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Gorilla Playsets Pioneer Peak Treehouse 1500DW Manual

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Pioneer Peak - Treehouse
Timber Shield Post Option
BOXES: W-1, CB, TSB, 120
*51-0055-W*
51-0055-W
™
™
plays ets
plays ets
Model: 1500DWF
[BOXES: 1501, 1503N, 1509N,
1509W, 1510, 1511, 1523, 1525,
1530, Tire Swing & Slide Box]
Copyright © 2016 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
™
™
playsets
playsets
Amber Post Option
BOXES: 1519, 1520-2bx,
1522, 1524

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Summary of Contents for Gorilla Playsets Pioneer Peak Treehouse 1500DW

  • Page 1 BOXES: 1519, 1520-2bx, BOXES: W-1, CB, TSB, 120 1522, 1524 [BOXES: 1501, 1503N, 1509N, 1509W, 1510, 1511, 1523, 1525, 1530, Tire Swing & Slide Box] Copyright © 2016 Gorilla Playsets All Rights Reserved *51-0055-W* 190 Etowah Industrial Court Canton, GA 30114 51-0055-W...
  • Page 2 ***IMPORTANT NOTICE FOR TREEHOUSE KIT PLAYSETS*** Read all instructions thoroughly before beginning construction, this is very important. The “Treehouse Add On Kit” (1525) box will require you to deviate slightly from the standard kit instructions. Typical deviations include: 1) The Telescope that is usually on the front of the set on the Front face board (arched board) must be moved to another location on the set.
  • Page 3 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 4 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 5 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 6 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 7 Warranty registration - pioneer peak treehouse - 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 option 1 strength and durability. We back...
  • 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 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 11 Model 1500DW shown. See cover of manual for the image of your model when it is completed. Models: 1500DW Timber Shield Post Option Amber Post Option BOXES: CB, W-1, TSB, BOXES: 1519, 1520 - 2bx, 1500DWF 1522, 1524 (BOXES: 1501, 1503N, 1509N, 1509W, 1510, 1511, 1525*, 1530, 1523, Tire Swing &...
  • Page 12 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 Checklist..……………………………..Pages 16-40 Adding T-Nuts to Corner Posts...…………………………………..………...…...
  • 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 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 22 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 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 1500 SERIES Please familiarize yourself with the manual, parts/components and general 1500DW PIONEER PEAK/CIMMARON - WOOD ROOF construction process of your new playset before getting started. HEIGHT = 11'-1 " SITE PLAN: 9'-10 8 " Swing Belt (2) Trapeze (1) 22'-8 16 "...
  • Page 25 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 7/64”, 11/64” and a 1” and 7/8” Paddle style bit. ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16”...
  • Page 26 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 27 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 28 1503N HARDWARE PAGE: 1 OF 1 REV C: 8/10/2015 JH #8 X 1-1/4" WOOD SCREW QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 104 #8 X 2" WOOD SCREW QTY: 30 #8 X 2-1/2" WOOD SCREW QTY: 8 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 4...
  • Page 29 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 30 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 31 3/8 X 3-1/2" 1510 HARDWARE HEX LAG SCREW QTY: 11 PAGE: 1 OF 1 REV B 8/19/2014 JH TORQUE WASHER QTY: 4 5/16" TEE NUT QTY: 2 5/16" PLASTIC 3/8" PLASTIC BOLT CAP BOLT CAP QTY: 2 QTY: 4 3/8" LOCK NUT QTY: 4 3/8"...
  • Page 32 1511 HARDWARE PAGE: 1 OF 1 REV A 2/4/2013 J.H. #8 X 2" WOOD SCREW QTY: 20 5/16" TEE NUT QTY: 10 5/16" X 3-1/2" HEX LAG 5/16 X 4-1/2" 5/16" WASHER SCREW HEX BOLT QTY: 26 QTY: 14 QTY: 12 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 33 1523 HARDWARE 5/16" X 2-1/2" 5/16" X 2-1/2" 5/16" X 1-1/2" LAG SCREW HEX BOLT HEX BOLT QTY: 4 QTY: 6 PAGE 1 OF 1 QTY: 4 9/10/2014 JH #8 X 3-1/2" WOOD SCREW QTY: 4 #8 X 2-1/2" WOOD SCREW #8 X 1-1/4"...
  • Page 34 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 35 PICTURE DESCRIPTION QTY. 2 X 4 X 32-1/2" PICNIC TABLE 2-4-3250-PTL 2 X 4 X 47 " SAFETY BOARD/ END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 51-1/8" LEFT ROOF SUPPORT (1 HOLE OFFSET) 2-4-5113-RSL 2-4-5113-RSR RIGHT 2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON...
  • Page 36 PICTURE DESCRIPTION QTY. 2 X 4 X 70" DECK SUPPORT (2 HOLES ON CENTER) 2-4-7000-DS 2 X 4 X 70" REAR TOP PANEL BOARD (2 HOLES OFFSET/ 1 CENTERED) 2-4-7000-RTPB 2 X 6 X 47 " BOTTOM PANEL SANDBOX BOARD (4 HOLES OFFSET) 2-6-4750-ESPB 2 X 6 X 47-1/2"...
  • Page 37 PICTURE DESCRIPTION QTY. 2 X 6 X 102" ROPE LADDER RUNNER - FRONT RIGHT 2-6-10200-RLRFR 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 5/4 X 3 X 18-3/4"...
  • Page 38 PICTURE DESCRIPTION QTY. X 4 X 40 " DECK SPACER 125-4-4038-DS X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS X 6 X 22" SANDBOX SEAT 125-6-2200-RPS X 6 X 23 " BOTTOM ROCK WALL BOARD 125-6-2387-BRW X 6 X 23 "...
  • Page 39 PICTURE DESCRIPTION QTY. " ROOF PEAK 1-6-4750-RP 1 X 4 X 47 " TONGUE ONLY ROOF FINISHER 1-4-4750-RF 1 X 4 X 47 " GROOVE ONLY ROOF STARTER 1-4-4750-RS 1 X 5 X 47 " TONGUE-GROOVE ROOF BOARD 1-5-4750-RB 2 X 2 X 16" RAMP FLOOR SUPPORT 2-2-1600-FS...
  • Page 40 PICTURE DESCRIPTION QTY. 2 X 4 X 33" RAMP POST 2-4-3300-RP 2 X 4 X 95-1/2" RAMP MIDDLE FLOOR BOARD 2-4-9550-MFB 2 X 4 X 96" RAMP SIDE BOARD 2-4-9600-SB 2 X 6 X 95-1/2" RAMP FLOOR BOARD 2-6-9550-FB 4 X 4 X 8" ROPE MOUNT 4-4-0800-RM 4 X 4 X 72"...
  • Page 41 PICTURE DESCRIPTION QTY. NOTE: ANYTHING ON THIS PAGE REFERRED TO AS "PLASTIC COATED" WILL BE AMBER STAINED WOOD FOR THE SOLID CEDAR WOOD OPTION. 4 X 4 X 96" HOLE AT TOP PLASTIC COATED CORNER POST (FORT) 4 X 4 X 96" PLASTIC COATED CORNER POST (CLATTER BRIDGE)
  • Page 42 PICTURE DESCRIPTION QTY. 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES 2-4-3675-SBH 2 X 4 X 36-3/4" RAILING/DECK SUPPORT 2-4-3675-SB 2 X 4 X 66" BRIDGE RAIL 2-4-6600-R 2 X 6 X 36-3/4" BOTTOM PANEL BOARD 2-6-3675-BPB 4 X 4 X 29" CENTER POST 4-4-2900-CP 5/4 X 3 X 16"...
  • Page 43 PICTURE DESCRIPTION QTY. 5/4 X 4 X 29-3/8" DECK SPACER 125-4-2937-DS 5/4 X 4 X 36-1/2" DECK BOARD 125-4-3650-DB...
  • Page 44 PICTURE DESCRIPTION QTY. 1509W 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"...
  • Page 45 PICTURE DESCRIPTION QTY. WIKI WAVE SLIDE ROCK WALL ROPE 12' OR 13' RAMP ROPE ROPE LADDER ROPE SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 46 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 ROCKS IS A PACK OF 5) A-FRAME SWING BRACKET 11-5010 HARDWARE BOXES HARDWARE BOXES: 1501, 1503N, 1523, 1509N, 1509W, 1510, 1511 INSTRUCTIONS...
  • Page 47 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 BRACKET 28-0001...
  • Page 48 PICTURE DESCRIPTION QTY. 90 GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...
  • Page 49 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY (1530 BOX) UNASSEMBLED DORMER (1530 BOX) GROUND STAKE (PAIR) 07-0016-P CLATTER- BRIDGE CHAIN 96" FLAG KIT 09-1014...
  • Page 50 PICTURE DESCRIPTION QTY. PLASTIC SUNBURST 07-0028-G (NOT SHOWN) MANUFACTURER LOGO PLATE CLATTER BRIDGE (NOT SHOWN) MESH PANELS 06-2004 TIC TAC TOE (UNASSEMBLED) 07-0010 PLASTIC DORMER SUNBURST 07-0031 STEERING WHEEL 07-0004 TIRE SWING SWIVEL 11-4010 TIRE SWING W/CHAINS 04-0014...
  • Page 51 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 52 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2"...
  • Page 53 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 54 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 55 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 HOLES FOR CLATTER BRIDGE CHAIN.
  • Page 56 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER 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 57 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON 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 58 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. THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE.
  • Page 59 STEP 6B: 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 60 STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" END 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. FRONT OF FORT 5/16"...
  • Page 61 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 A1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" IS THE CENTER OF THE BOARD AND ONLY NEEDS TO BE DRILLED ONCE.
  • Page 62 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 63 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. "...
  • Page 64 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 65 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 66 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 67 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 68 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT - RIGHT OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE;...
  • Page 69 STEP 16: CLIMBING RAMP 1: LAY OUT THE 2 X 4 X 96" RAMP SIDE BOARDS MAKING SURE THE LARGE HOLES ON TEH ENDS ARE CLOSEST TO THE FLOOR. 2: FIRST PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE SQUARE END OF THE 2 X 4 X 96" RAMP SIDE BOARDS.
  • Page 70 STEP 16A: CLIMBING RAMP 1: PLACE THE RAMP SIDE ON A FIRM LEVEL SURFACE. HAMMER A 5/16" T-NUT INTO EACH HOLE ON THE INSIDE OF THE RAMP SIDE. 2: REPEAT FOR THE OTHER RAMP SIDE. 5/16" T-NUT 5/16" T-NUT 5/16" T-NUT 5/16"...
  • Page 71 STEP 17: CLIMBING RAMP 1: PLACE ONE 2 X 6 X 95-1/2" FLOOR BOARD AGAINST EACH OF THE RAMP SIDE BOARDS. FASTEN THE FLOOR BOARDS TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SUPPORT. THE BOARDS SHOULD BE FLUSH AT THE SQUARE END OF THE RAMP SIDES.
  • Page 72 STEP 17A: CLIMBING RAMP 1: HAMMER A 3/8" T-NUT INTO THE INSIDE OF EACH POST. NOTE THIS IS THE SIDE OF THE POST THAT DOES NOT HAVE THE COUNTERBORED HOLE. 2: SCREW A 3/8" EYE BOLT WITH A WASHER INTO THE T-NUT SO IT LOOKS LIKE THE BOTTOM PICTURE.
  • Page 73 STEP 18: CLIMBING RAMP 1: ATTACH THE 2 X 2 X 16" FLOOR SUPPORT BOARDS TO THE FLOOR BOARDS WITH 2-1/2" WOOD SCREWS. (SEE DETAIL VIEW BELOW) 2: FASTEN THE 90 GREEN BRACKET TO THE RAMP SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2-1/2"...
  • Page 74 STEP 18A: CLIMBING RAMP 1: ATTACH A RAMP POST TO EACH RAMP SIDE WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS. THE EYE BOLTS SHOULD BE ON THE OUTSIDE OF THE RAMP POSTS 2: SQUARE THE RAMP POST TO THE RAMP SIDE AND DRIVE IN TWO 2-1/2" WOOD SCREWS TO SECURE IT.
  • Page 75 STEP 18B: CLIMBING RAMP 1: FASTEN A BRACKET AS SHOWN UNDERNEATH THE RAMP TO THE RAMP POST AND THE RAMP SUPPORT. 2: USE #8 X 1-1/4" PAN HEAD SQUARE DRIVE SCREWS TO ATTACH THE BRACKET. 3: REPEAT FOR THE RAMP POST ON THE OTHER SIDE. BRACKETS DETAIL A SCALE 1 : 2...
  • Page 76 STEP 18C: CLIMBING RAMP 1: LOCATE FOUR 2 X 4 X 18" RAMP POST SUPPORTS. 2: PLACE A RAMP POST SUPPORT AGAINST THE RAMP POST AND THE RAMP SIDE AS SHOWN BELOW. 3: THE BOTTOM OF THE RAMP POST SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE RAMP SIDE.
  • Page 77 STEP 19: CLIMBING RAMP TO FORT 1: PLACE THE CLIMBING RAMP INTO POSITION CENTERED ON THE RIGHT SIDE ON THE FORT. THE BOTTOM EDGE OF THE GREEN BRACKETS SHOULD BE 1-1/2" ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD. USING THE BRACKETS AS A TEMPLATE DRILL A 3/8”...
  • Page 78 STEP 19A: ROPE MOUNT 1: PLACE THE 4 X 4 X 8" ROPE MOUNTS ONTO THE FRONT OF THE ARCHED TOP PANEL BOARD FLUSH TO THE TOP. EACH ROPE MOUNT SHOULD BE 8-3/4" FROM THE END OF THE ARCHED TOP PANEL BOARD AS SHOWN IN DETAIL B BELOW.
  • Page 79 STEP 19B: RAMP ROPE HANDRAILS 1: LOCATE THE RAMP ROPES THAT ARE IDENTICAL IN LENGTH. THEY SHOULD BE APPROXIMATELY 12 TO 13 FEET IN LENGTH. IF YOU HAVE FIVE 13 FOOT ROPES THAT IS FINE, HOWEVER IF TWO ARE 12 FEET THEN USE THEM. 2: TIE A KNOT IN ONE END OF A ROPE WITH THE END HANGING OUT ABOUT 2"...
  • Page 80 STEP 20: CENTER POSTS FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 28-9/16" CENTER POST. 2: PLACE THE CENTER POST INSIDE THE RAILING AT THE REAR OF THE PLAYSET. LINE UP THE HOLE IN THE CENTER POST WITH THE HOLE IN THE RAILING.
  • Page 81 STEP 21: 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 82 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 TOP, AND 3/8" LOCK NUTS WITH 3/8"...
  • Page 83 STEP 23: 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 84 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 85 STEP 25: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE 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 86 STEP 26: 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 87 STEP 27: 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 88 STEP 28: 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 89 STEP 29: 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 90 STEP 30: 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 91 STEP 30A: INSTALLING ROOF SUPPORT ASSEMBLIES 1: PLACE THE ROOF SUPPORT ASSEMBLIES ON TOP OF THE DECK OF THE PLAY SET. CLIMB ONTO THE DECK TO INSTALL THE ROOF SUPPORT ASSEMBLIES. 2: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16"...
  • Page 92 STEP 31: ROOF STARTERS 1: PLACE THE 1 X 4 X 47-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE APPROXIMATELY CENTERED (SEE BELOW) 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 93 STEP 32: ROOF PEAK 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREW 47-1/2" ROOF PEAK...
  • Page 94 STEP 33: ROOF NOTE: THE SMALL PICTURE BELOW IS A GENERIC VIEW OF A PLAY SET IN OUR 1500 MODEL LINE. TYPICALLY THE ROCK WALL AND/OR SLIDE IS LOCATED ON THE FRONT OF THE 1500 SERIES PLAY SETS. THE BIG PICTURE BELOW SHOWS THE RIGHT SIDE ROOF WITH THE DORMER AND CHIMNEY.
  • Page 95 STEP 34: 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 96 STEP 35: 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 97 STEP 36: 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 98 STEP 37: PICNIC TABLE 1: MEASURE 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 INSIDE OF THE CORNER POST WITH #8 X 3"...
  • Page 99 STEP 38: 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 100 STEP 39: TIRE SWING 1: PLACE THE 4 X 4 X 72" TIRE SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. TIRE SWING LEGS FLUSH TO TOP OF SWING LEG BRACKET...
  • Page 101 STEP 40: TIRE SWING 1: LINE UP THE HOLES OF THE TIRE SWIVEL WITH THE HOLES IN THE TIRE SWING BEAM. 2: FASTEN THE TIRE SWIVEL TO THE TIRE SWING BEAM USING 3/8" X 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8"...
  • Page 103 STEP 42: TIRE SWING IMPORTANT: NOTE THE TIRE SWING LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THEY ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY NEED TO EITHER A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND, OR B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.
  • Page 104 STEP 43: TIRE SWING IN THIS STEP YOU WILL BE MOUNTING THE TIRE SWING BEAM TO THE FORT. AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: INSTALL T-NUTS IN THE PREVIOUSLY DRILLED HOLES AS SHOWN BELOW. 2: LINE UP THE PILOT HOLES AT THE END OF THE TIRE SWING BEAM WITH THE PREVIOUSLY DRILLED HOLES IN THE CORNER POST.
  • Page 105 STEP 44: LEVEL TIRE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE TIRE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE TIRE SWING BEAM LEVEL. IMPORTANT: NOTE THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE).
  • Page 106 STEP 45: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 47-1/2" TIRE SWING LEG CROSS-MEMBER AGAINST THE SWING LEGS. 2: LEVEL THE TIRE SWING CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS- MEMBER HOLES ONTO THE SWING LEGS. 3: USE 3/8 X 3-1/2"...
  • Page 107 STEP 46: HANGING THE TIRE SWING 1: START BY ATTACHING THREE SPRING CLIPS TO THE TIRE SWIVEL ON THE SWING BEAM. 2: ATTACH ONE CHAIN AT A TIME TO ONE SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED. SPRING CLIP TIRE SWING CHAIN...
  • Page 108 STEP 47: 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 109 STEP 48: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS TO THE TOP OF THE CENTER POST ON THE FRONT OF THE PLAY SET . 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4"...
  • Page 110 STEP 49: 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 50: INSTALLING CLIMBING ROPES 1: DRILL A 7/8" HOLE THROUGH THE ROPE LADDER SUPPORT (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 ROPE LADDER SUPPORT. 3: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD.
  • Page 112 STEP 51: FLAG KIT 1: PLACE A FLAGON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED. **DO NOT OVER-TIGHTEN** FLAG 1/2" PHILLIPS HEAD SCREW...
  • Page 113 STEP 52: SANDBOX SEATS AND NAMEPLATE 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 114 STEP 53: PLASTIC SUNBURST 1: LOCATE TWO PLASTIC SUNBURST PIECES. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2"...
  • Page 115 STEP 54: 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 116 STEP 55: 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 117 PART 2 CLATTER BRIDGE ASSEMBLY...
  • Page 118 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 119 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 120 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 121 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 122 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 123 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 124 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 125 STEP 8: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: IF YOUR DECK SPACERS AND DECKBOARDS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THEM TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 8 "...
  • Page 126 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 6 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS. THE TOP OF THE BOTTOM PANEL BOARD SHOULD FLUSH TO THE TOP OF THE DECK.
  • Page 127 STEP 10: REAR BOTTOM PANEL BOARD 1: LOOSEN UP THE FASTENERS IN THE 2 X 6 ON THE LEFT SIDE OF THE TOWER. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH HOLES) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
  • Page 128 STEP 11: DECK 1: INSTALL THE 5/4 X 6 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 2" WOOD SCREWS. 2" WOOD SCREWS 5/4 X 6 X 36-1/2" DECK BOARD FRONT OF TOWER...
  • Page 129 STEP 12: PANEL SLATS 1: FIND FOUR 5/4 X 3 X 28-1/2" PANEL SLATS. 2: IF THE SLATS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: ON THE LEFT SIDE OF THE TOWER INSTALL TWO PANEL SLATS 1-3/4"...
  • Page 130 STEP 13: 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 131 STEP 14: TIC-TAC-TOE PANEL 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE TOWER ON THE INSIDE. THE TIC TAC TOE SHOULD BE APPROXIMATELY 3" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS. PANEL SLATS AT LEFT SIDE OF TOWER TIC TAC TOE PANEL WITH...
  • Page 132 STEP 15: 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 133 STEP 16: MOUNTING BRIDGE RAILS TO FORT 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER 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 134 STEP 17: BRIDGE RAIL SLATS 1. IF THE BRIDGE RAIL SLATS ARE NOT ALREADY PRE-DRILLED THEN PRE-DRILL THEM ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2. PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS.
  • Page 135 STEP 18: 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 136 STEP 19: 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 137 STEP 20: 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 138 STEP 21: 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 139 STEP 22: 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 140 STEP 23: 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 141 STEP 24: 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 142 STEP 25: 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 143 STEP 26: 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 144 STEP 27: 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 145 STEP 28: 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 146 STEP 29: MOUNTING THE LADDER 1: PLACE THE TOP OF THE BRACKETS 1-1/2" DOWN FROM THE TOP OF THE 2 X 6. 2: CENTER THE LADDER SIDE TO SIDE. 3: MARK THROUGH EACH BRACKET ONTO THE 2 X 6. 4: DRILL 3/8" HOLES AT EACH MARK THROUGH THE 2 X 6. 5: INSTALL T-NUTS INTO THE BACK SIDE OF THE 2 X 6.
  • Page 147 STEP 30: SAFETY HANDLES 1: PLACE A PLASTIC SAFETY HANDLE ON EACH CORNER POST ABOVE THE LADDER. 2: ADJUST THE SAFETY HANDLE UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: FASTEN EACH SAFETY HANDLE WITH THE 1/4" FLAT WASHERS AND #14 X 1-1/4" PAN HEAD SCREWS PROVIDED WITH THE SAFETY HANDLES.
  • Page 148 STEP 31: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT RIGHT OF THE CLATTER BRIDGE. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK SPACER. 2: PREDRILL 1/8" HOLES INTO THE DECK SPACER AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK SPACER WITH 1-1/4"...
  • Page 149 STEP 32: PANEL SLAT 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLAT FLUSH TO THE SIDE OF THE BRIDGE RAILS AS SHOWN BELOW. 2: ATTACH THE PANEL SLAT TO THE ROPE LADDER SUPPORT AND FRONT FACE BOARD ON THE INSIDE WITH #8 X 2"...
  • Page 150 STEP 33: PLASTIC PLUGS 1: LOCATE FOUR PLASTIC PLUGS. 2: APPLY A DAB OF CLEAR SILICONE ONTO EACH PLUG AND TAP THEM INTO THE FRONT AND BACK SIDE OF THE HOLES SHOWN BELOW. PLASTIC PLUG (4) APPLY CLEAR SILICONE ONTO PLUGS AND TAP THEM INTO EACH END OF THESE HOLES.
  • Page 151 Leftover Parts List 1500DW/DWR/DT Play Sets Our 1500 series play sets are modular and include parts to construct many different models. Some of these parts included with your play set will not be used because they are for a different model. The list below includes parts for your play set that will be leftover when construction is completed.
  • Page 152 APPENDIX...
  • Page 153 Chimney and Dormers Hardware Kit 8/10/2015 JH #8 X 2-1/2" WOOD SCREW QTY: 2 #8 X 2" WOOD SCREW QTY: 4 #8 X 1-1/2" WOOD SCREW QTY: 14 #8 X 1-1/4 WOOD SCREW QTY: 6 #2 SQUARE DRIVE BIT QTY: 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 154 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
  • Page 155 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
  • Page 156 PICTURE DESCRIPTION QTY. PLASTIC DORMER SUNBURST (07-0031) DORMER RIGHT SIDE ASSEMBLY...
  • Page 157 STEP 1: DORMER 1: OVERLAP THE LEFT DORMER SIDE ONTO THE PEAK SUPPORT OF THE RIGHT DORMER SIDE. 2: MAKE SURE THE FRONT ROOF EDGES ARE FLUSH TO ONE ANOTHER 3: FASTEN THE LEFT DORMER SIDE TO THE PEAK SUPPORT WITH #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1-3 TO CONSTRUCT ANOTHER ROOF ASSEMBLY.
  • Page 158 STEP 2: DORMER 1: PLACE THE PLASTIC DORMER SUNBURST AGAINST THE FRONT FACE SUPPORT ON THE LEFT AND RIGHT ROOF SIDES. 2: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION. 3: INSTALL #8 X 1/2" PAN HEAD SCREWS TO FASTEN THE SUNBURST TO THE ROOF SIDES. REPEAT SUBSTEPS 1 THROUGH 3 TO CONSTRUCT THE SECOND DORMER.
  • Page 159 STEP 3: DORMER 1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: FOR 1500 SERIES UNITS LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 8TH ROOF BOARD. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF. 4: ATTACH THE DORMER TO THE ROOF WITH ONE #8 X 2-1/2"...
  • Page 160 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 161 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 162 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH #8 X 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE FOR A SUGGESTED PLACE TO MOUNT THE CHIMNEY. 2: AFTER INSTALLING THE CHIMNEY MOUNTING BLOCK PLACE THE CHIMNEY ASSEMBLY ON THE ROOF SO THAT THE INSIDE OF THE BACK WALL RESTS AGAINST THE BLOCK.
  • Page 163 (06-2004) Clatter Bridge Mesh Panels Tools Required: Kit Contents: #2 Phillips Bit or screwdriver 2 - Green Mesh Panels 66" x 24" 1/8" drill bit 44 - Phillips Pan Head Screws Pencil 5.5mm x 25.4mm long Drill 44 - Washers 16mm O.D. X 7.1mm I.D. Note: Your mesh panels will be completely green.
  • Page 164 5) It will be very helpful to have an assistant at this stage. We recommend predrilling holes for the screws on the bottom of the deckboards fastened to the chains. Align the edge of the mesh border with the end of the bridge deck boards.
  • Page 165 Treehouse Add On Kit Note: Plastic Sunburst and Flags shown come with your playset. These items are not included with the 1525 kit. Model: 1525 (BOXES: 1525 wood box, 1525 Hardware box & 2 Windows REV: 11.12.2015...
  • Page 166 ***IMPORTANT NOTICE FOR TREEHOUSE KIT PLAYSETS*** Read all instructions thoroughly before beginning construction, this is very important. The “Treehouse Add On Kit” (1525) box will require you to deviate slightly from the standard kit instructions. Typical deviations include: 1) The Telescope that is usually on the front of the set on the Front face board (arched board) must be moved to another location on the set.

  • Page 167: Table Of Contents

    TABLE OF CONTENTS General Information………………………………………..……......Page 4 Definitions……..………………………………………..........Page 5 Board Identification....................Page 6 Pre-Drill Lag Screw Directions……………………………………....……..Page 7 Tool List and Kit Contents ……………………..…………………………..……..Page 8 Hardware, Wood and Accessories………..……………….…………...…..Pages 9-12 Assembling The Roof Panels……………………………...…..……..…….....…. Step 1 Roof Peak Support.……………………..……............Step 2 Mounting Roof Sections to Play Set…….……………………..……......…...
  • Page 168 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 169 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 170: Board Identification

    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 171: 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 172 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil KIT CONTENTS...
  • Page 173 1525 HARDWARE #8 X 1-1/4" PAGE 1 OF 1 WOOD SCREW QTY: 32 11/18/2014 S.O. #8 X 1-1/2" WOOD SCREW QTY: 92 #8 X 2" WOOD SCREW QTY: 18 #8 X 2-1/2" WOOD SCREW QTY: 8 #8 X 3" WOOD SCREW QTY: 2 5/16"...
  • Page 174 PICTURE DESCRIPTION QTY. 1 X 2 X 9.88" WALL PANEL BOARD 1-2-0988-WPB 1 X 4 X 10.00" WALL PANEL BOARD 1-4-1000-WPB 1 X 3 X 11.50" WINDOW TOP/BOTTOM 1-3-1150-WTB 1 X 4 X 20.25" WALL PANEL BOARD 1-4-2025-WPB 1 X 4 X 20.50" WALL PANEL BOARD 1-4-2050-WPB...
  • Page 175 PICTURE DESCRIPTION QTY. 1 X 4 X 18.25" WALL PANEL BOARD 1-4-1825-WPB 1 X 5 X 6.88" ROOF PEAK 1-5-0688-RP 2 X 3 X 35.70" SUN SUPPORT 2-3-3570-SS 2 X 4 X 51.13" ROOF SUPPORT LEFT 2-4-5113-RSL 2 X 4 X 51.13" ROOF SUPPORT RIGHT 2-4-5113-RSR...
  • Page 176 PICTURE DESCRIPTION QTY. 4 X 10 X 43.50" ROOF PANEL LEFT ASSEMBLY 4-10-4350-RPLA 4 X 10 X 43.50" ROOF PANEL RIGHT ASSEMBLY 4-10-4350-RPRA WINDOW PANEL 07-0013 HARDWARE 1525 HARDWARE BOX...

  • Page 177: Assembling The Roof Panels

    STEP 1: ASSEMBLING THE ROOF PANELS 1: FIND THE 2 X 4 X 51.13" ROOF SUPPORT LEFT AND THE 4 X 10 X 43.50" ROOF PANEL LEFT ASSEMBLY. MOUNT THE ROOF PANEL LEFT ON TOP OF THE ROOF SUPPORT LEFT. 4 X 10 X 43.50"...

  • Page 178: Roof Peak Support

    STEP 2: ROOF PEAK SUPPORT 1:FIND ONE 5/4 X 6 X 10" ROOF PEAK SUPPORT FROM THE 1503 BOX. LAY THE ROOF SECTION LEFT AND THE ROOF SECTION RIGHT ON A FLAT SURFACE. ALIGN THE ANGLED ENDS FLUSH WITH ONE ANOTHER. 2: PLACE THE ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS, MAKE SURE THE ROOF PEAK SUPPORT TOP EDGES ARE FLUSH AGAINST THE BOTTOM FACE OF THE ROOF SECTION BOTTOM BATTEN.

  • Page 179: Mounting Roof Sections To Play Set

    STEP 3: MOUNTING ROOF SECTIONS TO PLAY SET 1: MOUNT THE ROOF SECTION ASSEMBLY TO THE FRONT OF THE PLAY SET. SLIDE THE ROOF SECTION UNTIL IT IS FLUSH UP AGAINST THE BOTTOM OF THE PLAY SET ROOF SUPPORTS, MAKE SURE THERE ARE NO GAPS IN BETWEEN.

  • Page 180: Roof Peak

    STEP 4: ROOF PEAK 1: MOUNT THE 1 X 5 X 6.88" ROOF PEAK ON TOP OF THE ROOF SECTION ASSEMBLY, FLUSH WITH THE PLAY SET ROOF SUPPORTS. FASTEN USING TWO #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREW PLAY SET ROOF SUPPORT 1 X 5 X 6.88"...

  • Page 181: Sun Support

    STEP 5: SUN SUPPORT 1: PLACE THE 2 X 3 X 35.70" SUN SUPPORT IN BETWEEN THE ROOF SUPPORTS. FASTEN USING #8 X 2-1/2" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ON EACH END, MAKE SURE THERE ARE NO GAPS IN BETWEEN THE SUN SUPPORT AND THE ROOF SUPPORT. #8 X 2-1/2"...

  • Page 182: Plastic Sunburst

    STEP 6: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBURST TO THE ROOF SUPPORTS ON THE ROOF SECTION ASSEMBLY, THE PLASTIC SUNBURST MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBURST TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS ON THE TOP AND SIX #8 X 2" WOOD SCREWS ON THE REMAINING HOLES.

  • Page 183: Wall Panel Boards

    STEP 7: WALL PANEL BOARDS 1: MOUNT THE 1 X 4 X 20.25" WALL PANEL BOARD ABOVE THE PLAY SET CENTER POST. THE END WITH TWO PRE-DRILLED HOLES SHOULD BE OFFSET TO THE TOP. MAKE SURE IT IS STRAIGHT VERTICALLY AND FASTEN IT TO THE SUN SUPPORT USING TWO #8 X 1-1/2"...

  • Page 184: Plastic Windows

    STEP 8: PLASTIC WINDOWS 1: PLACE EACH PLASTIC WINDOW INTO THE FRONT OPENINGS, WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS. 2: PLACE THE CROWN OVER THE SUN PIECE ON THE FRONT OF THE PLAY SET ABOVE THE PLASTIC WINDOWS.

  • Page 185: Wall Panel Boards

    STEP 9: WALL PANEL BOARDS 1:MOUNT THE 1 X 4 X 18.25" WALL PANEL BOARD NEXT TO THE PREVIOUSLY INSTALLED PANEL BOARD, LEAVING A 1/4" GAP BETWEEN THEM. FASTEN IT USING FOUR #8 X 1-1/2" WOOD SCREWS. 2: MOUNT THE 1 X 3 X 14.06" WALL PANEL BOARD NEXT 1 X 4 X 10.00"...

  • Page 186: Flag Kit

    STEP 10: FLAG KIT 1: PLACE A FLAG CENTERED ON THE WALL PANEL BOARD NEXT TO THE CORNER POST AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED. **DO NOT OVER TIGHTEN** FLAG CORNER POST 1/2"...
  • Page 187 Telescope (07-0001) Mounting to 2 x 4 board 1: Place one of the "L" shaped Telescope Brackets against the 2 x 4 so that the bracket section with the cutout faces up. Fasten the Telescope Bracket to the 2 x 4 with the 1-1/4" phillips countersunk head screws provided.
  • Page 188 Telescope (07-0001) Mounting to 4 x 4 board 1: Center the Telescope Stand on top of the 4 x 4 board. 2: Place the notched area of one of the half-circle shaped Telescope Brackets over the top of the Telescope Stand. Attach the half-circle shaped Telescope Bracket to the top of the 4 x 4 board with the1-1/4”...

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