Gorilla Playsets Malibu Treasure Trove II Manual
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Gorilla Playsets Malibu Treasure Trove II Manual

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Malibu Treasure Trove II
Timber Shield Post Option
BOXES: X2, X3, CB
*51-0078-W*
51-0078-W
Model: 1500KWR
(BOXES: 1501, 1504, 1506N,
1509N, 1509W, 1528, 1529, 1515,
Rad Ride 7 Box, Bagged 14' Scoop
Slide & Slide
Copyright © 2016 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
™
™
playsets
playsets
plays ets
plays ets
Amber Post Option
BOXES: 1519, 1533,
1534, 1522
Box)
™
™

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Summary of Contents for Gorilla Playsets Malibu Treasure Trove II

  • Page 1 ™ ™ playsets playsets ™ ™ plays ets plays ets Malibu Treasure Trove II Model: 1500KWR Timber Shield Post Option Amber Post Option BOXES: X2, X3, CB BOXES: 1519, 1533, 1534, 1522 (BOXES: 1501, 1504, 1506N, 1509N, 1509W, 1528, 1529, 1515, Rad Ride 7 Box, Bagged 14’...
  • Page 2 Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our “Quick Response Center”...
  • Page 3 This decision is subject to verification of the defect, which, at Gorilla’s discretion, may be accomplished by submitting photographs or by delivery of the defective part to Gorilla Playsets • 190 Etowah Industrial Ct. • Canton, GA 30114 • 1-800-882-0272 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase.
  • Page 4 Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used. WEIGHT LIMITS FOR GORILLA PLAYSETS • FORT PLATFORMS: 800 LBS. TOTAL WEIGHT • SWING BELT: 225 LBS.
  • Page 5 Warranty registration - MaLiBU treasUre trove ii - 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.
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 7 IMPORTANT – PLEASE READ Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years.
  • Page 8 Please review these safety rules regularly with your children. WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to ensure it has been properly installed. Gorilla Playsets 190 Etowah Industrial Court Canton, GA. 30114...
  • Page 9 Model: 1500KWR Timber Shield Post Option Amber Post Option BOXES: X2, X3, CB BOXES: 1519, 1533, 1534, 1522 (BOXES: 1501, 1504, 1506N, 1509N, 1509W, 1528, 1529, 1515, Rad Ride 7 Box, Bagged 14’ Scoop Box) Slide & Slide REV: 2.18.2016...
  • Page 10 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 4-7 Leveling Fort, General Information and Definitions…………………....Pages 7-9 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 10-14 Site Plan, Required Tool List and Kit Contents..........Pages 15-16 Hardware, Lumber and Accessory Checklists.………………………………..Pages 17-51 Adding T-Nuts to Lower Level Corner Posts..…………………..………...…...

  • Page 11: Table Of Contents

    TABLE OF CONTENTS Sandbox Seats/Name Plate.................. Step 77 Tic Tac Toe Assembly/Installation………………………………..……....Steps 78-79 Rock Wall Rope..................... Step 80 Safety Handles (Lower Level) and Safety Handles (Upper Level)....Steps 81-82 Steering Wheel...................... Step 83 Telescope......................Step 84 Hanging the Swings....................Step 85 Ground Stakes.......................
  • Page 12 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 13 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 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22 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 23 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 26'-10 " 5'-10" 10'-1 " 10'-11 16 " Ride 7 5'-7 " Tube Slide Scoop Slide Swing Belt (2) 6'-6" Ladder Trapeze (1) 2'-8"...
  • Page 24 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/16”, 3/8”, 7/64”, 9/64”, 11/64” and a 1” paddle bit ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16”...
  • Page 25 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 26 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 27 1504 HARDWARE PAGE: 1 OF 1 9/18/2012 J.H. #8 X 2" WOOD SCREW QTY: 71 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3" WOOD SCREW QTY: 5 #10 x 3-1/2" WOOD SCREW #14 x 3" QTY: 2 PAN HEAD SCREW QTY: 3 5/16"...
  • Page 28 1506 HARDWARE #8 X 1-1/4" WOOD SCREW PAGE: 1 OF 1 QTY: 6 REV A: #8 X 1-1/2" 10/31/2014 J.H. WOOD SCREW QTY: 104 #8 X 2" WOOD SCREW QTY: 31 #8 X 2-1/2" WOOD SCREW QTY: 6 #8 X 3" WOOD SCREW QTY: 2 5/16"...
  • 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 1515 HARDWARE PAGE: 1 OF 1 9/19/2012 J.H. 5/16" TEE NUT QTY: 14 5/16" X 3-1/2" 5/16 X 4-1/2" LAG SCREW HEX BOLT QTY: 16 QTY: 14 5/16" WASHER QTY: 30 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 32 1528 HARDWARE #8 X 1" PAGE 1 OF 1 WOOD SCREW QTY: 2 1/16/2015 SO. #8 X 1-1/4" WOOD SCREW QTY: 25 #8 X 1-1/2" WOOD SCREW QTY: 110 #8 X 2" WOOD SCREW QTY: 25 #8 X 2-1/2" WOOD SCREW QTY: 12 #2 SQUARE DRIVE BIT...
  • Page 33 11-2027 SUB BRACKET HARDWARE 3/8" X 2-1/2" 3/8" WASHER LAG SCREW QTY: 4 12/09/2015 QTY: 4 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 34 PICTURE DESCRIPTION QTY. 1501 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 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 18" ANGLE SUPPORT 2-4-1800-AS 2 X 4 X 24" ROPE LADDER STEP 2-4-2400-RLST...
  • Page 35 PICTURE DESCRIPTION QTY. 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 58" SWING BEAM CROSS MEMBER 2-4-5800-CM 2 X 4 X 66" LADDER RIGHT SIDE 2-4-6600-LRS 2 X 4 X 66" LADDER LEFT SIDE 2-4-6600-LLS 2 X 4 X 66"...
  • Page 36 PICTURE DESCRIPTION QTY. 2 x 4 x 70" REAR TOP PANEL BOARD 2-4-7000-RTPB 2 x 6 x 47-1/2" END SANDBOX/ BOTTOM PANEL BOARD 2-6-4750-ESPB 2 x 6 x 70" FRONT FACE BOARD 2-6-7000-FFB 2 x 6 x 70" SANDBOX BOARD 2-6-7000-SB 4 x 4 x 47-1/2"...
  • Page 37 PICTURE DESCRIPTION QTY. 5/4 X 3 X 18-3/4" LADDER BACK 125-3-1875-LB 5/4 X 3 X 23-7/8" ROCK WALL 125-3-2387-RWC 5/4 X 3 X 28-1/4" PANEL SLATS 125-3-2825-PS 5/4 X 4 X 40-3/8" DECK SPACER 125-4-4038-DS 5/4 X 6 X 22" SANDBOX SEAT 125-6-2200-SS...
  • Page 38 PICTURE DESCRIPTION QTY. 5/4 X 6 X 43" PICNIC TABLE & SEAT BOARD 125-6-4300-PTTS 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB...
  • Page 39 PICTURE DESCRIPTION QTY. 1528 1 X 4 X 29.29" LEFT ROOF FINISHER FRONT 1-4-2929-RFFL 1-4-2929-RFFR RIGHT 1 X 4 X 76-7/8" ROOF STARTER REAR 1-4-7688-RSR 1 X 4 X 76-7/8" ROOF STARTER FRONT 1-4-7688-RSF 1 X 4 X 76-7/8" ROOF FINISHER REAR 1-4-7688-RFR 1 X 5 X 76-7/8"...
  • Page 40 PICTURE DESCRIPTION QTY. 1 X 4 X 12-1/4" WALL PANEL BOARD 1-4-1225-WPB 1 X 4 X 15-3/4" WALL PANEL BOARD 1-4-1575-WPB 1 X 4 X 19-5/16" WALL PANEL BOARD 1-4-1931-WPB 5/4 X 5 X 10.81" ROOF PANEL PEAK SUPPORT 125-5-1081-RPPS 5/4 X 6 X 10"...
  • Page 41 PICTURE DESCRIPTION QTY. 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT (1 HOLE ON ON CENTER) 2-4-2275-WPSL RIGHT 2-4-2275-WPSR 2 X 4 X 35.15" LEFT ROOF SUPPORT (1 HOLE OFFSET) 2-4-3515-RSL 2-4-3515-RSR RIGHT 2 X 4 X 69.75" ROOF FINISHER SUPPORT (2 HOLES ON CENTER)
  • Page 42 PICTURE DESCRIPTION QTY. 1504 2 X 4 X 18" ANGLE SUPPORT- UPPER LEVEL RAD RIDE SIDE 2-4-1800-ULRDAS 2 X 4 X 18" ANGLE SUPPORT- UPPER LEVEL REAR 2-4-1800-ULRAS 2 X 4 X 21-1/2" ANGLE SUPPORT- UPPER LEVEL SWING SIDE 2-4-2150-ULSAS 2 X 4 X 30-7/16"...
  • Page 43 PICTURE DESCRIPTION QTY. 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD 2-6-3043-SBPB 2 X 6 X 42-1/2" REAR BOTTOM PANEL BOARD 2-6-4250-RBPB 2 X 6 X 70" BACK PANEL BOARD 2-6-7000-BPB5 4 X 4 X 23-1/2" SLIDE BLOCK 4-4-2350-SB 4 X 4 X 30-1/2"...
  • Page 44 PICTURE DESCRIPTION QTY. 5/4 X 3 X 34-1/2" PANEL SLAT 125-3-3450-PS 5/4 X 4 X 25" RAD RIDE DECK SPACER 125-4-2500-RRDS 5/4 X 4 X 29-1/2" UPPER DECK SPACER 125-4-2950-UDS 5/4 X 4 X 35-1/2" REAR DECK SPACER 125-4-3550-RDS 5/4 X 4 X 63" UPPER DECK SPACER 125-4-6300-UDS...
  • Page 45 PICTURE DESCRIPTION QTY. 1506 1 X 4 X 30-1/2" ROOF FINISHER 1-4-3050-RF 1 X 4 X 30-1/2" ROOF STARTER 1-4-3050-RS 1 X 5 X 30-1/2" ROOF BOARD 1-5-3050-RB 1 X 6 X 30-1/2" ROOF PEAK 1-6-3050-RP 2 X 4 X 18" THIS ITEM WON'T CLOSE OUT BE USED ON THIS...
  • Page 46 PICTURE DESCRIPTION QTY. 2 X 4 X 51-1/8" ROOF SUPPORT RIGHT 2-4-5113-RSR 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST 4-4-3331-ULCP 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST 4-4-5950-LLCP 4 X 4 X 60-1/4" LAG POST WOOD ROOF LEFT 4-4-6025-LPWL RIGHT HAS...
  • Page 47 PICTURE DESCRIPTION QTY. 1509N 2 X 4 X 29" BRIDGE DECK 2-4-2900-BD 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES 2-4-3675-SBH 2 X 4 X 36-3/4" SAFETY BOARD 2-4-3675-SB 2 X 4 X 66" RAIL 2-4-6600-R 2 X 6 X 36-3/4" BOTTOM PANEL BOARD/SANDBOX BOARD...
  • Page 48 PICTURE DESCRIPTION QTY. 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 36-1/2" DECK BOARD 125-4-3650-DB...
  • Page 49 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 50 PICTURE DESCRIPTION QTY. 1515 2 X 4 X 14" BOTTOM PANEL BOARD 2-4-1400-BPB 2 X 6 X 70" SANDBOX BOARD 2-6-7000-SB 2 X 6 X 78" SIDE SANDBOX BOARD-LEFT 2-6-7800-SBL 2 X 6 X 78" SIDE SANDBOX BOARD-RIGHT 2-6-7800-SBR 2 X 6 X 102" ROPE LADDER RUNNER- FRONT LEFT...
  • Page 51 PICTURE DESCRIPTION QTY. 4 X 4 X 108" PLASTIC COATED CORNER POST- FRONT 4 X 4 X 120" PLASTIC COATED CORNER POST- MIDDLE 4 X 4 X 120" PLASTIC COATED CORNER POST- REAR 4 X 4 X 108" PLASTIC COATED SWING LEG 4 X 6 X 120"...
  • Page 52 PICTURE DESCRIPTION QTY. WAVE SLIDE 03-0013 SUPER SCOOP 03-0007 RIDE SLIDE 03-0002...
  • Page 53 PICTURE DESCRIPTION QTY. ROCK WALL ROPE LADDER ROPES SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006 SUB BRACKET 11-5017...
  • Page 54 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: 1501,1504, 1506, 1509N, 1509W, 1515 , 1528, 11-2027 INSTRUCTIONS...
  • Page 55 PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 IRON DUCTILE SWING HANGER 11-4012...
  • Page 56 PICTURE DESCRIPTION QTY. UNASSEMBLED DORMER (1529 BOX) UNASSEMBLED CHIMNEY (1529 BOX SLIDE BOX ) TELESCOPE 07-0001...
  • Page 57 PICTURE DESCRIPTION QTY. PLASTIC SUNBURST 07-0028-G FRONT PLASTIC ARCH 07-0027-G DORMER WINDOW 07-0029-G SOLAR WALL LIGHT 09-2003...
  • Page 58 PICTURE DESCRIPTION QTY. (NOT SHOWN) MANUFACTURER LOGO PLATE CLATTER BRIDGE MESH PANEL (NOT SHOWN) (PAIR) 06-2004 GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004...
  • Page 59 PICTURE DESCRIPTION QTY. SAFETY HANDLE (2 HANDLES ARE IN ONE BAG) 07-0005 96" CHAIN SECTION...
  • Page 60 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 108"...
  • Page 61 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 78" SIDE SANDBOX BOARD- RIGHT ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 62 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 78" SIDE SANDBOX BOARD - LEFT ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 63 STEP 3A: DRILL HOLES FOR BRIDGE CHAINS 1: 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 64 STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16"...
  • Page 65 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 ROPE LADDER RUNNER TO THE T-NUTS INSTALLED IN THE CORNER POSTS.
  • Page 66 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 IN THE CORNER POSTS.
  • Page 67 STEP 7: 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 68 STEP 8: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAGSCREWS WITH 5/16" WASHERS. 2 X 4 X 14" BOTTOM PANEL BOARD 5/16"...
  • Page 69 STEP 9: 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 70 STEP 10: 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 71 STEP 11: 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 DRAW A LINE ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE.
  • Page 72 STEP 12: 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 73 STEP 13: 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 74 STEP 14: 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 75 STEP 15: 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 76 STEP 16: 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 77 STEP 17: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE FRONT - LEFT CUT OUT AREA 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; DRILL A 3/8”...
  • Page 78 STEP 18: 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 79 STEP 19: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE LEFT SIDE OF THE FORT AS SHOWN BELOW. CENTER THE LADDER HORIZONTALLY ON THE 2 X 6. CENTER THE 90 BRACKETS VERTICALLY ON THE 2 X 6. USE THE HOLES IN THE LADDER BRACKETS AS A TEMPLATE TO DRILL 3/8" HOLES THROUGH THE BOTTOM PANEL BOARD.
  • Page 80 STEP 20: UPPER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE UPPER LEVEL PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLY TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT POSTS PROPERLY.
  • Page 81 STEP 21: LAG POSTS 1: TWO 4 X 4 60-1/4" LAG POSTS WILL BE USED TO EXTEND THE MIDDLE CORNER POSTS TO ACCEPT THE UPPER LEVEL ROOF. 2: MAKE SURE TO INSTALL THE T-NUTS INTO THE LAG POSTS TOP HOLES AS SHOWN IN THE DRAWING BELOW BEFORE MOUNTING IT TO THE MIDDLE POSTS.
  • Page 82 STEP 22: REAR CORNER POSTS & DECK SUPPORTS & SIDE TOP PANEL BOARDS TIP: BEFORE YOU INSTALL THESE BOARDS LEAVE THEM ALL A LITTLE LOOSE. WHEN YOU HAVE FASTENERS IN ALL THE BOARDS GO BACK AND TIGHTEN THEM ALL UP. 1: ATTACH THE BOTTOM OF THE REAR CORNER POSTS TO THE SIDE SANDBOX BOARDS WITH 5/16"...
  • Page 83 STEP 23: UPPER LEVEL - RAILING & UNDER DECK SUPPORT 1: PLACE THE 2 X 4 X 70" UPPER LEVEL STEPS/RAILING BOARD (3 HOLES ON CENTER) AT THE TOP OF THE REAR CORNER POSTS. THIS BOARD WILL GET ATTACHED TO THE 2ND HOLE DOWN FROM THE TOP OF THE POSTS.
  • Page 84 STEP 24: CENTER DECK SUPPORT ASSEMBLY NOTE: IT IS BEST TO PLACE THESE BOARDS UPON A FLAT SURFACE BEFORE ATTACHING THEM TOGETHER. 1: PLACE ONE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET UP) ON THE RIGHT SIDE OF THE 4 X 4 X 30-1/2"...
  • Page 85 STEP 25: LOWER LEVEL CENTER POST 1: HAMMER A T-NUT INTO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST HOLE. 2: ATTACH THE LOWER LEVEL CENTER POST TO THE MIDDLE HOLE OF THE 2 X 6 X 70" BACK PANEL BOARD.
  • Page 86 STEP 26: CENTER DECK SUPPORT ASSEMBLY INSTALLATION AND LAGS 1: PLACE THE CENTER DECK SUPPORT ASSEMBLY ON TOP OF THE 4 X 4 X 70" UPPER LEVEL UNDER DECK SUPPORT. THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST SHOULD FIT INSIDE THE CENTER DECK SUPPORT ASSEMBLY.
  • Page 87 STEP 27: UPPER LEVEL DECK SPACERS 1: MAKE SURE THE LOWER LEVEL CENTER POST HAS AN EQUAL OPENING ON EACH SIDE. 2: PLACE THE 5/4 X 4 X 29-1/2" UPPER DECK SPACERS BETWEEN THE LOWER LEVEL CENTER POST AND THE MIDDLE CORNER POSTS. ATTACH EACH UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2"...
  • Page 88 STEP 28: SLIDE BLOCK 1: PLACE THE 4 X 4 X 23-1/2" SLIDE BLOCK AGAINST THE UPPER DECK SUPPORT ON THE LEFT SIDE (LADDER SIDE) OF THE PLAY SET. THE TOP OF THE BLOCK SHOULD BE FLUSH TO THE TOP OF THE DECK SUPPORT. THE BLOCK FITS BETWEEN THE LAG POST AND THE REAR CORNER POST.
  • Page 89 STEP 29: ANGLE SUPPORT - UPPER LEVEL REAR 1: PLACE A 2 X 4 X 18" ANGLE SUPPORT -UPPER LEVEL REAR AGAINST THE 4 X 4 X 70 UPPER LEVEL UNDER DECK SUPPORT ON EACH SIDE AT THE REAR OF THE PLAY SET. 2: THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH TO THE TOP OF THE UNDER DECK SUPPORT.
  • Page 90 STEP 30: SIDE REAR ANGLE SUPPORTS 1: (SEE DETAIL A) PLACE THE 2 X 4 X 18" ANGLE SUPPORT UPPER LEVEL RAD RIDE SIDE UNDER THE 4 X 4 X 23- 1/2" SLIDE BLOCK ON THE LEFT SIDE OF THE FORT. THE ANGLE SUPPORT SHOULD BE FLUSH TO THE LEFT SIDE OF THE LEFT REAR CORNER POST.
  • Page 91 STEP 31: UPPER LEVEL DECK BOARDS 1: PLACE FOUR 5/4 X 6 X 69-7/8" UPPER DECK BOARDS ACROSS THE DECK SUPPORTS AS SHOWN. EQUALLY SPACE THE DECK BOARDS 5/16" FROM ONE ANOTHER AND FROM THE DECK SPACER. 2: SECURE EACH UPPER DECK BOARD TO THE DECK SUPPORTS WITH FIVE #8 X 2" WOOD SCREWS.
  • Page 92 STEP 32: SLIDE POST ASSEMBLY 1: PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH IN THE 4 X 4 X 43-1/2" RAD RIDE CENTER POST. 2: PLACE ONE END OF THE 5/4 X 4 X 25" RAD RIDE DECK SPACER INTO THE NOTCH IN THE RAD RIDE CENTER POST.
  • Page 93 STEP 33: SLIDE POST INSTALLATION 1: PLACE THE END OF THE DECK SPACER AGAINST THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. FASTEN THE DECK SPACER TO THE DECK SUPPORT WITH #8 X 2" WOOD SCREWS. 2: MAKE THE DECK SPACER LEVEL WITH THE DECK BOARD BEHIND IT.
  • Page 94 STEP 34: UPPER LEVEL REAR DECK SPACER 1: PLACE THE 5/4 X 4 X 35-1/2" REAR DECK SPACER ON TOP OF THE DECK SUPPORTS. THE END SHOULD BE FLUSH TO THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST/CENTER POST. 2: FASTEN THE REAR DECK SPACER TO THE DECK SUPPORTS WITH FOUR #8 X 2"...
  • Page 95 STEP 35: UPPER LEVEL CENTER POST 1: PLACE THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST AGAINST THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST. FLUSH THE TOPS AND SIDES OF THE POSTS TOGETHER. 2: ATTACH THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST TO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST WITH 3/8"...
  • Page 96 STEP 36: RAILING 1: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD (RAILING) AGAINST THE MIDDLE POSTS, FLUSH WITH THE TOP END OF THE CENTER POST. 2: THE TOP OF THE RAILING SHOULD BE 33" ABOVE THE DECK BOARDS. 3: ATTACH THE RAILING TO THE LAG POSTS AND UPPER LEVEL CENTER POST WITH 5/16"...
  • Page 97 STEP 37: RADICAL RIDE TUBE SLIDE 1: ASSEMBLE THE RADICAL RIDE TUBE SLIDE ACCORDING TO THE DIRECTIONS INCLUDED WITH THE SLIDE. 2: PLACE THE SLIDE FACEPLATE AT THE OPENING AT THE REAR OF THE PLAY SET. THE SIDE OF THE FACE PLATE SHOULD BE 3/4"...
  • Page 98 STEP 38: UPPER LEVEL BOTTOM PANEL BOARDS 1: PLACE THE 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD (OFFSET UP) ON THE SWING BEAM SIDE (RIGHT SIDE) OF THE PLAYSET. ATTACH THE TOP HOLES OF THE BOARD TO THE POSTS WITH 5/16"...
  • Page 99 STEP 39: UPPER LEVEL REAR CENTER POST 1: PLACE THE 2 X 4 X 35-5/8" UPPER LEVEL REAR CENTER POST AGAINST THE REAR RAILING ON THE UPPER LEVEL. HAMMER A T-NUT INTO THE TOP HOLE IN THE UPPER LEVEL REAR CENTER POST.
  • Page 100 STEP 40: UPPER LEVEL PANEL SLATS 1: 5/4 X 3 X 34-1/2" PANEL SLATS WILL BE INSTALLED ON THE LEFT, RIGHT AND REAR-RIGHT SIDES OF THE PLAY SET. THE PANEL SLATS WILL BE INSTALLED ON THE INSIDE OF THE BOTTOM PANEL BOARDS AND RAILINGS. 2: SPACE THE PANEL SLATS IN THE OPENINGS AS SHOWN BELOW.
  • Page 101 STEP 41: LOWER LEVEL FRONT CENTER POST 1: LOCATE THE 2 X 4 X 28-9/16" CENTER POST. PLACE THE 2 X 4 X 28-9/16" CENTER POST CENTERED BEHIND THE HOLE IN THE ROPE LADDER SUPPORT. 2: HAMMER A T-NUT INTO THE HOLE IN THE BACK SIDE OF THE CENTER POST. FASTEN THE CENTER POST TO THE ROPE LADDER SUPPORT WITH A 5/16"...
  • Page 102 STEP 42: UPPER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" UPPER LEVEL STEP FLUSH WITH THE TOP OF THE UPPER LEVEL DECK SPACERS. UPPER LEVEL STEPS HAVE THREE HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16"...
  • Page 103 STEP 43: LOWER LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FOUR SLATS ON THE LEFT SIDE, SIX SLATS ON THE RIGHT SIDE AND TWO SLATS ON THE FRONT OF THE LOWER LEVEL.
  • Page 104 STEP 44: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT USING 3/8" X 3-1/2" CARRIAGE BOLTS ON TOP AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. USE BOLT CAPS TO COVER ANY EXPOSED THREADS.
  • Page 105 STEP 45: 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 106 STEP 46: 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 107 STEP 47: REST SWING BEAM ON FORT 1: REST THE SWING BEAM ASSEMBLY ON TOP OF THE UPPER RAILING BOARDS OF THE FORT. 2: THE END OF THE SWING BEAM WITH 2 HOLES SHOULD OVERHANG THE SWING BEAM SIDE OF THE FORT. IN THE NEXT STEP YOU WILL ATTACH THE SWING BEAM LEGS ONTO THIS END OF THE SWING BEAM.
  • Page 108 STEP 48: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH ONE TORQUE WASHER AND THE SUB BRACKET ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: PREDRILL AN 11/64"...
  • Page 109 STEP 49: MOUNT SWING BEAM TO FORT 1: PLACE A 3/8" X 9" CARRIAGE BOLT THROUGH A TORQUE WASHER. INSERT THE CARRIAGE BOLT INTO THE HOLE AT THE END OF THE SWING BEAM OVER THE SWING BEAM MOUNT. ALIGN THE SQUARE SHANK OF THE CARRIAGE BOLT WITH THE SQUARE HOLE IN THE TORQUE WASHER.
  • Page 110 STEP 50: 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 111 STEP 51: 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. 4: CHOOSE TWO HOLES IN THE SUB BRACKET THAT DO NOT INTERFERE WITH THE OTHER LAG SCREWS IN THE SWING LEG.
  • Page 112 STEP 52: 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 113 STEP 53: UPPER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE UPPER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LAG POSTS OR REAR CORNER POSTS WITH 5/16"...
  • Page 114 STEP 54: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" 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 115 STEP 55: UPPER LEVEL ROOF 1: PLACE THE 1 X 6 X 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH FOUR #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREW 1 X 6 X 30-1/2"...
  • Page 116 STEP 56: UPPER LEVEL ROOF 1: PLACE THE TONGUE OF A 1 X 5 X 30-1/2" ROOF BOARD INTO THE SLOT OF THE ROOF FINISHER. ALIGN THE ENDS OF THE BOARDS. FASTEN THE ROOF BOARD TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREW. REPEAT THIS PROCESS FOR TEN MORE ROOF BOARDS.
  • Page 117 STEP 57: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBURST TO THE ROOF SUPPORTS ON THE FRONT AND REAR SIDE OF THE ROOF, THE PLASTIC SUNBURST MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBURST TO THE ROOFSUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS ON THE TOP AND SIX #8 X 2"...
  • Page 118 STEP 58: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 35.15" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35.15" 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 DOWN.
  • Page 119 STEP 59: ROOF SUPPORTS (LOWER LEVEL) 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE LOWER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LOWER LEVEL CORNER POSTS WITH 5/16 X 4-1/2"...
  • Page 120 STEP 60: ROOF STARTER REAR 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER BOARD AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER SHOULD BE PLACED FLUSH TO THE PEAK OF THE ROOF SUPPORTS.
  • Page 121 STEP 61: ROOF REAR SECTION 1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR. THIS SIDE OF THE ROOF GETS FOUR BOARDS.
  • Page 122 STEP 62: ROOF FRONT SECTION 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPPING THE ROOF STARTER REAR. THE HOLES IN THE ROOF STARTER FRONT SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER FRONT SHOULD BE PLACED FLUSH TO THE TOP EDGE OF THE ROOF STARTER REAR.
  • Page 123 STEP 63: DORMERS 1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE DORMERS. AFTER INSTALLING THE SEVENTH ROOF BOARD, INSTALL THE DORMER MOUNTING BLOCK 9-3/4" FROM THE SIDE EDGE OF THE ROOF TO THE SIDE EDGE OF THE DORMER MOUNTING BLOCK, AND 15" FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE TOP EDGE OF THE DORMER MOUNTING BLOCK.
  • Page 124 STEP 64: FRONT GABLE ASSEMBLY 1: FIND ONE 5 X 11 X 46.97" ROOF PANEL LEFT ASSEMBLY, ONE 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY, ONE 5/4 X 5 X 10.81 ROOF PANEL PEAK SUPPORT AND A FRONT PLASTIC ARCH. 2: PLACE THE ROOF PANEL ASSEMBLIES ON A FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP, ALIGN THE ANGLED ENDS OF THE ROOF PANEL ASSEMBLIES FLUSH AT THE PEAK AND LEAVING A GAP AT THE BOTTOM OF THE SEAM, THIS PROVIDES YOU FREEDOM FOR ADJUSTABILITY.
  • Page 125 STEP 65: ATTACHING THE FRONT GABLE 1: MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE TOP PANEL BOARD, MAKE SURE THE GABLE ASSEMBLY IS FLUSH AGAINST THE FRONT CORNER POSTS. THE GABLE ROOF PEAK SHOULD BE RESTING ON TOP OF THE ROOF FRONT SECTION.
  • Page 126 STEP 66: WALL PANEL SUPPORTS 1: PLACE THE 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE AND THE OPPOSITE END WITH THE COUNTERSUNK HOLE FLUSH AGAINST THE LEFT FRONT CORNER POST. MAKE SURE THE ANGLED END OF THE WALL PANEL SUPPORT IS FLUSH TO THE INSIDE OF THE GABLE ASSEMBLY.
  • Page 127 STEP 67: ROOF FINISHERS FRONT 1: PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE. PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT ANGLED END ON TOP OF THE GABLE ASSEMBLY RIGHT SIDE.
  • Page 128 STEP 68: ROOF BATTEN 1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE FRONT ROOF PANEL, CENTERED BETWEEN THE ROOF SUPPORTS, FLUSH THE BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD, MAKE SURE IS PARALLEL TO THE ROOF SUPPORTS.
  • Page 129 STEP 69: WALL PANEL BOARDS 1: START MOUNTING THE 1 X 4 X 19.31" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT,THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE FRONT LEFT CORNER POST.
  • Page 130 STEP 70: PLASTIC SUNBEAM 1: MOUNT THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF, THE PLASTIC SUNBEAM MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2"...
  • Page 131 STEP 71: SOLAR WALL LIGHTS 1: WITH A PENCIL MAKE A CENTER MARK ON THE OUTSIDE FACE OF THE 1 X 4 X 19.31 WALL PANEL BOARD, MEASURE 4-7/8" HORIZONTALLY FROM THE OUTSIDE EDGE OF THE CORNER POST TOWARDS THE CENTER OF THE WALL PANEL BOARD AND 2-3/8" FROM THE BOTTOM EDGE OF THE WALL PANEL SUPPORT TOWARDS THE CENTER OF THE WALL PANEL BOARD AS SHOWN IN THE DIAGRAM BELOW.
  • Page 132 STEP 72: 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 133 STEP 7 : SAFETY BOARDS 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT 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 134 STEP 74: 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 135 STEP 75: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT 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 LEFT-MIDDLE CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSDE OF THE CORNER POST WITH #8 X 3"...
  • Page 136 STEP 76: 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 137 STEP 77: 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 138: Tic Tac Toe Assembly/Installation

    STEP 78: 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 139 STEP 79: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAYSET 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 #8 X 1-3/4"...

  • Page 140: Rock Wall Rope

    STEP 80: INSTALLING THE ROCK WALL ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE ROPE LADDER SUPPORT. 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 141 STEP 81: SAFETY HANDLES (LOWER LEVEL) 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 142 STEP 82: SAFETY HANDLES (UPPER LEVEL) 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 LAG POSTS AND CENTER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.

  • Page 143: Steering Wheel

    STEP 83: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK (UPPER LEVEL). 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 144: Telescope

    STEP 84: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT ON THE ROCK WALL SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOP INTO THE SLOT OF THE TELESCOPE BRACKET.

  • Page 145: Hanging The Swings

    STEP 85: 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 146: Ground Stakes

    STEP 86: 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 147: Scoop Slide

    STEP 87: ATTACHING SUPER SCOOP SLIDE 1: PLACE THE SUPER SCOOP SLIDE IN THE OPENING AT THE LEFT SIDE OF UPPER LEVEL OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH #14 X 3" PAN HEAD SCREWS. **DO NOT OVER TIGHTEN** #14 X 3"...
  • Page 148 PART II CLATTER BRIDGE...

  • Page 149: Attaching T-Nuts To The Corner Posts

    STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 96"...
  • Page 150 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 151 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 152 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 153 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 154 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 155 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 156 STEP 8: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK SPACERS AND DECKBOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 4"...
  • Page 157 STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-1/2" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
  • Page 158 STEP 10: DECK 1: INSTALL THE 5/4 X 4 X 36-1/2" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS. 2" WOOD SCREWS 5/4 X 4 X 36-1/2" DECK BOARD FRONT OF TOWER...

  • Page 159: Rear Bottom Panel Board

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

  • Page 160: Panel Slats

    STEP 12: PANEL SLATS 1: FIND TEN 5/4 X 3 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: INSTALL THE FIRST PANEL SLAT 2-1/2" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8"...
  • Page 161 STEP 13: BRIDGE RAILS 1: PLACE THE TOP SURFACE OF THE UPPER TWO 2 X 4 X 66" BRIDGE RAILS 5-1/2" BENEATH THE TOP SURFACE OF THE TOP PANEL BOARD. THE COUNTERSUNK HOLE IN THE END OF THE BRIDGE RAIL SHOULD FACE THE INSIDE.
  • Page 162 STEP 14: BRIDGE RAILS TO PLAY SET 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER CORNER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16"...
  • Page 163 STEP 15: BRIDGE RAIL SLATS 1. PRE-DRILL TWENTY 5/4 X 3 X 16" BRIDGE RAIL SLATS 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 164 STEP 16: BRIDGE DECK AND CHAIN ASSEMBLY 1: FIND FIFTEEN 2 X 4 X 29" BRIDGE DECK BOARDS AND INSERT T-NUTS INTO THE PRE-DRILLED HOLES. USE A HAMMER TO SEAT THE T-NUTS INTO THE BOARDS. T-NUT 2 X 4 X 29" BRIDGE DECK BOARD T-NUT...
  • Page 165 STEP 17: BRIDGE DECK AND CHAIN ASSEMBLY 1: LOCATE TWO 96" CHAIN SECTIONS THAT SHIPPED WITH THE CLATTER BRIDGE. 2: PLACE THE CHAINS OVER THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW. 3: LINE UP THE 18TH LINK IN THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES. 96"...
  • Page 166 STEP 18: BRIDGE DECK AND CHAIN ASSEMBLY 1: PLACE A 5/16" WASHER BETWEEN THE 18TH CHAIN LINK AND THE BRIDGE DECK BOARD. 2: PLACE A 5/16" X 1-3/4" HEX BOLT WITH 5/16" WASHER THROUGH THE 18TH CHAIN LINK, THEN THROUGH THE 5/16"...
  • Page 167 STEP 19: BRIDGE DECK/CHAIN INSTALLATION 1: LAY THE BRIDGE DECK/CHAINS ASSEMBLY BETWEEN THE PLAY SET AND THE TOWER WITH THE CHAINS FACING THE GROUND. THREAD THE CHAIN ENDS IN THE BRIDGE DECK ASSEMBLY THROUGH THE HOLES IN THE BOTTOM PANEL BOARD AND DECK SUPPORT BOARD ON THE TOWER. 2: THERE SHOULD BE AT LEAST A 1"...
  • Page 168 STEP 20: BRIDGE DECK/CHAIN INSTALLATION 1: TWO PEOPLE MAY BE REQUIRED FOR THIS STEP. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE FRONT FACE BOARD ON THE PLAY SET. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP.
  • Page 169 STEP 1: 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 170 STEP 2 : 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"...
  • Page 171 STEP 2 : 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 172 STEP 2 : 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.
  • Page 173 STEP 2 : 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 174 STEP 2 : 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 175 STEP 2 : ATTACHING WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING OF THE CLATTER BRIDGE TOWER AS SHOWN WITH THE LIP OF THE SLIDE RESTING ON TOP OF THE DECK BOARDS. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH FOUR #14 X 1-1/4"...

  • Page 176: Leftover Parts List

    Leftover Parts List 1500KWR Play Set 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 177: Appendix

    APPENDIX...
  • Page 178 1529 HARDWARE #8 X 1-1/4" PAGE 1 OF 1 WOOD SCREW QTY: 22 1/16/2015 S.O. #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 #2 SQUARE DRIVE BIT...
  • Page 179 PICTURE DESCRIPTION QTY. DORMER SUNRAY ASSEMBLY 2-10-1355-DS DORMER ROOF PANEL ASSEMBLY 2-13-1828-DRPA DORMER SIDE RIGHT ASSEMBLY 2-17-1850-DSRA DORMER SIDE LEFT ASSEMBLY 2-17-1850-DSLA DORMER MOUNT 2-3-1150-DM CHIMNEY FRONT ASSEMBLY 2-8-1500-CFA CHIMNEY RIGHT SIDE ASSEMBLY 2-10-1500-CRS...
  • Page 180 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY 2-10-1500-CLS CHIMNEY REAR ASSEMBLY 2-8-0700-CRA CHIMNEY MOUNTING BLOCK 2-3-0675-CMB...
  • Page 181 STEP 1: DORMER SUNRAYS AND SIDES 1: FIND ONE DORMER SIDE LEFT ASSEMBLY AND ONE DORMER SIDE RIGHT ASSEMBLY. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY. ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW.
  • Page 182 STEP 2: DORMER WINDOW 1: MOUNT THE DORMER WINDOW IN THE FRONT OF THE DORMER, THE WINDOW SHOULD FIT IN BETWEEN THE DORMER SIDES AND THE DORMER SUNRAY. THE BACK FACE OF THE WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS. 2: MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DORMER WINDOW AND FASTEN WITH #8 X 1-1/2"...
  • Page 183 STEP 3: DORMER ROOF PANELS 1: FIND TWO DORMER ROOF PANEL ASSEMBLIES. 2: PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY ASSEMBLIES, THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK, MAKE SURE THE PRE-DRILLED HOLES ON THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES.
  • Page 184 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 185 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 186 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.
  • Page 187 (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 188 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.

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