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PlayNation Play Systems Horizon Clubhouse - Tarp Roof 1500ATC Assembly Instructions Manual

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Horizon Clubhouse - Tarp Roof
Timber Shield Post Option
BOXES: W-1, 120
*52-2039-T*
52-2039-T
Model: 1500ATC
(BOXES: 1501, 1502,
1507, 1518 & Slide Box)
Copyright © 2016 PlayNation Play Systems, Inc.
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.playnation.com
Amber Post Option
BOXES: 1520-2bx, 1522

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Summary of Contents for PlayNation Play Systems Horizon Clubhouse - Tarp Roof 1500ATC

  • Page 1 Amber Post Option Timber Shield Post Option BOXES: 1520-2bx, 1522 BOXES: W-1, 120 (BOXES: 1501, 1502, 1507, 1518 & Slide Box) Copyright © 2016 PlayNation Play Systems, Inc. All Rights Reserved *52-2039-T* 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 2016 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 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 - HORIZON CLUBHOUSE - TARP ROOF - 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...
  • Page 8 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 9 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 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 FRONT VIEW REAR VIEW...
  • Page 12 1518 Clubhouse Walls (FOR MODELS 1500AWC/1500ATC) !!READ ME FIRST!! The Clubhouse Walls for this unit will require removal of some boards to install the walls. There will be some boards that will be leftover after the walls are installed. Have you assembled your play set? If “yes”, then READ the Leftover Parts notes at the bottom of this page, then turn the page and proceed.
  • Page 13 11-0054 1518 HARDWARE PAGE 1 OF 1 #8 X 1-1/4" REV C: 3/24/2014 JH. WOOD SCREW QTY: 58 #8 X 1-3/4" WOOD SCREW QTY: 118 #8 X 2" WOOD SCREW QTY: 28 5/16 x 3-1/2" LAG SCREW QTY: 12 #2 SQUARE DRIVE TIP QTY:1 3/8"...
  • Page 14 PICTURE DESCRIPTION QTY. 5/4 X 6 X 28-1/4" PANEL SLAT 125-6-2825-PS 1 X 3 X 18" WINDOW TOP BOARD 1-3-1800-WTB 1 X 3 X 29-7/8" OPEN WINDOW OUTSIDE SUPPORT 1-3-2988-OWOS 1 X 3 X 34-3/4" WINDOW BOTTOM BOARD 1-3-3475-WBB 1 X 3 X 40-1/2" PANEL BOARD BRACE 1-3-4050-PBB...
  • Page 15 PICTURE DESCRIPTION QTY. 1 X 4 X 27-3/4" BOTTOM WINDOW BOARD 1-4-2775-BWB 1 X 4 X 29-1/2" OPEN WINDOW BOARD 1-4-2950-OWB 1 X 4 X 51" WALL BOARD 1-4-5100-WB 1 X 6 X 8-7/16" TOP BOARD DOOR 2 1-6-0843-TBD2 1 X 6 X 10-3/16" TOP BOARD DOOR 1 1-6-1020-TBD1...
  • Page 16 PICTURE DESCRIPTION QTY. 1 X 6 X 27" ARCH TOP BOARD DOOR 1-6-2700-ATBD 1 X 6 X 27-3/4" BOTTOM BOARD OPEN WINDOW 1-6-2775-BBOW 1 X 6 X 34" TOP BOARD WINDOW 1-6-3400-TBW 1 X 6 X 51" WALL BOARD 1-6-5100-WB 2 X 4 X 47-1/2"...
  • Page 17 PICTURE DESCRIPTION QTY. WINDOW 07-0013 1518 (NOT SHOWN) HARDWARE 11-0054...
  • Page 18 STEP 1: REMOVING THE PICNIC TABLE 1: REMOVE THE PICNIC TABLE TO ATTACH THE RIGHT SIDE CLUBHOUSE WALL. 2: REMOVE THE SCREWS THAT CONNECT THE PICNIC TABLE SUPPORTS TO THE CORNER POSTS. 3: SET THE PICNIC TABLE ASSEMBLY AND SCREWS ASIDE IN CASE YOU WISH TO REINSTALL THE PICNIC TABLE ON THE OTHER SIDE OF THE FORT LATER.
  • Page 19 STEP 2: REMOVING SANDBOX SEATS 1: REMOVE THE TWO SANDBOX SEAT BOARDS TO ATTACH THE WALL BOARDS. SANDBOX SEAT...
  • Page 20 STEP 3: REMOVING THE ANGLE SUPPORTS 1: REMOVE THE BACK AND SIDE ANGLE SUPPORTS UNDER THE DECK. 2: KEEP THE TWO ANGLE SUPPORTS AT THE FRONT. 3: AFTER YOU INSTALL ALL THE CLUBHOUSE WALLS PUT THE ANGLE SUPPORTS BACK ON. IT IS A GOOD IDEA TO LEAVE SCREWS IN THE ANGLE SUPPORTS AND TO NUMBER THEM AND THEIR LOCATION FOR LATER.
  • Page 21 STEP 4: SAFETY BOARD 1: REMOVE THE SAFETY BOARD. SAFETY BOARD 2: PLACE THE SAFETY BOARD YOU JUST REMOVED FLUSH WITH 2 X 6 BOTTOM BOARD. USE TWO 5/16 X 3-1/2" LAG SCREWS AND TWO 5/16" WASHERS TO ATTACH IT TO CORNER POSTS. 3: DAB SOME SILICONE ON THE PLASTIC PLUGS AND PLACE THE PLASTIC PLUGS IN THE HOLES LEFT FROM REMOVING THE SAFETY BOARD IN THE CORNER POSTS.
  • Page 22 STEP 5: BACK SANDBOX BOARD AND BOTTOM BOARD 1: REMOVE THE SANDBOX BOARD ON THE BACK OF THE FORT . 2 X 6 X 70" SANDBOX BOARD 2: REPLACE SANDBOX BOARD YOU JUST REMOVED WITH 2 X 6 X 70" BOTTOM PANEL BOARD DOOR WITH CUT NOTCH UP.
  • Page 23 STEP 6: TOP PANEL BOARD 1: PLACE THE 2 X 4 X 47-1/2" TOP PANEL BOARD ON THE LADDER SIDE OF THE FORT. MAKE THE TOP PANEL BOARD FLUSH WITH 2 X 6 BOTTOM BOARD. 2: USE 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS TO ATTACH THE TOP PANEL BOARD TO THE CORNER POSTS.
  • Page 24 STEP 7: WALL BOARD SWING BEAM SIDE 1: FIND SIX 1 X 6 X 51" WALL BOARDS AND TWO 1 X 4 X 51" WALL BOARDS WITH PRE-DRILLED HOLES. 2: PLACE WALL BOARDS ON THE SWING BEAM SIDE OF THE FORT AGAINST THE TOP SAFETY BOARD AND SANDBOX BOARD AS SHOWN BELOW.
  • Page 25 STEP 8: ATTACHING PANEL BOARD BRACE 1: PLACE THE 1 X 3 X 40-1/2" PANEL BOARD BRACE AT THE CENTER OF THE WALL BOARDS YOU ATTACHED TO THE SWING BEAM SIDE. FASTEN IT TO THE WALL BOARDS WITH # 8 X 1-1/4" WOOD SCREWS.
  • Page 26 STEP 9: REAR WALL BOARDS 1: PLACE WALL BOARDS ON THE REAR SIDE OF THE FORT AGAINST THE BOTTOM PANEL BOARD DOOR AND BOTTOM PANEL BOARD AS SHOWN BELOW. THE BOTTOM OF THE WALL PANEL BOARDS SHOULD BE 1-1/2 " ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD DOOR . THE OPENING DIMENSIONS FOR ATTACHING THE WINDOWS IN NEXT STEP ARE SHOWN BELOW.
  • Page 27 STEP 10: INSTALL WINDOW 1: FIND THE PLASTIC WINDOW. PLACE WINDOW AT THE REAR OF THE FORT IN THE OPENING. THE 1" WIDE SECTION OF THE WINDOW FRAME SHOULD BE AT THE TOP. ATTACH THE WINDOW WITH FOUR 1-1/4" WOOD SCREWS. WINDOW 1"...
  • Page 28 STEP 11: WINDOW BOARD AND DOOR BOARD 1: PLACE THE 1 X 3 X 34-3/4" BOTTOM BOARD WINDOW FLUSH WITH BOTTOM OF THE WINDOW. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS. 2: PLACE THE 1 X 3 X 18" TOP BOARD WINDOW FLUSH WITH TOP OF THE WINDOW. FASTEN WITH # 8 X 1-1/4"...
  • Page 29 STEP 12: RIGHT SIDE WALL BOARDS 1: PLACE WALL BOARDS ON THE RIGHT SIDE OF THE FORT AGAINST THE TOP WALL PANEL BOARD AND ROPE LADDER RUNNER AS SHOWN BELOW. THE BOTTOM OF THE WALL BOARDS SHOULD BE 1-1/2 " ABOVE THE BOTTOM OF THE ROPE LADDER RUNNER . FASTEN WITH # 8 X 1-3/4" WOOD SCREWS LEAVING A 1/4"...
  • Page 30 STEP 13: PANEL BOARD BRACE AND BOARD WINDOW 1: PLACE THE 1 X 3 X 40-1/2" PANEL BOARD BRACE FLUSH WITH BOTTOM BOARD OPEN WINDOWS. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS. 2: PLACE THE 1 X 6 X 34" TOP BOARD WINDOW FLUSH WITH OPEN WINDOW TOP BOARDS. FASTEN WITH # 8 X 1-1/4"...
  • Page 31 STEP 14: OPEN WINDOW OUTSIDE SUPPORT 1: PLACE THE 1 X 3 X 29-7/8" OPEN WINDOW OUTSIDE SUPPORT ON THE OUTSIDE OF THE RIGHT WALL BOARDS. FLUSH THE SUPPORT WITH THE TOP OF THE BOTTOM BOARD OPEN WINDOWS. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS. 1 X 3 X 29-7/8"...
  • Page 32 STEP 15: OPEN WINDOW BOARD 1: PLACE THE 1 X 4 X 29-1/2" OPEN WINDOW BOARD ON TOP FLUSH TO INSIDE OF THE PANEL BOARD BRACE . FASTEN WITH # 8 X 1-3/4" WOOD SCREWS. #8 X 1-3/4" WOOD SCREW FLUSH PANEL BOARD BRACE 1 X 4 X 29-1/2"...
  • Page 33 STEP 16: BOTTOM WALL BOARD 1: PLACE THE 2 X 4 X 70" BOTTOM WALL BOARD AT THE FRONT OF THE FORT. THE TOP OF THE 2 X 4 X 70" BOTTOM WALL BOARD SHOULD BE 30-3/8" FROM THE BOTTOM OF THE 2 X 6 X 70" SANDBOX BOARD.
  • Page 34 STEP 17: PANEL SLATS 1: FIND SEVEN 5/4 X 6 X 28-1/4" PANEL SLATS. 2: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL 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 28-1/4"...
  • Page 35 STEP 18: ANGLE SUPPORTS 1: REPLACE THE ANGLE SUPPORTS YOU REMOVED IN STEP 3. 2: REFER TO STEP 6B IN THE MAIN MANUAL IF YOU DID NOT MARK YOUR ANGLE SUPPORTS IN STEP 3 OF THIS MANUAL. ANGLE SUPPORT...
  • Page 36 STEP 19: PICNIC TABLE 1: YOU MAY INSTALL THE PICNIC TABLE ON THE INSIDE-LEFT CORNER POSTS. 2: RE-ATTACH THE PICNIC TABLE SUPPORTS TO THE LEFT CORNER POSTS WITH THE SCREWS REMOVED IN STEP 1. IF THIS IS THE FIRST TIME INSTALLING THE PICNIC TABLE THEN REFER TO THE MAIN PART OF THE MANUAL STEP 34 TARP ROOF OR STEP 39 WOOD ROOF FOR DIMENSIONS.
  • Page 37 Model 1500AT shown. See cover of manual for the image of your model when it is completed.. Models: 1500AT Amber Post Option Timber Shield Post Option BOXES: 1520-2bx, 1522 BOXES: W-1, 120 1500ATC (BOXES: 1501, 1502, 1507,1518* & Slide Box) *1518 only included with 1500ATC Clubhouse model REV: 4.21.2016...
  • Page 38 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 Adding T-Nuts to Corner Posts...…………………………………..………...…...
  • Page 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part.
  • Page 48 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 49 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 50 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: Swing Belts (2) Trapeze Arm (1) Ladder Rock Wall Playset height: 11 feet - 2 inches Swing Beam height: 7 feet - 7-1/2 inches Deck height: 5 feet Approximate assembly time: 6-8 hours (6) foot unobstructed safety perimeter around playset recommended...
  • Page 51 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 52 1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" #8 X 1-3/4" PAN HEAD SCREW WOOD SCREW QTY: 4 QTY: 4 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 #8 X 3"...
  • Page 53 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 1501 HARDWARE PAGE: 2 OF 2 REV A: 9/10/2014 JH #2 SQUARE DRIVE BIT QTY: 1 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" 3/8 x 9"...
  • Page 54 1502N HARDWARE PAGE: 1 OF 1 REV B: 8/18/2015 JH #14 X 1-1/4" PAN HEAD SCREW QTY: 10 #8 X 1-3/4" WOOD SCREW QTY: 4 #8 X 2-1/2" WOOD SCREW QTY: 14 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 10 5/16"...
  • Page 55 1507 HARDWARE PAGE: 1 OF 1 REV A: 9/10/2014 JH #8 X 2" WOOD SCREW QTY: 20 5/16" TEE NUT QTY: 12 5/16" WASHER QTY: 25 5/16 X 4-1/2" 5/16" X 3-1/2" HEX BOLT LAG SCREW QTY: 12 QTY: 14 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 56 PICTURE DESCRIPTION QTY. 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-AS 2 X 4 X 14" BOTTOM PANEL BOARD 2-4-1400-BPB 2 X 4 X 14-3/4" PICNIC TABLE TOP SUPPORT 2-4-1475-PTTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 24"...
  • Page 57 PICTURE DESCRIPTION QTY. 2 X 4 X 47-3/8" TARP BOARD 2-4-4738-TB 2 X 4 X 47 " END PANEL/ SAFETY BOARD (2 HOLES OFFSET) 2-4-4750-SBEP 2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON CENTER) 2-4-5800-CM 2 X 4 X 66" LEFT LADDER SIDE 2-4-6600-LLS...
  • Page 58 PICTURE DESCRIPTION QTY. 2 X 4 X 70" REAR TOP PANEL BOARD (2 HOLES OFFSET/ 1 CENTERED) 2-4-7000-RTPB 2 X 4 X 71-7/8" CENTER TARP SUPPORT 2-4-7188-CTS 2 X 6 X 47 " BOTTOM PANEL AND SANDBOX BOARD (4 HOLES OFFSET) 2-6-4750-ESPB 2 X 6 X 70"...
  • Page 59 PICTURE DESCRIPTION QTY. 2 X 6 X 79-1/2" ROPE LADDER RUNNER(4 HOLES OFFSET, 3 HOLES ON CENTER) 2-6-7950-RLR 4 X 4 X 47 " SWING BEAM MOUNT 4-4-4750-SBM X 13 " PICNIC TABLE SLAT 125-3-1325-PTS X 17 " TIC TAC TOE MOUNT 125-3-1750-TTTM X 28...
  • Page 60 PICTURE DESCRIPTION QTY. X 3 X 23 " ROCK WALL CAP 125-3-2387-RWC X 6 X 22" SANDBOX SEAT 125-6-2200-SS X 6 X 23 " BOTTOM ROCK WALL BOARD 125-6-2387-BRW X 6 X 23 " ROCK WALL BOARD 125-6-2387-RWB X 6 X 43" PICNIC TABLE TOP AND SEATS 125-6-4300-PTTS...
  • Page 61 PICTURE DESCRIPTION QTY. NOTE: ANYTHING ON THIS PAGE REFERRED TO AS "PLASTIC COATED" PLASTIC COATED WILL BE AMBER STAINED WOOD FOR 4 X 4 X 108" THE SOLID CEDAR WOOD OPTION. SWING BEAM PLASTIC COATED 4 X 4 X 96" CORNER POST PLASTIC COATED 4 X 6 X 120"...
  • Page 62 PICTURE DESCRIPTION QTY. WIKI WAVE SLIDE 03-0013 ROCK WALL ROPE ROPE LADDER ROPE SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 63 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCK (07-0008 ROCKS IS A PACK OF 5) A-FRAME SWING BRACKET 11-5010 HARDWARE HARDWARE BOXES: 1501, 1502, 1507 BOXES...
  • Page 64 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGER 11-4012 TELESCOPE 07-0001 TARP (MATERIAL AND COLOR WILL VARY BY MODEL 47-3/8" X 105")
  • Page 65 PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...
  • Page 66 PICTURE DESCRIPTION QTY. FLAG KIT 09-1014 MANUFACTURER (NOT SHOWN) LOGO PLATE GROUND STAKES (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004...
  • Page 67 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 68 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 79-1/2" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 69 STEP 3: 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 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 70 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" WASHERS FROM THE INSIDE OF THE FORT 5/16"...
  • Page 71 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 72 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD AT THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST 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 73 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.
  • Page 74 STEP 6B: ANGLE SUPPORTS 1: FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 75 STEP 7: 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 OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 5/16"...
  • Page 76 ! ATTENTION ! IN THE FOLLOWING THREE STEPS YOU WILL BEGIN THE INSTALLATION OF THE DECK SPACERS AND DECK BOARDS. IF YOU HAVE DIFFICULTY GETTING THE DECK BOARDS/DECK SPACERS TO FIT BETWEEN THE FRONT FACE BOARD AND BOTTOM PANEL BOARD DO THE FOLLOWING: 1: LOOSEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET.
  • Page 77 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 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 78 STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND MAKE A MARK ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE.
  • Page 79 STEP 10: 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 80 STEP 11: 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 81 STEP 12: 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 82 STEP 13: 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. GREEN BRACKET 5/16"...
  • Page 83 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 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 84 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. THE BOTTOM OF THE GREEN BRACKETS SHOULD BE APPROXIMATELY 3/4"...
  • Page 85 STEP 16: 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 T-NUT SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
  • Page 86 STEP 17: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE LADDER 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” HOLES ON THE BOTTOM PANEL BOARD.
  • Page 87 STEP 18: CENTER POST FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF EACH 2 X 4 X 71-7/8" CENTER POST FRONT/REAR. 2: PLACE THE CENTER POSTS INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET. LINE UP THE HOLES IN THE CENTER POSTS WITH THE HOLES IN THE RAILINGS. 3: FASTEN THE CENTER POSTS TO THE RAILINGS WITH 5/16"...
  • Page 88 STEP 19: PANEL SLATS 1: FIND TWENTY-TWO 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2"...
  • Page 89 STEP 20: TARP BOARDS 1: LOCATE THREE 2 X 4 X 47-3/8" TARP BOARDS. 2: ATTACH EACH TARP BOARD TO THE TOP OF THE CORNER POSTS OR THE CENTER POSTS WITH #8 X 2-1/2" WOOD SCREWS. #8 X 2-1/2" WOOD SCREW 2 X 4 X47-3/8"...
  • Page 90 STEP 21: 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 TOP, AND 3/8" LOCK NUTS WITH 3/8"...
  • Page 91 STEP 22: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7"...
  • Page 92 STEP 23: 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 93 STEP 24: REST SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: REST THE SWING BEAM ON TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM.
  • Page 94 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 X 3-1/2"...
  • Page 95 STEP 26: MOUNT SWING BEAM ON 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 HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
  • Page 96 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 97 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 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. 3/8 X 3-1/2"...
  • Page 98 STEP 29: TARP 1: PLACE THE 47-3/8" X 105" 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 BOARDS WITH #14 X 1-1/4" PAN HEAD SCREWS WITH 1/4" WASHERS. REPEAT FOR OTHER SIDE.
  • Page 99 STEP 30: 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. SPRING CLIP SWING CHAIN...
  • Page 100 STEP 31: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 101 STEP 32: PICNIC TABLE 1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS. 2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4"...
  • Page 102 STEP 33: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSDE OF THE CORNER POST WITH #8 X 3"...
  • Page 103 STEP 34: PICNIC TABLE 1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS. 2: CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS. 3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS. 5/4 X 6 X 43"...
  • Page 104 STEP 35: 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 36: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT-LEFT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH 1-1/4"...
  • Page 106 STEP 37: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE FRONT TOP PANEL BOARD ON THE SLIDE SIDE OF THE CENTER POST. 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 THE 1-1/4"...
  • Page 107 STEP 38: INSTALLING CLIMBING ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE TOP PANEL BOARD. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
  • Page 108 STEP 39: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 3: LOCATE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS.
  • Page 109 STEP 40: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE PLAY SET ON THE INSIDE. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS. SWING BEAM TIC TAC TOE WITH BOARDS...
  • Page 110 STEP 41: 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 PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
  • Page 111 STEP 42: FLAG KIT 1: PLACE A FLAG ON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED. FLAG 1/2" PHILLIPS HEAD SCREW...
  • Page 112 STEP 43: SANDBOX SEATS AND NAME PLATE 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. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET.
  • Page 113 STEP 44: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE AGAINST THE SWING LEG.
  • Page 114 STEP 45: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK. 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2"...
  • Page 115 APPENDIX...
  • Page 116 CANOPY ACCENT (07-0032) *SOLD SEPARATELY* *SOLD SEPARATELY* 1: Center the Canopy Accent over the front or rear center post. The top of the Canopy Accent should be flush to the top of the center tarp board. 2: Install two #8 x 1-3/4" wood screws to secure the Canopy Accent to the front or rear center post. Note: The Canopy Accent is sold individually with two screws.

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