK HOLE ON THE FLAT END FACES OUT.

  • Page 43: Framing The Play Set

    STEP 7: INSTALLING OUTER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 66-1/4" OUTER FORT SUPPORTS. THE EASIEST WAY TO DIFFERENTIATE THE OUTER SUPPORTS FROM THE INNER SUPPORTS IS TO LOOK FOR THE COUNTER-SUNK HOLES AT 12-1/4" FROM EACH END. THE TWO BOARDS WITH THE HOLES CLOSEST TO THE BOTTOM (LONGER) SIDE ARE THE OUTER FORT SUPPORTS, THE BOARDS WITH THE HOLES CLOSEST TO THE TOP (SHORTER) SIDE ARE THE INNER FORT SUPPORTS.
  • Page 44 STEP 8: INSTALLING INNER FORT SUPPORTS 1: FIND THE TWO 2 X 6 X 65-3/8" INNER FORT SUPPORTS. 2: LINE UP THE 3/8" HOLE CLOSEST TO THE BOTTOM OF THE LADDER ASSEMBLY WITH THE BOTTOM HOLE OF THE INNER FORT SUPPORT. 3: ATTACH THE INNER FORT SUPPORT TO THE LADDER ASSEMBLY WITH 5/16"...
  • Page 45 STEP 9: INSTALLING T-NUTS ON CORNER POSTS 1: FIND FOUR 4 X 4 X 57" CORNER POSTS. 2: USING THE DIAGRAM BELOW, INSTALL T-NUTS INTO THE APPROPRIATE HOLES. PLACE T-NUTS INTO THE HOLES OF THE CORNER POST AND SET WITH A HAMMER. 3: THE CORNER POSTS ARE SHOWN RELEVANT TO THEIR ORIENTATION ON THE UNIT.
  • Page 46 STEP 10: MOUNTING CORNER POSTS TO FRAME 1: TAKE THE CORNER POSTS WITH THE T-NUTS INSTALLED FROM THE PREVIOUS STEP AND ARRANGE THE POSTS IN THEIR PROPER ORIENTATION. (SHOWN BELOW WITH NUMBERS TO REFERENCE THE PREVIOUS STEP). 2: THE CORNER POSTS SHOULD BE ORIENTED WITH THE COUNTER-SUNK HOLES FACING TOWARDS EACH OTHER ON BOTH SIDES.
  • Page 47 STEP 11: ATTACHING THE SWING BEAM PLATE TO THE SWING BEAM MOUNT 1: FIND THE 4 X 4 X 45" SWING BEAM MOUNT. 2: FIND THE SWING BEAM PLATE. NOTICE THE TWO SQUARE HOLES ON THE SWING BEAM PLATE. 3: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT AND LINE UP THE THREE HOLES ON THE PLATE WITH THE THREE HOLES ON THE SWING BEAM MOUNT.
  • Page 48 STEP 12: ATTACHING THE SWING BEAM MOUNT 1: FIND TWO TORQUE WASHERS. PLACE A 3/8 X 6-1/2" CARRIAGE BOLT INSIDE THE TORQUE WASHER. PLACE THE TORQUE WASHER/CARRIAGE BOLT ASSEMBLY INTO THE HOLES OF THE CORNER POST SO THAT THE HEAD OF THE CARRIAGE BOLT IS INSIDE THE FORT.
  • Page 49 STEP 13: ATTACHING THE PANEL BOARD 1: TAKE THE 2 X 4 X 45" PANEL BOARD AND LINE IT UP WITH THE PILOT HOLES IN THE CORNER POSTS. 2: FASTEN THE PANEL BOARD TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS INTO THE T-NUTS OF THE CORNER POSTS.

  • Page 50: Site Plan, Required Tool List And Kit Contents

    STEP 14: ATTACHING THE ROPE LADDER SUPPORT AND THE ROCK WALL ROPE SUPPORT 1: FIND THE 2 X 4 X 83-11/16" ROPE LADDER SUPPORT AND LINE UP THE PILOT HOLES IN THE CORNER POSTS WITH THE TOP HOLES IN THE ROPE LADDER SUPPORT, AND FASTEN WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS. 2: FIND THE 2 X 6 X 48"...
  • Page 51 STEP 15: INSTALLING LAG SCREWS 1: MAKE SURE THAT THE UNIT IS LEVEL AND SQUARE. 2: STARTING AT THE INNER AND OUTER SUPPORTS, USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS IN THE EMPTY HOLES ON THE 2 X 6 PARTS TO SECURE THE BASE OF THE FORT. 3:THE UPPER PART OF THE FORT NEEDS TO BE SECURED WITH 3/8 X 5"...

  • Page 52: Hardware, Lumber And Accessory Checklists

    STEP 16: INSTALLING ROCK WALL BOARDS 1: FIND TEN 5/4 X 6 X 48" ROCK WALL BOARDS AND ONE 5/4 X 6 X 48" BOTTOM ROCK WALL BOARD (WITH ONE 7/8" HOLE IN THE CENTER). 2: LAY THE FIRST ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES AGAINST THE ALREADY EXISTING ROCK WALL BOARD, MAKE SURE IT IS TIGHT AND THE ENDS FLUSH TO THE ROCK WALL SIDES.

  • Page 53: Installing Deck, Bottom Panel Boards And Top Panel Boards

    STEP 17: DECK 1: FIND SEVEN 2 X 6 X47-3/4" DECK BOARDS. 2: LAY THE DECK BOARDS ACROSS THE FORT SUPPORTS, BETWEEN THE CORNER POSTS. 3: FIND FOUR 2 X 6 X 41-1/4" DECK SPACERS. 4: LAY TWO DECK SPACERS ACROSS THE FORT SUPPORTS ON THE LADDER AND ROCK WALL SIDES OF THE FORT.
  • Page 54 STEP 18: INSTALLING THE BOTTOM PANEL BOARDS 1: FIND THE 2 X 4 X 45" REAR BOTTOM PANEL BOARD. 2: LAY THE BOARD ACROSS THE OUTER FORT SUPPORT ON THE SWING BEAM SIDE OF THE FORT, CENTERED BETWEEN THE TWO CORNER POSTS. 3: ATTACH THE REAR BOTTOM PANEL BOARD WITH 3/8 X 3-1/2"...
  • Page 55 STEP 19: INSTALLING TOP PANEL BOARDS 1: FIND TWO 2 X 4 X47-7/8" TOP PANEL BOARDS. 2: LINE UP THE COUNTER-SUNK HOLES OF THE TOP PANEL BOARD WITH THE HOLES IN THE CORNER POSTS, MAKE SURE THAT THE TOP PANEL BOARD HOLES ARE OFFSET DOWN. ATTACH WITH 5/16 X 4-1/2" HEX BOLT AND 5/16"...

  • Page 56: Roof And Sun Ray Assembly

    STEP 20: ROOF SUPPORTS 1: FIND TWO 2 X 4 X 39" ROOF SUPPORT LEFT, AND TWO 2 X 4 X 39" ROOF SUPPORT RIGHT. 2: ON A FLAT SURFACE LAY OUT THE ROOF SUPPORTS LEFT AND RIGHT, THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FROM A RIGHT ANGLE.
  • Page 57 STEP 21: MOUNTING THE ROOF SUPPORTS TO THE FORT 1: PLACE THE ROOF SUPPORT ASSEMBLY WITH THE COUNTER-SUNK HOLES LINING UP WITH THE HOLES IN THE CORNER POSTS, MAKE SURE THE ROOF PEAK SUPPORT IS FACING OUT . SECURE WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16"...
  • Page 58 STEP 22: ROOF STARTERS AND ROOF PEAK 1: FIND TWO 1 X 5 X 55" ROOF STARTERS (GROOVE ONLY) AND 3-1/2" X 3-1/2" ROOF PEAK. 2: PLACE THE 1 X 5 X 55" ROOF STARTERS (GROOVE ONLY) AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED OVER THE TOP OF THE ROOF SUPPORTS, THE TOP EDGE OF THE ROOF STARTER SHOULD BE PLACED AS CLOSE TOGETHER AS POSSIBLE NEAR THE PEAK WITHOUT THE BOARDS OVERLAPPING.
  • Page 59 STEP 23: ROOF BOARDS, FINISHERS/ CHIMNEY AND DORMER 1: PLACE THE 1 X 6 X 55" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE INTO THE GROOVE OF THE ROOF STARTER. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED OVER THE ROOF SUPPORTS. THERE ARE SIX ROOF BOARDS ON EACH SIDE OF THE ROOF.
  • Page 60 STEP 24: SUN/SUN SUPPORT ASSEMBLY 1: PLACE THE 2 X 6 X 16" SUN ON TOP OF THE 2 X 4 X 43-1/8" SUN SUPPORT AS SHOWN IN THE BOTTOM PICTURE. 2: ATTACH THE SUN TO THE SUN SUPPORT WITH #8 X 2-1/2" WOOD SCREWS. 3: REPEAT SUB STEPS 1 &...
  • Page 61 STEP 25: SUN RAY INSTALLATION 1: CENTER THE 5/4 X 2-5/8 X 18" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS. FASTEN THE LARGE RAY WITH TWO #8 X 2" WOOD SCREWS. 2: EQUALLY SPACE THE 5/4 X 2-5/8 X 12" SMALL RAYS ABOUT THE HALF SUN IN THE PATTERN SHOWN BELOW. SECURE THE SMALL RAYS WITH TWO #8 X 2"...

  • Page 62: Panel Slats, Window Panel Boards And Windows

    STEP 26: PANEL SLATS 1: FIND SEVEN 5/4 X 4 X 27-1/2" PANEL SLATS ARRANGE FIVE PANEL SLATS SO THAT THEY ARE EVENLY SPACED ACROSS THE SWING BEAM SIDE OF THE FORT AND TWO OF THEM ARE FLUSH TO THE END OF THE BOTTOM PANEL BOARDSON THE FRONT OF THE FORT.
  • Page 63 STEP 27: WINDOW PANEL BOARDS/ WINDOW FRONT WALL 1: IN THIS STEP THE WOOD COMPONENTS TO ATTACH THE WINDOW WILL BE INSTALLED IN THE INSIDE OF THE FRONT OF THE PLAYSET. 2: START WITH ONE OF THE 5/4 X 6 X 22-3/4" WINDOW PANEL BOARD AND PLACE IT AGAINST THE SUN SUPPORT AND THE PANEL BOARD FLUSH TO THE PANEL BOARD BOTTOM EDGE AND 13-1/2"...
  • Page 64 STEP 28: WINDOW PANEL BOARDS/ WINDOWS SIDE WALLS 1: IN THIS STEP THE WOOD COMPONENTS TO ATTACH THE WINDOW WILL BE INSTALLED IN THE INSIDE OF THE SIDES OF THE PLAYSET (LADDER SIDE AND ROCK WALL SIDE). 2: START ON THE ROCK WALL SIDE WITH ONE OF THE 5/4 X 6 X 22-3/4" WINDOW PANEL BOARDS AND PLACE IT AGAINST THE TOP PANEL BOARD AND THE ROCK WALL ROPE SUPPORT AND 14-3/4"...

  • Page 65: Tire Swing And Completing The Rock Wall

    STEP 29: TIRE SWING SUPPORT 1: FIND THE 4 X 4 X 56" TIRE SWING SUPPORT, AND CENTER IT UNDERNEATH THE DECK. 2: ATTACH THE TIRE SWING SUPPORT WITH A 3/8 X 5" LAG SCREW AND 3/8" WASHER THROUGH THE LADDER CENTER. FROM THE TOP, ADD TWO 2-1/2"...
  • Page 66 STEP 30: TIRE SWING SWIVEL 1: USING THE TIRE SWING SUPPORT PRE-DRILLED HOLES AS A GUIDE, DRILL THROUGH THE CENTER DECK BOARD WITH A 3/8" DRILL BIT. 2: USE A 3/8 X 6" CARRIAGE BOLT TO CLEAR OUT ANY DEBRIS LEFT OVER FROM DRILLING, MATE WITH A TORQUE WASHER AND SET THE TORQUE WASHER ON TOP OF THE DECK WITH A HAMMER.
  • Page 67 STEP 31: ROCK WALL CENTER SUPPORT 1: FIND THE 2 X 4 X 58" ROCK WALL CENTER SUPPORT, AND CENTER IT ON THE BACK OF THE ROCK WALL, MAKE SURE THAT THE HOLE IN THE BOTTOM ROCK WALL BOARD IS NOT OBSTRUCTED BY THE ROCK WALL CENTER SUPPORT.

  • Page 68: Swing Beam Assembly

    STEP 32: 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 3/8 X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS AND WASHERS ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER ANY EXPOSED THREADS AFTER SECURING.
  • Page 69 STEP 33: ATTACH SWING LEG BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LAG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. SWING LEG BRACKET 3/8 X 3-1/2"...
  • Page 70 STEP 34: ATTACHING SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM LEG BRACKET USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS UNDERNEATH. 2: USE A 3/8 X 3-1/2"...
  • Page 71 STEP 35: ATTACHING THE SWING BEAM TO THE FORT * AN EXTRA PERSON IS REQUIRED FOR THIS STEP. 1: AFTER THE LEGS ARE ATTACHED, HAVE ONE PERSON ON THE GROUND PICK UP THE SWING BEAM BY THE LEGS, AND ANOTHER PERSON PICK UP THE SWING BEAM FROM INSIDE THE FORT. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
  • Page 72 STEP 36: 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. LEVEL...
  • Page 73 STEP 37: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 70" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER, AND FASTEN TO THE SWING LEGS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. LEVEL 3/8 X 3-1/2"...

  • Page 74: Rock Wall Rocks And Rock Wall Rope

    STEP 38: INSTALLING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGARED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. 2: THE ROCKS INCLUDED IN YOUR PLAYSET MAY VARY, IN ANY CASE, THE #14 X 1-1/4" PAN HEAD SCREWS WITH WASHERS WILL BE USED TO ATTACH THE ROCKS.
  • Page 75 STEP 39: CLIMBING ROPE 1: THREAD ONE END OF THE 10" ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN ROPE TO AID IN CLIMBING. SET KNOTS ACCORDING TO YOUR CHILD'S NEEDS.

  • Page 76: Rope Ladder Assembly/Installation

    STEP 40: ROPE LADDER ASSEMBLY 1: FIND THE 15' LENGTHS OF ROPE. THREAD THE ROPE THROUGH THE HOLES OF THE ROPE LADDER SUPPORT AND TIE A KNOT TO SECURE. 2: FOLLOWING THE ROPE, MEASURE 12" DOWN FROM THE HOLE OF THE ROPE LADDER SUPPORT AND TIE A KNOT IN EACH ROPE.

  • Page 77: Safety Handles, Steering Wheel And Telescope

    STEP 41: SAFETY HANDLES 1: FIND FOUR SAFETY HANDLES. 2: PLACE THE SAFETY HANDLE JUST ABOVE THE ROCK WALL OPPENING, AND ATTACH WITH #14 X 1-1/4" PANHEAD SCREWS AND 1/4" WASHERS. 3: REPEAT THIS PROCESS FOR THE LADDER SIDE OF THE FORT. SAFETY HANDLE #14 X 1-1/4"...
  • Page 78 STEP 42: 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 END OF THE SWING BEAM,. 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 79 STEP 43: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS ONTO THE SWING MOUNT. 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 80: Slide, Tic Tac Toe Panel And Hanging Swings

    STEP 44: INSTALLING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH 1-1/4" PAN HEAD SCREWS. **DO NOT OVER TIGHTEN** #14 X 1-1/4"...
  • Page 81 STEP 45: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. IGNORE STEP 6 & 7 IN THE INSTRUCTIONS. 2: ATTACH THE TWO 1-3/8" X 1-5/8" X 10-1/2"L TIC TAC TOE BOARDS TO THE GREEN PLASTIC BRACKET WITH THE 1"...
  • Page 82 STEP 46: HANGING SWINGS 1: CLIP EACH OF THE SPRING CLIPS ONTO THE IRON DUCTILES SWING HANGERS, THEN CLIP 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 83 STEP 47: HANGING THE TIRE SWING 1: HANG THREE SPRING CLIPS FROM THE TIRE SWIVEL. 2: HANG A CHAIN IN A SPRING CLIP AT THE DESIRED HEIGHT. 3: CONTINUE THE PROCESS WITH THE REMAINING CHAINS, MAKING SURE THAT THE TIRE SWING IS LEVEL WHEN FINISHED.

  • Page 84: Flag Kit, Name Plate, Ground Stakes And Crown

    STEP 48: FLAG KITS 1: INSTALL THE FLAG KITS IN THE DESIRED LOCATION ON YOUR PLAY SET. THE RECOMMENDED LOCATION IS ON THE CORNER POSTS AT THE FRONT OF THE FORT. ATTACH THE FLAG KITS WITH THE HARDWARE PROVIDED. DETAIL A...
  • Page 85 STEP 49: NAME PLATE 1: ATTACH THE NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO 1-1/4" WOOD SCREWS. ATTACH NAME PLATE HERE WITH TWO 1-1/4" WOOD SCREWS.
  • Page 86 STEP 50: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: HAMMER EACH GROUND STAKE IN AT AN ANGLE SIMILAR TO WHAT IS SHOWN. LEAVE THE TOP PORTION OF THE GROUND STAKE ABOVE THE GROUND FAR ENOUGH SO THAT YOU CAN STILL GET THE SCREW INTO THE HOLE AT THE TOP OF THE STAKE.
  • Page 87 STEP 51: CROWN 1: PLACE THE CROWN OVER THE SUN AT THE FRONT OF THE PLAY SET OVER THE SLIDE. 2: ATTACH THE CROWN TO THE SUN WITH #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREWS CROWN...

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