Gorilla Playsets Chateau Treehouse with Fort Add On 1500AWF Assembly Instructions Manual
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Gorilla Playsets Chateau Treehouse with Fort Add On 1500AWF Assembly Instructions Manual

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Chateau Treehouse with Fort Add On
Timber Shield Post Option
BOXES: W-1, 120
*51-0064-W*
51-0064-W
™
™
play sets
play sets
Model: 1500AWF
(BOXES: 1501, 1503N,
1507, 1525, 1530, 1531 & 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: 1520-2bx, 1522

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Summary of Contents for Gorilla Playsets Chateau Treehouse with Fort Add On 1500AWF

  • Page 1 Amber Post Option Timber Shield Post Option BOXES: 1520-2bx, 1522 BOXES: W-1, 120 (BOXES: 1501, 1503N, 1507, 1525, 1530, 1531 & Slide Box) Copyright © 2016 Gorilla Playsets All Rights Reserved *51-0064-W* 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com 51-0064-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 - Chateau treehouse With Fort aDD on - 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 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 The main manual that follows this page outlines how to construct the playset without the options shown below. You must read the 1525 Treehouse kit instructions in the appendix and the 1531 Fort Add On kit instructions packet BEFORE you construct the playset. The 1525 and 1531 instructions will tell you how to deviate from the main manual.
  • Page 12 Model 1500AW shown. See cover of manual for the image of your model when it is completed. Models: 1500AW Amber Post Option Timber Shield Post Option BOXES: 1520-2bx, 1522, BOXES: W-1, 120 1500AWF 1500AWC 1500AWCF (BOXES: 1501, 1503N, 1507, 1530, 1518*, 1525* &...
  • Page 13 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 3-6 Leveling Fort, General Information and Definitions…………………....Pages 6-8 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 9-13 Site Plan, Required Tool List and Kit Contents..........Pages 14-15 Hardware, Lumber and Accessory Checklists.………………………………..Pages 16-32 Adding T-Nuts to Corner Posts...…………………………………..………...…...
  • Page 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. 1500 SERIES CHATEAU SITE PLAN: HEIGHT - 11' - 1 " 19'- 8 " 2'-8 16 " 10'-1 " 5'-10" 3'-1 " Swing Belts (2) 3'-11 2 "...
  • Page 26 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” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill)
  • Page 27 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 28 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 3-1/2" 3/8 x 9" 3/8 x 6-1/2"...
  • Page 29 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 30 1507 HARDWARE PAGE: 1 OF 1 REV A: 9/10/2014 JH #8 X 2" WOOD SCREW QTY: 20 5/16" TEE NUT QTY: 12 5/16" WASHER QTY: 25 5/16 X 4-1/2" 5/16" X 3-1/2" HEX BOLT LAG SCREW QTY: 12 QTY: 14 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 31 PICTURE DESCRIPTION QTY. COUNT AND ORGANIZE YOUR LUMBER INTO LIKE STACKS (2 X 4, 2 X 6, 4 X 4, 4 X 6, ETC.). THIS WILL HELP IN IDENTIFYING 2 X 4 X 13" COMPONENTS AND REDUCE YOUR BUILDING TIME ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 18"...
  • Page 32 PICTURE DESCRIPTION QTY. 2 X 4 X 32-1/2" PICNIC TABLE 2-4-3250-PTL 2 X 4 X 47 " END PANEL/ SAFETY BOARD (2 HOLES OFFSET) 2-4-4750-SBEP 2 X 4 X 51-1/8" ROOF SUPPORT LEFT (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 33 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 AND SANDBOX BOARD (4 HOLES OFFSET) 2-6-4750-ESPB...
  • Page 34 PICTURE DESCRIPTION QTY. 2 X 6 X 79-1/2" ROPE LADDER RUNNER(4 HOLES OFFSET, 3 HOLES ON CENTER) 2-6-7950-RLR 4 X 4 X 47 " SWING BEAM MOUNT 4-4-4750-SBM X 13 " PICNIC TABLE SLAT 125-3-1325-PTS X 17 " TIC TAC TOE MOUNT 125-3-1750-TTTM X 28...
  • Page 35 PICTURE DESCRIPTION QTY. X 3 X 23 " ROCK WALL CAP 125-3-2387-RWC X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 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 36 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-AND- GROOVE ROOF BOARD 1-5-4750-RB NOTE: ANYTHING ON THIS PAGE REFERRED TO AS "PLASTIC COATED"...
  • Page 37 PICTURE DESCRIPTION QTY. WIKI WAVE SLIDE ROPE LADDER ROPES (13' ROPE) SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
  • Page 38 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, 1507 INSTRUCTIONS...
  • Page 39 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 ROCK WALL (10' ROPE)
  • Page 40 PICTURE DESCRIPTION QTY. 90 GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...
  • Page 41 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY (1530 BOX) UNASSEMBLED DORMER (1530 BOX) FLAG KIT 09-1014...
  • Page 42 PICTURE DESCRIPTION QTY. PLASTIC SUNBURST 07-0028-G MANUFACTURER (NOT SHOWN) LOGO PLATE GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004 PLASTIC DORMER SUNBURST 07-0031...
  • Page 43 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 44 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 79-1/2" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 45 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 46 STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT 5/16"...
  • Page 47 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 48 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD AT THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 49 STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS.
  • Page 50 STEP 6B: ANGLE SUPPORTS 1: FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 51 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. 5/16"...
  • Page 52 STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 53 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 54 STEP 10: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 5/4 X 6 X 47-3/8"...
  • Page 55 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 56 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 57 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 58 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 59 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE FRONT FACE BOARD. THE BOTTOM OF THE GREEN BRACKETS SHOULD BE APPROXIMATELY 3/4"...
  • Page 60 STEP 16: LADDER 2 X 4 X 66" 1: FIND TWO 2 X 4 X 66" LADDER SIDES. LADDER SIDE 2: POSITION THE LADDER SIDES SO THAT THE T-NUT SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
  • Page 61 STEP 17: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE RIGHT SIDE OF THE FORT AS SHOWN BELOW. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE BOTTOM PANEL BOARD.
  • Page 62 STEP 18: CENTER POST FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF EACH 2 X 4 X 28-9/16" CENTER POST FRONT/REAR. 2: PLACE THE CENTER POSTS INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET. LINE UP THE HOLES IN THE CENTER POSTS WITH THE HOLES IN THE RAILINGS. 3: FASTEN THE CENTER POSTS TO THE RAILINGS WITH 5/16"...
  • Page 63 STEP 19: PANEL SLATS 1: FIND TWENTY-TWO 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2"...
  • Page 64 STEP 20: 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 65 STEP 20A: 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 66 STEP 21: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8"...
  • Page 67 STEP 22: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7"...
  • Page 68 STEP 23: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 108" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8" WASHERS. SWING LEGS FLUSH TO TOP OF SWING LEG BRACKET...
  • Page 69 STEP 24: REST SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: REST THE SWING BEAM ON TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM.
  • Page 70 STEP 25: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2"...
  • Page 71 STEP 26: MOUNT SWING BEAM ON FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
  • Page 72 STEP 27: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE).
  • Page 73 STEP 28: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS. 3/8 X 3-1/2"...
  • Page 74 STEP 29: 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 75 STEP 30: 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 76 STEP 31: 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 77 STEP 32: 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 78 STEP 33: 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 79 STEP 34: 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 80 STEP 35: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSDE OF THE CORNER POST WITH #8 X 3"...
  • Page 81 STEP 36: 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 82 STEP 37: 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 83 STEP 38: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT-LEFT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH 1-1/4"...
  • Page 84 STEP 39: MOUNTING THE TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE FRONT TOP PANEL BOARD ON THE SLIDE SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH THE 1-1/4"...
  • Page 85 STEP 40: INSTALLING CLIMBING ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE TOP PANEL BOARD. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
  • Page 86 STEP 41: 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 87 STEP 42: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE LEFT SIDE OF THE PLAY SET ON THE INSIDE. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS. SWING BEAM TIC TAC TOE WITH BOARDS...
  • Page 88 STEP 43: 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 89 STEP 44: FLAG KIT 1: PLACE A FLAG ON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED. FLAG 1/2" PHILLIPS HEAD SCREW...
  • Page 90 STEP 45: 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 91 STEP 46: 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 92 STEP 47: 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 93 STEP 48: 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 94 APPENDIX...
  • Page 95 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 96 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
  • Page 97 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
  • Page 98 PICTURE DESCRIPTION QTY. PLASTIC DORMER SUNBURST (07-0031) DORMER RIGHT SIDE ASSEMBLY...
  • Page 99 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 100 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 101 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 102 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 103 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 104 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 105 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 106 ***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 107: 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 108 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 109 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 110: 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 111: 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 112 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 113 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 114 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 115 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 116 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 117: 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 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124: 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 125: 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 126: 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 127 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 128 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”...
  • Page 129 1531 Fort Add On **!!IMPORTANT-PLEASE READ!!** This “Add-On” kit will require you to deviate from the main instruction manual. Please follow the outline below so that you will know what steps to be aware of in the main manual. Get a yellow highlighter and use it to highlight the items below in your main assembly manual.
  • Page 130 FORT ADD ON KIT Note: Plastic Sunburst shown comes with your playset. This item is not included with the 1531 kit. Model: 1531 (BOXES: 1531 wood box, 1531, Hardware box & 2 Windows REV: 3.1.2016...
  • Page 131 REAR OF Plastic Sunburst FORT (included with playset NOT with 1531 kit) Some playsets have a Tire Swing Beam attached here. For those playsets the panel slat steps in this manual outline how to arrange the panel slats around where the Tire Swing Beam is attached.
  • Page 132 TABLE OF CONTENTS General Information………………………………………..……......Page 5 Definitions, Board Identification and Lag Screw Directions........Pages 6-8 Kit Contents and Tool List…………..………………………………………....Page 9 Hardware, Lumber and Accessory Checklists..……………………………..Pages 10-15 Assembling the Roof Panels………………………………..………...…..... Step 1 Roof Peak Support…………………..…………………………..……......Step 2 Rear Panel Support………………………..……………….…………...…....Step 2A Mounting Roof Sections to Playset……………………...…..……..……...….……..
  • Page 133 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 134 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 136 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 137 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 138 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 139 1531 - Rear Treehouse HARDWARE rev A PAGE 1 OF 1 7/16/2015 S.O. #8 X 2" WOOD SCREW QTY: 48 5/16" WASHER QTY: 2 5/16" X 4-1/2" HEX BOLT QTY: 2 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 140 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 141 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 142 PICTURE DESCRIPTION QTY. 2 X 6 X 70.00" REAR PANEL SUPPORT 2-6-7000-RPS 1 X 6 X 28-1/4" PANEL SLAT 1-6-2825-PS 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...
  • Page 143 PICTURE DESCRIPTION QTY. WINDOW PANEL 07-0029-G THIS PIECE IS INCLUDED WITH PLAYSET PARTS NOT THIS ADD ON KIT. PLASTIC SUNBURST 07-0028-G HARDWARE BOXES: 1525, 1531 HARDWARE BOXES...

  • Page 144: 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 145: 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 146: Rear Panel Support

    STEP 2A: REAR PANEL SUPPORT 1: PLACE THE 2 X 6 X 70" REAR PANEL SUPPORT ON THE REAR OF THE CORNER POSTS. THE CENTER HOLE IN THE REAR PANEL SUPPORT MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE HOLES OF THE REAR PANEL SUPPORT TO THE T-NUTS INSTALLED ON THE CORNER POSTS.

  • Page 147: Mounting Roof Sections To Playset

    STEP 3: MOUNTING ROOF SECTIONS TO PLAYSET 1: MOUNT THE ROOF SECTION ASSEMBLY TO THE REAR 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. 2: SECURE THE ROOF SECTION TO THE CORNER POSTS USING TWO 5/16 X 3-1/2"...

  • Page 148: 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. PLAYSET ROOF SUPPORT #8 X 1-1/4" WOOD SCREW 1 X 5 X 6.88"...

  • Page 149: 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. ROOF SUPPORT 2 X 3 X 35.70"...

  • Page 150: 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 151: Wall Panel Boards

    STEP 7: WALL PANEL BOARDS 1: MOUNT THE 1 X 4 X 20.25" WALL PANEL BOARD ABOVE THE PLAYSET 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 152: Rear Plastic Windows

    STEP 8: REAR PLASTIC WINDOWS 1: PLACE EACH PLASTIC WINDOW INTO THE REAR OPENINGS, WITH THE ARCHED SECTION OF THE WINDOW FRAME AT THE TOP. 2: ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS. SUN SUPPORT #8 X 1-1/4" WOOD SCREW 1 X 3 X 11.50"...

  • Page 153: 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 TO THE PREVIOUS WALL PANEL BOARD LEAVING A 1/4"...

  • Page 154: Panel Slats

    STEP 10: PANEL SLATS 5/4 X 2-5/8 X 28-1/4" PANEL SLAT 1: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 5/4 X 6 X 28-1/4" PANEL SLAT 2: ATTACH THE PANEL SLATS TO THE FORT WITH 2"...
  • Page 155 STEP 10A: PANEL SLATS **ATTENTION: USE THIS STEP ONLY IF YOUR LADDER IS INSTALLED ON THE REAR OF THE PLAYSET** 5/4 X 2-5/8 X 28-1/4" PANEL SLAT 1: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. 5/4 X 6 X 28-1/4" SEE DETAIL BELOW FOR MEASUREMENTS.

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