Gorilla Playsets Treasure Trove II Assembly Instructions Manual
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Gorilla Playsets Treasure Trove II Assembly Instructions Manual

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Treasure Trove II - Wood Roof
Model: 1500KW
(BOXES: 1501, 1503, 1504
1506, 1509, (110 or 1513), 1515,
Rad Ride 7 Box & Slide Box)
Copyright © 2014 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
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  • Page 1 ™ ™ play sets play sets Treasure Trove II - Wood Roof Model: 1500KW (BOXES: 1501, 1503, 1504 1506, 1509, (110 or 1513), 1515, Rad Ride 7 Box & Slide Box) Copyright © 2014 Gorilla Playsets All Rights Reserved...
  • 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 - TREASURE TROVE II WOOD ROOF- 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.
  • Page 6 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 7 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 8 Model: 1500KW (BOXES: 1501, 1503, 1504, 1506, (110 or 1513), 1509, 1515, Rad Ride 7 Box & SLIDE BOX) REV: 10.6.2014...
  • Page 9 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 4-7 Leveling Fort, General Information and Definitions…………………....Pages 7-9 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 10-14 Site Plan, Required Tool List and Kit Contents..........Pages 15-16 Hardware, Lumber and Accessory Checklists.………………………………..Pages 17-47 Adding T-Nuts to Lower Level Corner Posts..…………………..………...…...
  • Page 10 TABLE OF CONTENTS Rope Ladder......................Step 77 Rock Wall Rope..................... Step 78 Safety Handles (Lower Level) and Safety Handles (Upper Level)....Steps 79-80 Flag Kit........................Step 81 Telescope......................Step 82 Steering Wheel...................... Step 83 Hanging the Swings....................Step 84 Ground Stakes....................... Step 85 Super Scoop Slide....................
  • 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 Treasure Trove II / The Reserve II 1500KW Height: 13 feet - 1-5/8 inches Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 26'-10 " 10'-11 16 " 10'-1 "...
  • Page 23 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/16”, 3/8”, 9/64”, 11/64” and a 1” paddle bit ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16”...
  • Page 24 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 1501 HARDWARE PAGE: 1 OF 2 9/20/2012 J.H. #2 SQUARE DRIVE BIT QTY: 1 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" 3/8 x 9" PLASTIC CARRIAGE BOLT CARRIAGE BOLT...
  • Page 25 1501 HARDWARE PAGE: 2 OF 2 #8 X 1" WOOD SCREW 9/20/2012 J.H. QTY: 2 #14 X 1-1/4" #8 X 1-3/4" PAN HEAD SCREW WOOD SCREW QTY: 4 QTY: 4 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 #8 X 3"...
  • Page 26 1503 HARDWARE PAGE: 1 OF 1 #8 X 1-1/4" 9/20/2012 J.H. WOOD SCREW QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 88 #8 X 2" WOOD SCREW QTY: 50 #8 X 2-1/2" WOOD SCREW QTY: 4 5/16" TEE NUT QTY: 6 5/16 X 4-1/2"...
  • Page 27 1504 HARDWARE PAGE: 1 OF 1 9/18/2012 J.H. #8 X 2" WOOD SCREW QTY: 71 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3" WOOD SCREW QTY: 5 #10 x 3-1/2" WOOD SCREW #14 x 3" QTY: 2 PAN HEAD SCREW QTY: 3 5/16"...
  • Page 28 1506 HARDWARE #8 X 1-1/4" WOOD SCREW PAGE: 1 OF 1 QTY: 6 #8 X 1-1/2" 9/20/2012 J.H. WOOD SCREW QTY: 88 #8 X 2" WOOD SCREW QTY: 31 #8 X 2-1/2" WOOD SCREW QTY: 6 #8 X 3" WOOD SCREW QTY: 2 5/16"...
  • Page 29 1509 HARDWARE PAGE: 1 OF 1 1/3/2013 J.H. #8 X 2" WOOD SCREW QTY: 94 #8 X 2-1/2" #14 x 1-1/4" WOOD SCREW PAN HEAD SCREW QTY: 18 QTY: 6 #8 X 3" WOOD SCREW QTY: 5 5/16" TEE NUT QTY: 55 1/4"...
  • Page 30 1515 HARDWARE PAGE: 1 OF 1 9/19/2012 J.H. 5/16" TEE NUT QTY: 14 5/16" X 3-1/2" 5/16 X 4-1/2" LAG SCREW HEX BOLT QTY: 16 QTY: 14 5/16" WASHER QTY: 30 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
  • Page 31 PICTURE DESCRIPTION QTY. 1501 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 14-3/4" PICNIC TABLE TOP SUPPORT 2-4-1475-PTTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-AS 2 X 4 X 24" ROPE LADDER STEP 2-4-2400-RLST...
  • Page 32 PICTURE DESCRIPTION QTY. 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 58" SWING BEAM CROSS MEMBER 2-4-5800-CM 2 X 4 X 66" LADDER RIGHT SIDE 2-4-6600-LRS 2 X 4 X 66" LADDER LEFT SIDE 2-4-6600-LLS 2 X 4 X 66"...
  • Page 33 PICTURE DESCRIPTION QTY. 2 x 4 x 70" REAR TOP PANEL BOARD 2-4-7000-RTPB 2 x 6 x 47-1/2" END SANDBOX/ BOTTOM PANEL BOARD 2-6-4750-ESPB 2 x 6 x 70" FRONT FACE BOARD 2-6-7000-FFB 2 x 6 x 70" SANDBOX BOARD 2-6-7000-SB 4 x 4 x 47-1/2"...
  • Page 34 PICTURE DESCRIPTION QTY. 5/4 X 3 X 18-3/4" LADDER BACK 125-3-1875-LB 5/4 X 3 X 23-7/8" ROCK WALL 125-3-2387-RWC 5/4 X 3 X 28-1/4" PANEL SLATS 125-3-2825-PS 5/4 X 4 X 40-3/8" DECK SPACER 125-4-4038-DS 5/4 X 6 X 22" SANDBOX SEAT 125-6-2200-SS...
  • Page 35 PICTURE DESCRIPTION QTY. 5/4 X 6 X 43" PICNIC TABLE & SEAT BOARD 125-6-4300-PTTS 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB 10/06/2014 28 of 159...
  • Page 36 PICTURE DESCRIPTION QTY. 1503 1 X 4 X 47-1/2" ROOF FINISHER 1-4-4750-RF 1 X 4 X 47-1/2" ROOF STARTER 1-4-4750-RS 1 X 6 X 47-1/2" ROOF BOARD 1-6-4750-RB 1 X 6 X 47-1/2" ROOF PEAK 1-6-4750-RP 2 X 4 X 28-9/16" CENTER POST- FRONT - REAR 2-4-2856-CPFR...
  • Page 37 PICTURE DESCRIPTION QTY. 2 X 6 X 13-5/8" 2-6-1363-S 5/4 X 2 X 10" SMALL RAY 125-2-1000-SR 5/4 X 2 X 16" LARGE RAY 125-2-1600-LR 5/4 X 3 X 42" SUN SUPPORT 125-3-4200-SS 5/4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 10/06/2014...
  • Page 38 PICTURE DESCRIPTION QTY. 1504 2 X 4 X 18" ANGLE SUPPORT- UPPER LEVEL RAD RIDE SIDE 2-4-1800-ULRDAS 2 X 4 X 18" ANGLE SUPPORT- UPPER LEVEL REAR 2-4-1800-ULRAS 2 X 4 X 21-1/2" ANGLE SUPPORT- UPPER LEVEL SWING SIDE 2-4-2150-ULSAS 2 X 4 X 30-7/16"...
  • Page 39 PICTURE DESCRIPTION QTY. 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD 2-6-3043-SBPB 2 X 6 X 42-1/2" REAR BOTTOM PANEL BOARD 2-6-4250-RBPB 2 X 6 X 70" BACK PANEL BOARD 2-6-7000-BPB5 4 X 4 X 23-1/2" SLIDE BLOCK 4-4-2350-SB 4 X 4 X 30-1/2"...
  • Page 40 PICTURE DESCRIPTION QTY. 5/4 X 3 X 34-1/2" PANEL SLAT 125-3-3450-PS 5/4 X 4 X 25" RAD RIDE DECK SPACER 125-4-2500-RRDS 5/4 X 4 X 29-1/2" UPPER DECK SPACER 125-4-2950-UDS 5/4 X 4 X 35-1/2" REAR DECK SPACER 125-4-3550-RDS 5/4 X 4 X 63" UPPER DECK SPACER 125-4-6300-UDS...
  • Page 41 PICTURE DESCRIPTION QTY. 1506 1 X 4 X 30-1/2" ROOF FINISHER 1-4-3050-RF 1 X 4 X 30-1/2" ROOF STARTER 1-4-3050-RS 1 X 6 X 30-1/2" ROOF BOARD 1-6-3050-RB 1 X 6 X 30-1/2" ROOF PEAK 1-6-3050-RP 2 X 4 X 18" CLOSE OUT BOARD 2-4-1800-COB...
  • Page 42 PICTURE DESCRIPTION QTY. 2 X 4 X 51-1/8" ROOF SUPPORT RIGHT 2-4-5113-RSR 2 X 6 X 13-5/8" 2-6-1363-S 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST 4-4-3331-ULCP 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST 4-4-5950-LLCP 4 X 4 X 60-1/4" LAG POST WOOD ROOF LEFT...
  • Page 43 PICTURE DESCRIPTION QTY. 5/4 X 2 X 16" LARGE RAY 125-2-1600-SR 5/4 X 3 X 42" SUN SUPPORT 125-3-4200-SS 5/4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 10/06/2014 36 of 159...
  • Page 44 PICTURE DESCRIPTION QTY. 1509 2 X 4 X 29" BRIDGE DECK 2-4-2900-BD 2 X 4 X 33" VERTICAL TARP SUPPORT 2-4-3300-VTS 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES 2-4-3675-SBH 2 X 4 X 36-3/4" SAFETY BOARD 2-4-3675-SB 2 X 4 X 36-3/4"...
  • Page 45 PICTURE DESCRIPTION QTY. 4 X 4 X 29" CENTER POST 4-4-2900-CP 5/4 X 3 X 16" RAIL SLAT 125-3-1600-RS 5/4 X 3 X 28-1/2" PANEL SLAT 125-3-2850-PS 5/4 X 4 X 29-3/8" DECK SPACER 125-4-2937-DS 5/4 X 4 X 36-11/16" DECK BOARD 125-4-3668-DB 10/06/2014...
  • Page 46 PICTURE DESCRIPTION QTY. 1515 2 X 4 X 14" BOTTOM PANEL BOARD 2-4-1400-BPB 2 X 6 X 70" SANDBOX BOARD 2-6-7000-SB 2 X 6 X 78" SIDE SANDBOX BOARD-LEFT 2-6-7800-SBL 2 X 6 X 78" SIDE SANDBOX BOARD-RIGHT 2-6-7800-SBR 2 X 6 X 102" ROPE LADDER RUNNER- FRONT LEFT...
  • Page 47 PICTURE DESCRIPTION QTY. 4 X 4 X 96" PLASTIC COATED CORNER POST- FRONT EXTRA HOLE HERE 4 X 4 X 96" PLASTIC COATED CORNER POST- MIDDLE 4 X 4 X 120" PLASTIC COATED CORNER POST- REAR 4 X 4 X 108" SWING LEG 4 X 6 X 120"...
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  • Page 55 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 TODIS-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 56 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" SIDE SANDBOX BOARD- RIGHT ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 57 STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" SIDE SANDBOX BOARD - LEFT ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 58 STEP 4: DRILL HOLES FOR BRIDGE CHAINS 1: 1: LOCATE ONE 2 X 4 X 70" DECK SUPPORT AND ONE 2 X 6 X 70" FRONT FACE BOARD. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD. 3: PLACE A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES WITH A SPADE BIT.
  • Page 59 STEP 5: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16"...
  • Page 60 STEP 6: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER RUNNER TO THE T-NUTS INSTALLED IN THE CORNER POSTS.
  • Page 61 STEP 7: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED IN THE CORNER POSTS.
  • Page 62 STEP 8: 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 63 STEP 9: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 64 STEP 10: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. FRONT OF FORT 2 X 4 X 14"...
  • Page 65 STEP 11: 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 66 STEP 12: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND DRAW A LINE ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE.
  • Page 67 STEP 13: 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 68 STEP 14: 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 69 STEP 15: 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 70 STEP 16: 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 71 STEP 17: 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 72 STEP 18: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE FRONT - LEFT CUT OUT AREA OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8”...
  • Page 73 STEP 19: 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 74 STEP 20: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE LEFT SIDE OF THE FORT AS SHOWN BELOW. CENTER THE LADDER HORIZONTALLY ON THE 2 X 6. CENTER THE 90 BRACKETS VERTICALLY ON THE 2 X 6. USE THE HOLES IN THE LADDER BRACKETS AS A TEMPLATE TO DRILL 3/8" HOLES THROUGH THE BOTTOM PANEL BOARD.
  • Page 75 STEP 21: UPPER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE UPPER LEVEL PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THEN RE-ASSEMBLY TO MAKE YOUR CORRECTIONS. 2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT POSTS PROPERLY.
  • Page 76 STEP 22: LAG POSTS 1: TWO 4 X 4 X 60-1/4" LAG POSTS WILL BE USED TO EXTEND THE MIDDLE CORNER POSTS TO ACCEPT THE UPPER LEVEL ROOF. 2: REST THE BOTTOM OF EACH LAG POST ON TOP OF THE 2 X 6 X 70 BACK PANEL BOARD. 3: CENTER EACH LAG POST DIRECTLY OVER THE CENTER OF THE MIDDLE CORNER POSTS.
  • Page 77 STEP 23: REAR CORNER POSTS & DECK SUPPORTS & SIDE TOP PANEL BOARDS 1: HAMMER A T-NUT INTO THE HOLES AT THE TOP OF THE LAG POSTS. TIP: BEFORE YOU INSTALL THESE BOARDS LEAVE THEM ALL A LITTLE LOOSE. WHEN YOU HAVE FASTENERS IN ALL THE BOARDS GO BACK AND TIGHTEN THEM ALL UP.
  • Page 78 STEP 24: UPPER LEVEL - RAILING & UNDER DECK SUPPORT 1: PLACE THE 2 X 4 X 70" UPPER LEVEL STEPS/RAILING BOARD (3 HOLES ON CENTER) AT THE TOP OF THE REAR CORNER POSTS. THIS BOARD WILL GET ATTACHED TO THE 2ND HOLE DOWN FROM THE TOP OF THE POSTS.
  • Page 79 STEP 25: CENTER DECK SUPPORT ASSEMBLY NOTE: IT IS BEST TO PLACE THESE BOARDS UPON A FLAT SURFACE BEFORE ATTACHING THEM TOGETHER. 1: PLACE ONE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET UP) ON THE RIGHT SIDE OF THE 4 X 4 X 30-1/2"...
  • Page 80 STEP 26: LOWER LEVEL CENTER POST 1: HAMMER A T-NUT INTO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST HOLE. 2: ATTACH THE LOWER LEVEL CENTER POST TO THE MIDDLE HOLE OF THE 2 X 6 X 70" BACK PANEL BOARD.
  • Page 81 STEP 27: CENTER DECK SUPPORT ASSEMBLY INSTALLATION AND LAGS 1: PLACE THE CENTER DECK SUPPORT ASSEMBLY ON TOP OF THE 4 X 4 X 70" UPPER LEVEL UNDER DECK SUPPORT. THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST SHOULD FIT INSIDE THE CENTER DECK SUPPORT ASSEMBLY.
  • Page 82 STEP 28: UPPER LEVEL DECK SPACERS 1: MAKE SURE THE LOWER LEVEL CENTER POST HAS AN EQUAL OPENING ON EACH SIDE. 2: PLACE THE 5/4 X 4 X 29-1/2" UPPER DECK SPACERS BETWEEN THE LOWER LEVEL CENTER POST AND THE MIDDLE CORNER POSTS. ATTACH EACH UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2"...
  • Page 83 STEP 29: SLIDE BLOCK 1: PLACE THE 4 X 4 X 23-1/2" SLIDE BLOCK AGAINST THE UPPER DECK SUPPORT ON THE LEFT SIDE (LADDER SIDE) OF THE PLAY SET. THE TOP OF THE BLOCK SHOULD BE FLUSH TO THE TOP OF THE DECK SUPPORT. THE BLOCK FITS BETWEEN THE LAG POST AND THE REAR CORNER POST.
  • Page 84 STEP 30: ANGLE SUPPORT - UPPER LEVEL REAR 1: PLACE A 2 X 4 X 18" ANGLE SUPPORT -UPPER LEVEL REAR AGAINST THE 4 X 4 X 70 UPPER LEVEL UNDER DECK SUPPORT ON EACH SIDE AT THE REAR OF THE PLAY SET. 2: THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH TO THE TOP OF THE UNDER DECK SUPPORT.
  • Page 85 STEP 31: SIDE REAR ANGLE SUPPORTS 1: (SEE DETAIL A) PLACE THE 2 X 4 X 18" ANGLE SUPPORT UPPER LEVEL RAD RIDE SIDE UNDER THE 4 X 4 X 23- 1/2" SLIDE BLOCK ON THE LEFT SIDE OF THE FORT. THE ANGLE SUPPORT SHOULD BE FLUSH TO THE LEFT SIDE OF THE LEFT REAR CORNER POST.
  • Page 86 STEP 32: UPPER LEVEL DECK BOARDS 1: PLACE FOUR 5/4 X 6 X 69-7/8" UPPER DECK BOARDS ACROSS THE DECK SUPPORTS AS SHOWN. EQUALLY SPACE THE DECK BOARDS 5/16" FROM ONE ANOTHER AND FROM THE DECK SPACER. 2: SECURE EACH UPPER DECK BOARD TO THE DECK SUPPORTS WITH FIVE #8 X 2" WOOD SCREWS.
  • Page 87 STEP 33: SLIDE POST ASSEMBLY 1: PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH IN THE 4 X 4 X 43-1/2" RAD RIDE CENTER POST. 2: PLACE ONE END OF THE 5/4 X 4 X 25" RAD RIDE DECK SPACER INTO THE NOTCH IN THE RAD RIDE CENTER POST.
  • Page 88 STEP 34: SLIDE POST INSTALLATION 1: PLACE THE END OF THE DECK SPACER AGAINST THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. FASTEN THE DECK SPACER TO THE DECK SUPPORT WITH #8 X 2" WOOD SCREWS. 2: MAKE THE DECK SPACER LEVEL WITH THE DECK BOARD BEHIND IT.
  • Page 89 STEP 35: UPPER LEVEL REAR DECK SPACER 1: PLACE THE 5/4 X 4 X 35-1/2" REAR DECK SPACER ON TOP OF THE DECK SUPPORTS. THE END SHOULD BE FLUSH TO THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST/CENTER POST. 2: FASTEN THE REAR DECK SPACER TO THE DECK SUPPORTS WITH FOUR #8 X 2"...
  • Page 90 STEP 36: UPPER LEVEL CENTER POST 1: PLACE THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST AGAINST THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST. FLUSH THE TOPS AND SIDES OF THE POSTS TOGETHER. 2: ATTACH THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST TO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST WITH 3/8"...
  • Page 91 STEP 37: RAILING 1: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD (RAILING) OFFSET UP INSIDE THE LAG POSTS OF THE UPPER LEVEL. 2: THE TOP OF THE RAILING SHOULD BE 33" ABOVE THE DECK BOARDS. 3: ATTACH THE RAILING TO THE LAG POSTS AND UPPER LEVEL CENTER POST WITH 5/16" X 3-1/2"...
  • Page 92 STEP 38: RADICAL RIDE TUBE SLIDE 1: ASSEMBLE THE RADICAL RIDE TUBE SLIDE ACCORDING TO THE DIRECTIONS INCLUDED WITH THE SLIDE. 2: PLACE THE SLIDE FACEPLATE AT THE OPENING AT THE REAR OF THE PLAY SET. THE SIDE OF THE FACE PLATE SHOULD BE 3/4"...
  • Page 93 STEP 39: UPPER LEVEL BOTTOM PANEL BOARDS 1: PLACE THE 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD (OFFSET UP) ON THE SWING BEAM SIDE (RIGHT SIDE) OF THE PLAYSET. ATTACH THE TOP HOLES OF THE BOARD TO THE POSTS WITH 5/16"...
  • Page 94 STEP 40: UPPER LEVEL REAR CENTER POST 1: PLACE THE 2 X 4 X 35-5/8" UPPER LEVEL REAR CENTER POST AGAINST THE REAR RAILING ON THE UPPER LEVEL. HAMMER A T-NUT INTO THE TOP HOLE IN THE UPPER LEVEL REAR CENTER POST.
  • Page 95 STEP 41: UPPER LEVEL PANEL SLATS 1: 5/4 X 3 X 34-1/2" PANEL SLATS WILL BE INSTALLED ON THE RIGHT AND REAR-RIGHT SIDES OF THE PLAY SET. THE PANEL SLATS WILL BE INSTALLED ON THE INSIDE OF THE BOTTOM PANEL BOARDS AND RAILINGS. 2: SPACE THE PANEL SLATS IN THE OPENINGS AS SHOWN BELOW.
  • Page 96 STEP 42: LOWER LEVEL FRONT CENTER POST 1: LOCATE THE 4 X 4 X 29" CENTER POST. PLACE THE 4 X 4 X 29" CENTER POST CENTERED BEHIND THE HOLE IN THE ROPE LADDER SUPPORT. CAREFULLY DRILL A 3/8" HOLE THROUGH THE CENTER POST USING THE HOLE IN THE ROPE LADDER SUPPORT AS A GUIDE.
  • Page 97 STEP 43: UPPER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" UPPER LEVEL STEP FLUSH WITH THE TOP OF THE UPPER LEVEL DECK SPACERS. UPPER LEVEL STEPS HAVE THREE HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16"...
  • Page 98 STEP 44: LOWER LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FOUR SLATS ON THE LEFT SIDE, SIX SLATS ON THE RIGHT SIDE AND TWO SLATS ON THE FRONT OF THE LOWER LEVEL.
  • Page 99 STEP 45: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT USING 3/8" X 3-1/2" CARRIAGE BOLTS ON TOP AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. USE BOLT CAPS TO COVER ANY EXPOSED THREADS.
  • Page 100 STEP 46: 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 101 STEP 47: 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 102 STEP 48: REST SWING BEAM ON FORT 1: REST THE SWING BEAM ASSEMBLY ON TOP OF THE UPPER RAILING BOARDS OF THE FORT. 2: THE END OF THE SWING BEAM WITH 2 HOLES SHOULD OVERHANG THE SWING BEAM SIDE OF THE FORT. IN THE NEXT STEP YOU WILL ATTACH THE SWING BEAM LEGS ONTO THIS END OF THE SWING BEAM.
  • Page 103 STEP 49: 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 104 STEP 50: MOUNT SWING BEAM TO FORT 1: PLACE A 3/8" X 9" CARRIAGE BOLT THROUGH A TORQUE WASHER. INSERT THE CARRIAGE BOLT INTO THE HOLE AT THE END OF THE SWING BEAM OVER THE SWING BEAM MOUNT. ALIGN THE SQUARE SHANK OF THE CARRIAGE BOLT WITH THE SQUARE HOLE IN THE TORQUE WASHER.
  • Page 105 STEP 51: 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 106 STEP 52: 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 107 STEP 53: ROOF SUPPORT ASSEMBLY 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN.
  • Page 108 STEP 54: UPPER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE UPPER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LAG POSTS OR REAR CORNER POSTS WITH 5/16"...
  • Page 109 STEP 55: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE UPPER LEVEL ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH TOP SIDE OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 110 STEP 56: UPPER LEVEL ROOF 1: PLACE THE 1 X 6 X 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH FOUR #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREW 1 X 6 X 30-1/2"...
  • Page 111 STEP 57: UPPER LEVEL ROOF 1: PLACE THE TONGUE OF A 1 X 6 X 30-1/2" ROOF BOARD INTO THE SLOT OF THE ROOF FINISHER. ALIGN THE ENDS OF THE BOARDS. FASTEN THE ROOF BOARD TO THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREW. REPEAT THIS PROCESS FOR EIGHT MORE ROOF BOARDS.
  • Page 112 STEP 58: SUN SUPPORT ASSEMBLY 1: CENTER A 2 X 6 X 13-5/8" SUN ON TOP OF A 5/4 X 3 X 42" SUN SUPPORT. THE BOTTOM OF THE SUN SHOULD BE 1" ABOVE THE BOTTOM OF THE SUN SUPPORT 2 X 6 X 13-5/8"...
  • Page 113 STEP 59: SUN SUPPORT INSTALLATION 1: PLACE A SUN SUPPORT ASSEMBLY ON THE INSIDE OF THE ROOF SUPPORTS AT THE FRONT AND REAR OF THE UPPER LEVEL ROOF. THE SUN SHOULD FACE THE OUTSIDE AT THE FRONT AND THE REAR OF THE UPPER LEVEL ROOF. 2: ATTACH THE SUN SUPPORT ASSEMBLY TO THE ROOF SUPPORTS WITH FOUR #8 X 2"...
  • Page 114 STEP 60: SUN RAYS 1: LOCATE TWELVE 5/4 X 2 X 10" SMALL RAYS AND TWO 5/4 X 2 X 16" LARGE RAYS. 2: PLACE THE LARGE RAY CENTERED OVER THE MIDDLE OF THE SUN ON THE INSIDE OF THE SUN SUPPORT ASSEMBLY.
  • Page 115 STEP 61: CROWN 1: PLACE A PLASTIC CROWN OVER THE SUN ON THE FRONT SIDE OF THE UPPER LEVEL ROOF. 2: ATTACH THE PLASTIC CROWN TO THE SUN WITH #8 X 1-1/4" WOOD SCREWS. NOTE: THERE WILL NOT BE A PLASTIC CROWN ON THE REAR SIDE OF THE UPPER LEVEL. CROWN #8 X 1-1/4"...
  • Page 116 STEP 62: CLOSE OUT BOARDS 1: LOCATE TWO 2 X 4 X 18" CLOSE OUT BOARDS. PLACE A CLOSE OUT BOARD ON THE OUTSIDE OF THE UPPER LEVEL RAILING AS SHOWN BELOW. 2: MAKE THE TOP OF THE CLOSE OUT BOARD FLUSH TO THE TOP OF THE UPPER LEVEL RAILING.
  • Page 117 STEP 63: LOWER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE LOWER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LOWER LEVEL CORNER POSTS WITH 5/16"...
  • Page 118 STEP 64: LOWER LEVEL ROOF 1: PLACE THE 1 X 4 X 47-1/2" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE LOWER LEVEL ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH TOP SIDE OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 119 STEP 65: LOWER LEVEL ROOF 1: PLACE THE 1 X 6 X 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH FOUR #8 X 1-1/4" WOOD SCREWS. 1 X 6 X 47-1/2" ROOF PEAK #8 X 1-1/4"...
  • Page 120 STEP 66: LOWER LEVEL 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 121 STEP 67: SUN SUPPORT INSTALLATION 1: PLACE A SUN SUPPORT ASSEMBLY ON THE INSIDE OF THE ROOF SUPPORTS AT THE FRONT LOWER LEVEL ROOF. THE SUN SHOULD FACE THE OUTSIDE AT THE FRONT OF THE LOWER LEVEL ROOF. 2: ATTACH THE SUN SUPPORT ASSEMBLY TO THE ROOF SUPPORTS WITH FOUR #8 X 2" WOOD SCREWS.
  • Page 122 STEP 68: SUN RAYS 1: LOCATE SIX 5/4 X 2 X 10" SMALL RAYS AND ONE 5/4 X 2 X 16" LARGE RAY. 2: PLACE THE LARGE RAY CENTERED OVER THE MIDDLE OF THE SUN ON THE INSIDE OF THE SUN SUPPORT ASSEMBLY.
  • Page 123 STEP 69: CROWN 1: PLACE A PLASTIC CROWN OVER THE SUN ON THE FRONT SIDE OF THE LOWER LEVEL ROOF. 2: ATTACH THE PLASTIC CROWN TO THE SUN WITH #8 X 1-1/4" WOOD SCREWS. CROWN #8 X 1-1/4" WOOD SCREWS 10/06/2014 116 of 159...
  • Page 124 STEP 70: SAFETY BOARDS 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 125 STEP 71: 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 126 STEP 72: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE LEFT-MIDDLE CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSDE OF THE CORNER POST WITH #8 X 3"...
  • Page 127 STEP 73: 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 128 STEP 74: 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 129 STEP 75: 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 130 STEP 76: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAYSET ON THE INSIDE. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS. SWING BEAM #8 X 1-3/4"...
  • Page 131 STEP 77: 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 132 STEP 78: ROCK WALL ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE ROPE LADDER SUPPORT. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
  • Page 133 STEP 79: SAFETY HANDLES (LOWER LEVEL) 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLATS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
  • Page 134 STEP 80: SAFETY HANDLES (UPPER LEVEL) 1: LOCATE THE SAFETY HANDLE BAG 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE LAG POSTS AND CENTER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
  • Page 135 STEP 81: FLAG KIT 1: PLACE A FLAG ON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH 1/2" PHILLIPS HEAD SCREWS PROVIDED. **DO NOT OVER-TIGHTEN** FLAG 1/2" PHILLIPS HEAD SCREW 10/06/2014 128 of 159...
  • Page 136 STEP 82: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE SQUARE TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT ON THE ROCK WALL SIDE OF THE CENTER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET.
  • Page 137 STEP 83: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK (UPPER LEVEL). 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 2" DEEP. 3: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 4: USE THE 2-1/2"...
  • Page 138 STEP 84: 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 10/06/2014 131 of 159...
  • Page 139 STEP 85: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. 2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #8 X 2" WOOD SCREW PROVIDED WITH THE GROUND STAKE. #8 X 2"...
  • Page 140 STEP 86: ATTACHING SUPER SCOOP SLIDE 1: PLACE THE SUPER SCOOP SLIDE IN THE OPENING AT THE LEFT SIDE OF THE UPPER LEVEL OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: ATTACH THE SLIDE TO THE DECK WITH #14 X 3" PAN HEAD SCREWS. **DO NOT OVER TIGHTEN** #14 X 3"...
  • Page 141 PART II CLATTER BRIDGE 10/06/2014 134 of 159...
  • Page 142 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 143 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2"...
  • Page 144 STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE 2 X 6 X 36-3/4" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE COUNTERSUNK HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2"...
  • Page 145 STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 36-3/4" DECK SUPPORTS TO THE HOLES AT 54-1/2" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST.
  • Page 146 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 147 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 148 STEP 7: LAG SCREWS 1: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. TO SQUARE AND LEVEL THE DECK OF THE TOWER TO THE DECK OF THE FORT PLACE A DECK BOARD ACROSS THE 2 X 4'S.
  • Page 149 STEP 8: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK SPACERS AND DECKBOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 8 "...
  • Page 150 STEP 9: FRONT FACE BOARD 1: PLACE THE 5/4 X 4 X 36-11/16" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
  • Page 151 STEP 10: DECK 1: INSTALL THE 5/4 X 4 X 36-11/16" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS. 2" WOOD SCREWS 5/4 X 4 X 36-11/16" DECK BOARD FRONT OF TOWER 10/06/2014...
  • Page 152 STEP 11: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 2: FASTEN THE SAFETY BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2 X 4 X 36-3/4"...
  • Page 153 STEP 12: PANEL SLATS 1: FIND TEN 5/4 X 3 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: INSTALL THE FIRST PANEL SLAT 2-1/2" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8"...
  • Page 154 STEP 13: BRIDGE RAILS 1: PLACE THE TOP SURFACE OF THE UPPER TWO 2 X 4 X 66" BRIDGE RAILS 5-1/2" BENEATH THE TOP SURFACE OF THE TOP PANEL BOARD. THE COUNTERSUNK HOLE IN THE END OF THE BRIDGE RAIL SHOULD FACE THE INSIDE.
  • Page 155 STEP 14: BRIDGE RAILS TO PLAY SET 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER CORNER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16"...
  • Page 156 STEP 15: BRIDGE RAIL SLATS 1. PRE-DRILL TWENTY 5/4 X 3 X 16" BRIDGE RAIL SLATS ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2. PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS.
  • Page 157 STEP 16: BRIDGE DECK AND CHAIN ASSEMBLY 1: FIND FIFTEEN 2 X 4 X 29" BRIDGE DECK BOARDS AND INSERT T-NUTS INTO THE PRE-DRILLED HOLES. USE A HAMMER TO SEAT THE T-NUTS INTO THE BOARDS. T-NUT 2 X 4 X 29" BRIDGE DECK BOARD T-NUT...
  • Page 158 STEP 17: BRIDGE DECK AND CHAIN ASSEMBLY 1: LOCATE TWO 96" CHAIN SECTIONS THAT SHIPPED WITH THE CLATTER BRIDGE. 2: PLACE THE CHAINS OVER THE HOLES IN THE BRIDGE DECK BOARDS AS SHOWN BELOW. 3: LINE UP THE 18TH LINK IN THE CHAINS WITH THE FIRST BRIDGE DECK BOARD HOLES. 96"...
  • Page 159 STEP 18: BRIDGE DECK AND CHAIN ASSEMBLY 1: PLACE A 5/16" WASHER BETWEEN THE 18TH CHAIN LINK AND THE BRIDGE DECK BOARD. 2: PLACE A 5/16" X 1-3/4" HEX BOLT WITH 5/16" WASHER THROUGH THE 18TH CHAIN LINK, THEN THROUGH THE 5/16"...
  • Page 160 STEP 19: BRIDGE DECK/CHAIN INSTALLATION 1: LAY THE BRIDGE DECK/CHAINS ASSEMBLY BETWEEN THE PLAY SET AND THE TOWER WITH THE CHAINS FACING THE GROUND. THREAD THE CHAIN ENDS IN THE BRIDGE DECK ASSEMBLY THROUGH THE HOLES IN THE BOTTOM PANEL BOARD AND DECK SUPPORT BOARD ON THE TOWER. 2: THERE SHOULD BE AT LEAST A 1"...
  • Page 161 STEP 20: BRIDGE DECK/CHAIN INSTALLATION 1: TWO PEOPLE MAY BE REQUIRED FOR THIS STEP. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE FRONT FACE BOARD ON THE PLAY SET. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP.
  • Page 162 STEP 21: VERTICAL TARP SUPPORTS 1: PLACE THE 2 X 4 X 33" VERTICAL TARP SUPPORTS ON THE INSIDE OF THE TOP PANEL BOARDS. THE END OF EACH VERTICAL TARP SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE TOP PANEL BOARD. CENTER EACH VERTICAL TARP SUPPORT WITH THE CENTER OF THE TOP PANEL BOARD.
  • Page 163 STEP 22: TARP BOARDS 1: LOCATE THREE 2 X 4 X 36-3/4" TARP BOARDS. 2: PLACE ONE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE END OF THE TARP BOARD SHOULD BE FLUSH WITH THE SIDES OF THE VERTICAL TARPS SUPPORTS. 3: ATTACH THE TARP BOARD TO THE VERTICAL TARP SUPPORTS WITH 2-1/2"...
  • Page 164 STEP 23: CLATTER BRIDGE TARP 1: LOCATE THE 34-1/4" X 57-1/2" CLATTER BRIDGE TARP. 2: PLACE THE TARP OVER THE TOP OF THE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. 3: THE TARP WILL OVERLAP THE SIDE OF THE TARP BOARDS ON TOP OF THE CORNER POSTS. 4: ATTACH THE TARP THROUGH THE GROMMETS TO THE TARP BOARDS WITH #14 X 1-1/4"...
  • Page 165 STEP 24: ATTACHING WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING OF THE CLATTER BRIDGE TOWER AS SHOWN WITH THE LIP OF THE SLIDE RESTING ON TOP OF THE DECK BOARDS. 2: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH FOUR #14 X 1-1/4"...
  • Page 166 Leftover Parts List 1500KW Play Set Our 1500 series play sets are modular and include parts to construct many different models. Some of these parts included with your play set will not be used because they are for a different model. The list below includes parts for your play set that will be leftover when construction is completed.
  • Page 167 APPENDIX...
  • Page 168 #8 X 1-1/4" WOOD SCREW QTY: 22 #8 X 1-1/2" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 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 169 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
  • Page 170 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
  • Page 171 PICTURE DESCRIPTION QTY. DORMER ROOF PEAK ASSEMBLY DORMER RIGHT SIDE ASSEMBLY DORMER SUNRAY ASSEMBLY...
  • Page 172 STEP 1: 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 1-1/4"...
  • Page 173 STEP 2: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/4" WOOD SCREWS. DORMER ROOF PEAK...
  • Page 174 STEP 3: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE A 2" WOOD SCREW TO FASTEN THE DORMER PEAK TO THE ROOF. 3: USE 1-1/2" WOOD SCREWS TO FASTEN THE FACE OF THE DORMER TO THE ROOF. USE A 2"...
  • Page 175 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 176 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 177 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.
  • Page 178 1509W Wood Roof for Clatter bridge running change 2015 Dear Customer, We are doing a running change to our Clatter Bridge. Your playset was probably shown having a Tarp Roof. For 2015 we are upgrading the clatter bridge to have a wood roof if the main fort of the play set has a wood roof.
  • Page 179 11-0071 1509N HARDWARE PAGE: 1 OF 1 REV A: 9/19/2014 JH #8 X 2" WOOD SCREW QTY: 94 #8 X 2-1/2" #14 x 1-1/4" WOOD SCREW PAN HEAD SCREW QTY: 18 QTY: 6 #8 X 3" WOOD SCREW QTY: 5 3/8"...
  • Page 180 Clatter Bridge Wood Roof Add On Kit Note: 1509 Clatter Bridge and Accessories sold separately or are included with your play set. Model: 1509W (BOXES: 1509W wood box, 1509 Hardware Box) REV: 3.12.2015...

  • Page 181: Table Of Contents

    TABLE OF CONTENTS General Information………………………………………..……......Page 3 Definitions……..………………………………………..........Page 4 Board Identification....…………………………………………......Page 5 Pre-Drill Lag Screw Directions………………………………..………...…....Page 6 Tool List and Kit Contents………………………..…………………………..……..Page 7 Hardware and Wood Lists……………..……………….…………...…....Pages 8-9 Roof Support Assemblies…………..……………………......... Step 1 Drilling Corner Post Holes……………………..…..…………..….………….... Step 2 Install Roof Support Assemblies................Step 3 Roof Starters......................
  • Page 182 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 183 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 184: Board Identification

    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 185: 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 186 REQUIRED TOOL LIST: ___ Standard or Cordless Drill ___ #2 square bit ___ Drill Bit 9/64” ___ ½” Wrench and Socket ___ Tape Measure ___ Extension Cord (if using standard drill) ___ Hammer ___ Pencil KIT CONTENTS Swings, Slides, Accessories: NONE Hardware: see following pages...
  • Page 187 1509W HARDWARE #8 X 1-1/4" WOOD SCREW PAGE 1 OF 1 QTY: 8 9/11/2014 JH #8 X 1-1/2" WOOD SCREW QTY: 60 #8 X 2" WOOD SCREW QTY: 8 5/16" x 3-1/2" HEX LAG SCREW QTY: 4 5/16" WASHER QTY: 4 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 188 PICTURE DESCRIPTION QTY. 1 X 3 X 36-3/4" ROOF PEAK BOARD 2 1-3-3675-RPB2 1 X 4 X 36-3/4" ROOF PEAK BOARD 1 1-4-3675-RPB1 1 X 5 X 36-3/4" ROOF BOARD 1-5-3675-RB 1 X 5 X 36-3/4" ROOF FINISHER 1-5-3675-RF 1 X 5 X 36-3/4" ROOF STARTER 1-5-3675-RS...

  • Page 189: Roof Support Assemblies

    STEP 1: ROOF SUPPORT ASSEMBLIES 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN.

  • Page 190: Drilling Corner Post Holes

    STEP 2: DRILLING CORNER POST HOLES 1: CHECK THE DIMENSION OF THE ROOF SUPPORT ASSEMBLIES AS SHOWN BELOW BEFORE DRILLING HOLES. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON THE CORNER POSTS ON THE INSIDE. 3: DRILL A 9/64" HOLE BY 2-1/2" DEEP AT EACH MARK. 4: REPEAT SUBSTEPS 2-3 ON THE INSIDE OF THE OTHER POSTS AS POINTED OUT BELOW.

  • Page 191: Install Roof Support Assemblies

    STEP 3: INSTALL ROOF SUPPORT ASSEMBLIES 1: PLACE TWO ROOF SUPPORT ASSEMBLIES ON THE CLATTER BRIDGE TOWER DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TOTHE HOLES DRILLED ON THE INSIDE OF THE CORNER POSTS WITH TWO 5/16"...

  • Page 192: Roof Starters

    STEP 4: ROOF STARTERS 1: PLACE THE 1 X 5 X 36-3/4" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE ROOF. REFER TO THE DIAGRAM BELOW AND MAKE THE OVERHANG THE SAME ON EACH SIDE OF THE STARTER. 2: PLACE THE STARTERS AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THEM OVERLAPPING. 3: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 193 STEP 5: ROOF PEAK 1: FASTEN ROOF PEAK BOARD 1 TO ROOF PEAK BOARD 2 WITH FOUR #8 X 1-1/2" WOOD SCREWS TO MAKE A ROOF PEAK ASSEMBLY 2: PLACE THE ROOF PEAK ASSEMBLY ON TOP OF THE ROOF STARTERS. FASTEN THE ROOF PEAK ASSEMBLY TO THE ROOF STARTERS WITH EIGHT #8 X 1-1/4"...

  • Page 194: Roof Boards And Roof Finishers

    STEP 6: ROOF BOARDS AND ROOF FINISHERS 1: LOCATE TEN 1 X 5 X 36-3/4" ROOF BOARDS. SLIDE THE TONGUE OF THE ROOF BOARD INTO THE GROOVE OF THE ROOF STARTER. SECURE THE ROOF BOARD TO THE ROOF SUPPORTS WITH FOUR #8 X 1-1/2"...
  • Page 195 Treehouse Add On Kit Note: Crown 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: 2.17.2015...
  • Page 196 ***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 197 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 198 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 199 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 200: Board Identification

    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 201: 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 202 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 203 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 204 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 205 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 206 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 207: 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 208: 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 OVER HANGING ROOF BOARDS.

  • Page 209: 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 210: 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 211: Sun Support

    STEP 5: SUN SUPPORT 1: PLACE THE 2 X 6 X 13-5/8" SUN CENTERED ON TOP OF THE 2 X 3 X 35.70" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH TWO #8 X 3" WOOD SCREWS. 2: PLACE THE ASSEMBLY MADE IN THE PREVIOUS SUB-STEP IN BETWEEN THE ROOF SUPPORTS. FASTEN USING #8 X 2-1/2"...

  • Page 212: Sun Rays

    STEP 6: SUN RAYS 1: CENTER THE 5/4 X 1-1/2 X 16" LARGE RAY ONTO THE SUN AND THE ROOF SUPPORT BOARDS UP AGAINST THE BOTTOM ROOF BATTENS AND FASTEN WITH TWO #8 X 2" WOOD SCREWS. 2: EQUALLY SPACE THE 5/4 X 1-1/2 X 10" SMALL RAYS BETWEEN THE LARGE RAY AND THE SUN SUPPORT UP AGAINST THE BOTTOM BATTEN (THREE ON EACH SIDE OF THE LARGE RAY).

  • Page 213: 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 214: 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 215: 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 216: 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 217 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 218 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”...

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