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Gorilla Playsets Hemisphere 2500W Assembly Instructions Manual
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Gorilla Playsets Hemisphere 2500W Assembly Instructions Manual

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play sets
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Hemisphere
Model: 2500W
(BOXES: 2500-1, 2500-2, 2502,
& Slide Box)
Copyright © 2015 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
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Summary of Contents for Gorilla Playsets Hemisphere 2500W

  • Page 1 ™ ™ playsets playsets ™ ™ play sets play sets Hemisphere Model: 2500W (BOXES: 2500-1, 2500-2, 2502, & Slide Box) Copyright © 2015 Gorilla Playsets All Rights Reserved 190 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com...
  • Page 2 Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our “Quick Response Center”...
  • Page 3 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 - HEMISPHERE - 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 strength and durability. OPTION 1 (678) 880-3329...
  • 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: 2500W (BOXES: 2500-1, 2500-2, 2502, & Slide Box) REV C: 4.13.2015...
  • Page 10 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 16-28 Arranging Corner Posts and adding T-Nuts to Corner Posts...……..…..
  • Page 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18 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 19 BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled into place. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part. Example: a tag reads "2-4-3600-BPB" •...
  • Page 20 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 21 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 22 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 15'-5 " 9'- 16 " 3'-11 " 2'-0" 3'-11 2 " Swing Belts (2) 8'-9" Trapeze (1) 12'-8 2 " 1'-6 "...
  • Page 23 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill)
  • Page 24 #8 X 1-1/4" 11-0057 WOOD SCREW 2500 HARDWARE QTY: 4 PAGE 1 OF 2 REV A: 8/28/2013 JH #8 X 1-1/2" WOOD SCREW QTY: 10 #8 X 1-3/4" WOOD SCREW QTY: 4 #8 X 2" WOOD SCREW QTY: 212 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3"...
  • Page 25 3/8" X 2-1/2" 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG HEX LAG 11-0057 SCREW SCREW SCREW 2500 HARDWARE QTY: 8 QTY: 4 QTY: 4 PAGE 2 OF 2 REV A: 8/28/2013 JH #2 SQUARE DRIVE BIT QTY: 1 PLASTIC 3/8"...
  • Page 26 11-0058 2502 HARDWARE PAGE 1 OF 1 REV D: 12/8/2014 JH #8 X 1-1/2" WOOD SCREW QTY: 74 #8 X 1-3/4" WOOD SCREW QTY: 32 #8 X 2" WOOD SCREW QTY: 16 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3" WOOD SCREW QTY: 8 #10 X 3-1/2"...
  • Page 27 PICTURE DESCRIPTION QTY. 2500 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 47" STRINGER 2-4-4700-S 2 X 4 X 47-1/2" FORT SIDE SUPPORT 2-4-4750-FSS 2 X 4 X 47-1/2" FRONT FACE BOARD 2-4-4750-FFB 2 X 4 X 47-1/2" PANEL AND DECK SUPPORT 2-4-4750-PDS...
  • Page 28 PICTURE DESCRIPTION QTY. 2 X 4 X 57" LADDER SIDE RIGHT 2-4-5700-LSR 2 X 4 X 58" SWING BEAM CROSS MEMBER 2-4-5800-SBCM 2 X 6 X 47-1/2" END SANDBOX BOARD 2-6-4750-ESB 2 X 6 X 47-1/2" ARCH FACE BOARD 2-6-4750-AFB 2 X 6 X 50"...
  • Page 29 PICTURE DESCRIPTION QTY. 2 X 6 X 75" SIDE SANDBOX BOARD LEFT 2-6-7500-SSBL 2 X 6 X 75" SIDE SANDBOX BOARD RIGHT 2-6-7500-SSBR 2 X 6 X 95-1/2" END SANDBOX BOARD 2-6-9550-ESB 3 X 3 X 96" CORNER POST 1 3-3-9600-CP1 3 X 3 X 96"...
  • Page 30 PICTURE DESCRIPTION QTY. 3 X 3 X 96" SWING LEG 3-3-9600-SL 4 X 4 X 47-1/2" SWING BEAM MOUNT 4-4-4750-SBM 4 X 6 X 108" SWING BEAM 4-6-10800-SB 5/4 X 3 X 11-1/2" WINDOW PANEL BOARD 125-3-1150-WPB 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT 125-3-1750-TTTM...
  • Page 31 PICTURE DESCRIPTION QTY. 5/4 X 4 X 18-1/2" LADDER BACK 125-4-1850-LB 5/4 X 4 X 20" WINDOW PANEL BOARD 125-4-2000-WPB 5/4 X 4 X 47-1/2" ROCK WALL BOARD 125-4-4750-RWB 5/4 X4 X 47-1/2" DECK BOARD 125-4-4750-DB 5/4 X 4 X 47-1/2" ROCK WALL BOARD BOTTOM 125-4-4750-RWBB...
  • Page 32 PICTURE DESCRIPTION QTY. 2502 1 X 4 X 57" ROOF FINISHER 1-4-5700-RF 1 X 4 X 57" ROOF PEAK 1 1-4-5700-RP1 1 X 3 X 57" ROOF PEAK 2 1-3-5700-RP2 1 X 5 X 57" ROOF BOARD 1-5-5700-RB 2 X 4 X 23-3/4" REAR CENTER POST 2-4-2370-RCP...
  • Page 33 PICTURE DESCRIPTION QTY. 2 X 6 X 34-3/16" ROOF SUPPORT 2-6-3416-RS 5/4 X 2 X 13" SUN RAY 125-2-1300-SR 5/4 X 2 X 16" SUN RAY 125-2-1600-SR 5/4 X 6 X 8-7/16" ROOF PEAK SUPPORT 125-6-0840-RPS...
  • Page 34 PICTURE DESCRIPTION QTY. WAVE SLIDE 03-0010 10' ROPE (GREEN) SWING W/CHAINS 04-0002 TRAPEZE BAR W/CHAINS 04-0006 SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A ROCKS PACK OF 5) A-FRAME SWING LEG BRACKET 11-5010...
  • Page 35 PICTURE DESCRIPTION QTY. 2500 11-0057 HARDWARE BOXES: 2500, 2502 2502 11-0058 IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 90 GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005 FLAG KIT 09-1014...
  • Page 36 PICTURE DESCRIPTION QTY. MANUFACTURER (NOT SHOWN) LOGO PLATE GROUND STAKE (PAIR) 07-0016 TIC TAC TOE (UNASSEMBLED 07-0010 STEERING WHEEL 07-0004 WINDOW 07-0013 CROWN 07-0019...
  • Page 37 STEP 1: CORNER POST LAYOUT 1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THE RE-ASSEMBLE TO MAKE YOUR CORRECTIONS. 2: LAY OUT EACH OF THE 3 X 3 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET.
  • Page 38 STEP 2: INSERTING T-NUTS INTO CORNER POSTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IS FLUSH/ALMOST FLUSH TO THE CORNER POSTS.
  • Page 39 STEP 3: ATTACHING SANDBOX BOARD AND ROPE SUPPORT 1: THE 2 X 6 X 47-1/2" SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHT SIDE CORNER POSTS WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS OFFSET UP. 2: THE 2 X 4 X 47-1/2"...
  • Page 40 STEP 4: ATTACHING END SANDBOX BOARD 1: THE 2 X 6 X 95-1/2" END SANDBOX BOARD (WITH 6 PREDRILLED HOLES) ATTACHES TO THE BOTTOM OF THE LEFT SIDE CORNER POSTS OFFSET UP WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS.
  • Page 41 STEP 5: ATTACHING THE SIDE SANDBOX BOARDS 1: THE 2 X 6 X 75" SIDE SANDBOX BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE FRONT AND REAR CORNER POSTS WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS. 2: THE STRUCTURE SHOULD BE ABLE TO STAND ON ITS OWN WITHOUT ANY SUPPORT AT THIS STAGE.
  • Page 42 STEP 6: ATTACHING ARCH FACE BOARD AND DECK SUPPORTS 1: THE 2 X 6 X 47-1/2" ARCH FACE BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE SET OF HOLES BELOW THE TOP MOST HOLES. ATTACH THE TOP ARCH FACE BOARD HOLES USING 5/16" X 4" HEX BOLTS AND 5/16" WASHERS.
  • Page 43 STEP 7: ATTACHING PANEL SUPPORT BOARDS AT REAR 1: THE 2 X 4 X 47-1/2" PANEL SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES BELOW THE TOP MOST HOLES ON THE REAR OF THE FORT WITH 5/16" X 4" HEX BOLTS AND 5/16"...
  • Page 44 STEP 8: ATTACHING PANEL SUPPORTS AND SAFETY BOARD 1: THE 2 X 4 X 47-1/2" PANEL SUPPORTS SHOULD HAVE THE HOLES OFFSET UP. USE 5/16" X 4" HEX BOLTS AND 5/16" WASHERS TO SECURE THE BOARDS TO THE CORNER POSTS. 2: PLACE THE TOP OF THE PANEL SUPPORT (USED AS SAFETY BOARD) 24"...
  • Page 45 STEP 9: ATTACHING FORT SIDE SUPPORTS 1: LAY THE 2 X 4 X 47-1/2" FORT SIDE SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PLACE A T-NUT IN THE PRE-DRILLED HOLE ON THE END AND SECURE WITH HAMMER.
  • Page 46 STEP 10: ATTACHING THE ROCK WALL SUPPORTS 1: LAY THE 2 X 6 X 53-1/2" ROCK WALL SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTED THE WAY THEY WILL BE INSTALLED ONTO THE PLAY SET. PLACE A T-NUT INTO THE PRE- DRILLED HOLE ON THE END AND SECURE WITH A HAMMER.
  • Page 47 STEP 11: ATTACHING THE ARCH ROCK WALL SIDE SUPPORTS 1: MOUNT THE ARCH ROCK WALL SIDE SUPPORT ON TOP OF THE ROCK WALL SUPPORT, MAKE SURE THAT THE TOP END OF THE ARCH ROCK WALL SIDE SUPPORT IS FLUSH WITH THE CORNER POST. 2: FIRST FASTEN THE 3"...
  • Page 48 STEP 12: ATTACHING THE ROCK WALL CENTER SUPPORT 1: BEGIN WITH THE 5/4 X 4 X 47-1/2" ROCK WALL BOARD AND SECURE IT TO THE ARCH ROCK WALL SIDE SUPPORT WITH TWO #8 X 2" WOOD SCREWS PER SIDE. THE ROUNDED EDGE OF THE ROCK WALL BOARD SHOULD BE AGAINST THE CORNER POSTS BEFORE ATTACHING.
  • Page 49 STEP 13: ATTACHING THE ROCK WALL BOARDS 1: PLACE A 3/8" WASHER OR A QUARTER BETWEEN THE ROCK WALL BOARDS. MOUNT THE NEXT ROCK WALL BOARD TO THE ROCK WALL SUPPORTS WITH #8 X 2" WOOD SCREWS. 2: REMOVE THE WASHERS OR QUARTERS AND PLACE THEM BETWEEN THE NEXT ROCK WALL BOARD AND THE PREVIOUS ONE.
  • Page 50 STEP 14: ATTACHING THE ROCKS 1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT CONFIGURATION CAN BE USED. MAKE SURE THE SCREWS ARE AWAY FROM THE EDGE OF THE BOARDS TO AVOID SPLITTING. 2: THE ROCKS INCLUDED WITH YOUR PLAYSET MAY VARY, IN ANY CASE, THE #14 X 1-1/4" PANHEAD SCREWS AND 1/4"...
  • Page 51 STEP 15: ATTACHING THE DECK BOARDS AND DECK SPACERS 1: THE 5/4 X 3 X 41-1/4" DECK SPACER MOUNTS BETWEEN THE REAR CORNER POSTS AND BETWEEN THE FRONT CORNER POSTS FLUSH TO THE INSIDE EDGES. DRIVE THE 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORTS.
  • Page 52 STEP 16: ATTACHING THE FRONT FACE BOARD 1: THE TOP SURFACE OF THE 2 X 4 X 47-1/2" FACE BOARD WILL BE FLUSH TO THE TOP OF THE DECK SPACER. SECURE THE FACE BOARD TO THE CORNER POSTS WITH THREE 2-1/2" WOOD SCREWS PER SIDE.
  • Page 53 STEP 17: SWING BEAM PLATE 1: LAY THE SWING BEAM MOUNT ON A FLAT SURFACE WITH THE THREE COUNTER SUNK CENTER HOLES FACING THE GROUND, THE COUNTER SUNK HOLES ON THE ENDS MUST BE FACING TOWARDS YOU. 2: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP PILOT HOLES. 3: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT ON THE OUTSIDE HOLES USING 3/8"...
  • Page 54 STEP 18: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. 2: FASTEN THE IRON DUCTILE SWING HANGERS TO THE SWING BEAM USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8"...
  • Page 55 STEP 19: ATTACHING THE SWING BEAM MOUNT 1: THE 4 X 4 X 47-1/2" SWING BEAM MOUNT HAS COUNTER-SUNK HOLES IN THE CENTER AND ON THE ENDS. INSTALL THE SWING BEAM MOUNT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES AT THE CENTER FACE DOWN.
  • Page 56 STEP 20: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57" LADDER SIDE ON A FLAT SURFACE WITH THE CHANNELS FACING DOWN. PLACE THE BARREL OF A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE AND SECURE WITH A HAMMER. REPEAT THIS STEP FOR THE OTHER LADDER SIDE.
  • Page 57 STEP 21: LADDER TO FORT 1: THE LADDER ATTACHES TO THE FRONT SIDE AT THE RIGHT, FLUSH TO THE INSIDE EDGE OF THE CORNER POST. 2: THE BOTTOM EDGE OF EACH 90 GREEN BRACKET SHOULD BE 3/4" FROM THE BOTTOM OF THE 2 X 4. 3: MAKE SURE THE LADDER IS LEVEL, USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8"...
  • Page 58 STEP 22: ATTACHING SWING LEGS TO BRACKET 1: PLACE THE 3 X 3 X 96" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: USING THE SWING LEG BRACKET AS A TEMPLATE, DRILL 11/64" PILOT HOLES 2-1/2" DEEP THROUGH EACH SWING LEG BRACKET HOLE.
  • Page 59 STEP 23: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 3/8" X 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: PREDRILL AN 11/64"...
  • Page 60 STEP 24: MOUNT SWING BEAM TO FORT AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE FREE END OF THE SWING BEAM TO THE SWING BEAM MOUNT ON THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES THE LEGS. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE OVER THE SWING BEAM MOUNT.
  • Page 61 STEP 25: LEVEL SWING BEAM 1: PLACE THE LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE SWING LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
  • Page 62 STEP 26: SWING LEG CROSS MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE CROSS MEMBER, AND MARK THROUGH THE HOLES ONTO THE LEGS. 3: PREDRILL 11/64" HOLES 2" DEEP AT EACH MARK. 4: SECURE THE CROSS MEMBER TO THE SWING LEGS WITH 3/8"...
  • Page 63 STEP 27: ATTACHING ROOF SUPPORTS 1: THE 2 X 4 X 50" FRONT AND BACK ROOF SUPPORTS ATTACH TO THE CORNER POSTS WITH 5/16" X 4" HEX BOLTS AND 5/16" WASHERS. THE HOLES SHOULD BE OFFSET DOWN ON BOTH BOARDS. NOTE THE FRONT AND BACK ROOF SUPPORTS ARE IDENTICAL.
  • Page 64 STEP 28: ATTACHING CENTER POSTS 1: THE 2 X 4 X 68-3/8" AND 2 X 4 X 23-3/4" CENTER POSTS WILL ATTACH TO THE ROOF SUPPORT BOARDS WITH 5/16" X 2-1/2" HEX BOLTS, 5/16" WASHERS, AND T-NUTS. 2: THE FRONT CENTER POST WILL SECURE TO THE ROOF SUPPORT WITH 5/16" X 2-1/2" HEX BOLT, 5/16" WASHER AND T-NUT.
  • Page 65 STEP 29: ATTACHING THE DECK STRINGER 1: FIND THE 2 X 4 X 47" STRINGER WITHOUT HOLES. 2: PLACE THE STRINGER UNDEREATH THE CENTER OF THE DECK BOARDS (USE THE HOLE AT THE CENTER AS A GUIDE) MAKE SURE THE END OF THE STRINGER IS FLUSH WITH THE FRONT FACE BOARD. 3: ATTACH EACH DECK BOARD AND DECK SPACER WITH 2"...
  • Page 66 STEP 30: INSTALLING WINDOW SUPPORTS / WINDOWS IN THIS STEP THE WOOD COMPONENTS TO ATTACH THE WINDOWS WILL BE INSTALLED ON THE INSIDE OF THE FRONT OF THE PLAYSET. GO UP ON TOP OF THE FORT AND LOOK FOR THE FRONT OF THE PLAY SET. 1: ATTACH THE 5/4 X 4 X 20"...
  • Page 67 STEP 31: PANEL SLATS 1: BEGIN ON THE REAR SIDE OF THE FORT WITH THE TWO INNER SLATS BOARDS. THEY ARE GOING TO BE 17-1/2" APART AFTER THEY ARE ATTACHED. THEY ARE SPACED 15" FROM THE OUTSIDE OF THE POSTS. SPACE THE REMAINING TWO SLATS ON EACH SIDE 2-1/4"...
  • Page 68 STEP 32: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. FIND THE GREEN BRACKETS INSIDE AND THE SCREWS. 2: LOCATE THE 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNT BOARDS. 3: CENTER THE GREEN BRACKETS ON THE TIC TAC TOE BOARDS AND KEEP THE LIP OF THE GREEN BRACKET AS FLUSH TO THE SIDE OF THE BOARD AS YOU CAN.
  • Page 69 STEP 33: MOUNTING THE TIC TAC TOE PANEL 1: GO UP ONTO THE DECK AND PLACE THE TIC TAC TOE PANEL ASSEMBLY FROM THE PREVIOUS STEP ONTO THE BACK WALL. THE GREEN BRACKETS SHOULD FACE THE INSIDE OF THE FORT. THE BOTTOM OF THE LOWER TIC TAC TOE MOUNT BOARD SHOULD BE 4"...
  • Page 70 STEP 34: ROOF SUPPORTS 1: PLACE TWO 2 X 6 X 34-3/16" ROOF SUPPORTS ON A FLAT SURFACE. ALIGN THE TIPS OF THE ROOF SUPPORTS. NOW DRIVE A 2" AND A 3" WOOD SCREW INTO THE PREDRILLED HOLES TO SECURE THE ROOF SUPPORTS TOGETHER. 2: REPEAT SUBSTEP 1 TO COMPLETE A SECOND ROOF SUPPORT ASSEMBLY.
  • Page 71 STEP 35: MOUNTING THE FRONT ROOF SUPPORT ASSEMBLY 1: PLACE A ROOF SUPPORT ASSEMBLY ON TOP OF THE FRONT ROOF SUPPORT. THE ROOF SUPPORT ASSEMBLY SHOULD HAVE THE ROOF PEAK SUPPORTS FACING OUT. 2: CENTER THE ROOF SUPPORT ASSEMBLY WITH THE FRONT ROOF SUPPORT. FROM THE INSIDE DRIVE FOUR #8 X 2-1/2"...
  • Page 72 STEP 36: MOUNTING THE REAR ROOF SUPPORT ASSEMBLY 1: MAKE SURE THE REAR CENTER POST IS SQUARE TO THE REAR ROOF SUPPORT. 2: PLACE A ROOF SUPPORT ASSEMBLY ON TOP OF THE REAR ROOF SUPPORT. THE ROOF SUPPORT ASSEMBLY SHOULD HAVE THE ROOF PEAK SUPPORTS FACING OUT. 3: CENTER THE ROOF SUPPORT ASSEMBLY WITH THE REAR ROOF SUPPORT.
  • Page 73 STEP 37: SUN AND CROWN 1: PLACE THE 5/4 X 6 X 13-5/8" WOOD SUN ON TOP OF THE FRONT ROOF SUPPORT. CENTER THE SUN WITH THE FRONT CENTER POST. ATTACH THE SUN TO THE FRONT CENTER POST WITH THREE #8 X 2" WOOD SCREWS. PLACE THE PLASTIC CROWN OVER THE SUN AND SECURE IT WITH TWO #8 X 1-1/4"...
  • Page 74 STEP 38: SUN RAYS 1: ALL THE SUN RAY PIECES GET INSTALLED ONTO THE INSIDE SURFACE OF THE ROOF SUPPORTS AND SUN PIECE. 2: START FROM THE RIGHT SIDE OF THE FORT PLACING THE 13" SUN RAY AT AN APPROXIMATE 34 ANGLE FROM THE CENTER POST, SECURE WITH TWO #8 X 1-3/4"...
  • Page 75 STEP 38A: ROOF PEAK ASSEMBLY 1: PLACE THE 1 X 4 X 57" ROOF PEAK 1 PART ON TOP OF THE 1 X 3 X 57" ROOF PEAK 2 PART. THE EDGES SHOULD BE FLUSH AS SHOWN BELOW. 2: DRIVE SIX 1-1/2" SCREWS INTO THE BOARDS TO SECURE THEM TOGETHER. #8 X 1-1/2"...
  • Page 76 STEP 39: ROOF PEAK ASSEMBLY 1: BEFORE ATTACHING THE 1 X 4 X 57 ROOF PEAK, MAKE A MEASUREMENT AT THE INSIDE OF THE BOTTOM OF THE ROOF SUPPORTS AND THEN AT THE INSIDE OF THE ROOF SUPPORTS AT THE PEAK OF THE ROOF.
  • Page 77 STEP 40: ROOF BOARDS DUE TO THE CURVATURE OF THE ROOF SUPPORTS IT IS NECESSARY TO INSTALL THE ROOF BOARDS IN A CERTAIN WAY. 1) FIRST PLACE THE TONGUE OF THE FIRST ROOF BOARD INTO THE GROOVE OF THE ROOF PEAK.
  • Page 78 STEP 41: ROOF FINISHERS 1: INSTALL THE TONGUE OF THE 1 X 4 X 57" ROOF FINISHER INTO THE GROOVE OF THE LAST ROOF BOARD. 2: LOOK AT EACH HOLE IN THE ROOF FINISHER. IF IT LOOKS LIKE A SCREW IN THAT HOLE WILL BARELY CATCH THE END OF THE ROOF SUPPORT THEN INSTALL THE SCREW ABOVE THE HOLE IN THE BOARD.
  • Page 79 STEP 42: SANDBOX SEATS 1: PLACE THE SANDBOX SEATS ON TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH EACH 5/4 X 6 X 22" SANDBOX SEAT TO THE TOP OF THE SANDBOX BOARD WITH FOUR #8 X 2" WOOD SCREWS. #8 X 2"...
  • Page 80 STEP 43: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE END OF THE SWING BEAM. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN.
  • Page 81 STEP 44: INSTALLING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH #8 X 1-1/4" WOOD SCREWS. **DO NOT OVER TIGHTEN** #8 X 1-1/4"...
  • Page 82 STEP 45: CLIMBING ROPE 1: THREAD ONE END OF THE 10" ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE SECURE KNOT ON THE INSIDE OF THE TOP PANEL BOARD. ADD KNOTS IN ROPE TO AID IN CLIMBING. SET KNOTS ACCORDING TO YOUR CHILD'S NEEDS.
  • Page 83 STEP 46: FLAG KITS 1: INSTALL THE FLAG KITS IN THE DESIRED LOCATION ON YOUR PLAY SET. THE RECOMMENDED LOCATION IS ON THE CORNER POSTS AT THE FRONT OF THE FORT. ATTACH THE FLAG KITS WITH THE HARDWARE PROVIDED. FLAG DETAIL A FLAG FLAG...
  • Page 84 STEP 47: HANGING SWINGS 1: LOCATE TWO SWING BELTS WITH CHAINS ATTACHED AND ONE TRAPEZE BAR WITH CHAINS ATTACHED. 2: SNAP A SPRING CLIP THROUGH THE SWING HANGER LOOP ON THE SWING BEAM. 3: SNAP A CHAIN ONTO EACH SPRING CLIP. ADJUST EACH SWING UP OR DOWN BY CLIPPING ONTO HIGHER OR LOWER CHAIN LINKS.
  • Page 85 STEP 48: NAME PLATE 1: ATTACH THE NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO #8 X 1-1/2" WOOD SCREWS. ATTACH NAME PLATE HERE WITH TWO #8 X 1-1/2" WOOD SCREWS...
  • Page 86 STEP 49: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: HAMMER EACH GROUND STAKE IN AT AN ANGLE SIMILAR TO WHAT IS SHOWN. USE CAUTION WHEN HAMMERING SO THAT YOU DO NOT MAR THE WOOD. LEAVE THE TOP PORTION OF THE GROUND STAKE ABOVE THE GROUND FAR ENOUGH SO THAT YOU CAN STILL GET THE SCREW INTO THE HOLE AT THE TOP OF THE STAKE.
  • Page 87 STEP 50: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. PLACE A SAFETY HANDLE ON THE CORNER POST AND FRONT CENTER POST. ADJUST THE HEIGHT TO SUIT THE NEEDS OF YOUR CHILD. 2: USE THE HARDWARE INCLUDED WITH THE SAFETY HANDLES TO ATTACH EACH HANDLE TO THE CORNER POST OR FRONT CENTER POST.
  • Page 88 STEP 51: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE ROCK WALL ROPE SUPPORT. 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"...