Page 1 (BOXES: 1501, 1503N, 1509N, 1509W, 1512, 1512A, 1519. 1520(X2), 1522, 1530, 1542, 1500A, 1500B, 1500E, 1500G, 1500H, Quick Connect Turbo box & Slide Box) Copyright © 2023 Gorilla Playsets All Rights Reserved *51-1126* 166 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 • 166 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 PRODUCT REGISTRATION - WILDERNESS GYM WITH SKYLOFT (1500JWSL) - Gorilla Playsets manufactures ™ 3 EASY WAYS TO REGISTER the finest quality products that are designed for outstanding Complete the online registration form at: OPTION 1 https://www.gorillaplaysets.com/product-registration strength and durability. We back...
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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 . . Gorilla Playsets 166 Etowah Industrial Court Canton, GA.
Page 9 Model: 1500JWSL (BOXES: 1501, 1503N, 1509N, 1509W, 1512, 1512A, 1519, 1520(X2), 1522, 1530, 1542 1500A, 1500B, 1500E, 1500G, 1500H, Quick Connect Turbo Slide box & Slide box) REV: 7.24.2023...
Page 10 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 3-7 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, Safety Zone, Required Tool List and Kit Contents......Pages 15-17 Hardware, Lumber and Accessory Checklists……………………………..Pages 18-42 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 PLAYGROUND SURFACING MATERIALS SECTION 4 OF THE CONSUMER PRODUCT SAFETY COMMISSION’S OUTDOOR HOME PLAYGROUND SAFETY HANDBOOK Select Protective Surfacing One of the most important things you can do to reduce the likelihood of serious head injuries is to install shock-absorbing protective surfacing under and around your play equipment.
Page 14 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/PageFiles/122149/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
Page 15 2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6’...
Page 16 General Info to Review Before Installation • Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly. •...
Page 17 This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board.
Page 18 Common Installation Practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.
Page 19 HOW A T-NUT WORKS THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS.
Page 20 BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part.
Page 21 PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole.
Page 22 SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs. Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs.
Page 23 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 1500 Series Wilderness Gym/Adelade with Skyloft HEIGHT: 11'-1-7/8" 19'-11 " 15'-11 " 5'-10" 1'-6 " Ladder Rope Ladder Swing Belts (2) Trapeze 3'-11 "...
Page 24 Wilderness Gym & Adelade with Sky Loft Safety Zone - 2023 SAFETY ZONE 31'11" 15'0" 6'0" 6'0" 31'1" 6'0" 15'0" 6'0" (6) foot unobstructed safety perimeter around playset recommended...
Page 25 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 7/64”, 9/64”, 11/64” and a 1” Paddle style bit. ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16”...
Page 26 1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" #8 X 1-3/4" PAN HEAD SCREW WOOD SCREW QTY: 4 QTY: 4 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 #8 X 3"...
Page 27 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 1501 HARDWARE PAGE: 2 OF 2 REV A: 9/10/2014 JH #2 SQUARE DRIVE BIT QTY: 1 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" 3/8 x 9"...
Page 28 1503N HARDWARE PAGE: 1 OF 1 REV C: 8/10/2015 JH #8 X 1-1/4" WOOD SCREW QTY: 6 #8 X 1-1/2" WOOD SCREW QTY: 104 #8 X 2" WOOD SCREW QTY: 30 #8 X 2-1/2" WOOD SCREW QTY: 8 3/8" X 1-1/8" BLACK PLASTIC PLUG QTY: 4...
Page 29 11-0071 1509N HARDWARE PAGE: 1 OF 1 REV A: 9/19/2014 JH #8 X 2" WOOD SCREW QTY: 94 #8 X 2-1/2" #14 x 1-1/4" WOOD SCREW PAN HEAD SCREW QTY: 18 QTY: 6 #8 X 3" WOOD SCREW QTY: 5 3/8"...
Page 30 1509W HARDWARE #8 X 1-1/4" WOOD SCREW PAGE 1 OF 1 QTY: 8 9/11/2014 JH #8 X 1-1/2" WOOD SCREW QTY: 60 #8 X 2" WOOD SCREW QTY: 8 5/16" x 3-1/2" HEX LAG SCREW QTY: 4 5/16" WASHER QTY: 4 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
Page 31 1512 HARDWARE PAGE: 1 OF 1 REV A 1/16/2014 J.H. #8 X 2" WOOD SCREW QTY: 35 #8 X 2-1/2" WOOD SCREW QTY: 6 #8 X 3" WOOD SCREW QTY: 3 5/16" TEE NUT QTY: 10 5/16 X 4-1/2" 5/16" X 3-1/2" HEX BOLT LAG SCREW QTY: 10...
Page 32 11-0126 1512A Hardware Kit 5/19/2023 JH 5/16" X 3-1/2" #8 X 2" HEX LAG SCREW WOOD SCREW 1342Z QTY: 10 QTY: 4 #8 X 2-1/2" WOOD SCREW 1327Z QTY: 25 1741Z 1336Z 5/16" WASHER QTY: 10 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 33 PICTURE DESCRIPTION QTY. 1501 WOOD BOX 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-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 24"...
Page 34 PICTURE DESCRIPTION QTY. 2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON CENTER) 2-4-5800-CM LEFT 2 X 4 X 66" LEFT LADDER SIDE 2-4-6600-LLS 2-4-6600-LRS RIGHT RIGHT 2 X 4 X 66" ROCK WALL SIDE (1 HOLE ON CENTER) 2-4-6600-RWS 2 X 4 X 70"...
Page 35 PICTURE DESCRIPTION QTY. 2 X 6 X 70" FRONT FACE BOARD (4 HOLES OFFSET) 2-6-7000-FFB 2 X 6 X 70" BOTTOM PANEL AND SANDBOX BOARD (4 HOLES OFFSET) 2-6-7000-SB 4 X 4 X 47 " SWING BEAM MOUNT 4-4-4750-SBM X 13 "...
Page 36 PICTURE DESCRIPTION QTY. X 28 " PANEL SLAT 125-3-2825-PS X 4 X 40 " DECK SPACER 125-4-4038-DS X 6 X 22" SANDBOX SEAT 125-6-2200-SS X 6 X 23 " BOTTOM ROCK WALL BOARD 125-6-2387-BRW X 6 X 23 " ROCK WALL BOARD 125-6-2387-RWB X 6 X 43"...
Page 37 PICTURE DESCRIPTION QTY. 1503N WOOD KIT 1 X 4 X 47 " TONGUE-ONLY ROOF FINISHER 1-4-4750-RF 1 X 4 X 47 " GROOVE-ONLY ROOF STARTER 1-4-4750-RS 1 X 5 X 47 " TONGUE-AND- GROOVE ROOF BOARD 1-5-4750-RB " ROOF PEAK 1-6-4750-RP 2 X 4 X 28-9/16"...
Page 38 PICTURE DESCRIPTION QTY. 1512 WOOD KIT 2 X 4 X 21-1/2" END PANEL BOARD 2-4-2150-EPB 2 X 4 X 29-1/4" SLIDE HEADER BOARD 2-4-2925-SHB 2 X 4 X 70" CENTER DECK SUPPORT 2-4-7000-CDS 2 X 6 X 21 " END PANEL BOARD (4 HOLES OFFSET) 2-6-2150-EPB...
Page 39 PICTURE DESCRIPTION QTY. 2 X 6 X 79-1/2" ROPE LADDER SUPPORT (4 HOLES OFFSET, 3 HOLES ON CENTER) 2-6-7950-RLS 2 X 6 X 79-1/2" ROPE LADDER RUNNER(4 HOLES OFFSET, 3 HOLES ON CENTER) 2-6-7950-RLR 4 X 4 X 40" END WALL SLIDE MOUNT POST 4-4-4000-EWSMP X 28...
Page 40 PICTURE DESCRIPTION QTY. 1512A WOOD KIT 2 X 4 X 23-1/8" VERTICAL FRAME BOARD 2 2-4-2313-VFB2 2 X 4 X 26-5/8" VERTICAL FRAME BOARD 1 2-4-2663-VFB1 2 X 4 X 47-1/2" TOP FRAME BOARD 2-4-4750-TFB 2 X 6 X 47-1/2" BOTTOM FRAME BOARD (6 HOLES OFFSET)
Page 41 PICTURE DESCRIPTION QTY. 4 X 6 X 120" SWING BEAM 4-6-12000-SB END OF 1522 WOOD KIT 1509N WOOD KIT 2 X 4 X 29" BRIDGE DECK 2-4-2900-BD 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES 2-4-3675-SBH 2 X 4 X 36-3/4" RAILING/DECK SUPPORT 2-4-3675-SB...
Page 42 PICTURE DESCRIPTION QTY. 5/4 X 3 X 16" BRIDGE 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 36-1/2" DECK BOARD 125-4-3650-DB END OF 1509N WOOD KIT 1519 WOOD KIT 4 X 4 X 96"...
Page 43 PICTURE DESCRIPTION QTY. 1 X 5 X 36-3/4" ROOF BOARD 1-5-3675-RB 1 X 4 X 36-3/4" ROOF FINISHER 1-4-3675-RF 1 X 4 X 36-3/4" ROOF STARTER 1-4-3675-RS 2 X 4 X 27" ROOF SUPPORT LEFT 2-4-2700-RSL 2 X 4 X 27" ROOF SUPPORT RIGHT 2-4-2700-RSR...
Page 44 PICTURE DESCRIPTION QTY. WAVE SLIDE ROPE LADDER ROPES ROCK WALL ROPE SWING W/CHAINS TRAPEZE W/CHAINS...
Page 45 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A PACK ROCKS OF 5) A-FRAME SWING BRACKET 11-5010 HARDWARE HARDWARE BOXES: 1501, 1503N, 1509N, 1509W, 1512, 1512A BOXES Note: Hardware may be in a wood box or it may be in an accessory box.
Page 46 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE CHANNEL BRACKET 11-5018...
Page 47 PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...
Page 48 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY (1530 BOX) UNASSEMBLED DORMER (1530 BOX) PLASTIC DORMER SUNBURST 07-0031 FLAG KIT 09-1014...
Page 49 PICTURE DESCRIPTION QTY. PLASTIC SUNBURST 07-0028-G MANUFACTURER (NOT SHOWN) LOGO PLATE SAFETY WARNING PLATE 11-5023 GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL QUICK CONNECT TURBO SLIDE 03-0031...
Page 50 PICTURE DESCRIPTION QTY. CLATTER- BRIDGE CHAIN 96" CLATTER- BRIDGE MESH (NOT SHOWN) PANELS 06-2004...
Page 51 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 52 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 79-1/2" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2"...
Page 53 STEP 2A: ASSEMBLING THE RIGHT SIDE FRAME 1: MAKE MARKS ON THE CORNER POSTS AT 27-9/16" FROM THE BOTTOM OF THE POSTS GOING 2: ALIGN THE TOP OF THE TOP FRAME BOARD WITH THE MARKS AND ATTACH WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16"...
Page 54 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 HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 2: USE 5/16 X 4-1/2"...
Page 55 STEP 3A: DRILL HOLES FOR BRIDGE CHAINS 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 56 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.
Page 57 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS AT THE BOTTOM. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
Page 58 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
Page 59 STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AND THE ROPE LADDER SUPPORT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE POSTS AND THEN INSTALL THE LAG SCREWS.
Page 60 STEP 6B: ANGLE SUPPORTS 1: ONE 2 X 4 X 18" ANGLE SUPPORT IS MOUNTED UNDER THE DECK ON THE LEFT REAR OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. TWO MORE 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE RIGHT SIDE TO THE BOTTOM FRAME BOARD.
Page 61 STEP 6C: ANGLE SUPPORTS 1: ONE 2 X 4 X 18" ANGLE SUPPORT IS MOUNTED UNDER THE DECK ON THE LEFT FRONT OF THE PLAY SET TO THE DECK SUPPORT. THE TOP OF THE ANGLE SUPPORT SHOULD BE LOWER THAN THE TOP OF THE DECK SUPPORT; POSITION SO HOLE IS NOT COVERED. 2: AT THE TOP USE 2-1/2"...
Page 62 STEP 7: BOTTOM PANEL BOARD 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. 5/16"...
Page 63 STEP 8: DECK SPACER AND DECK BOARD 1: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER BETWEEN THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. LEAVE A 1/4" GAP BETWEEN THE SIDE OF THE DECK SPACER AND THE INSIDE OF THE 2 X 4 BOTTOM PANEL BOARD. FASTEN THE DECK SPACER TO THE DECK SUPPORTS WITH FOUR 2"...
Page 64 STEP 9: END WALL SLIDE MOUNT POST 1: FIND THE 4 X 4 X 40" END WALL SLIDE MOUNT POST. 2: MEASURE 26" INCHES FROM THE FRONT OF THE FRONT RIGHT CORNER POST AND MARK THE MEASUREMENT ON THE INSIDE OF THE 2 X 6 X 79-1/2" ROPE LADDER SUPPORT. MEASURE DOWN 2" FROM THE TOP OF THE ROPE LADDER SUPPORT AND MARK THE MEASUREMENT ON THE INSIDE.
Page 65 STEP 10: DECK SUPPORTS 1: PLACE TWO 2 X 4 X 70" DECK SUPPORTS UNDER THE DECK BOARD/DECK SPACER AND BESIDE THE POST. HAVE AN ASSISTANT HOLD UP THE END OF THE DECK SUPPORT ON THE LEFT END. THE LEFT END SHOULD BE FLUSH AGAINST THE 2 X 6 BOTTOM PANEL BOARD.
Page 66 STEP 10A: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE MIDDLE TWO HOLES FOR ALL OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE- DRILL WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. TIP: PLACE A SCRAP PIECE OF WOOD UNDER THE DRILL LOCATION TO PREVENT WOOD TEAR-OUT ON THE BOTTOM SIDE.
Page 67 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 68 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 69 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 70 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
Page 71 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8”...
Page 72 STEP 16: LADDER 2 X 4 X 66" 1: FIND TWO 2 X 4 X 66" LADDER SIDES. LADDER SIDE 2: POSITION THE LADDER SIDES SO THAT THE T-NUT SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
Page 73 STEP 17: LADDER TO FORT 1: CENTER THE LADDER IN THE OPENING OF THE REAR FACE BOARD ON THE REAR OF THE FORT AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE REAR FACE BOARD. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8”...
Page 74 STEP 18: CENTER POST FRONT/REAR 1: HAMMER A T-NUT INTO THE HOLE OF 2 X 4 X 28-9/16" CENTER POST. 2: PLACE THE CENTER POST INSIDE THE RAILINGS AT THE REAR OF THE PLAYSET. LINE UP THE HOLE IN THE CENTER POST WITH THE HOLES IN THE RAILING.
Page 75 DEVIATION 1 DO NOT INSTALL PANEL SLATS ON THE SWING BEAM SIDE IN THE NEXT STEP.
Page 76 STEP 19: PANEL SLATS 1: FIND FIFTEEN 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: INSTALL THE PANEL SLATS WITH EQUAL GAPS. SEE DETAIL BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. REAR PANEL SLAT SPACING 2-3/4"...
Page 77 STEP 20: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8"...
Page 78 STEP 21: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWINGBEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 7"...
Page 79 STEP 22: 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 80 STEP 23: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE TOP OF THE FORT RAILINGS.THE END OF THE SWING BEAM WITH TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE. 2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM.
Page 81 DETOUR 1 GO TO APPENDIX AND FOLLOW STEP 21 OF SKYLOFT INSTRUCTIONS. RETURN HERE AND THEN SKIP STEP 24.
Page 82 STEP 24: 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. 2: PLACE THE CHANNEL BRACKET UNDERNEATH THE SWING BEAM BRACKET. 3: FASTEN THE 3/8"...
Page 83 STEP 25: MOUNT SWING BEAM ON FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
Page 84 STEP 26: 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 85 DETOUR 2 GO TO APPENDIX AND FOLLOW STEP 23 OF SKYLOFT INSTRUCTIONS. RETURN HERE AND THEN SKIP STEP 27.
Page 86 STEP 27: 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 87 STEP 28: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), TWO 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP.
Page 88 STEP 28A: INSTALLING ROOF SUPPORT ASSEMBLIES 1: PLACE THE ROOF SUPPORT ASSEMBLIES ON TOP OF THE DECK OF THE PLAY SET. CLIMB ONTO THE DECK TO INSTALL THE ROOF SUPPORT ASSEMBLIES. 2: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16"...
Page 89 DETOUR 3 GO TO APPENDIX AND FOLLOW STEPS 1-16A OF SKYLOFT INSTRUCTIONS. YOU WILL NEED TO USE STEPS 29-31 IN THE MAIN MANUAL TO SEE HOW TO CONSTRUCT THE MAIN ROOF. AFTER THE ROOF IS CONSTRUCTED YOU WILL HAVE ONE DORMER AND ONE 07-0031 DORMER SUNBURST LEFTOVER.
Page 90 STEP 29: ROOF STARTERS 1: PLACE THE 1 X 4 X 47-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE APPROXIMATELY CENTERED (SEE BELOW) ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
Page 91 STEP 30: ROOF PEAK 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREW 47-1/2" ROOF PEAK...
Page 92 STEP 31: ROOF NOTE: THE SMALL PICTURE BELOW IS A GENERIC VIEW OF A PLAY SET IN OUR 1500 MODEL LINE. TYPICALLY THE ROCK WALL AND/OR SLIDE IS LOCATED ON THE FRONT OF THE 1500 SERIES PLAY SETS. THE BIG PICTURE BELOW SHOWS THE RIGHT SIDE ROOF WITH THE DORMER AND CHIMNEY.
Page 93 STEP 32: HANGING THE SWINGS 1: START BY ATTACHING ONE SPRING CLIP TO EACH IRON DUCTILE ON THE SWING BEAM. 2: ATTACH ONE CHAIN PER ACCESSORY TO EACH SPRING CLIP. 3: ADJUST HEIGHT AS NEEDED SPRING CLIP SWING CHAIN...
Page 94 STEP 33: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2"...
Page 95 STEP 34: PICNIC TABLE 1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS. 2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4"...
Page 96 STEP 35: PICNIC TABLE 1: MEASURE 26-3/8” FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8" 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3"...
Page 97 STEP 36: PICNIC TABLE 1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS AND ONE 5/4 X 4 X 40-3/8" DECK SPACER. 2: CENTER THE HOLES IN THE PT TOP AND SEAT BOARDS OVER THE TOP SUPPORTS OR SEAT SUPPORTS. 3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2"...
Page 98 STEP 37: ROPE LADDER 1: FIND THREE ROPE LADDER ROPES. MAKE A KNOT IN THE END OF EACH ROPE AND THREAD THE FREE END THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT. PULL EACH ROPE TAUGHT. 2: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 14" AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 14 INCHES BELOW THE ROPE LADDER SUPPORT.
Page 99 STEP 38: END PANEL AND VERTICAL FRAME BOARDS 1: FIND THE 2 X 4 X 21-1/2" END PANEL BOARD AND THE 2 X 4 X 23-1/8" VERTICAL FRAME BOARD 2. 2: PLACE THE 2 X 4 X 21-1/2" END PANEL BOARD ABOVE THE 2 X 6 X 47-1/2" BOTTOM FRAME BOARD. FASTEN IT TO THE CENTER POST AND CORNER POST WITH 5/16 X 3-1/2"...
Page 100 STEP 38A: PANEL SLATS 1: LOCATE TWO 5/4 X 3 X 33" PANEL SLATS. 2: PLACE THE SLATS AS SHOWN ON THE INSIDE OF FORT SPACING THEM 1" OFF THE DECK AND 3" AWAY FROM THE POSTS. 3: FASTEN EACH PANEL SLAT WITH #8 X 2" WOOD SCREWS. 5/4 X 3 X 33"...
Page 101 STEP 39: 5' QUICK CONNECT TURBO SLIDE 1: ASSEMBLE THE 5' QUICK CONNECT TURBO SLIDE USING THE INSTRUCTIONS INCLUDED WITH THE SLIDE NOTING THE OPTIONS/EXCEPTIONS BELOW: 2: USE STEP 16A EXIT ASSEMBLY (LOW SETTING) TO CONSTRUCT THE EXIT ASSEMBLY 3: USE STEP 17A EXIT SUPPORT ASSEMBLY (LOW SETTING) TO CONSTRUCT THE EXIT SUPPORT ASSEMBLY.
Page 102 STEP 39A: ATTACHING THE SLIDE TO THE FORT IT IS BEST TO USE AN ASSISTANT FOR THIS STEP. 1: AS YOU ARE LIFTING THE SLIDE BE CAREFUL NOT TO DRAG THE WOOD EXIT SUPPORT AS THIS MAY DAMAGE THE PLASTIC FLANGE WHERE IT IS ATTACHED.
Page 103 STEP 40: INSTALLING THE ROCK WALL ROPE 1: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE BACK SIDE OF THE HOLE IN THE FRONT TOP PANEL BOARD. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD. TIE A SECURE KNOT AT THE END MAKING SURE THAT THE ROPE IS TIGHT AND WILL NOT WRAP AROUND YOUR HAND.
Page 104 STEP 41: SAFETY HANDLES 1: LOCATE THE SAFETY HANDLE BAG. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE CENTER POST OR CORNER POST WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.
Page 105 DETOUR 4 GO TO APPENDIX AND FOLLOW STEPS 17-20 OF SKYLOFT INSTRUCTIONS. FOLLOW THE REMAINDER OF THE MAIN MANUAL SKIPPING STEP 42.
Page 106 STEP 42: TELESCOPE 1: FASTEN THE TELESCOPE BASE TO THE TOP OF THE CENTER POST WITH THE 2" SCREW INCLUDED. 2: SNAP THE ENDS OF THE TELESCOPE BASE INTO THE SOCKETS ON THE TELESCOPE SIDES. TELESCOPE 2" WOOD SCREW SNAP ENDS INTO SOCKETS ON SIDE OF TELESCOPE...
Page 107 STEP 43: FLAG KIT 1: PLACE A FLAG ON THE CORNER POSTS AT THE FRONT OF THE FORT. 2: ATTACH THE BASE OF THE FLAG WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED. **DO NOT OVER-TIGHTEN** FLAG 1/2" PHILLIPS HEAD SCREW...
Page 108 STEP 44: SANDBOX SEATS AND PLATES 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 109 STEP 45: PLASTIC SUNBURST 1: LOCATE TWO PLASTIC SUNBURST PIECES. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2"...
Page 110 STEP 46: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE AGAINST THE SWING LEG.
Page 111 STEP 47: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK. 2: DRILL A 3/16" PILOT HOLE BY 1" DEEP LOCATED 1" BELOW THE T-NUT INTO THE REAR CENTER POST. 3: PLACE THE SPACER INSIDE THE STEERING WHEEL. 4: SECURE THE STEERING WHEEL TO THE REAR CENTER POST WITH THE WASHER AND THE LAG SCREW RPOVIDED.
Page 112 PART 2 CLATTER BRIDGE ASSEMBLY...
Page 113 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 114 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 115 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 116 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 117 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 118 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 119 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 120 STEP 8: DECK BOARDS 1: PLACE THE 5/4 X 4 X 29-3/8" DECK SPACERS BETWEEN THE CORNER POSTS. MAKE EACH DECK SPACER FLUSH TO THE INSIDE SURFACE OF THE 2 X 6 OR THE OUTSIDE SURFACE OF THE CORNER POSTS. DO NOT ATTACH THE DECK SPACERS YET.
Page 121 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 6 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS. THE TOP OF THE BOTTOM PANEL BOARD SHOULD BE 1/4"...
Page 122 STEP 10: REAR BOTTOM PANEL BOARD 1: LOOSEN UP THE FASTENERS IN THE 2 X 6 ON THE LEFT SIDE OF THE TOWER. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH HOLES) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
Page 123 STEP 11: DECK 1: INSTALL THE 5/4 X 6 X 36-1/2" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH 2" WOOD SCREWS. 2" WOOD SCREWS 5/4 X 6 X 36-1/2" DECK BOARD FRONT OF TOWER...
Page 124 STEP 12: PANEL SLATS 1: FIND NINE 5/4 X 3 X 28-1/2" PANEL SLATS. 2: ON THE LEFT SIDE OF THE TOWER INSTALL THE FIRST PANEL SLAT 2-5/8" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8" APART AS SHOWN IN THE PICTURE AT THE TOP LEFT BELOW. ATTACH THE PANEL SLATS WITH 2"...
Page 125 STEP 13: 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 126 STEP 14: TIC-TAC-TOE PANEL 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE FRONT OF THE PLAY SET ON THE INSIDE. THE TIC TAC TOE SHOULD BE APPROXIMATELY 3" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4" WOOD SCREWS. PANEL SLATS AT FRONT OF TOWER #8 X 1-3/4"...
Page 127 STEP 15: 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 128 STEP 16: MOUNTING BRIDGE RAILS TO FORT 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER 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"...
Page 129 STEP 17: BRIDGE RAIL SLATS 1. 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. 3. ATTACH THE REMAINING SLATS TO THE UNIT WITH 3" SPACING BETWEEN THE SLATS. 2"...
Page 130 STEP 18: 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 131 STEP 19: 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 132 STEP 20: 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 133 STEP 21: 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 134 STEP 22: 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 UP.
Page 135 STEP 23: 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 136 STEP 24: 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 137 STEP 25: ROOF STARTERS 1: PLACE THE 1 X 4 X 36-3/4" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE ROOF. REFER TO THE DIAGRAM BELOW AND MAKE THE OVERHANG THE SAME ON EACH SIDE OF THE STARTER. 2: PLACE THE STARTERS AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THEM OVERLAPPING. 3: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
Page 138 STEP 26: 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 139 STEP 27: 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 140 STEP 28: MOUNTING THE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT RIGHT OF THE CLATTER BRIDGE. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK SPACER. 2: PREDRILL 1/8" HOLES INTO THE DECK SPACER AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK SPACER WITH 1-1/4"...
Page 141 STEP 29: PANEL SLAT 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLAT FLUSH TO THE SIDE OF THE BRIDGE RAILS AS SHOWN BELOW. 2: ATTACH THE PANEL SLAT TO THE ROPE LADDER SUPPORT AND FRONT FACE BOARD ON THE INSIDE WITH #8 X 2"...
Page 142 STEP 30: PLASTIC PLUGS 1: LOCATE 4 PLASTIC PLUGS 2: TAP EACH PLUG INTO THE FRONT AND BACK SIDE OF THE HOLES SHOWN BELOW. PLASTIC PLUG (X4) TAP PLUGS INTO HOLES...
Page 143 STEP 31: PLASTIC SUNBURST 1: LOCATE TWO OF THE PLASTIC DORMER SUNBURST PIECES AS SHOWN. 2: PLACE THE PIECES AGAINST THE UNDERSIDE OF THE CLATTER BRIDGE ROOF OVERHANG. 3: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION 4: INSTALL A #8 X 1/2"...
Page 144 Leftover Parts List 1500JW/1500JWF Play Sets 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 145 APPENDIX...
Page 146 Chimney and Dormers Hardware Kit 8/10/2015 JH #8 X 2-1/2" WOOD SCREW QTY: 2 #8 X 2" WOOD SCREW QTY: 4 #8 X 1-1/2" WOOD SCREW QTY: 14 #8 X 1-1/4 WOOD SCREW QTY: 6 #2 SQUARE DRIVE BIT QTY: 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
Page 147 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
Page 148 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
Page 149 PICTURE DESCRIPTION QTY. PLASTIC DORMER SUNBURST (07-0031) DORMER RIGHT SIDE ASSEMBLY...
Page 150 STEP 1: DORMER 1: OVERLAP THE LEFT DORMER SIDE ONTO THE PEAK SUPPORT OF THE RIGHT DORMER SIDE. 2: MAKE SURE THE FRONT ROOF EDGES ARE FLUSH TO ONE ANOTHER 3: FASTEN THE LEFT DORMER SIDE TO THE PEAK SUPPORT WITH #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1-3 TO CONSTRUCT ANOTHER ROOF ASSEMBLY.
Page 151 STEP 2: DORMER 1: PLACE THE PLASTIC DORMER SUNBURST AGAINST THE FRONT FACE SUPPORT ON THE LEFT AND RIGHT ROOF SIDES. 2: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION. 3: INSTALL #8 X 1/2" PAN HEAD SCREWS TO FASTEN THE SUNBURST TO THE ROOF SIDES. REPEAT SUBSTEPS 1 THROUGH 3 TO CONSTRUCT THE SECOND DORMER.
Page 152 STEP 3: DORMER 1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: FOR 1500 SERIES UNITS LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 8TH ROOF BOARD. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF. 4: ATTACH THE DORMER TO THE ROOF WITH ONE #8 X 2-1/2"...
Page 153 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 154 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 155 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH #8 X 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE FOR A SUGGESTED PLACE TO MOUNT THE CHIMNEY. 2: AFTER INSTALLING THE CHIMNEY MOUNTING BLOCK PLACE THE CHIMNEY ASSEMBLY ON THE ROOF SO THAT THE INSIDE OF THE BACK WALL RESTS AGAINST THE BLOCK.
Page 156 (06-2004) Clatter Bridge Mesh Panels Tools Required: Kit Contents: #2 Phillips Bit or screwdriver 2 - Green Mesh Panels 66" x 24" 1/8" drill bit 44 - Phillips Pan Head Screws Pencil 5.5mm x 25.4mm long Drill 44 - Washers 16mm O.D. X 7.1mm I.D. Note: Your mesh panels will be completely green.
Page 157 5) It will be very helpful to have an assistant at this stage. We recommend predrilling holes for the screws on the bottom of the deckboards fastened to the chains. Align the edge of the mesh border with the end of the bridge deck boards.
Page 158 ™ ™ playsets playsets Skyloft Add-On* Model: 1542 (BOXES: 1542 wood box, 1542 accessory box) *playset sold separately Copyright © 2023 Gorilla Playsets All Rights Reserved *51-3052* 166 Etowah Industrial Court Canton, GA 30114 www.gorillaplaysets.com 51-3052 REV: 6-19-2023...
Page 159 !!READ BEFORE BEGINNING PLAYSET ASSEMBLY - EXTREMELY IMPORTANT!! There will be deviations and detours in the main playset manual to allow the addition of this 1542 Skyloft Add On kit. If your playset has a 1525 Treehouse Add on Kit make sure you read through all of that manual thoroughly before beginning assembly of the playset.
Page 160 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 161 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 • 166 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 162 IMPORTANT SAFETY GUIDELINES This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls.
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Page 164 PRODUCT REGISTRATION - SKY LOFT ADD-ON (1542) - Gorilla Playsets manufactures ™ 3 EASY WAYS TO REGISTER the finest quality products that are designed for outstanding Complete the online registration form at: OPTION 1 http://www.gorillaplaysets.com/register strength and durability. We back...
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Page 166 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 167 . . Gorilla Playsets 166 Etowah Industrial Court Canton, GA.
Page 168 Model: 1542 (BOXES: 1542 wood box, 1542 accessory box) REV: 3.10.2019...
Page 169: Table Of Contents
TABLE OF CONTENTS Safety Guidelines………………………………………..…......…...Pages 3-6 Leveling Fort, General Information and Definitions………………………....Pages 6-9 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 17-23 Deck Frame……………………………..………...…..........
Page 170 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 171 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 172 PLAYGROUND SURFACING MATERIALS SECTION 4 OF THE CONSUMER PRODUCT SAFETY COMMISSION’S OUTDOOR HOME PLAYGROUND SAFETY HANDBOOK Select Protective Surfacing One of the most important things you can do to reduce the likelihood of serious head injuries is to install shock-absorbing protective surfacing under and around your play equipment.
Page 173 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/PageFiles/122149/325.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 174 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 175 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 176 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 177 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 178 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 179 BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part.
Page 180 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 181: Beam Loading
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 182 1542 - Overhead with Dimensions Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 48" 29 4 " (DECK) ENTRY 4 " " OPENING " " (DECK) 2 " "...
Page 183 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” bits. ___ 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 184 11-0115 1542 Hardware PAGE 1 OF 1 REV A: 2/27/2020 JH #8 X 1-1/2" WOOD SCREW QTY: 40 #2 SQUARE DRIVE BIT #8 x 1-3/4" QTY: 1 WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 90 #8 X 2-1/2" WOOD SCREW QTY: 60 5/16"...
Page 185 11-2027 SUB BRACKET HARDWARE 3/8" X 2-1/2" 3/8" WASHER LAG SCREW QTY: 4 12/09/2015 QTY: 4 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
Page 186 1542 PICTURE DESCRIPTION QTY. 1 X 4 X 7-3/16" TONGUE-ONLY ROOF FINISHER 1542A 1 X 5 X 7-3/16" TONGUE-AND- GROOVE ROOF BOARD 1542B 5/4 X 3 X 18" PANEL SLAT-1 1542C 5/4 X 3 X 22-3/4" PANEL SLAT-2 1542D 5/4 X 3 X 31-1/8" PANEL SLAT-3 1542E 5/4 X 4 X 17-1/2"...
Page 187 1542 PICTURE DESCRIPTION QTY. 5/4 X 6 X 32-1/2" ENTRY BOARD 1542H 5/4 X 6 X 29-3/4" DECK BOARD 1542I 2 X 4 X 16" END POST 1542J 2 X 4 X 21-1/4" LADDER STEP 1542K 2 X 4 X 25.28" END BOTTOM PANEL BOARD 1542L...
Page 188 1542 PICTURE DESCRIPTION QTY. 2 X 4 X 30-7/8" LADDER SIDE 1542O 2 X 4 X 44-1/4" TOP PANEL SUPPORT 1542P 2 X 6 X 12" CONNECTOR BOARD 1542Q 2 X 6 X 20-1/4" CENTER DECK SUPPORT 1542R 2 X 6 X 29-3/4" DECK SUPPORT 1542S 2 X 6 X 29-3/4"...
Page 189 1542 PICTURE DESCRIPTION QTY. 4 X 4 X 41-5/16" CORNER POST 1542V 4 X 4 X 72-3/8" SUPPORT POST 1542W...
Page 190 PICTURE DESCRIPTION QTY. TELESCOPE TIC TAC TOE (UNASSEMBLED) 07-0010 FLAG KIT 09-1014 SUB BRACKET 11-5017 GRAB HANDLES (2 HANDLES ARE IN ONE BAG) 07-0005 SKYLOFT HARDWARE 11-0115 (NOT SHOWN) SUB BRACKET HARDWARE 11-2027...
Page 191: Deck Frame
STEP 1: DECK FRAME 1: INSTALL BOARDS AS SHOWN BELOW: * NOTE POSITION OF COUNTERBORED HOLES. * NOTE DIRECTION OF NOTCH. 1542S DECK SUPPORT " 1542R CENTER DECK SUPPORT 1542S DECK SUPPORT 8 " COUNTERBORED HOLES TOWARDS THE INSIDE OF THE FRAME. #8 X 2-1/2"...
Page 192: Deck Spacers
STEP 2: DECK SPACERS 1: INSTALL DECK SPACER AS SHOWN BELOW. 1542G 1542G DECK SPACER DECK SPACER 16 " 23" #8 X 2" WOOD SCREWS FLUSH FLUSH FLUSH FLUSH FLUSH...
Page 193: Corner Posts
STEP 3: CORNER POSTS 1: INSTALL BOARDS AS SHOWN BELOW. * NOTE POSITION OF COUNTERBORED HOLES. * NOTE: CORNER POSTS, MUST BE 90 DEGREES FROM DECK SUPPORT BEFORE SECURING WITH WOOD SCREWS. 1542V 1542V CORNER POST CORNER POST 5/16" WASHER 5/16"...
Page 194: Braces
STEP 4: BRACES 1: INSTALL BOARDS AS SHOWN BELOW. 5/16" WASHER 5/16" X 4-1/2" HEX BOLT 1542T DECK MOUNT 1542U 1542U ANGLE SUPPORT ANGLE SUPPORT 5/16" T-NUT 90.00° 2 "...
Page 195: Attaching Braces To Deck Frame
STEP 5: ATTACHING BRACES TO DECK FRAME 1: INSTALL BOARDS AS SHOWN BELOW. NOTE: MAKE SURE CORNER POSTS ARE 90 DEGREES FROM DECK SUPPORT BEFORE SECURING WITH WOOD SCREWS. 5/16" WASHER 5/16" X 4-1/2" HEX BOLT 5/16" T-NUT 90° 90° #8 X 2-1/2"...
Page 196 STEP 5A: MOUNTING THE PLATFORM TO SWING BEAM 1: SET THE PLATFORM ON TOP OF THE SWING BEAM AND USE THE NOTCHES TO CENTER IT AS SHOWN BELOW. FLUSH...
Page 197: Support Posts
STEP 6: SUPPORT POSTS 1: ATTACH SUPPORT POSTS AS SHOWN BELOW. * NOTE: MAKE SURE SUPPORT POSTS ARE 90 DEGREES FROM DECK SUPPORT BEFORE SECURING WITH WOOD SCREWS. * NOTE POSITION OF COUNTERBORED HOLES. 1542W 1542W SUPPORT POST SUPPORT POST 5/16"...
Page 198 STEP 7: LADDER 1: ASSEMBLE LADDER AS SHOWN BELOW: 1542O LADDER SIDE 1542K 1542O LADDER STEP LADDER SIDE #8 X 2" WOOD SCREWS TOP OF LADDER STEP SHOULD BE FLUSH TO BOTTOM/SIDE OF NOTCH.
Page 199 STEP 8: ATTACHING LADDER TO POSTS. 1: ATTACH LADDER ASSEMBLY IN BETWEEN SUPPORT POSTS AS SHOWN BELOW. NOTE: MAKE SURE LADDER ASSEMBLY IS FLUSH TO SUPPORT POSTS. THE BOTTOM OF THE LADDER AND THE BOTTOM OF THE SUPPORT POST SHOULD BE SITTING ON TOP OF DECK BEFORE SECURING WITH WOOD SCREWS.
Page 200 STEP 9: SECURING TO FORT. *IMPORTANT* - CENTER THE POSTS EQUALLY BEFORE INSTALLING LAG SCREWS INTO POSTS. PRE-DRILL 11/64"PILOT HOLES AT ALL LOCATIONS BEFORE INSTALLING LAG SCREWS. 1: SECURE SUPPORT POSTS TO SWING BEAM MOUNT AS SHOWN BELOW. 2: SECURE ANGLE SUPPORTS TO SWING BEAM AS SHOWN BELOW. POST 3/8"...
Page 201 STEP 9A: POST BOTTOM ATTACHMENT 1: CAREFULLY DRILL 3/8" HOLES THROUGH THE BOTTOM PANEL BOARD USING THE POST HOLES AS A GUIDE. 2: INSTALL T-NUTS. 3: FASTEN AS SHOWN. POSTS DRILL 3/8" HOLES USING POST HOLES AS A GUIDE. 5/16" T-NUT BOTTOM PANEL BOARD...
Page 202: Deck Boards
STEP 10: DECK BOARDS 1: PLACE ALL DECK BOARDS ON DECK SUPPORTS FIRST. MAKE SURE ALL BOARDS ARE EVENLY SPACED AND FLUSH TO THE CORNER POSTS. 1542I DECK BOARD #8 X 2" WOOD SCREW...
Page 203 STEP 11: ATTACHING PANEL SUPPORTS 1: INSTALL BOARDS AS SHOWN BELOW. * NOTE COUNTERBORED HOLE POSITIONS. 1542N 5/16" T-NUT 5/16" WASHER END PANEL SUPPORT 5/16" X 4-1/2" HEX BOLT 1542P TOP PANEL SUPPORT 1542N END PANEL SUPPORT COUNTERBORED HOLE TOWARDS THE TOP COUNTERBORED HOLE TOWARDS THE BOTTOM 1542N...
Page 204 STEP 11A: SECURING RAILS. 1: ENSURE ALL RAILS ARE SQUARE BEFORE SECURING TO THE POSTS. 2: SECURE WITH WOOD SCREWS. 90° 90° #8 X 2-1/2" WOOD SCREW 2 SCREWS HERE...
Page 205 STEP 12: FRONT PANEL ASSEMBLY 1: INSTALL BOARDS AS SHOWN BELOW. #8 X 2-1/2" WOOD SCREW 1542M END TOP PANEL BOARD 1542J END POST 1542M 1542J END TOP PANEL BOARD END POST FLUSH 4 " FLUSH 8 " FLUSH...
Page 206 STEP 13: FRONT PANEL & BOTTOM PANEL BOARD 1: INSTALL T-NUTS ON THE INSIDE OF THE END POSTS WHERE SHOWN. 2: INSTALL BOARDS AS SHOWN BELOW. 5/16" X 2-1/2" HEX BOLT 5/16" T-NUT 5/16" WASHER 5/16" X 2-1/2" HEX BOLT 5/16"...
Page 207 STEP 14: PANEL SLATS 1: INSTALL PANEL SLATS AS SHOWN BELOW. #8 X 2" WOOD SCREW 1542D 1542E FLUSH PANEL SLAT-2 PANEL SLAT-3 1542E 1542C PANEL SLAT-3 PANEL SLAT-1 FLUSH " 4 " " SPACING 8 " SPACING 2" 4 "...
Page 208 STEP 15: CONNECTOR BOARDS TO FORT 1: INSTALL BOARDS AS SHOWN BELOW. #8 X 2-1/2" WOOD SCREW 5/16" X 3" LAG SCREW 5/16" WASHER END FLUSH TO SIDE OF DECK SUPPORT. TOP FLUSH TO BOTTOM OF DECK. 1542Q CONNECTOR BOARDS...
Page 209 STEP 16: INSTALLING PLAY SET WOOD ROOF 1: COMPLETE WOOD ROOF INSTALLATION ON THE RIGHT SIDE OF YOUR PLAY SET AS SHOWN IN YOUR MAIN PLAY SET INSTRUCTION MANUAL. 2: THE CHIMNEY WILL BE INSTALLED ON THE RIGHT SIDE OF THE ROOF AS SHOWN BELOW. 3: INSTALL 4 ROOF BOARDS ON THE LEFT SIDE OF YOUR PLAY SET AS SHOWN BELOW.
Page 210 STEP 16A: SKY LOFT WOOD ROOF. 1: INSTALL ROOF BOARDS AS SHOWN BELOW. #8 X 1-1/2" WOOD SCREW. FLUSH 1542B ROOF BOARD 1542A ROOF FINISHER...
Page 211 STEP 17: ENTRY BOARD 1: INSTALL ENTRY BOARD BETWEEN THE SHORT ROOF BOARDS, FLUSH TO THE BOTTOM OF THE LONG ROOF BOARD. #8 X 2" WOOD SCREWS 1542H (TOP) ENTRY BOARD FLUSH TO BOTTOM EDGE OF LONG ROOF BOARD. #8 X 2-1/2" WOOD SCREW (BOTTOM)
Page 212 STEP 17A: TIC TAC TOE ASSEMBLY 1: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 2: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS. EACH GREEN BRACKET SHOULD BE CENTERED OVER THE TIC TAC TOE MOUNT.
Page 213 STEP 17B: TIC TAC TOE ASSEMBLY 1: PLACE THE TIC TAC TOE ASSEMBLY ON THE INSIDE OF THE PANEL SLATS AS SHOWN IN THE BOTTOM IMAGE. 2: PLACE THE TOP OF THE TIC TAC TOE BOARD 4" DOWN FROM THE TOP OF THE PANEL SLAT.
Page 214: Accessories
STEP 18: ACCESSORIES 1: INSTALL THE ACCESSORIES BELOW USING THE INSTRUCTIONS INCLUDED WITH THEM FOR ASSEMBLY. USE THE BOTTOM IMAGES BELOW FOR PLACEMENT. FLAG ASSEMBLIES TELESCOPE FLAG PLACEMENT 9" " TELESCOPE PLACEMENT 3" 3"...
Page 215: Panel Slats At Deck
STEP 19: PANEL SLATS AT DECK 1: LOCATE THE 5/4 X 3 X 28-1/4" PANEL SLATS FROM THE MAIN PLAYSET PARTS BOXES. 2: EQUALLY SPACE A PANEL SLAT BETWEEN THE CORNER POST AND THE SUPPORT POST ON EACH SIDE. 3: FASTEN EACH SLAT WITH #8 X 2" WOOD SCREWS.. SUPPORT POST CORNER...
Page 216: Grab Handles
STEP 20: GRAB HANDLES 1: PLACE THE GRAB HANDLES AS SHOWN AND FASTEN THEM WITH THE HARDWARE THAT IS INCLUDED WITH THEM. 8 " GRAB HANDLES GRAB HANDLES...
Page 217 STEP 21: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH ONE TORQUE WASHER AND THE SUB BRACKET ON TOP OF THE SWING BEAM, AND THE CHANNEL BRACKET, 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH.
Page 218 STEP 22: 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 219 STEP 23: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS. 4: CHOOSE TWO HOLES IN THE SUB BRACKET THAT DO NOT INTERFERE WITH THE OTHER LAG SCREWS IN THE SWING LEG.

Gorilla Playsets 1500JWSL Assembly Instructions Manual

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