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Gorilla Playsets Journey Assembly Manual

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®
Journey
ASSEMBLY MANUAL
Copyright © 2011 Gorilla Playsets
All Rights Reserved
Gorilla Playsets • 190 Etowah Industrial Court Canton, GA 30114
(800) 882-0272 • www.gorillaplaysets.com
Latest Revision: May 6, 2011

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  • Page 1 ® Journey ASSEMBLY MANUAL Copyright © 2011 Gorilla Playsets All Rights Reserved Gorilla Playsets • 190 Etowah Industrial Court Canton, GA 30114 (800) 882-0272 • www.gorillaplaysets.com Latest Revision: May 6, 2011...
  • Page 2 TABLE OF CONTENTS Warranty and Safety Guidelines………………………………………..……...Pages 3-10 Leveling the play set, General Information and Definitions......Pages 10-13 Site Plan, Tool List and Kit Contents………………………………………..Pages 14-15 Hardware, Lumber and Accessory Checklist..……......……..Pages 16-24 Adding T-Nuts to Corner Posts and Deck Supports……………..………...…..Steps 1-5 Framing Play Set…………………………..………………………..…..……..

  • Page 3: Important - Please Read

    We appreciate your purchase and know that you will enjoy your play system for many years to come. IF YOU HAVE MISSING OR DAMAGED PARTS OR NEED ASSISTANCE ASSEMBLING, PLEASE CALL Gorilla Playsets MANUFACTURING DIRECT. (800) 882-0272 FACTORY HOURS – MON.–FRI., 8AM-5PM EST DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECT.
  • Page 4 Quality Lumber At Gorilla Playsets, we use only the finest, hand selected lumber available. You can be assured that our lumber is strong, durable, and conforms to the national standards for use in children’s play equipment. It’s this quality that allows us to offer a 10 year warranty on the lumber used in our play sets.

  • Page 5: Limited Manufacturer's Warranty

    Limited Manufacturers Warranty Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under normal use and conditions at its original installation, for 10 years for structural wood components and for one year for all other components (e.g., hardware, plastics, tarps, rope ladder, etc.)

  • Page 6: Important Safety Guidelines

    Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from the 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 PLATFORM: 250 LBS. TOTAL WEIGHT • SWING BELTS: 275 LBS.
  • Page 7 Safety and Maintenance Tips for Your New Play Set: NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with your children. •...
  • Page 8 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 9 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 10 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 11 General Info to Review Before Installation • Depending on your experience, assembly of Gorilla Playsets can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly.
  • Page 12 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 13 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 Insert the barrel of the T-nut into the T-nut predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.
  • Page 14 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 8 " Rock Wall/ 2 " Ladder 16 " Swing Belts (2) 8 " 8 " Trapeze Arm (1) 16 " Wave Slide Playset height: 8 feet - 4 inches Swing Beam height: 79-1/2 inches...
  • Page 15 Swings, Slides, Accessories: ___ (Qty ) Description ___ (2) Swingbelts w/ Chains ___ (1) 8ft. Wave Slide ___ (1) Journey Assembly Manual ___ (5) Rock Wall Grips (assorted colors) ___ (1) Trapeze Swing ___ (1) Telescope ___ (2) Plastic Safety Handles...
  • Page 16 Use the ruler to the right to measure your bolts and screws. Picture views shown below are 1:1 scale and can be used to match bolt and screw sizes. #8 x 1-1/4” Wood Screw Qty: 2 3/8” Lock Nut Qty: 14 #8 x 2”...
  • Page 17 Use the ruler to the right to measure your bolts and screws. Picture views shown below are 1:1 scale and can be used to match bolt and screw sizes. #14 x 1-1/4” Pan Head Screw Qty: 8 5/16” Tee Nut Qty: 58 #2 Square Drive Bit...

  • Page 18: Description Qty

    Picture Description Qty. 2 x 4 x 11” Table Support 2 x 4 x 24-1/2” Center Tarp Support 2 x 4 x 26” Seat Support 2 x 4 x 26-1/4” Upper Slat Board 2 x 4 x 26-3/4” Center Tarp Board 2 x 4 x 38-1/16”...
  • Page 19 Picture Description Qty. 2 x 4 x 40-1/4” Deck Support 2 x 4 x 46-1/2” Table Leg 2 x 4 x 47-3/16” Diagonal Brace 2 x 4 x 84” Corner Post Left - Front 2 x 4 x 84” Corner Post Left - Rear 2 x 4 x 84”...
  • Page 20 Picture Description Qty. 2 x 4 x 84” Corner Post Right - Rear 2 x 6 x 29-1/2” End Tarp Board 2 x 6 x 29-1/2” Front - Rear Panel Board 2 x 6 x 42” Side Tarp Support - Left 2 x 6 x 42”...
  • Page 21 Picture Description Qty. 4 x 4 x 24” Swing Beam Support 5/4 x 2-5/8 x 20-1/4” Panel Slat 5/4 x 5 x 24” Deck Spacer 5/4 x 5-1/2 x 26-3/4” Rock Wall - Deck Panel Board 5/4 x 5-3/8 x 24”” Seat - Table Board 5/4 x 5-3/8 x 29”...
  • Page 22 Picture Description Qty. 2 x 4 x 94” Swing Leg Cross Member 2 x 4 x 86” Swing Leg 4 x 6 x 96” Swing Beam (Not Shown) Hardware Box Green Bracket 2” x 2” x 4-1/2” Bracket ® Page 22...
  • Page 23 Picture Description Qty. Swing Leg Bracket Swing Leg Angle Bracket Tarp 26-3/4” x 65-3/4” Flag Kit Telescope Climbing Rocks ® Page 23...
  • Page 24 Picture Description Qty. 8’ Wave Slide Swing w/Chains Trapeze Bar w/Chains Safety Handle Ground Stake Mini Iron Ductile Swing Hanger Gorilla Logo Plate ® Page 24...
  • Page 25 Step 1: Installing T-Nuts (Right Front Corner Post) 1: Locate one 2 x 4 x 84” Corner Post (Right - Front) The top will have four holes. The countersunk hole is on the BACK side that you cannot see in the picture. 2: Use a hammer to set t-nuts after inserting them into the holes shown in the diagram.
  • Page 26 Step 2: Installing T-Nuts (Right Rear Corner Post) 1: Locate one 2 x 4 x 84” Corner Post (Right - Rear). The top will have four holes. The countersunk hole is on the BACK side that you cannot see in the picture. 2: Use a hammer to set t-nuts after inserting them into the holes shown in the diagram.
  • Page 27 Step 3: Installing T-Nuts (Left Front Corner Post) 1: Locate one 2 x 4 x 84” Corner Post (Left Front). The top will have three holes. The countersunk hole is on the BACK side that you cannot see in the picture. 2: Use a hammer to set t-nuts after inserting them into the holes shown in the diagram.
  • Page 28 Step 4: Installing T-Nuts (Left Rear Corner Post) 1: Locate one 2 x 4 x 84” Corner Post (Left - Rear). The top will have three holes. The countersunk hole is on the BACK side that you cannot see in the picture. 2: Use a hammer to set t-nuts after inserting them into the holes shown in the diagram.
  • Page 29 Step 5: Installing T-Nuts (Deck Supports) 1: Locate two 2 x 4 x 40-1/4” Deck Supports. 2: Use a hammer to set t-nuts after inserting them into the holes shown in the diagram. 3: The barrel of the t-nut should go in the hole first. Hammer the t-nut until it is flush/al- most flush to the Deck Support.
  • Page 30 Step 6: Right Side Frame Assembly (Outside Face) 1: Place the Right Front and Right Rear corner posts as shown below. The flange of the T-nuts should be on the INSIDE of the corner posts facing each other at the bottom. 2: The flange of the T-nuts should be on the BACK side of the corner posts where a board is attached.
  • Page 31 Step 7: Right Side Frame Assembly (Inside Face) 1: The Right Side Frame Assembly should still be turned over from putting in four T-Nuts in the previous step. If the frame is not turned over then turn it over now. 2: The flange of the T-nuts should be on the side of the Deck Support shown below.
  • Page 32 Step 8: Left Side Frame Assembly (Outside Face) 1: Place the Left Front and Left Rear corner posts as shown below. The flange of the T- nuts should be on the INSIDE of the corner posts facing each other at the bottom. 2: The flange of the T-nuts should be on the BACK side of the corner posts where a board is attached.
  • Page 33 Step 9: Left Side Frame Assembly (Inside Face) 1: Flip the Left Side Frame Assembly over. 2: The flange of the T-nuts should be on the side of the Deck Support shown below. 3: Attach the 2 x 4 x 40-1/4” Deck Support to the corner posts with 5/16” x 2-1/2” hex bolts and 5/16”...
  • Page 34 Step 10: Picnic Table parts (T-Nuts) 1: Hammer a t-nut into the side opposite the countersunk holes in the 2 x 4 x 46-1/2” Table Leg as shown below. Repeat this three more times for the other three Table Legs. 2: Hammer two t-nuts into the 2 x 4 x 11”...
  • Page 35 Step 11: Picnic Table Legs 1: Locate the Right Side Frame Assembly. 2: Place the 2 x 4 x 46-1/2” Table Legs against the Deck Support at the top and BEHIND the 2 x 6 x 70 Bottom Panel Board at the bottom. 3: Line up the holes at the top and LOOSELY attach the Table Legs to the Deck Support with 5/16”...
  • Page 36 Step 12: Picnic Table Supports 1: Locate the Right Side Frame Assembly. 2: Place the 2 x 4 x 11” Table Support behind the Table Legs as shown below. The flange of the t-nuts in the Table Support should be on the BACK side. 3: Line up the top most holes in the Table Legs to the holes in the Table Support and attach with 5/16”...
  • Page 37 Step 13: Picnic Table Seat Supports 1: Locate the Right Side Frame Assembly. 2: Place the 2 x 4 x 26” Seat Support behind the Table Legs as shown below. The flange of the t-nuts in the Seat Support should be on the BACK side. 3: Line up the bottom most holes in the Table Legs to the holes in the Seat Support and attach with 5/16”...
  • Page 38 Step 13A: Leveling the Side Frame Assemblies 1: At this point you may have noticed that the 2 x 6 x 42” Side Tarp Support at the top appears crooked. This step will fix that. Have an assistant help hold the frame assem- bly while you level and tighten the bolts in the substeps that follow.
  • Page 39 Step 14: Front - Rear Panel Boards and Deck Spacers 1: Have an assistant hold up the Right Side Frame and Left Side Frame assemblies. 2: The flange of the T-nuts should be on the BACK side of the corner posts where the bottom boards are attached.
  • Page 40 Step 15: Diagonal Brace 1: Now is the time to level and square up your play set. Refer to the directions at the beginning of the manual for this process. Also see Step 29 for placement instructions. 2: Once you have the play set level and square proceed to substep 3. 3: Place the bottom surface of the 2 x 4 x 47-3/16”...
  • Page 41 Step 16: Deck Panel Board 1: Place the 5/4 x 5-1/2 x 26-3/4” Deck Panel Board on top of the Diagonal Brace. The ends of the Deck Panel Board should be flush to the corner posts. The Deck Panel Board should be square to the corner posts. 2: Attach the Deck Panel Board to the corner posts with #8 x 2-1/2”...
  • Page 42 Step 17: Rock Wall Boards 1: Space the bottom 5/4 x 5-1/2 x 26-3/4” Rock Wall Board 3-5/16” off the Front - Rear Panel Board as shown. 2: Attach the Rock Wall Board to the corner posts with four #8 x 2” Wood Screws. 3: Place another Rock Wall Board above the bottom Rock Wall Board leaving a 3-1/4”...
  • Page 43 Step 18: Seat and Table Boards 1: Place two 5/4 x 5-3/8 x 24” Table Boards on top of the Table Supports. Attach each Table Board to the Table Support with #8 x 2” wood screws. 2: Place one 5/4 x 5-3/8 x 24” Seat Board on top of the Seat Supports at each end. At- tach each Seat Board to the Seat Supports with #8 x 2”...
  • Page 44 Step 19: Deck Boards 1: Place five 5/4 x 5-3/8 x 29” Deck Boards on top of the Deck Supports as shown be- low. Leave an equal space between all the Deck Boards and Deck Spacers. Line up the holes in the Deck Boards along the center of the Deck Supports. Each Deck Board will overlap the side of the Deck Supports by about 2-1/2”...

  • Page 45: Step 20: Panel Slats

    Step 20: Panel Slats 1: Attach one 5/4 x 2-5/8” x 20-1/4” Panel Slat to the inside of the Upper and Lower Slat Boards in the center. Attach it with two #8 x 2” wood screws. 2: Arrange two Panel Slats on either side of the center Panel Slat as shown in the top picture below.
  • Page 46 Step 21: Center Tarp Supports 1: Hammer a T-Nut into the 2 x 4 x 24-1/2” Center Tarp Support. (See Detail A) Attach the Center Tarp Support to the Side Tarp Support with a 5/16” x 2-1/2” hex bolt and a 5/16’...
  • Page 47 Step 22: Top Tarp Board and End Tarp Boards 1: Place the 2 x 4 x 26-3/4” Center Tarp Board on the top of the Center Tarp Supports boards that were just installed. Attach the Center Tarp Board to the Center Tarp sup- ports with four #8 x 2-1/2”...
  • Page 48 Step 23: Tarp 1: Place the 26-3/4” x 65-3/4” Tarp over the top of the Center Tarp Board. 2: The ends of the Tarp should overlap the End Tarp Boards equally on the front and rear. 3: Attach the Tarp to the End Tarp Boards through the grommets with six #14 x 1-1/4” Pan Head Screws and six 1/4”...
  • Page 49 Step 24: Swing Beam Support 1: Place the 4 x 4 x 24” Swing Beam Support against the outside of the right corner posts. 2: Attach the Swing Beam Support to the corner posts with 5/16” x 3-1/2” hex bolts and 5/16”...
  • Page 50 Step 25: Mini Iron Ductile Swing Hangers 1: Attach each Mini Iron Ductile Swing Hanger to the 4 x 6 x 96” Swing Beam with 3/8” x 7” carriage bolts and torque washers on top and 3/8” washers with 3/8” lock nuts on the bottom.
  • Page 51 Step 26: Swing Leg Bracket and Swing Leg Angle Bracket 1: First, attach the Swing Leg Bracket to the swing beam with the 3/8” x 6-1/2” carriage bolt and torque washer on top and a 3/8” washer, 3/8” lock nut and 3/8” bolt cap on bot- tom.
  • Page 52 Step 27: Swing Legs 1: Place the end of the 2 x 4 x 86” Swing Leg with two holes in it inside the “u” shaped channel in the Swing Leg Bracket. Line up the holes in the leg with the holes in the bracket.
  • Page 53 Step 28: Swing Leg Crossmember 1: Hammer a t-nut into the bottom hole on the inside of each Swing Leg. 2: Attach the 2 x 4 x 94” Swing Leg Crossmember to the outside of the Swing Legs with 5/16” x 2-3/4” hex bolts and 5/16” washers. 3: Now go back and tighten up the bolts at the top of the Swing Legs.
  • Page 54 Step 29: Placement of your Play Set 1: This play set is designed to be placed upon a relatively flat and level surface. If your yard is relatively flat and level where you are placing your play set then the Swing Leg Crossmember will sit flush to grade.
  • Page 55 Step 30: Attaching Swing Beam to Play Set 1: Place the Swing Beam on top of the 4 x 4 x 24” Swing Beam Support. 2: Check the Swing Beam for level. If the swing beam is level then proceed to substep 3. If the swing beam is not level then use a shovel to mark around the Swing Leg Crossmember.
  • Page 56 Step 31: 90 Green Bracket 1: Place a 90 Green Bracket centered underneath the Swing Beam and against the Swing Beam Support. 2: Attach the 90 Green Bracket to the Swing Beam and Swing Beam Support with #14 x 1-1/4 pan head screws and 1/4” washers. Green Bracket #14 x 1-1/4”...
  • Page 57 Step 32: Wave Slide 1: Place the Wave Slide in the opening at the front of the play set. 2: The lip of the Wave Slide should sit on top of the Deck Spacer as shown. 3: Attach the Wave Slide to the deck with two #8 x 1-1/4” wood screws. * DO NOT OVER TIGHTEN * 4: Once the slide is installed DO NOT lift the end of the slide.
  • Page 58 Step 33: Telescope 1: Place one of the L-shaped Telescope Mounting Brackets on the Side Tarp Support - Left on the left side of the play set. 2: Attach the L-shaped bracket with two screws provided with the Telescope. 3: Place the base of the Telescope into the cut out area of the L-shaped bracket. 4: Attach another L-shaped Telescope Mounting Bracket directly across from the previ- ously installed bracket and secure with the provided hardware.

  • Page 59: Step 34: Safety Handles

    Step 34: Safety Handles 1: Place the Safety Handles against the corner posts as shown above the Rock Wall boards. 2: Space the Safety Handles up or down to suit the needs of your child. 3: Attach each Safety Handle with two 1-1/4” phillips pan head screws and 1/4” washers provided with each Safety Handle.
  • Page 60 Step 35: Flags 1: Place the Flags on the left and right sides of the play set on the Center Tarp Supports as shown below. Note Tarp has been removed for clarity. 2: Attach the plastic base of each Flag to the Center Tarp Support with the 1/2” phillips head screws provided with the Flags.

  • Page 61: Step 36: Ground Stakes

    Step 36: Ground Stakes 1: Hammer each Ground Stake into the ground at an inward angle next to the 2 x 6 and 2 x 4 boards as shown below. Place a scrap piece of cardboard behind the Ground Stake to avoid hitting the board with your hammer. 2: Once the Ground Stake is hammered into the ground remove the scrap cardboard.
  • Page 62 Step 37: Hanging Swings 1: Hang each swing to the Mini Iron Ductile Swing Hangers by placing a chain link over the hook end of the swing hanger. 2: Count equal numbers of chain links on each swing chain to move the swing up or down.
  • Page 63 Step 38: Rock Wall Rocks 1: Place the Rock Wall Rocks onto the Rock Wall Boards in a staggered pattern as shown below. 2: Attach each Rock Wall Rock to the Rock Wall Board with the #14 x 1-1/4” pan head screws and 1/4”...
  • Page 64 Step 39: Gorilla Name Plate 1: Attach the Gorilla Name Plate to the middle of the Swing Beam with two 2” wood screws. 2: Your play set is finished! Enjoy your play set! ® Page 64...
  • Page 65 Thank you for registering with Gorilla Playsets™! The information you provided will be kept confidential and will ONLY be used to better serve our customers. Remove this page from the manual and mail to the address below. Thank you from everyone here at Gorilla Playsets™! Mail to:...

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