PlayNation Play Systems Biscayne 802 Assembly Instructions Manual
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PlayNation Play Systems Biscayne 802 Assembly Instructions Manual

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Biscayne
Model: 802
(BOXES: 801N-1, 801N-2, 802,
1509N, 1509W, 1513, RV, CB,
120 & Slide Box)
Copyright © 2015 PlayNation Play Systems, Inc.
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.playnation.com

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Summary of Contents for PlayNation Play Systems Biscayne 802

  • Page 1 Biscayne Model: 802 (BOXES: 801N-1, 801N-2, 802, 1509N, 1509W, 1513, RV, CB, 120 & Slide Box) Copyright © 2015 PlayNation Play Systems, Inc. All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.playnation.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 use our “Quick Response Center”...
  • Page 3 2015 MANUFACTURER'S LIMITED LIFETIME WARRANTY PlayNation Play Systems, Inc. warrants its Lifetime™ series of swing sets to be free from defects in workmanship and materials, under normal use and conditions, for the lifetime of the product for above ground structural wood components and for two years for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.) except PlayNation's Super Scoop Slides™...
  • Page 4 PlayNation's discretion, may be accomplished by submitting photographs or by delivery of the defective part to PlayNation. PlayNation Play Systems, Inc. • 190 Etowah Industrial Ct. • Canton, GA 30114 • 770-704-9300 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase.

  • Page 5: Important Safety Guidelines

    IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set.
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 7 WARRANTY REGISTRATION - BISCAYNE- PlayNation manufactures the 3 EASY WAYS TO REGISTER finest quality products that Mail this completed form to: are designed for outstanding Fax this completed form to: PlayNation Playsets strength and durability. OPTION 1 (800) 880-3300 190 Etowah Industrial Court back our products with an Canton, GA 30114 unparalleled warranty.
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 9: Important - Please Read

    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 10: Important Documents

    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. PlayNation Play Systems, Inc. 190 Etowah Industrial Court Canton, GA. 30114...
  • Page 11 Model: 802 (BOXES: 801N-1, 801N-2, 802, 1509N, 1509W, 1513, RV, CB, 120 & Slide Box) REV: 3.31.2015...
  • Page 12 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 4-6 Level Fort, General Information and Definitions.…………………………....Pages 7-8 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 16-31 Framing the play set………………………………………......…...
  • Page 13 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 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21: Board Identification

    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 22: Pre-Drill Lag Screw Directions

    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 23: 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 24 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 20'11" 5'10" 10'1" Ladder 3'1 16 " 2'6 2 " Swing Belts (2) 9'10 8 " Trapeze Bar (1) 3'11 "...
  • Page 25 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” and a 7/8” & 1” Paddle style bit. ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16”...
  • Page 26 5/16" X 3-1/2" 3/8 X 3-1/2" 11-0072 HEX LAG HEX LAG SCREW SCREW QTY: 24 QTY: 26 801N HARDWARE SHEET 1 OF 2 9/19/2014 JH #2 SQUARE DRIVE BIT QTY: 1 PLASTIC 3/8 x 9" 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2"...
  • Page 27 11-0072 #8 X 1" 801N HARDWARE WOOD SCREW QTY: 8 SHEET 2 OF 2 #8 X 1-1/4" 9/19/2014 JH WOOD SCREW QTY: 24 #14 X 1-1/4" #8 X 1-1/2" PAN HEAD SCREW WOOD SCREW QTY: 16 QTY: 394 #8 X 2" WOOD SCREW QTY: 200 #8 X 2-1/2"...
  • Page 28 PICTURE DESCRIPTION QTY. 1 X 4 X 25" PANEL SLAT 1-4-2500-PS 1 X 4 X 26" FRONT PANEL SLAT 1-4-2600-FPS 1 X 4 X 51" REAR PANEL SLAT 1-4-5100-RPS 1 X 5 X 25" PANEL SLAT 1-5-2500-PS 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55"...
  • Page 29 PICTURE DESCRIPTION QTY. 1 X 6 X 14-1/4" FRONT PANEL SLAT 1-6-1425-FPS 1 X 6 X 16" TIC TAC TOE SUPPORT 1-6-1600-TTTS 1 X 6 X 17" PANEL SLAT 1-6-1700-PS 1 X 6 X 26" FRONT PANEL SLAT 1-6-2600-FPS 1 X 6 X 27-3/4" PANEL SLAT 1-6-2775-PS 1 X 6 X 29-1/2"...

  • Page 30: Description Qty

    PICTURE DESCRIPTION QTY. 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 55" ROOF PEAK 1-6-5500-RP 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 15" PICNIC TABLE SUPPORT 2-4-1500-PTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 18"...
  • Page 31 PICTURE DESCRIPTION QTY. 2 X 4 X 23" BENCH SUPPORT 2-4-2300-BS 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 51" PICNIC TABLE SEATS AND TOP 2-4-5100-PTST 2 X 4 X 51-1/8" ROOF SUPPORT LEFT LEFT AND RIGHT 2-4-5113-RSL 2-4-5113-RSR RIGHT...
  • Page 32 PICTURE DESCRIPTION QTY. 2 X 4 X 70" CENTER DECK SUPPORT 2-4-7000-CDS 2 X 4 X 70" DECK SUPPORT 2-4-7000-DS 2 X 4 X 70" PANEL SUPPORT 2-4-7000-PS 2 X 6 X 13-5/8" 2-6-1363-S 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD 2-6-4750-ASTB 2 X 6 X 47-1/2"...
  • Page 33 PICTURE DESCRIPTION QTY. 2 X 6 X 67-1/4" SUNBURST BOARD 2-6-6725-SB 2 X 6 X 70" FRONT FACE BOARD 2-6-7000-FFB 2 X 6 X 70" FRONT TOP PANEL BOARD 2-6-7000-FTPB 2 X 6 X 70" REAR FACE BOARD 2-6-7000-RFB 2 X 6 X 70" REAR TOP PANEL BOARD 2-6-7000-RPTB...
  • Page 34 PICTURE DESCRIPTION QTY. 4 X 4 X 47-1/2" SWING BEAM MOUNT 4-4-4750-SBM 4 X 4 X 78" ROPE LADDER SUPPORT 4-4-7800-RLS 5/4 X 2 X 16" SMALL RAY 125-2-1600-SR 5/4 X 2 X 18" SMALL RAY 125-2-1800-SR 5/4 X 2 X 23" LARGE RAY 125-2-2300-LR 5/4 X 3 X 18-3/4"...
  • Page 35 PICTURE DESCRIPTION QTY. 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB 5/4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 4 X 4 X 108" PLASTIC COATED CORNER POST 4 X 4 X 108" PLASTIC COATED SWING LEG 4 X 6 X 120" PLASTIC COATED SWING BEAM 2 X 4 X 24"...
  • Page 36 Charleston - Accessories PICTURE DESCRIPTION QTY. WAVE SLIDE 03-0013 ROPE SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 37 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A PACK ROCKS OF 5 ROCKS) A-FRAME SWING BRACKET 11-5010 801N HARDWARE NOT SHOWN 11-0072...
  • Page 38 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 10' ROPE (ROCK WALL)

  • Page 39: Safety Handles

    PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 GROUND STAKES (PAIR) 07-0016-P SAFETY HANDLES (PAIR) 07-0005...
  • Page 40 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY 1513 BOX UNASSEMBLED DORMER 1513 BOX BOXED TIC-TAC-TOE SPINNER PANEL 07-0010 FLAG KIT 09-1014...
  • Page 41 PICTURE DESCRIPTION QTY. CROWN CROWN 07-0019 WINDOW PANEL WINDOW PANEL 07-0013 STEERING WHEEL 07-0004 SUNBURST SCREEN 06-2001...
  • Page 42 STEP 1: ATTACHING THE T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE PLAY SET PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DISASSEMBLE THEN REASSEMBLE TO MAKE YOUR CORRECTIONS. MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS.
  • Page 43 STEP 2: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" ROPE LADDER RUNNER ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 44 STEP 3: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 47-1/2" END SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 45 STEP 3A: DRILL HOLES FOR BRIDGE CHAINS 1: LOCATE ONE 2 X 4 X 70" DECK SUPPORT AND ONE 2 X 6 X 70" FRONT FACE BOARD. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD. 3: PLACE A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES WITH A SPADE BIT.

  • Page 46: Step 4: Deck Supports

    STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16"...

  • Page 47: Step 5: Front Frame Assembly

    STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T- NUTS INSTALLED ON THE CORNER POSTS.

  • Page 48: Step 6: Rear Frame Assembly

    STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR CORNER POSTS. THE HOLES IN THE SANDBOX BOARD ARE OFFSET UP. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHER TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 49 STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS.
  • Page 50 STEP 7: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 51 STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-1/4" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/8" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 52 STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: USE THE HOLE IN THE CENTER OF THE DECK SPACER AS A GUIDE TO DRAW A LINE ON THE OUTSIDE OF THE BOTTOM PANEL BOARD ON EACH SIDE OF THE PLAY SET.
  • Page 53 STEP 10: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH HOLES OFFSET DOWN AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16"...
  • Page 54 STEP 11: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 5/4 X 6 X 47-3/8"...

  • Page 55: Step 12: Rock Wall

    STEP 12: ROCK WALL 1: FIND TWO 2 X 4 X 66" 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 2 X 4 X 66"...
  • Page 56 STEP 13: ROCK WALL 1: FIND ELEVEN 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 TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2"...
  • Page 57 STEP 14: ROCK WALL 1: FASTEN THE 90 BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME. GREEN BRACKET 5/16" WASHER 5/16"...
  • Page 58 STEP 15: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND THIRTY 1/4" WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH THREE 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 16: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT SIDE - RIGHT OF THE PLAY SET AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 BRACKETS AS A TEMPLATE;...
  • Page 60 STEP 17: LADDER 2 X 4 X 66" 1: FIND TWO 2 X 4 X 66" LADDER SIDES. LADDER SIDE 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH T-NUT OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
  • Page 61 STEP 18: LADDER TO PLAY SET 1: THE LADDER WILL ATTACH TO THE REAR OF THE PLAY SET. PLACE THE LADDER AGAINST THE BOTTOM PANEL BOARD CENTERED IN THE NOTCHED OUT AREA. 2: THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE BOTTOM PANEL BOARD.
  • Page 62 STEP 19: FRONT PANEL SLATS 1: FIND ONE 1 X 4 X 25" FRONT PANEL SLATS AND ONE 4 X 4 X 26" CENTER POST. 2: PREDRILL THE SLAT 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3: INSTALL THE PANEL SLAT AS SHOWN ON THE FIGURE BELOW AND ATTACH WITH 2"...
  • Page 63 STEP 20: SIDE PANEL SLATS 1: FIND ELEVEN 1 X 6 X 27-3/4" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END WITH TWO EQUALLY SPACED HOLES WITH A 1/8" DRILL BIT. 3. INSTALL THE PANEL SLATS AS SHOWN LEAVING 1/4" GAP BETWEEN EACH PANEL SLAT OR A 1/4" GAP BETWEEN THE CORNER POST AND PANEL SLAT.
  • Page 64 STEP 21: TIC TAC TOE SUPPORT 1:FIND TWO 1 X 6 X 16" TIC TAC TOE SUPPORT SLATS. 2: PRE-DRILL THE SLATS 2" FROM EACH END, AND 4" OVER FROM THE FIRST HOLE AS SHOWN ON THE DIAGRAM USING A 1/8" DRILL BIT. 3: INSTALL THE SLATS IN THE GAP LEFT FROM THE PREVIOUS INSTALLATION LEAVING A 3/4"...

  • Page 65: Step 22: Swing Beam Plate

    STEP 22: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON THE TOP, AND 3/8"...
  • Page 66 STEP 23: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWING BEAM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 67 STEP 24: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG 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 LEGS FLUSH TO TOP OF SWING LEG BRACKET...
  • Page 68 STEP 25: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8"...
  • Page 69 STEP 26: 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 OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLES AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLES ON THE SWING BEAM PLATE.
  • Page 70 STEP 27: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE).
  • Page 71 STEP 28: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8" X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS.
  • Page 72 STEP 29: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP.
  • Page 73 STEP 30: ROOF SUPPORT 1: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE FORT WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. NOTE: THE ROOF PEAK SUPPORTS (TRIANGLES) SHOULD FACE OUT. ROOF PEAK SUPPORT ROOF PEAK SUPPORT FACES OUT FACES OUT 2 X 4 X 51-1/8"...
  • Page 74 STEP 31: ROOF 1: PLACE THE 1 X 5 X 55" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.

  • Page 75: Step 32: Roof Peak

    STEP 32: ROOF PEAK 1: PLACE THE 55" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH EIGHT 1-1/4" WOOD SCREWS. 55" ROOF PEAK...
  • Page 76 STEP 33: ROOF 1: PLACE THE 1 X 6 X 55" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2. FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 5 X 55"...
  • Page 77 STEP 34: SUNBURST BOARD 1: FIND TWO 2 X 6 X 56-1/2" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS.
  • Page 78 STEP 35: BOTTOM SUNBURST BOARD 1: FIND TWO 2 X 6 X 67-1/4" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS.
  • Page 79 STEP 36: FRONT TOP PANEL SLATS 1: FIND SIX 1 X 6 X 26" AND TWO 1 X 4 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT THE DIMENSIONS SHOWN ON THE DIAGRAM.
  • Page 80 STEP 37: REAR PANEL SLATS 1: FIND FOUR 1 X 6 X 51" REAR PANEL SLATS AND TWO 1 X 4 X 51" REAR PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3.
  • Page 81 STEP 38: FINAL REAR PANEL BOARDS 1: FIND TWO 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS AND TWO 1 X 6 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS 3/4" FROM THE BOTTOM END AND 4" FROM THE TOP END WITH TWO HOLES EQUALLY SPACED WITH A 1/8"...
  • Page 82 STEP 39: WINDOW SUPPORTS 1: FIND THE SIX 1 X 6 X 4-1/2" BOTTOM WINDOW SUPPORTS. PRE-DRILL THREE 1/8" HOLES IN THE BOTTOM OF EACH SUPPORT AS SHOWN IN THE DIAGRAM. 2: PLACE TWO SUPPORTS IN EACH OF THE TWO OPENINGS IN THE FRONT OF THE FORT, AND THE FINAL TWO SUPPORTS IN THE OPENING AT THE REAR OF THE FORT.
  • Page 83 STEP 40: INSTALL WINDOWS 1: FIND FOUR WINDOW PANELS AND FOUR SUN PIECES. PLACE EACH WINDOW IN THE OPENING WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. TEST FIT THE SUN PIECES ABOVE THE WINDOW FRAME (THESE WILL BE INSTALLED LATER).
  • Page 84 STEP 41: INSTALL PANEL SLATS AND SUN PIECES 1: FIND EIGHT 1 X 6 X 14-1/4" FRONT PANEL SLATS AND EIGHT SUN PIECES. 2: PRE-DRILL EACH SLAT WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOW BELOW. 3: ATTACH THE PANEL SLATS AS SHOWN BELOW WITH THE BOTTOM OF THE SLAT RESTING UPON THE INSIDE FLANGE OF THE WINDOW FRAME.
  • Page 85 STEP 42: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. DISREGARD STEPS 6 & 7. 2: CENTER THE TIC TAC TOE PANEL BETWEEN THE SUPPORTS ON THE SIDE WALL AND ATTACH WITH EIGHT 1" WOOD SCREWS PROVIDED IN THE TIC TAC TOE BOX.
  • Page 86 STEP 43: SUNBURST 1: PRE-DRILL TWO 1/8" HOLES IN EACH SUN. THE HOLES WILL BE DRILLED NEAR THE OUTER EDGE ON EACH SIDE GOING STRAIGHT DOWN. 2: CENTER SUN ON THE PANEL BOARD AND ATTACH USING TWO 2" WOOD SCREWS. 3: REPEAT FOR OTHER SIDE OF FORT.
  • Page 87 STEP 44: SUNBURST 1: LOCATE TWO 5/4 X 2 X 23" LARGE RAYS, TWO 5/4 X 2 X 16" SMALL RAYS AND TWO 5/4 X 2 X 18" SMALL RAYS. 2: PRE-DRILL ALL SMALL RAYS AT 3/4" ON CENTER FROM EACH END WITH A 1/8" DRILL BIT. PRE-DRILL ALL LARGE RAYS 3/4"...
  • Page 88 STEP 45: SUNBURST 1: INSTALL SUNBURST SCREENS AS SHOWN BELOW, SO THAT IT IS FLUSH TO THE ROOF SUPPORTS. FASTEN EACH SCREEN WITH SIX 1-1/4" PAN HEAD SCREWS INTO THE GROMMETS IN THE SCREEN.

  • Page 89: Step 46: Panel Support

    STEP 46: PANEL SUPPORT 1: MEASURE 17-3/4" FROM THE BOTTOM OF THE SANDBOX BOARD ON THE FRONT FACE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. LINE UP THE TOP OF THE 2 X 4 X 70" PANEL SUPPORT WITH THE MARKS.

  • Page 90: Step 47: Safety Board

    STEP 47: SAFETY BOARD 1: MEASURE 17-3/4" FROM BOTTOM OF THE SANDBOX BOARD ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. 2: ALIGN THE TOP OF THE SAFETY PANEL BOARD WITH THE MARKS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH "OFFSET HOLES DOWN"...

  • Page 91: Step 48: Picnic Table

    STEP 48: PICNIC TABLE 1: PLACE EACH OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORTS 15" OVER FROM THE CORNER POSTS. (SEE REAR VIEW) 2: MAKE SURE THE PICNIC TABLE VERTICAL SUPPORTS ARE SQUARE TO THE SANDBOX BOARDS. ATTACH THEM TO THE SANDBOX BOARDS FROM THE INSIDE USING TWO 2-1/2"...
  • Page 92 STEP 4 : PICNIC TABLE 1: FIND TWO 2 X 4 X 15" PICNIC TABLE SUPPORTS. 2: ATTACH EACH PICNIC TABLE SUPPORT TO THE TOP OF THE PICNIC TABLE VERTICAL SUPPORT AND TO THE CORNER POSTS. 3: ATTACH EACH PICNIC TABLE SUPPORT TO THE PICNIC TABLE VERTICAL SUPPORT AND THE CORNER POST USING SIX 2-1/2"...
  • Page 93 STEP : PICNIC TABLE 1: FIND FIVE 2 X 4 X 51" PICNIC TABLE SEATS AND PICNIC TABLE TOP BOARDS. 2: ATTACH EACH BOARD WITH FOUR 2-1/2" WOOD SCREWS AS SHOWN BELOW TO CREATE THE PICNIC TABLE SEATS AND TOP. NOTE: LADDER AND ROCK WALL REMOVED FOR CLARITY.
  • Page 94 STEP 51: BOTTOM PANEL SLATS 1: FIND TWENTY 1 X 6 X 17" PANEL SLATS AND TWO 1 X 6 X 30" PANEL SLATS. 2: PRE-DRILL SLATS WITH TWO EQUALLY SPACED HOLES 1" FROM EACH END WITH A 1/8" DRILL BIT. 3: ATTACH PANEL SLATS ALONG THE SAFETY BOARDS AND PANEL BOARD EQUALLY SPACED.
  • Page 95 STEP 52: ARCHED SIDE TOP BOARDS 1: PLACE THE 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD UP AGAINST THE TOP OF THE CORNER POSTS ON THE SIDE OF THE FORT. 2: ATTACH THE ARCHED SIDE TOP BOARD WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3: ATTACH ANOTHER ARCHED SIDE TOP BOARD ON THE OPPOSITE SIDE OF FORT.
  • Page 96 STEP53: CHIMNEY/DORMER 1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO ASSEMBLE AND THEN INSTALL THE CHIMNEY AND DORMERS. TIP: WHEN INSTALLING THE ROOF BOARDS ONLY INSTALL A FEW ROOF BOARDS THEN ASSEMBLE AND INSTALL THE CHIMNEY. AFTERWARDS INSTALL MORE ROOF BOARDS THEN ASSEMBLE ANDINSTALL THE DORMER. FINALLY INSTALL THE REMAINING ROOF BOARDS AND ROOF FINISHER.
  • Page 97 STEP 54: INSTALLING THE CLIMBING ROPE 1:DRILL A 7/8" HOLE THROUGH THE FRONT TOP PANEL BOARD (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE FRONT TOP PANEL BOARD. 3: YOU CAN TIE A FEW (NO MORE THAN THREE) KNOTS IN THE ROPE TO AID IN CLIMBING APPROXIMATELY 18"...
  • Page 98 STEP 55: PLASTIC FLAGS 1: FIND THE PLASTIC FLAG KIT. 2: ATTACH THE FLAGS TO THE FRONT CORNER POSTS AS SHOWN BELOW. 3: ATTACH EACH FLAG TO THE CORNER POST THROUGH THE PRE-DRILLED HOLES USING 1/2" PHILLIPS HEAD WOOD SCREWS PROVIDED WITH THE FLAG KIT. PLASTIC FLAG KIT PLASTIC FLAG KIT...
  • Page 99 STEP 56: MOUNTING TELESCOPE 1: PLACE THE TELESCOPE ASSEMBLY ON THE ROPE LADDER SUPPORT ABOVE THE TIC TAC TOE PANEL. USING THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE ROUND TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT. 2: PLACE THE TELESCOPE STAND INTO THE SLOT OF THE TELESCOPE BRACKET.

  • Page 100: Step 57: Steering Wheel

    STEP 57: 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 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 101 STEP 58: ATTACHING THE SAFETY HANDLES 1: LOCATE TWO SAFETY HANDLES PROVIDED WITH YOUR PLAYSET. 2: LOCATE THE HARDWARE PROVIDED IN THE BAG WITH THE HANDLES. **DO NOT USE THE SCREWS PROVIDED IN THE BAG WITH THE HANDLES** 3: LOCATE FOUR #14 X 1" LONG PAN HEAD SCREWS IN YOUR MAIN HARDWARE PACKAGE. USE THE 1/4" FLAT WASHERS PROVIDED IN THE BAG WITH THE HANDLES.

  • Page 102: Step 59: Hanging The Swings

    STEP 59: HANGING THE SWINGS 1: START BY ATTACHING ONE SPRING CLIP TO EACH IRON DUCTILE ON THE SWING BEAM. 2: ATTACH ONE CHAIN PER ACCESSORY TO EACH SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED BY CLIPPING CHAINS ON HIGHER OR LOWER LINKS. TRAPEZE BAR W/CHAINS SWING BELT...

  • Page 103: Step 60: Rope Ladder

    STEP 60: ROPE LADDER VIEW OF COMPLETED ROPE LADDER ASSEMBLY. THE NEXT STEP SHOWS YOU HOW TO ASSEMBLE THIS. THESE BEAD SHAPES REPRESENT KNOTS THAT YOU WILL TIE.
  • Page 104 STEP 61: ROPE LADDER 1: FIND THREE ROPE LADDER ROPES. MAKE A KNOT IN THE END OF EACH ROPE AND THREAD THE FREE END THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT. PULL EACH ROPE TAUGHT. 2: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 6 INCHES AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 6 INCHES BELOW THE ROPE LADDER SUPPORT.
  • Page 105 STEP 62: CROWN 1: PLACE THE CROWN OVER THE WOOD SUN PIECE ON THE FRONT OF THE PLAY SET. 2: ATTACH THE CROWN TO THE SUN WITH TWO #8 X 1-1/2" WOOD SCREWS. #8 X 1-1/2" WOOD SCREWS CROWN...

  • Page 106: Step 63: Ground Stakes

    STEP 63: GROUND STAKES 1: HAMMER GROUND STAKES INTO THE GROUND AT AN ANGLE BESIDE THE SWING LEGS AS SHOWN BELOW. 2: FASTEN EACH GROUND STAKE TO THE SWING LEG WITH THE #8 X 2" SCREW PROVIDED. DETAIL A SCALE 1 : 9 GROUND STAKE 2"...
  • Page 107 STEP 64: NAME PLATE 1: PLACE THE MANUFACTURER'S NAME PLATE CENTERED ON THE SWING BEAM. 2: FASTEN THE NAME PLATE TO THE SWING BEAM WITH TWO #8 X 1-1/2" WOOD SCREWS. PLACE NAME PLATE HERE AND SECURE WITH SCREWS.
  • Page 108 PART II CLATTER BRIDGE...
  • Page 109 11-0071 1509N HARDWARE PAGE: 1 OF 1 REV A: 9/19/2014 JH #8 X 2" WOOD SCREW QTY: 94 #8 X 2-1/2" #14 x 1-1/4" WOOD SCREW PAN HEAD SCREW QTY: 18 QTY: 6 #8 X 3" WOOD SCREW QTY: 5 3/8"...
  • Page 110 1509W HARDWARE #8 X 1-1/4" WOOD SCREW PAGE 1 OF 1 QTY: 8 9/11/2014 JH #8 X 1-1/2" WOOD SCREW QTY: 60 #8 X 2" WOOD SCREW QTY: 8 5/16" x 3-1/2" HEX LAG SCREW QTY: 4 5/16" WASHER QTY: 4 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 111 11-0026 802 - HARDWARE SUPPLIER LIST REV D 9/12/2014 J.H. 3/8" X 1-1/8" 3/8 X 5" 5/16" X 3-1/2" HEX LAG SCREW BLACK PLASTIC HEX LAG SCREW QTY: 4 QTY: 4 PLUG QTY: 8 #8 x 2" WOOD SCREW 5/16" WASHER QTY: 8 QTY: 4 #8 x 2-1/2"...

  • Page 112: Description Qty

    PICTURE DESCRIPTION QTY. THESE POSTS ARE IN THE CB BOX NOTE: THIS IS A LIST OF CLATTER BRIDGE PARTS. IT IS A 4 x 4 x 96" COMBINATION OF CORNER POST THE 1509N, 1509W AND 802 WOOD KITS. 2 X 6 X 36-3/4" SANDBOX BOARDS 2 X 4 X 36-3/4"...
  • Page 113 PICTURE DESCRIPTION QTY. 2 X 4 X 29" BRIDGE DECK BOARD 5/4 X 2-5/8" X 28-1/2" PANEL SLAT 5/4 X 2-5/8" X 16" BRIDGE SLAT 802 BOX 5/4 x 2-5/8" x 25" PANEL SLAT LEFT 802 BOX 4 X 4 X 32" RAD RIDE 5 LAG POST 96"...
  • Page 114 PICTURE DESCRIPTION QTY. 1 X 3 X 36-3/4" ROOF PEAK BOARD 2 1-3-3675-RPB2 1 X 4 X 36-3/4" ROOF PEAK BOARD 1 1-4-3675-RPB1 1 X 5 X 36-3/4" ROOF BOARD 1-5-3675-RB 1 X 4 X 36-3/4" ROOF FINISHER 1-4-3675-RF 1 X 4 X 36-3/4" ROOF STARTER 1-4-3675-RS...

  • Page 115: Step 1: Attaching T-Nuts To The Corner Posts

    STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 96"...
  • Page 116 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2"...
  • Page 117 STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2"...
  • Page 118 STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 36-3/4" DECK SUPPORTS TO THE HOLES AT 54-1/2" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST.
  • Page 119 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 120 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 121 STEP 7: LAG SCREWS 1: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. TO SQUARE AND LEVEL THE DECK OF THE TOWER TO THE DECK OF THE FORT PLACE A DECK BOARD ACROSS THE 2 X 4'S.
  • Page 122 STEP 8: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: YOUR DECK SPACERS AND DECK BOARDS SHOULD BE PRE-DRILLED FROM THE FACTORY. IF THEY ARE NOT PRE- DRILLED OR IF HOLES ARE MISSING THEN DRILL 1/8" HOLES USING THE DIMENSIONS SHOWN BELOW. 4"...
  • Page 123 STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-1/2" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
  • Page 124 STEP 10: DECK 1: INSTALL SEVEN 5/4 X 4 X 36-1/2" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS. MAKE SURE THE ENDS OF THE DECK BOARDS DO NOT PROTRUDE BEYOND THE OUTSIDE FACE OF POSTS B AND D.

  • Page 125: Step 11: Rear Bottom Panel Board

    STEP 11: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH CHAIN HOLES) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 2: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.

  • Page 126: Step 12: Panel Slats

    STEP 12: PANEL SLATS 1: FIND FIVE 5/4 X 3 X 28-1/2" PANEL SLATS. 2: THE PANEL SLATS SHOULD BE PRE-DRILLED FROM THE FACTORY FOR YOU. IF THEY ARE NOT THEN DRILL EACH PANEL SLAT 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: INSTALL THE FIRST PANEL SLAT 2-1/2"...
  • Page 127 STEP 13: BRIDGE RAILS 1: PLACE THE TOP SURFACE OF THE UPPER TWO 2 X 4 X 66" BRIDGE RAILS 5-1/2" BENEATH THE TOP SURFACE OF THE TOP PANEL BOARD. THE COUNTERSUNK HOLE IN THE END OF THE BRIDGE RAIL SHOULD FACE THE INSIDE.
  • Page 128 STEP 14: BRIDGE RAILS TO PLAY SET 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER CORNER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 3- 1/2"...
  • Page 129 STEP 15: BRIDGE RAIL SLATS 1. THE BRIDGE RAIL SLATS SHOULD BE PRE-DRILLED FROM THE FACTORY. IF THEY ARE NOT PRE-DRILLED THEN DRILL THE 5/4 X 3 X 16" BRIDGE RAIL SLATS ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2.
  • Page 130 STEP 16: BRIDGE DECK AND CHAIN ASSEMBLY 1: FIND FIFTEEN 2 X 4 X 29" BRIDGE DECK BOARDS AND INSERT T-NUTS INTO THE PRE-DRILLED HOLES. USE A HAMMER TO SEAT THE T-NUTS INTO THE BOARDS. T-NUT 2 X 4 X 29" BRIDGE DECK BOARD T-NUT...
  • Page 131 STEP 17: BRIDGE DECK AND CHAIN ASSEMBLY 1: LOCATE TWO 96" CHAIN SECTIONS THAT SHIPPED WITH THE CLATTER BRIDGE. 2: PLACE THE CHAINS OVER THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW. 3: LINE UP THE 18TH LINK IN THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES. 96"...
  • Page 132 STEP 18: BRIDGE DECK AND CHAIN ASSEMBLY 1: PLACE A 5/16" WASHER BETWEEN THE 18TH CHAIN LINK AND THE BRIDGE DECK BOARD. 2: PLACE A 5/16" X 1-3/4" HEX BOLT WITH 5/16" WASHER THROUGH THE 18TH CHAIN LINK, THEN THROUGH THE 5/16"...
  • Page 133 STEP 19: BRIDGE DECK/CHAIN INSTALLATION 1: LAY THE BRIDGE DECK/CHAINS ASSEMBLY BETWEEN THE PLAY SET AND THE TOWER WITH THE CHAINS FACING THE GROUND. THREAD THE CHAIN ENDS IN THE BRIDGE DECK ASSEMBLY THROUGH THE HOLES IN THE BOTTOM PANEL BOARD AND DECK SUPPORT BOARD ON THE TOWER. 2: THERE SHOULD BE AT LEAST A 1"...
  • Page 134 STEP 20: LAG POSTS 1: LOCATE TWO 4 X 4 X 32" LAG POSTS. 2: PLACE THE LAG POSTS ON THE INSIDE OF CORNER POSTS A AND B AS SHOWN. THE COUNTERSUNK HOLE THAT IS 4" FROM THE END SHOULD BE AT THE TOP. 3: ATTACH EACH LAG POST TO THE CORNER POST WITH 3/8"...
  • Page 135 STEP 21: ROOF SUPPORT ASSEMBLIES 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN.
  • Page 136 STEP 22: DRILLING CORNER POST HOLES 1: CHECK THE DIMENSION OF THE ROOF SUPPORT ASSEMBLIES AS SHOWN BELOW BEFORE DRILLING HOLES. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON THE CORNER POSTS ON THE INSIDE. 3: DRILL A 9/64" HOLE BY 2-1/2" DEEP AT EACH MARK. 4: REPEAT SUBSTEPS 2-3 ON THE INSIDE OF THE OTHER POSTS AS POINTED OUT BELOW.
  • Page 137 STEP 23: INSTALL ROOF SUPPORT ASSEMBLIES 1: PLACE TWO ROOF SUPPORT ASSEMBLIES ON THE CLATTER BRIDGE TOWER DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TOTHE HOLES DRILLED ON THE INSIDE OF THE CORNER POSTS WITH TWO 5/16"...
  • Page 138 STEP 24: ROOF STARTERS 1: PLACE THE 1 X 4 X 36-3/4" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE ROOF. REFER TO THE DIAGRAM BELOW AND MAKE THE OVERHANG THE SAME ON EACH SIDE OF THE STARTER. 2: PLACE THE STARTERS AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THEM OVERLAPPING. 3: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 139 STEP 25: ROOF PEAK 1: FASTEN ROOF PEAK BOARD 1 TO ROOF PEAK BOARD 2 WITH FOUR #8 X 1-1/2" WOOD SCREWS TO MAKE A ROOF PEAK ASSEMBLY 2: PLACE THE ROOF PEAK ASSEMBLY ON TOP OF THE ROOF STARTERS. FASTEN THE ROOF PEAK ASSEMBLY TO THE ROOF STARTERS WITH EIGHT #8 X 1-1/4"...
  • Page 140 STEP 26: ROOF BOARDS AND ROOF FINISHERS 1: LOCATE TEN 1 X 5 X 36-3/4" ROOF BOARDS. SLIDE THE TONGUE OF THE ROOF BOARD INTO THE GROOVE OF THE ROOF STARTER. SECURE THE ROOF BOARD TO THE ROOF SUPPORTS WITH FOUR #8 X 1-1/2"...

  • Page 141: Step 27: Board Removal

    STEP 27: BOARD REMOVAL 1: REMOVE THE 2 X 4 AT THE TOP LEFT AS SHOWN BELOW. 2: REMOVE THE 2 X 6 AT THE MIDDLE LEFT AS SHOWN BELOW. 3: WHERE THE 2 X 4 AND 2 X 6 WERE BOLTED TO THE POSTS THREAD ONE OF THE 5/16" X 4- 1/2"...
  • Page 142 STEP 28: PLASTIC PLUGS 1: IN THE AREA WHERE YOU REMOVED THE BOARDS IN THE PRIOR STEP YOU WILL NEED TO INSTALL BLACK PLASTIC PLUGS TO FILL IN THE HOLES IN THE CORNER POSTS. 2: APPLY A DAB OF CLEAR SILICONE TO EACH PLUG AND HAMMER THEM INTO THE CORNER POST HOLES.
  • Page 143 STEP 29: ATTACHING EXTREME TUBE SLIDE 1: FOLLOW THE INSTRUCTIONS IN THE SLIDE BOX TO ASSEMBLE THE EXTREME TUBE SLIDE. 2: THE ENTRY OPENING OF THE TUBE SLIDE SHOULD BE FLUSH TO THE DECK. CENTER THE TUBE SLIDE ACROSS THE OPENING SIDE TO SIDE.
  • Page 144 STEP 30: ATTACHING 2 X 4 AND 2 X 6 PANEL BOARDS 1: LOCATE THE 2 X 4 X 36-3/4" TOP PANEL BOARD AND THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD THAT YOU REMOVED IN STEP 27. 2: PLACE THE BOTTOM OF THE 2 X 4 FLUSH TO THE TOP OF THE ENTRY SECTION. ATTACH THE 2 X 4 TO THE CORNER POSTS WITH 5/16"...
  • Page 145 STEP 31: ATTACHING WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING OF THE CLATTER BRIDGE TOWER AS SHOWN WITH THE LIP OF THE SLIDE RESTING ON TOP OF THE DECK BOARDS. 2: ATTACH THE SLIDE TO THE DECK BOARDS WITH FOUR #14 X 1-1/4" PAN HEAD SCREWS **DO NOT OVER TIGHTEN** 1-1/4"...
  • Page 146 STEP 32: FINAL PANEL SLAT 1: LOCATE THE 5/4 X 2-5/8" X 25" PANEL SLAT. 2: THIS SLAT WILL GO INSIDE THE PLAY SET ON TOP OF THE DECK ON THE LEFT HAND SIDE. IT WILL BE FLUSH AGAINST THE BRIDGE RAILS AS SHOWN IN DETAIL A BELOW. 3: ATTACH THE PANEL SLAT TO THE INSIDE OF THE 2 X 6 X 70 FRONT FACE BOARD AND INSIDE OF THE 2 X 6 X 70 TOP PANEL BOARD WITH TWO 2"...
  • Page 147 APPENDIX...
  • Page 148 #8 X 1-1/4" WOOD SCREW QTY: 22 #8 X 1-1/2" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.

  • Page 149: Left Side Assembly

    PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...

  • Page 150: Description Qty

    PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
  • Page 151 PICTURE DESCRIPTION QTY. DORMER ROOF PEAK ASSEMBLY DORMER RIGHT SIDE ASSEMBLY DORMER SUNRAY ASSEMBLY...
  • Page 152 STEP 1: DORMER 1: FIND TWO LEFT SIDE AND TWO RIGHT SIDE DORMER ROOF ASSEMBLIES. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE LEFT AND RIGHT ROOF ASSEMBLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW. 4: ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1-1/4"...
  • Page 153 STEP 2: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/4" WOOD SCREWS. DORMER ROOF PEAK...
  • Page 154 STEP 3: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE A 2" WOOD SCREW TO FASTEN THE DORMER PEAK TO THE ROOF. 3: USE 1-1/2" WOOD SCREWS TO FASTEN THE FACE OF THE DORMER TO THE ROOF. USE A 2"...
  • Page 155 STEP 4: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW. USE A 2" WOOD SCREW IN THIS LOCATION CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY.
  • Page 156 STEP 5: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS. USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE) USE 1-1/4" WOOD SCREWS IN THIS LOCATION (EACH SIDE)
  • Page 157 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.

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