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Gorilla Playsets Pioneer Peak 1500DT Manual
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Gorilla Playsets Pioneer Peak 1500DT Manual

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Pioneer Peak - Tarp Roof
Model: 1500DT
[BOXES: 1501, 1502, (105 or
1508), (106 or 1509), (107 or
1510), 1511, 1517 & SLIDE BOX]
Copyright © 2013 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
™
™
playsets
playsets

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Summary of Contents for Gorilla Playsets Pioneer Peak 1500DT

  • Page 1 Pioneer Peak - Tarp Roof Model: 1500DT [BOXES: 1501, 1502, (105 or 1508), (106 or 1509), (107 or 1510), 1511, 1517 & SLIDE BOX] Copyright © 2013 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com...
  • Page 2 Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our “Quick Response Center”...
  • Page 3 GORILLA PLAYSETS WARRANTY - 2013 Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions, for 10 years for above ground structural wood components and for one year for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
  • Page 4 Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used. WEIGHT LIMITS FOR GORILLA PLAYSETS • FORT PLATFORMS: 800 LBS. TOTAL WEIGHT • SWING BELT: 225 LBS.
  • Page 5 WARRANTY REGISTRATION - PIONEER PEAK - TARP ROOF - Gorilla Playsets manufactures 3 EASY WAYS TO REGISTER Gorilla Playsets (678) 880-3329 Where did you buy this product?: Date of Place of Purchase Purchase Name: Email: Street City State Please select...
  • Page 6 IMPORTANT – PLEASE READ As fresh lumber acclimates to its new environment, the natural tendencies of the tree can show itself in the form of checks, or “cracks” in the lumber. In almost all cases this is normal and it will not affect the structural integrity of your play set.
  • Page 7 Model: 1500DT [BOXES: 1501, 1502, (105 or 1508), (106 or 1509), (107 or 1510), 1511, 1517 & SLIDE BOX] REV: 5.13.2013 (A)
  • Page 8 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 16-35 Adding T-Nuts to Corner Posts...…………………………………..………...…...
  • Page 9 Safety and Maintenance Tips for Your New Play Set: NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with your children. •...
  • Page 10 Safety and Maintenance Tips for Your New Play Set: (continued) Playgrounds should be inspected on a regular basis. If any of the following conditions are noted, they should be removed, corrected, or repaired immediately to prevent injuries. • Hardware that is loose, worn or that has protrusions or projections. •...
  • Page 11 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
  • Page 12 2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6’...
  • Page 13 General Info to Review Before Installation • Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly. •...
  • Page 14 This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board.
  • Page 15 Common Installation Practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood Corner Post T-nut Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.
  • Page 16 HOW A T-NUT WORKS THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS.
  • Page 17 BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled into place. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" •...
  • Page 18 PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole.
  • Page 19 SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs. Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs.
  • Page 20 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: Swing Belt (2) Trapeze Arm (1) 10'-1 " 3'-11 " 8'-9 " Clatter Bridge 22'-8 " " 4'-11 " 4 " 5'-10"...
  • Page 21 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/16”, 3/8”, 9/64”, 11/64” and a 1” and 7/8” Paddle style bit. ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16”...
  • Page 22 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: 1 OF 2 9/20/2012 J.H. #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" PLASTIC CARRIAGE BOLT CARRIAGE BOLT...
  • Page 23 1501 HARDWARE PAGE: 2 OF 2 #8 X 1" WOOD SCREW 9/20/2012 J.H. 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 24 1502 HARDWARE PAGE: 1 OF 1 9/18/2012 J.H. #14 X 1-1/4" PAN HEAD SCREW QTY: 10 #8 X 2-1/2" WOOD SCREW QTY: 14 5/16" TEE NUT QTY: 2 1/4" WASHER QTY: 10 5/16 X 2-1/2" HEX BOLT 5/16" WASHER QTY: 2 QTY: 2 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 25 1508 HARDWARE PAGE: 1 OF 1 9/19/2012 J.H. #8 x 2-1/2" WOOD SCREW QTY: 92 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 26 1509 HARDWARE PAGE: 1 OF 1 1/3/2013 J.H. #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 5/16" TEE NUT QTY: 55 1/4"...
  • Page 27 3/8 X 3-1/2" 1510 HARDWARE HEX LAG SCREW QTY: 11 PAGE: 1 OF 1 REV A 2/4/2013 J.H. TORQUE WASHER QTY: 4 5/16" TEE NUT QTY: 2 PLASTIC BOLT CAP QTY: 4 3/8" LOCK NUT QTY: 4 3/8" WASHER QTY: 17 1/2"...
  • Page 28 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 29 1517 HARDWARE PAGE: 1 OF 1 9/19/2012 J.H. #8 X 3" WOOD SCREW QTY: 5 5/16" TEE NUT QTY: 1 5/16" WASHER QTY: 1 5/16 X 4-1/2" HEX BOLT QTY: 1 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 30 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 NOTE: THIS ITEM WILL NOT BE USED FOR THIS PLAY SET.
  • Page 31 PICTURE DESCRIPTION QTY. 2 X 4 X 32-1/2" PICNIC TABLE 2-4-3250-PTL 2 X 4 X 47-3/8" TARP BOARD SUPPORT 2-4-4738-TBS 2 X 4 X 47 " SAFETY BOARD/ END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON CENTER) 2-4-5800-CM...
  • Page 32 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 4 X 71-7/8" CENTER TARP SUPPORT 2-4-7186-CTS 2 X 6 X 47 "...
  • Page 33 PICTURE DESCRIPTION QTY. 2 X 6 X 102" ROPE LADDER SUPPORT - FRONT RIGHT 2-6-10200-RLSFR 2 X 6 X 102" ROPE LADDER RUNNER - FRONT RIGHT 2-6-10200-RLRFR 4 X 4 X 47-1/2" SWING BEAM MOUNT 4-4-4750-SBM 4 X 4 X 72" CENTER TARP SUPPORT 4-4-7200-CTS...
  • Page 34 PICTURE DESCRIPTION QTY. X 3 X 23 " ROCK WALL 125-3-2387-RWC X 2 X 28 " PANEL SLAT 125-3-2825-PS X 4 X 40 " DECK SPACER 125-4-4038-DS 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...
  • Page 35 PICTURE DESCRIPTION QTY. X 6 X 47 " DECK BOARD 125-6-4737-DB 2 X 2 X 16" RAMP FLOOR SUPPORT 2-2-1600-FS 2 X 4 X 18 " RAMP SUPPORT 2-4-1875-RS 2 X 4 X 94" RAMP MIDDLE FLOOR BOARD 2-4-9400-MFB 2 X 4 X 96" RAMP SIDE BOARD 2-4-9600-SB...
  • Page 36 PICTURE DESCRIPTION QTY. 4 X 6 X 108" PLASTIC COATED TIRE SWING BEAM 2 X 4 X 47 " TIRE SWING CROSS MEMBER 2-4-4750-CM 4 X 4 X 96" PLASTIC COATED CORNER POST 4 X 4 X 108" PLASTIC COATED SWING LEG 4 X 6 X 120"...
  • Page 37 PICTURE DESCRIPTION QTY. 2 X 4 X 33" VERTICAL TARP SUPPORT 2-4-3300-VTS 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 36-3/4" TARP BOARD 2-4-3675-TB 2 X 4 X 66" BRIDGE RAIL 2-4-6600-R 2 X 6 X 36-3/4"...
  • Page 38 PICTURE DESCRIPTION QTY. 5/4 X 3 X 16" BRIDGE RAIL SLAT 125-3-1600-RS 5/4 X 3 X 28-1/2" PANEL SLAT 125-3-2850-PS 5/4 X 4 X 29-3/8" DECK SPACER 125-4-2937-DS 5/4 X 4 X 36-11/16" DECK BOARD 125-4-3668-DB...
  • Page 39 PICTURE DESCRIPTION QTY. SLIDE ROCK WALL AND RAMP ROPE ROPE LADDER ROPES SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 40 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCK (5 ROCKS ARE IN BAG) 07-0008 A-FRAME SWING BRACKET 11-5010 HARDWARE BOXES HARDWARE BOXES: 1501, 1502, 1508, 1509, 1510, 1511, 1517 INSTRUCTIONS...
  • Page 41 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGER 11-4012 TELESCOPE 07-0001 TIRE SWING W/CHAINS 04-0014...
  • Page 42 PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...
  • Page 43 PICTURE DESCRIPTION QTY. TARP 05-0010 (MATERIAL COLOR WILL VARY BY MODEL) CLATTER- BRIDGE TARP 57-1/2" X 34- 1/4" 05-1012 CLATTER- BRIDGE CHAIN 96" FLAG KIT 09-1014...
  • Page 44 PICTURE DESCRIPTION QTY. MANUFACTURER (NOT SHOWN) LOGO PLATE GROUND STAKE (PAIR) 07-0016 TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004 TIRE SWING SWIVEL 11-4010...
  • Page 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 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 54 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 55 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 56 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 57 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 58 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 59 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 60 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 61 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 62 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 63 STEP 16: CLIMBING RAMP 1: LAY OUT THE 2 X 4 X 96" RAMP SIDE BOARDS MAKING SURE THE ANGLED END FACES ALIGN WITH ONE ANOTHER. THE SHORT FACE ON THE ANGLED END SHOULD FACE DOWN. 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 64 STEP 17: CLIMBING RAMP 1: FLIP THE CLIMBING RAMP OVER. PLACE ONE 2 X 6 X 94" 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.
  • Page 65 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: PLACE T-NUTS ON THE INSIDE OF THE HOLES IN THE RAMP SIDE BOARDS. SET THE T-NUTS WITH A HAMMER FLUSH/NEAR FLUSH WITH THE RAMP SIDES.
  • Page 66 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 67 STEP 20: CENTER POSTS FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 71-7/8" CENTER TARP SUPPORT. 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 68 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 69 STEP 21A: TARP BOARDS 1: LOCATE THREE 2 X 4 X 47-3/8" TARP BOARDS. 2: ATTACH EACH TARP BOARD TO THE TOP OF THE CENTER TARP SUPPORT OR THE CORNER POSTS WITH #8 X 2-1/2 WOOD SCREWS. 2 X 4 X 47-3/8" TARP BOARD #8 X 2-1/2"...
  • Page 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 STEP 30: TARP 1: PLACE THE TARP ACROSS THE TARP BOARDS WITH THE HEMS ON THE INSIDE. 2: FASTEN THE OUTSIDE CORNERS OF THE TARP TO THE SIDE OF THE TARP BOARD FIRST. ATTACH THE GROMMETS IN THE TARP TO THE TARP BOARD WITH #14 X 1-1/4" PAN HEAD SCREWS WITH 1/4" WASHERS. REPEAT FOR OTHER SIDE. (NOTE IF YOU WISH YOU MAY PREDRILL HOLES FOR THE PAN HEAD SCREWS WITH A 1/8"...
  • Page 79 STEP 31: 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 80 STEP 32: 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 HOLES OFFSET UP OR DOWN (YOUR CHOICE) TO THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 81 STEP 33: 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 82 STEP 34: 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 83 STEP 35: 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 84 STEP 36: 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 85 STEP 37: 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 86 STEP 38: 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 87 STEP 39: 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 88 STEP 40: 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 89 STEP 41: 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 1-1/4"...
  • Page 90 STEP 42: 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 91 STEP 43: 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 92 STEP 44: 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 93 STEP 45: 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 94 STEP 46: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. 2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #8 X 2" WOOD SCREW PROVIDED WITH THE GROUND STAKE. #8 X 2"...
  • Page 95 STEP 47: STEERING WHEEL 1: GO TO THE REAR CENTER TARP SUPPORT 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 96 PART 2 CLATTER BRIDGE ASSEMBLY...
  • Page 97 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 98 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 99 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 100 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 101 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 102 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 103 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 104 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 105 STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-11/16" 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 BE 1/4"...
  • Page 106 STEP 10: DECK 1: INSTALL THE 5/4 X 6 X 36-11/16" 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 36-11/16" DECK BOARD FRONT OF TOWER...
  • Page 107 STEP 11: REAR BOTTOM PANEL BOARD 1: 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. 2: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
  • Page 108 STEP 12: PANEL SLATS 1: FIND NINE 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 THE FIRST PANEL SLAT 2-5/8"...
  • Page 109 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 110 STEP 14: TIC-TAC-TOE PANEL 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE FRONT OF THE PLAY SET 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 FRONT OF TOWER #8 X 1-3/4"...
  • Page 111 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 112 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 113 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 114 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 115 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 116 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 117 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 118 STEP 22: VERTICAL TARP SUPPORTS 1: PLACE THE 2 X 4 X 33" VERTICAL TARP SUPPORTS ON THE INSIDE OF THE TOP PANEL BOARDS. THE END OF EACH VERTICAL TARP SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE TOP PANEL BOARD. CENTER EACH VERTICAL TARP SUPPORT WITH THE CENTER OF THE TOP PANEL BOARD.
  • Page 119 STEP 23: TARP BOARDS 1: LOCATE THREE 2 X 4 X 36-3/4" TARP BOARDS. 2: PLACE ONE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE END OF THE TARP BOARD SHOULD BE FLUSH WITH THE SIDES OF THE VERTICAL TARPS SUPPORTS. 3: ATTACH THE TARP BOARD TO THE VERTICAL TARP SUPPORTS WITH 2-1/2"...
  • Page 120 STEP 24: CLATTER BRIDGE TARP 1: LOCATE THE 34-1/4" X 57-1/2" CLATTER BRIDGE TARP. 2: PLACE THE TARP OVER THE TOP OF THE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE HEMS SHOULD FACE THE INSIDE. 3: THE TARP WILL OVERLAP THE SIDE OF THE TARP BOARDS ON TOP OF THE CORNER POSTS. 4: ATTACH THE TARP THROUGH THE GROMMETS TO THE TARP BOARDS WITH #14 X 1-1/4"...
  • Page 121 STEP 25: 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 122 STEP 26: 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"...

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