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Gorilla Playsets Blue Ridge Frontier 2009 Assembly Manual

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Frontier 2009
Blue Ridge
ASSEMBLY MANUAL
Copyright © 2008 Gorilla Playsets
All Rights Reserved
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA 30114
(800) 882-0272
12/MAR/2009 – Version 1.2.0

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Summary of Contents for Gorilla Playsets Blue Ridge Frontier 2009

  • Page 1 Frontier 2009 Blue Ridge ASSEMBLY MANUAL Copyright © 2008 Gorilla Playsets All Rights Reserved Gorilla Playsets 190 Etowah Industrial Court Canton, GA 30114 (800) 882-0272 12/MAR/2009 – Version 1.2.0...
  • Page 2 STOP…PLEASE READ!! IF YOU HAVE MISSING OR DAMAGED PARTS OR NEED ASSISTANCE ASSEMBLING, PLEASE CALL gorilla playsets MANUFACTURING DIRECT. (800) 882-0272 FACTORY HOURS – MON.–FRI., 8AM-5PM EST DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECT. THE RETAILER DOES NOT STOCK COMPONENTS.
  • Page 3 Blue Ridge Frontier TABLE OF CONTENTS Warranty and Safety Guidelines………………………….……………………….…..4-10 Kit Contents and Tool List…………..……………………….……………………….11-30 Framing the play set...………………………………………...……………..…...steps 1-7 Constructing deck and upper panel boards………………..……………..…..steps 8-10 Constructing rock - wall and securing to fort…………………………..…..steps 11-15 Constructing and attaching climbing ramp..….……..………….…………...steps 16-19 Installing panel slats...……………………………..………..…………...…………step 20 Assembling Swing……………………………..………..…..………..…..steps 21-38 Assembling roof…………………………………..………..…..………..…...steps 29-33...
  • Page 4 Yet you’ll appreciate how quick and easy construction really is! Our playset kits are designed for children ages 3 to 11. gorilla playsets® believes every child should have a playset and with our kits they can! You can rest assured your new playset is safe, durable and designed to hold up to the elements.
  • Page 5 This decision is subject to verification of the defect upon delivery of the defective part to gorilla playsets®...
  • Page 6 • ROCK WALL: 150 LBS. • ALL SLIDES: 125 LBS. Gorilla Playsets recommends that the weight limits for all components must not be exceeded. Failure to adhere to these and other safety guidelines could result in damage to the playset and injury to the users.
  • Page 7 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 8 Ropes, cables and chains should be removed and replaced if excessive wear is found. Contact Gorilla Playsets for warranted replacement parts.
  • Page 9 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) Handbook for Public Playground Safety offers from its . 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 10 LEVELING YOUR FORT DURING ASSEMBLY • Complete the steps which will be the basic frame of the fort {i.e. four corner posts with base (sand box boards) and deck supports} • Position in the most level area chosen for the playset, keeping in mind the location and size of the swing beam, ladder, slides, etc.
  • Page 11 Blue Ridge Frontier KIT CONTENTS COMPONENTS Description Check List (Swings, Slides, Accessories) Swingbelts w/ Chains __________ Telescope __________ Rope Ladder __________ 10ft. Wave Slide __________ The Frontier Assembly Manual __________ Rockwall Grips (assorted colors) __________ Trapeze Swing __________ Tire Swing __________ Tic-Tac-Toe Panel __________...
  • Page 12 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 19’ TIRE SWING ROCK WALL SWING BELTS (2) 20’ TRAPEZE ARM (1) ROPE LADDER CLIMBING RAMP WAVE SLIDE Playset height: 11’ 2” Approximate assembly time: 12-16 Hours { 6 foot unobstructed safety perimeter around playset recommended }...
  • Page 13 Helpful Installation Hints • Depending on your experience, assembly of Gorilla playsets can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly.
  • Page 14 General Info To Review Before Installation This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your playset. 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.
  • Page 15 Common installation practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.
  • Page 16 #8 X 1-1/4" WOOD SCREW QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 140 #8 X 2" WOOD SCREW QTY: 196 #8 X 2-1/2" WOOD SCREW QTY: 121 #14 X 1-1/4" PAN HEAD SCREW QTY: 28 5/16" TEE NUT 3/8" LOCK NUT QTY: 40 QTY: 23 1/2"...
  • Page 17 5/16 X 3-1/2" 3/8 X 3-1/2" HEX LAG SCREW HEX LAG SCREW QTY: 22 QTY: 23 #8 SQUARE DRILL BIT QTY: 1 GREEN PLASTIC 3/8 x 3-1/2" 5/16 X 4" 3/8 x 9" 3/8 x 7" BOLT CAP CARIAGE BOLT CARIAGE BOLT CARIAGE BOLT EYEBOLT LAG...
  • Page 18 PICTURE DESCRIPTION QTY. 2 X 4 X 14" BOTTOM PANEL BOARD 2 X 4 X 15" PICNIC TABLE SUPPORT 2 X 4 X 23" PICNIC TABLE BENCH SUPPORT 2 X 4 X 30" PICNIC TABLE VERT. SUPPORT 2 X 4 X 47 "...
  • Page 19 PICTURE DESCRIPTION QTY. 2 X 4 X 58" SWING BEAM CROSS MEMBER 2 X 4 X 66" ROCK WALL SIDE 2 X 4 X 70" CENTER DECK SUPPORT 2 X 4 X 70" DECK SUPPORT 2 X 4 X 70" REAR TOP PANEL BOARD 2 X 4 X 100"...
  • Page 20 PICTURE DESCRIPTION QTY. 2 X 6 X 47 " END PANEL/ SANDBOX BOARD 2 X 6 X 70" FRONT FACE BOARD 2 X 6 X 70" BOTTOM PANEL/ SANDBOX BOARD 2 X 6 X 100" ROPE LADDER RUNNER 4 X 4 X 47 "...
  • Page 21 PICTURE DESCRIPTION QTY. X 3 X 28 " PANEL SLAT X 3 X 42" SUN SUPPORT X 4 X 40 " DECK SPACER X 3 X 23 " ROCK WALL X 6 X 23 " BOTTOM ROCK WALL BOARD X 6 X 23 "...
  • Page 22 PICTURE DESCRIPTION QTY. X 10" ROOF PEAK SUPPORT X 6 X 51" PICNIC TABLE SEAT AND TOP 1 X 4 X 47 " TONGUE ONLY ROOF FINISHER 1 X 4 X 47 " GROOVE ONLY ROOF STARTER 1 X 6 X 47 "...
  • Page 23 PICTURE DESCRIPTION QTY. 2 X 4 X 18 " RAMP SUPPORT 2 X 4 X 94" RAMP MIDDLE FLOOR BOARD 2 X 4 X 96" RAMP SIDE 2 X 6 X 94" RAMP FLOOR BOARD 4 X 4 X 72" TIRE SWING 4 X 6 X 108"...
  • Page 24 PICTURE DESCRIPTION QTY. 4 X 4 X 96" PLASTIC COATED CORNER POST 4 X 4 X 96" PLASTIC COATED SWING LEG 4 X 6 X 120" PLASTIC COATED SWING BEAM 2 X 4 X 17" LADDER STEP 5/4 X 3 X 18-1/2" LADDER BACK 2 X 4 X 66"...
  • Page 25 PICTURE DESCRIPTION QTY. RADICAL WAVE SLIDE ROPE LADDER ASSEMBLY SWINGS W/CHAINS TRAPEZE W/CHAINS...
  • Page 26 PICTURE DESCRIPTION QTY. SWING PLATE CLIMBING ROCKS A-FRAME SWING BRACKET HARDWARE NOT SHOWN INSTRUCTION...
  • Page 27 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS TELESCOPE 10' ROPE...
  • Page 28 PICTURE DESCRIPTION QTY. " X 1 " GREEN BRACKET SPRING CLAMP TIRE SWING SWIVEL...
  • Page 29 PICTURE DESCRIPTION QTY. TIRE SWING WITH CHAINS TIC-TAC-TOE ASSEMBLY SAFETY HANDLES (PAIR)
  • Page 30 PICTURE DESCRIPTION QTY. UNASSEMBLED DORMER UNASSEMBLED CHIMNEY...
  • Page 31 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 32 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE DOWNWARD. 2: USE 5/16 X 4-1/2"...
  • Page 33 STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: 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. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE DOWNWARD. 2: USE 5/16 X 4-1/2"...
  • Page 34 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 35 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 100" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE OFFSET HOLES IN THE ROPE LADDER RUNNER SHOULD FACE 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 36 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE 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 37 STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" 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. 2: PLACE THE 2 X 4 X 14"...
  • Page 38 STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/8" IS THE CENTER OF THE BOARD AND ONLY NEEDS TO BE DRILLED ONCE.
  • Page 39 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 40 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. THE HOLE AT 23-11/16" IS THE CENTER OF THE BOARD AND ONLY NEEDS TO BE DRILLED ONCE.
  • Page 41 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 42 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 43 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 44 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND TWENTY 1-1/4" PAN HEAD SCREWS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. TWO PAN HEAD SCREWS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW.
  • Page 45 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 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 46 STEP 16: CLIMBING RAMP 1: PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE END OF THE 2 X 4 X 96" RAMP SIDE BOARDS. OFFSET THE BOARD 1" FROM THE EDGE. FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
  • Page 47 STEP 17: CLIMBING RAMP 1: PLACE ONE 2 X 6 X 94" FLOOR BOARD AGAINST EACH OF THE RAMP SIDE BOARDS. FASTEN THE FLOOR BOARDS TO THE RAMP SUPPORT BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SUPPORT. 2: PLACE THE 2 X 4 X 94" FLOOR BOARD ON THE CENTER OF THE RAMP. THE HOLE AT 7" SHOULD BE TOWARDS THE ANGLED END OF THE RAMP.
  • Page 48 STEP 18: CLIMBING RAMP 1: ATTACH THE 1-5/8 X 2 X 16" FLOOR SUPPORT BOARDS TO THE FLOOR BOARDS WITH 2-1/2" WOOD SCREWS. (SEE DETAIL VIEW BELOW) 2: PLACE T-NUTS ON THE INSIDE OF THE HOLES IN THE RAMP SIDE BOARDS. SET THE T-NUTS WITH A HAMMER FLUSH/NEAR FLUSH WITH THE RAMP SIDES.
  • Page 49 STEP 19: CLIMBING RAMP TO FORT 1: PLACE THE RAMP INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE RAMP BRACKETS AS A TEMPLATE DRILL A 3/8” HOLE THROUGH THE FRONT FACE BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE FRONT FACE BOARD.
  • Page 50 STEP 20: PANEL SLATS 1: FIND TWENTY-SEVEN 5/4 X 3 X 28" 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 51 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 WITH 1/2" WASHERS ON TOP, AND 3/8"...
  • Page 52 STEP 22: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 53 STEP 23: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 96" 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 54 STEP 24: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE FORT AND POSITION THE LEGS UNDERNEATH THE END OF THE BEAM. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND SWING LEGS.
  • Page 55 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 56 STEP 26: MOUNT SWING BEAM ON FORT IN THIS STEP YOU WILL BE MOUNTING THE SWING BEAM TO THE FORT. YOU WILL NEED YOUR 9/16" SOCKET WRENCH OR IMPACT WRENCH AND PLIERS. AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: RAISE THE FREE END OF THE SWING BEAM TO FIT ON TOP OF THE SWING BEAM PLATE.
  • Page 57 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 58 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 59 STEP 29: ROOF SUPPORTS 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 51" ROOF SUPPORTS TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE. USE A 2"...
  • Page 60 STEP 30: SUNBURST 1: PRE-DRILL HOLES IN THE 5/4 X 10" ROOF PEAK SUPPORT TO THE PATTERN SHOWN BELOW. 5/4 X 10" ROOF PEAK SUPPORT 2: PLACE THE 5/4 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 1-1/2"...
  • Page 61 STEP 31: ROOF 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 CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 62 STEP 32: ROOF 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STATER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH 1-1/2" WOOD SCREWS. 47-1/2" ROOF PEAK...
  • Page 63 STEP 33: ROOF 1: PLACE THE 1 X 6 X 47-1/2" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 64 STEP 34: SUNBURST 1: PRE-DRILL HOLES IN THE 2 X 6 X 16" SUN TO THE PATTERN SHOWN BELOW. 2 X 6 X 16" 4" 4" 2: PLACE THE 2 X 6 X 16" SUN CENTERED AGAINST THE 5/4 X 2-5/8 X 42" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2"...
  • Page 65 STEP 35: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP AGAINST THE ANGLED ROOF SUPPORTS, WITH THE ENDS OF THE SUN SUPPORT FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. MAKE SURE THAT THE BOARD IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP.
  • Page 66 STEP 36: SUNBURST 1: CENTER THE 5/4 X 2 X 16" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS AND FASTEN WITH TWO 1-1/2" SCREWS. 2: EQUALLY SPACE THE SMALL RAYS ABOUT THE HALF SUN (THREE ON EACH SIDE OF LARGE RAY) AND MARK THE POSITION OF THE SMALL SUNRAYS WITH A PENCIL.
  • Page 67 STEP 37: 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 68 STEP 38: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH HOLES ON CENTER TO THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 69 STEP 39: PICNIC TABLE 1: PLACE THE 2 X 4 X 15" PICNIC TABLE SUPPORT ON TOP OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORT AND POSITION THE BOARDS AT A RIGHT ANGLE. 2: ENSURE THAT THE PICNIC TABLE SUPPORT AND THE PICNIC TABLE VERTICAL SUPPORT ARE SQARE AND FASTEN THE PICNIC TABLE SUPPORT TO THE VERTICAL SUPPORT WITH THREE 2 1/2"...
  • Page 70 STEP 40: PICNIC TABLE 1: MEASURE 18” FROM THE GROUND UP AND MARK THIS POINT ON THE CORNERPOST. 2: ATTACH THE SEAT SUPPORT TO THE OUTSIDE OF THE CORNER POST SO THAT THE TOP IS AT 18” FROM THE GROUND. ATTACH IT WITH THREE 2-1/2” WOOD SCREWS IN EACH END, THEN LEVEL SEAT SUPPORT AND ATTACH IT TO THE VERTICAL SUPPORT ON EACH SIDE.
  • Page 71 STEP 41: PICNIC TABLE 1: ATTACH THE PICNIC TABLE SEAT ON THE SEAT SUPPORTS WITH TWO 2” WOOD SCREWS IN EACH END. 2: ATTACH THE PICNIC TABLE TOPS TO THE TABLE SUPPORTS WITH TWO 2” WOOD SCREWS IN EACH END. 2"...
  • Page 72 STEP 42: TIRE SWING 1: PLACE THE 4 X 4 X 72" TIRE SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. 2: FASTEN THE TIRE SWING LEGS TO THE SWING LEG BRACKET WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS.
  • Page 73 STEP 43: TIRE SWING 1: LINE UP THE HOLES OF THE TIRE SWIVEL WITH THE HOLES IN THE TIRE SWING BEAM. 2: FASTEN THE TIRE SWIVEL TO THE TIRE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 74 STEP 44: TIRE SWING 1: FASTEN THE TIRE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE TIRE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3-1/2" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET. 3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.
  • Page 75 STEP 45: TIRE SWING AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: SIT THE SWING BEAM LEGS UPRIGHT. 2: TAKE THE ASSEMBLED TIRE SWING AND LEGS AND INSERT THE SWING BEAM INTO THE GAP BETWEEN THE BACK LEFT CORNER POST AND THE PANEL SLAT. PLACE A SMALL LEVEL ON TOP OF THE BEAM IN ORDER TO LEVEL CORRECTLY..
  • Page 76 STEP 46: TIRE SWING IN THIS STEP YOU WILL BE MOUNTING THE TIRE SWING BEAM TO THE FORT. AN EXTRA PERSON IS NEEDED FOR THIS STEP 1: INSTALL T-NUTS IN THE PREVIOUSLY DRILLED HOLES. 2: LINE UP THE PILOT HOLES AT THE END OF THE TIRE SWING BEAM WITH THE PREVIOUSLY DRILLED HOLES IN THE CORNER POST.
  • Page 77 STEP 47: LEVEL TIRE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE TIRE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE TIRE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN...
  • Page 78 STEP 48: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 47-1/2" TIRE 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 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS. 3/8 X 3-1/2"...
  • Page 79 STEP 49: HANGING THE TIRE SWING 1: START BY ATTACHING THE SPRING CLIP TO THE TIRE SWIVEL ON THE SWING BEAM. 2: ATTACH ONE CHAIN AT A TIME TO THE SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED SRING CLIP TIRE SWING CHAIN...
  • Page 80 STEP 50: ROPE LADDER ASSEMBLY 1: DRILL THREE 1/8" PILOT HOLES 1-1/2" DEEP INTO THE BOTTOM OF THE ROPE LADDER SUPPORT (SEE DIMENSIONS BELOW). 2: PLACE THE EYEBOLT LAGS INTO THE HOLES AT THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIGHTEN. 5-1/2"...
  • Page 81 STEP 51: ROPE LADDER ASSEMBLY 1: PLACE THE HOOKS ON THE END OF THE ROPE LADDER ASSEMBLY THROUGH THE EYE OF THE EYBOLT LAG. 2: THREAD THE BOTTOM OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE A SECURE KNOT.
  • Page 82 STEP 52: MOUNTING THE SLIDE 1: POSITION THE SLIDE SO THAT IT RESTS FLUSH ON THE DECK BOARDS IN THE FRONT OPENING. 2: FASTEN TO THE FORT WITH 1-1/4" WOOD SCREWS...
  • Page 83 STEP 53: 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, BETWEEN THE TWO PANEL SLATS. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4"...
  • Page 84 STEP 54: TIC TAC TOE 1: LOCATE THE GREEN DOWELS AND MATCH THEM AS FOLLOWS: ONE THREADED STUD END, AND ONE THREADED INSERT. 2: SCREW THE STUDS INTO THE INSERTS UNTIL TIGHT. 3: REPEAT STEPS 1 AND 2 WITH THE REMAINING TWO SETS 4: LOCATE ONE OF THE GREEN BRACKETS AND PLACE THE DOWELS IN AS SHOWN.
  • Page 85 STEP 55: TIC TAC TOE 3: LOCATE THE GREEN 1: LOCATE THE TIC-TAC- BRACKET AND PLACE TOE TUMBLERS AND PLACE ON TOP OF ASSEMBLY. ONE ON EACH DOWEL LINE UP THE HOLES IN ABOVE THE COLLARS. THE BRACKET WITH THE DOWELS ON THE UNIT.
  • Page 86 STEP 56: TIC-TAC-TOE PANEL 1: CENTER THE TIC-TAC-TOE PANEL BETWEEN THE PANEL SLATS ON THE BACK WALL, AND ATTACH WITH 2" WOOD SCREWS.
  • Page 87 STEP 57: DORMER 1: FIND TWO LEFT SIDE AND TWO RIGHT SIDE DORMER ROOF ASSEMBLIES. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE LEFT AND RIGHT ROOF ASSEMBLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW. 4: ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1-1/2"...
  • Page 88 STEP 58: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/2" WOOD SCREWS. DORMER ROOF PEAK...
  • Page 89 STEP 59: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: MEASURE THE DISTANCE FROM THE EDGE OF THE ROOF TO THE FRONT OF THE DORMER FROM OUTSIDE THE FORT, AND THEN MEASURE THE SAME DISTANCE FROM THE EDGE OF THE ROOF FROM INSIDE THE FORT. ADD APPROXIMATELY 1/2"...
  • Page 90 STEP 60: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH 1-1/2" WOOD SCREWS CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY. 2: ATTACH THE REAR AND RIGHT SIDES OF THE CHIMNEY WITH 1-1/2"...
  • Page 91 STEP 61: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS STEPS TO FORM THE CHIMNEY...
  • Page 92 STEP 62: CHIMNEY 1: THE CHIMNEY WILL INSTALL IN A SIMILAR MANNER TO THE DORMERS; PLACING THE CHIMNEY ON THE ROOF; TOWARDS THE TOP; ABOUT 6" FROM THE EDGE; AT THE REAR OF THE FORT. 2: MEASURE FROM THE EDGE OF THE ROOF TO THE EDGE OF THE CHIMNEY FROM THE OUTSIDE, THEN FROM THE INSIDE OF THE FORT, MEASURE THE SAME DISTANCE, ADDING APPROXIMATELY 3/8", AND MARK THE LOCATION WITH A PENCIL.
  • Page 93 STEP 63: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT AND BACK OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS THROUGH THE TOP OF THE BRACE. INTO THE DECK SUPPORTS, AND ONE 2" AND ONE 3"...
  • Page 94 STEP 64: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS ON TOP OF THE BRACE, AND ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORTS TO THE CORNER POSTS.
  • Page 95 STEP 54: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES ON THE UNIT AS SHOWN BELOW AND ATTACH WITH THE PROVIDED HARDWARE.
  • Page 96 STEP 66: INSTALLING CLIMBING ROPES 1: DRILL A 7/8" HOLE THROUGH THE END PANEL BOARD (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10" ROPE AND THREAD IT THROUGH THE HOLE IN THE END PANEL BOARD. 3: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD.
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