Gorilla Playsets Rio Manual

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Rio

Model: 2400

(BOXES: 2400-1, 2400-2 &

Slide Box)

190 Etowah Industrial Court

Canton, GA 30114

www.gorillaplaysets.com

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Summary of Contents for Gorilla Playsets Rio

Page 1 ™ ™ playsets playsets ™ ™ play sets play sets Model: 2400 (BOXES: 2400-1, 2400-2 & Slide Box) Copyright © 2015 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 This decision is subject to verification of the defect, which, at Gorilla’s discretion, may be accomplished by submitting photographs or by delivery of the defective part to Gorilla Playsets • 190 Etowah Industrial Ct. • Canton, GA 30114 • 1-800-882-0272 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase.
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 - RIO - Gorilla Playsets manufactures 3 EASY WAYS TO REGISTER the finest quality products that Mail this completed form to: are designed for outstanding Fax this completed form to: Gorilla Playsets strength and durability. OPTION 1 (678) 880-3329...
Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...
Page 7 IMPORTANT – PLEASE READ Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years.
Page 8 Please review these safety rules regularly with your children. WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to ensure it has been properly installed. Gorilla Playsets 190 Etowah Industrial Court Canton, GA. 30114...
Page 9 Model: 2400 (BOXES: 2400-1, 2400-2 & Slide Box) REV B: 2.24.2015...
Page 10 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Page 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 16-27 Corner Post Layout and Adding T-Nuts to Corner Posts...……..………...…..
Page 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 14'- " 8 " 4'-0" 8'-0" DECK 3'-1 " 1'-7 " 3'-0" 8'-8 " DECK Swing Belts (2) 12'-6 " Rock Wall 1'-7 2 "...
Page 23 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 24 11-0056 2400 HARDWARE PAGE 1 OF 2 #8 X 1-1/4" REV A: 8/28/2013 MM WOOD SCREW QTY: 6 #8 X 1-3/4" WOOD SCREW QTY: 4 #8 X 2" WOOD SCREW QTY: 138 #8 X 2-1/2" WOOD SCREW QTY: 44 #8 X 3" WOOD SCREW QTY: 14 3/8"...
Page 25 3/8 x 3-1/2" 3/8 x 2-1/2" 5/16 x 3-1/2" 11-0056 LAG SCREW LAG SCREW LAG SCREW QTY: 4 QTY: 8 QTY: 14 2400 HARDWARE PAGE 2 OF 2 REV A: 8/28/2013 MM #2 SQUARE DRIVE TIP QTY:1 PLASTIC BOLT CAP 3/8 x 7"...
Page 26 PICTURE DESCRIPTION QTY. 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT 125-3-1750-TTTM 5/4 X 3 X 23-7/8" ROCK WALL TOP CAP 125-3-2388-RWTC 5/4 X 3 X 41-7/8" DECK SPACER 125-3-4188-DS 5/4 X 4 X 23-7/8" ROCK WALL 125-4-2388-RWT 5/4 X 5 X 48" DECK BOARD 125-5-4800-DB 5/4 X 6 X 13-3/16"...
Page 27 PICTURE DESCRIPTION QTY. 5/4 X 6 X 23-7/8" ROCK WALL BOARD BOTTOM 125-6-2388-RWBB 5/4 X 6 X 23-7/8" ROCK WALL BOARD 125-6-2388-RWB 5/4 X 6 X 28' PANEL SLAT 125-6-2800-PS 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 14" BOTTOM PANEL BOARD 2-4-1400-BPB...
Page 28 PICTURE DESCRIPTION QTY. 2 X 4 X 36" PANEL AND DECK SUPPORT 2-4-3600-PDS 2 X 4 X 36" STRINGER 2-4-3600-S 2 X 4 X 36" TARP BOARD 2-4-3600-TB 2 X 4 X 36" ROCK WALL ROPE SUPPORT 2-4-3600-RWRS 2 X 4 X 48" FRONT FACE BOARD 2-4-4800-FFB...
Page 29 PICTURE DESCRIPTION QTY. 2 X 4 X 50-1/2" ROCK WALL SIDE 2-4-5050-RWS 2 X 4 X 58" CROSS MEMBER 2-4-5800-CM 2 X 6 X 13-5/8" 2-6-1363-S 2 X 6 X 36" END SANDBOX BOARD 2-6-3600-ESB 2 X 6 X 48" SANDBOX BOARD 2-6-4800-SB 2 X 6 X 48"...
Page 30 PICTURE DESCRIPTION QTY. 2 X 6 X 75" END SANDBOX BOARD 2-6-7500-ESB 3 X 3 X 96" CORNER POST 1 3-3-9600-CP1 3 X 3 X 96" CORNER POST 2 3-3-9600-CP2 3 X 3 X 96" CORNER POST 3 3-3-9600-CP3 3 X 3 X 96" CORNER POST 4 3-3-9600-CP4 3 X 3 X 96"...
Page 31 PICTURE DESCRIPTION QTY. 4 X 4 X 73-1/2" TRAP ARM 4-4-7350-TA 4 X 6 X 96" SWING BEAM 4-6-9600-SB...
Page 32 PICTURE DESCRIPTION QTY. LOONEY PERISCOPE 07-0021 LOONEY TELESCOPE 07-0020 CROWN 07-0019 FLAG KIT 09-1014...
Page 33 PICTURE DESCRIPTION QTY. STEERING WHEEL 07-0004 SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006 TIC TAC TOE (UNASSEMBLED) 07-0010 (NOT SHOWN) MANUFACTURER NAME PLATE 11-0056 (2400 HARDWARE BOX) WAVE SLIDE 03-0010...
Page 34 PICTURE DESCRIPTION QTY. TARP 05-0014 A-FRAME SWING LEG BRACKET 11-5010 SWING PLATE 11-5002 CHALKBOARD 07-0018 GROUND STAKE (PAIR) 07-0016-P...
Page 35 PICTURE DESCRIPTION QTY. CLIMBING ROCK (5 ROCKS ARE IN ONE BAG) ROCKS 07-0008 SPRING CLIP 11-4003 IRON DUCTILE SWING HANGER 11-4012 ROPE GREEN GREEN BRACKET 11-5013 SAFETY HANDLE (PAIR) 07-0005...
Page 36 STEP 1: CORNER POST LAYOUT 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THE RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: LAY OUT EACH OF THE 3 X 3 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET.
Page 37 STEP 2: INSERTING T-NUTS INTO CORNER POSTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
Page 38 STEP 3: ATTACHING SANDBOX AND ROPE SUPPORT 1: THE 2 X 6 X 36" END SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHTSIDE CORNER POSTS WITH 4" HEX BOLTS AND 5/16" WASHERS. 2: THE 2 X 4 X 36" PANEL AND DECK SUPPORT ATTACHES TO THE MIDDLE OF THE RIGHT SIDE OF THE CORNER POSTS, OFFSET HOLES DOWN, WITH 4"...
Page 39 STEP 4: ATTACHING END SANDBOX BOARD 1: THE 2 X 6 X 75" END SANDBOX BOARD (WITH SIX PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE LEFT SIDE CORNER POSTS WITH 4" HEX BOLTS AND 5/16" WASHERS. 5/16"WASHER 4" HEX BOLT CORNER POST #3 2 X 6 X 75"...
Page 40 STEP 5: ATTACHING THE SANDBOX BOARDS 1: THE 2 X 6 X 48" SANDBOX BOARDS (OFFSET DOWN) ATTACH TO THE BOTTOM OF THE FRONT AND REAR CORNER POSTS WITH 4" HEX BOLTS , 3-1/2" LAG SCREWS AND 5/16" WASHERS. 2: INSTALL THE 4" HEX BOLTS AND 5/16" WASHERS FIRST. 3: SQUARE THE SANDBOX BOARD TO THE CORNER POSTS AND THEN PREDRILL 9/64"...
Page 41 STEP 6: ATTACHING TARP SUPPORT BOARDS 1: THE 2 X 6 X 48" FRONT TARP SUPPORT BOARD (WITH THE PRE-DRILLED HOLES) ATTACHES TO THE TOP OF THE FRONT CORNER POSTS WITH 4" HEX BOLTS AND 5/16 " WASHERS. THE CENTER HOLE IS OFFSET UP.
Page 42 STEP 7: ATTACHING ARCH FACE BOARD AND DECK SUPPORTS 1: THE 2 X 6 X 48" ARCH FACE BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE SET OF HOLES BELOW THE FRONT TARP SUPPORT BOARD. ATTACH THE TOP ARCH FACE BOARD HOLES USING 4"...
Page 43 STEP 8: ATTACHING PANEL BOARDS 1: THE 2 X 4 X 48" PANEL BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES BELOW THE REAR TARP SUPPORT BOARD ON THE REAR OF THE FORT WITH 4" HEX BOLTS AND 5/16"...
Page 44 STEP 9: ATTACHING PANEL SUPPORTS AND SAFETY BOARD 1: THE 2 X 4 X 36" PANEL SUPPORT BOARD (TOP BOARD) SHOULD HAVE THE HOLES OFFSET UP. USE 4" HEX BOLTS AND 5/16" WASHERS TO SECURE THE BOARD TO THE CORNER POSTS. 2: THE 2 X 4 X 36"...
Page 45 STEP 10: ATTACHING FORT SIDE SUPPORTS 1: LAY THE 2 X 4 X 33-1/8"" FORT SIDE SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PLACE A T-NUT IN THE PRE-DRILLED HOLE ON EACH END AND SECURE WITH HAMMER.
Page 46 STEP 11: ATTACHING THE DECK BOARDS AND DECK SPACERS 1: THE 5/4 X 3 X 41-7/8" DECK SPACERS MOUNT BETWEEN THE REAR CORNER POSTS AND BETWEEN THE FRONT CORNER POSTS FLUSH TO THE EDGES. DRIVE THE 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS. 2: SIX 5/4 X 5 X 48"...
Page 47 STEP 12: ATTACHING THE STRINGER 1: FIND THE 2 X 4 X 36" STRINGER WITHOUT HOLES. 2: PLACE THE STRINGER UNDERNEATH THE CENTER OF THE DECK BOARDS (USE THE HOLE AT THE CENTER AS A GUIDE) MAKE SURE THE END OF THE CENTER DECK SUPPORT IS FLUSH WITH THE DECK SPACER ROUND EDGE.
Page 48 STEP 13: ATTACHING THE FRONT FACE BOARD 1: THE TOP EDGE OF THE 2 X 4 X 48" FRONT FACE BOARD WILL BE FLUSH TO THE TOP OF THE DECK SPACER. SECURE THE FRONT FACE BOARD TO THE CORNER POSTS WITH THREE 2-1/2" WOOD SCREWS PER SIDE.
Page 49 STEP 14: ATTACHING THE PANEL BOARD 1: THE 2 X 4 X 48" PANEL BOARD SHOULD HAVE THE HOLES OFFSET DOWN. MAKE THE TOP OF THE BOARD FLUSH WITH THE BOTTOM OF THE PANEL BOARD (TOP) 2: PREDRILL 9/64" HOLES 2-1/2" DEEP THROUGH THE HOLES IN THE PANEL BOARD. ATTACH THE PANEL BOARD USING 5/16 X 3-1/2"...
Page 50 STEP 15: ANGLE SUPPORTS 1: EIGHT 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK OF THE PLAY SET TO THE 2 X 4 X 36" DECK SUPPORTS, 2 X 4 X 48 FRONT FACE BORD AND 2 X 4 X 48" PANEL BOARD.
Page 51 STEP 16: SWING BEAM PLATE 1: LAY THE SWING BEAM MOUNT ON A FLAT SURFACE WITH THE THREE COUNTER SUNK CENTER HOLES FACING THE GROUND, THE COUNTER SUNK HOLES ON THE ENDS MUST BE FACING TOWARDS YOU. 2: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP PILOT HOLES.
Page 52 STEP 17: 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 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM.
Page 53 STEP 18: ATTACHING THE SWING BEAM SUPPORT AND TRAP ARM 1: THE 4 X 4 X 36" SWING BEAM MOUNT HAS COUNTER-SUNK HOLES IN THE CENTER AND ON THE ENDS. INSTALL THE SWING BEAM MOUNT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES AT THE CENTER FACE DOWN.
Page 54 STEP 19: ROCK WALL 1: FIND TWO 2 X 4 X 50-1/2" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER. T-NUT DETAIL A SCALE 1 : 3...
Page 55 STEP 20: ROCK WALL 1: FIND FIVE 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE BOTTOM, PLACE THE BOTTOM ROCK WALL BOARD ON BOTTOM OF THE ROCK WALL SIDES, FLUSH TO THE BOTTOM OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2"...
Page 56 STEP 21: ROCK WALL 1: FIND A 5/4 X 3 X 23-7/8" ROCK WALL TOP CAP AND 5/4 X 4 X 23-7/8" ROCK WALL TOP. 2: PLACE THE 5/4 X 3 X 23-7/8" ROCK WALL TOP CAP ON ENDS OF THE ROCK WALL SIDES. FLUSH THE ROCK WALL BOARD TOP CAP TO TOP AND SIDE OF ROCK WALL SIDES, FASTEN THE ROCK WALL TOP CAP TO THE ROCK WALL SIDES WITH 2"...
Page 57 STEP 22: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME. 90 GREEN BRACKET 5/16"...
Page 58 STEP 23: ROCK WALL 1: FIND FIVE ROCKS AND FIFTEEN 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
Page 59 STEP 24: ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE RIGHT SIDE ON THE FORT. THE BOTTOM EDGE OF THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD. USING THE BRACKETS AS A TEMPLATE DRILL A 3/8" HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8"...
Page 60 STEP 25: ATTACHING SWING LEGS TO BRACKET 1: PLACE THE 3 X 3 X 96" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: USING THE SWING LEG BRACKET AS A TEMPLATE, DRILL 11/64" PILOT HOLES 2-1/2" DEEP AT EACH SWING LEG BRACKET HOLE.
Page 61 STEP 26: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH.
Page 62 STEP 27: MOUNT SWING BEAM TO FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END ON THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES THE LEGS. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
Page 63 STEP 28: LEVEL SWING BEAM 1: PLACE THE LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. LEVEL...
Page 64 STEP 29: SWING LEG CROSS MEMBER 1: POSITION THE 2 X 4 X 58" CROSS MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS MEMBER, AND MARK THROUGH THE HOLES ONTO THE LEGS. DRILL AN 11/64" HOLE AT EACH MARK 2-1/2" DEEP. 3: FASTEN THE CROSS MEMBER TO THE LEGS WITH 3/8 X 3-1/2"...
Page 65 STEP 30: BOTTOM PANEL BOARDS 2: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 4 FRONT FACE BOARD AND FASTEN TO THE CORNER POSTS. DRILL A 9/64" HOLE 2-1/2" DEEP THROUGH THE BOTTOM PANEL BOARD HOLE.
Page 66 STEP 31: PANEL SLATS 1: FIND TWELVE 5/4 X 6 X 28" PANEL SLATS. 2: INSTALL THE PANEL SLATS AS SHOWN BELOW. SEE DETAILS BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. 5/4 X 6 X 28"...
Page 67 STEP 32: ATTACHING CENTER POSTS 1: THE 2 X 4 X 25" CENTER POSTS WILL SECURE TO THE FRONT AND REAR TARP SUPPORT WITH A 5/16" X 2-1/2" HEX BOLT, A 5/16" WASHER AND A T-NUT. NOTE: MAKE SURE THE 2 X 4 X 25" CENTER POSTS ARE VERTICAL. 2: FASTEN EACH CENTER POST TO THE TARP SUPPORT WITH TWO 2-1/2"...
Page 68 STEP 33: TARP BOARDS 1: THE 2 X 4 X 36" (CENTER) TARP BOARD WILL SECURE ON TOP OF THE TARP CENTER POSTS WITH TWO 2-1/2" WOOD SCREWS PER SIDE. 2: THE TWO 2 X 4 X 36" TARP BOARDS WILL SECURE ON THE TOP OF THE CORNER POSTS WITH TWO 2-1/2"...
Page 69 STEP 34: SUN 1: PLACE THE WOOD SUN ON TOP OF THE TARP SUPPORTS LEANING AGAINST THE TARP CENTER POST, MAKE SURE IT IS CENTERED AND SECURE WITH TWO #8 X 2-1/2" WOOD SCREWS. 2: PLACE THE PLASTIC SUN ON TOP OF THE FRONT SUN AND SECURE WITH TWO #8 X 1-1/4" WOOD SCREWS.
Page 70 STEP 35: TARP 1: PLACE THE TARP ACROSS THE TARP BOARDS WITH THE HEMS ON THE INSIDE. 2: FASTEN THE OUTSIDE CORNERS OF THE TARP TO THE SIDE OF THE TARP BOARD FIRST. ATTACH THE GROMMETS IN THE TARP TO THE TARP BOARD WITH #14 X 1-1/4" PAN HEAD SCREWS WITH 1/4"...
Page 71 STEP 36: ROOF PEAK SUPPORT 1: PLACE THE ROOF PEAK SUPPORT ON TOP OF THE FRONT TARP CENTER POSTS AND FLUSH WITH TOP TARP BOARD , MAKE SURE IT IS CENTERED AND SECURE WITH TWO #8 X 2" WOOD SCREWS. 5/4 X 6 X 13"...
Page 72 STEP 37: 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 #8 X 1-1/4" WOOD SCREWS. *DO NOT OVER TIGHTEN*.
Page 73 STEP 38: 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. 2-3 KNOTS SHOULD BE SUFFICIENT. 2: THREAD THE OTHER END OF THE ROPE THROUGH THE HOLE IN THE BOTTOM ROCK WALL BOARD.
Page 74 STEP 39: TIC TAC TOE ASSEMBLY 1: LOCATE THE 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 2: FASTEN THE TIC TAC TOE MOUNTS TO THE GREEN TIC TAC TOE BRACKETS WITH THE SHORT SCREWS PROVIDED IN THE TIC TAC TOE BOX. 3: ASSEMBLE THE TIC TAC TOE ACCORDING TO THE INSTRUCTIONS IN THE BOX.
Page 75 STEP 40: MOUNTING TIC TAC TOE PANEL 1: PLACE THE TIC TAC TOE PANEL ASSEMBLY FROM THE PREVIOUS STEP ONTO THE BACK WALL. THE LOWER TIC TAC TOE MOUNT BOARD SHOULD BE 4" ABOVE THE DECK. 2: ATTACH EACH TIC TAC TOE MOUNT TO THE PANEL SLATS WITH #8 X 1-3/4 WOOD SCREWS. #8 X 1-3/4"WOOD SCREW TIC TAC TOE MOUNT BOARD PANEL SLAT...
Page 76 STEP 41: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. DRILL AN 11/64" HOLE 2" DEEP INTO THE END OF THE SWING BEAM. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE END OF THE SWING BEAM.
Page 77 STEP 42: 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. FLAG DETAIL A SCALE 2 : 13...
Page 78 STEP 43: 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 79 STEP 44: HANGING SWINGS 1: LOCATE TWO SWING BELTS WITH CHAINS ATTACHED. 2: SNAP A SPRING CLIP THROUGH THE SWING HANGER LOOP ON THE SWING BEAM. 3: SNAP A CHAIN ONTO EACH SPRING CLIP. ADJUST EACH SWING UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS.
Page 80 STEP 45: CHALKBOARD 1: ATTACH CHALKBOARD TO THE SLATS UNDER STEERING WHEEL WITH 3/4" PAN HEAD SCREWS. NOTE: CHALKBOARD COMES WITH A MAGNETIC CHALK HODER WHICH WILL STICK TO THE CHALKBOARD. CHALKBOARD 3/4" PAN HEADSCREW...
Page 81 STEP 46: LOONEY PERISCOPE 1: FASTEN THE U-SHAPED BASE ON THE REAR SLAT WITH 1-1/4" PHILIPS COUNTERSUNK HEAD SCREWS PROVIDED. 2: WHEN THE U-SHAPED BASE IS MOUNTED VERTICALLY AS SHOWN BELOW THE CHILD MAY SIMULATE THE UP AND DOWN MOVEMENT OF A REAL PERISCOPE. THE U-SHAPED BASE MAY ALSO BE MOUNTED HORIZONTALLY IF MOUNTING VERTICALLY IS NOT POSSIBLE.
Page 82 STEP 47: LOONEY TELESCOPE 1: FASTEN THE U-SHAPED BASE ON TOP OF A 2 X 6 X 48" ARCH FACE BOARD WITH 1-1/4" PHILLIPS COUNTERSUNK HEAD SCREWS PROVIDED. !WARNING!**DO NOT LOOK INTO SUN OR OTHER BRIGHT LIGHTS WITH TELESCOPE** TELESCOPE 1-1/4"...
Page 83 STEP 48: 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. USE CAUTION WHEN HAMMERING SO THAT YOU DO NOT MAR THE WOOD. 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 84 STEP 49: SANDBOX SEATS 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. #8 X 2"WOOD SCREW 5/4 X 6 X 22"...
Page 85 STEP 50: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE CORNER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.

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