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Big Backyard HILLCREST F23270 Installation And Operating Instructions Manual

Hillcrest play system
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HILLCREST PLAY SYSTEM – F23270
INSTALLATION AND OPERATING INSTRUCTIONS
28'
21'-4"
26'
15'-2"
32'-9"
HILLCREST
10-14 Hrs
Two person
assembly
3403270
WARNING
and give them to any future owner of this play system. Manufacturer contact information provided below.
OBSTACLE FREE SAFETY ZONE - 32'9" x 28' area requires Protective Surfacing. See page 3.
MAXIMUM VERTICAL FALL HEIGHT - 6'5"
28'
CAPACITY - 11 Users Maximum, Ages 3 to 10; Weight Limit 110 lbs. (49.9 kg) per child.
RESIDENTIAL HOME USE ONLY. Not intended for public areas such as schools, churches, nurseries, day cares or parks.
Solowave Design
375 Sligo Rd. West, PO Box 10
Mount Forest, ON Canada N0G 2L0
General Inquiries:
8:00am - 4:30pm EST
Toll Free: 1-877-966-3738
support@solowavedesign.com
To reduce the risk of serious injury or death, you must read and
follow these instructions. Keep and refer to these instructions often
Table of Contents
Warnings and Safe Play Instructions. . . . . . . . . . . . . . . pg. 2
Protective Surfacing Guidelines. . . . . . . . . . . . . . . . . . . pg. 3
Instructions for Proper Maintenance . . . . . . . . . . . . . . . pg. 4
About Our Wood – Limited Warranty . . . . . . . . . . . . . . pg. 5
Keys to Assembly Success . . . . . . . . . . . . . . . . . . . . . . pg. 6
Metric Conversion Sheets . . . . . . . . . . . . . . . . . . . . . pg. 7,8
Part ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pg. 9
Installation of I.D./Warning Plaque . . . . . . . . . . . .Final Step
Rev 02/14/2013

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  • Page 1 HILLCREST PLAY SYSTEM – F23270 INSTALLATION AND OPERATING INSTRUCTIONS WARNING To reduce the risk of serious injury or death, you must read and follow these instructions. Keep and refer to these instructions often and give them to any future owner of this play system. Manufacturer contact information provided below.
  • Page 2 Warnings and Safe Play Instructions Warnings and Safe Play Instructions CONTINUOUS ADULT SUPERVISION REQUIRED. Most serious injuries and deaths on playground equipment have occurred CONTINUOUS ADULT SUPERVISION REQUIRED. Most serious injuries and deaths on playground equipment have occurred while children were unsupervised! Our products are designed to meet mandatory and voluntary safety standards. Complying while children were unsupervised! Our products are designed to meet mandatory and voluntary safety standards.
  • Page 3 support@solowavedesign.com...
  • Page 4 support@solowavedesign.com...
  • Page 5 support@solowavedesign.com...

  • Page 6: Keys To Assembly Success

    Keys to Assembly Success Tools Required Shovel Measuring Drill (1/8” Safety Hammer Ratchet 1/2”, Level #2 & #3 Phillips Square Step Tape 3/16” Bit) Glasses 7/16” & 9/16” or Robertson Ruler Ladder Part Identification Key 1234 Post 2 x 4 x 83” On each page, you will find the parts and quantities required to complete the assembly step illustrated on that page.
  • Page 7 support@solowavedesign.com...
  • Page 8 support@solowavedesign.com...
  • Page 9 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size Nominal Size 10 pc. - 2411 - CE Siding 3/8 x 3 1/2 x 5 7/8 "  ‐  Box 3  ‐  3632411 "...
  • Page 10 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size Nominal Size 4 pc. - 1858 - Short Wall Support 1 x 4 x 24-1/4 "  ‐  Box 4  ‐ 3641858 " x 3¼" ½...
  • Page 11 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size 2 pc. - 2406 - Wall Board 1 x 5 x 19 3/4 "  ‐  Box 2  ‐ 3632406 Nominal Size " x 3¼" ½...
  • Page 12 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size 2 pc. - 2368 - A Frame Floor 1 x 6 x 20 11/16 "  ‐  Box 2  ‐ 3632368 Nominal Size " x 3¼" ½...
  • Page 13 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size 4 pc. - 2360 - A Frame Tread 5/4 x 4 x 22 1/8 "  ‐  Box 4  ‐ 3632360 Nominal Size " x 3¼" ½...
  • Page 14 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size 1 pc. - 2140 - Short Upright 2 x 3 x 33 "  ‐  Box 4  ‐ 3632140 Nominal Size " x 3¼" ½...
  • Page 15 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size Centre Post 2 x 4 x 32 3/4 3632366 Nominal Size 1 pc. - 2366 "  ‐  Box 4  ‐  " x 3¼" ½...
  • Page 16 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size 2 pc. - 0620 - SL Brace 2 x 2 x 12-1/2 "  ‐  Box 3  ‐ 3640620 Nominal Size " x 3¼" ½...
  • Page 17 Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Part Identification (Reduced Part Size) Actual Size 1-1/4 x 1-1/2 x 14 3650318 Nominal Size 7 pc. - 0318 - Ground Stake "  ‐  Box 1  ‐  " x 3¼" ½...
  • Page 18 Hardware Identification (Actual Size) 1/4 x 3" 7pc. LS3 - Lag Screw 1/4 x 1-1/2" - (9262230) 12pc. LS1 - Lag Screw - (9262212) 1/4 x 2-1/2" 2pc. LS2 - Lag Screw - (9272222) 1/4 x 4" 1pc. LS4 - Lag Screw - (9262240) Hex Bolt 1/4 x 1-1/2" 4pc. H1 - - (9277212) Hex Bolt 1/4 x 2" 35pc. H2 - - (9277220) Hex Bolt 1/4 x 2-1/2" 9pc. H3 - - (9277222) Hex Bolt 1/4 x 2-3/4" 10pc. H11 - - (9277223) Hex Bolt 1/4 x 3"...
  • Page 19 Hardware Identification (Actual Size) Hex Bolt 5/16 x 1-1/2" 4pc. G1 - - (9277312) Hex Bolt 5/16 x 2" 2pc. G8 - - (9277320) Hex Bolt 5/16 x 3" 2pc. G10 - - (9277330) Hex Bolt 5/16 x 3-3/4" 4pc. G21 - - (9277333) Hex Bolt 5/16 x 4" 3pc. G4 - - (9277340) Hex Bolt 5/16 x 4-1/2" 7pc. G5 - - (9277342) Hex Bolt 5/16 x 5-1/2" 4pc. G7 - - (9277352) Hex Bolt 5/16 x 6" 2pc. - (9277360) support@solowavedesign.com...
  • Page 20 Hardware Identification (Actual Size) 93pc. TN1 - 1/4" T - Nut (9285200) 10pc. FW3 - #8 Flat Washer - (9251500) 20pc. LW2 - 5/16" Lock Washer - (9253300) 15pc. FW0 - 3/16" Flat Washer - (9251100) 102pc. LW1 - 1/4" Lock Washer - (9253200) 20pc. TN2 - 5/16" T- Nut (9285300) 115pc. FW1 - 1/4" Flat Washer - (9251200) 12pc. LN2 - 5/16" Lock Nut (9283300) 9pc. BN1 - 1/4" Barrel Nut (9248200) 44pc. FW2 - 5/16" Flat Washer - (9251300) #8 x 7/8" 172pc. S0/S22 - Truss Screw - (9229505) #6 x 5/8"...
  • Page 21 (2pk) Spiral Wave Slide Bottom 1X 3320386 Rocks (5pk) (Green) 3-Green 2-Yellow 1X 3320356 1X 3533860 Big Backyard I.D 39" Glider Rope & Chain Plaque w hardware (4pk) w. welded chain 1X 3200184 Triangle Plate (4pk) 2X 9200300 Monkey Brkt...
  • Page 22 • T he wood pieces will have the four digit key number stamped on the ends of the boards. The wood pieces are referenced throughout the instructions with this number. • Please refer to Page 6 for proper hardware assembly. • E ach step indicates which bolts and/or screws you will need for assembly, as well as any flat washers, lock washers, t-nuts or lock nuts. I f there are any missing or damaged pieces or you need assistance with assembly please contact the Consumer Relations Department directly. Call us before going back to the store. 1-877-966-3738 support@solowavedesign.com R ead the assembly manual completely, paying special attention to ANSI warnings; C. notes; and safety/maintenance information on pages 1 - 6. B efore you discard your cartons fill out the form below. D. • T he carton I.D. stamp is located on the end of each carton. The tracking number is located on the Big Backyard ID Plaque (3320356). • P lease retain this information for future reference. You will need this information if you contact the Consumer Relations Department. MODEL NUMBER: F23270 CARTON I.D. STAMP: __ __ __ __ __ 14459 ___ (Box 1) CARTON I.D. STAMP: __ __ __ __ __ 14459 ___ (Box 4) CARTON I.D. STAMP: __ __ __ __ __ 14459 ___ (Box 2) CARTON I.D. STAMP: __ __ __ __ __ 14459 ___ (Box 5) CARTON I.D. STAMP: __ __ __ __ __ 14459 ___ (Box 3) CARTON I.D. STAMP: __ __ __ __ __ 14459 ___ (Box 6) TRACKING NUMBER (from ID Plaque): support@solowavedesign.com...
  • Page 23 Step 2: Access Ladder Assembly Pre-drill all pilot holes using a 1/8” drill bit before installing wood screws. A: Insert 4 (858) 1-1/8 x 18-5/8” Dowels into (2410) Right Access and (2374) Left Access, as shown in fig. 2.1. B: Make sure shoulder of dowel is against each rail before pre-drilling pilot holes. Drill 1/8” pilot holes through the rails and into the dowels to prevent splitting. (fig. 2.2) C: Attach (858) 1-1/8 x 18-5/8” Dowels to both rails with 2 (S3) #8 x 2-1/2” Wood Screws per dowel. (fig. 2.3) D: Measure 3” down from the edge of the angle on both (2410) Right Access and (2374) Left Access then attach (0822) Ladder Bottom to each rail with 4 (S15) #8 x 1-3/4” Wood Screws. (fig. 2.4) Fig. 2.1 2410 Fig. 2.2 2374 Fig. 2.3 Fig. 2.4 2410 2374 2410 0822 2374 3” Wood Parts Hardware Right Access 2 x 4 x 58”...
  • Page 24 Step 3: Swing Beam Assembly WARNING: Fig. 3.4 For your child’s safety, orientate the swing hangers as shown to ensure your swing will have proper swing motion when installed. Failure to do so could result in premature failure of the swing hanger or swing chain.
  • Page 25 Step 4: Swing End Assembly A: Attach 2 (1863) SW Posts to (1856) SW Upright using 2 (G4) 5/16 x 4” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 4.1) Fig. 4.1 1863 5/16” 1856 T-Nut 5/16” T-Nut 5/16” Flat Washer 1862 5/16” Lock Washer 5/16” Flat Washer 5/16” Lock Washer 1863 B: Attach (1862) SW Support to both (1863) SW Posts and (1856) SW Upright using 3 (G5) 5/16 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 4.1) Wood Parts Hardware 5/16 x 4” Hex Bolt SW Post 2 x 4 x 86-11/16” 1863 (5/16”...
  • Page 26 SW Rail Block 2 x 4 x 5-3/8” 4919 5/16 x 4-1/2” Hex Bolt (5/16” lock washer, 5/16” flat washer, 5/16” t-nut) 1 x Big Backyard Plaque (with hardware) 5/16 x 5-1/2” Hex Bolt (5/16” flat washer x2, 5/16” lock nut) 5/16 x 2”...

  • Page 27: Step 6: Door Assembly

    Step 6: Door Assembly Part 1 A: On the inside of (8197) Door Panel, measure 19” up from the bottom and 1/2” in from the outside edge then attach Catch Plate using 2 (S18) #6 x 1” Wood Screws. (fig. 6.1 and 6.2) B: On the inside of (8197) Door Panel beside the Catch Plate attach 1 Door Handle using 2 (S13) #6 x 5/8” Pan Screws. (fig. 6.1 and 6.2) Door Handle 8197 Fig. 6.1 Fig. 6.2 Catch Plate 1/2” 19” Inside View Wood Parts Hardware Other Parts #6 x 5/8” Pan Screw 1 x Door Handle Door Panel 1-3/16 x 16-3/8 x 43-5/16” 8197 #6 x 1”...
  • Page 28 Step 6: Door Assembly Part 2 C: On the outside of the (8197) Door Panel attach the second Door Handle at approximately the same place as the one on the inside. Use 2 (S13) #6 x 5/8” Pan Screws. (fig. 6.3 and 6.5) D: In the window opening of (8197) Door Panel insert 1 Small Window from the outside and attach with 8 (S13) #6 x 5/8” Pan Screws. (fig. 6.3) E: Attach 2 Door Hinges on the outside of the (8197) Door Panel on the opposite side from the Door Handle. Judge spacing based on fig. 6.3. Use 3 (S13) # 6 x 5/8” Pan Screws per Hinge. (fig. 6.4) Small Door Window Hinge Fig. 6.3 Fig. 6.4 Door Handle Outside View 8197 Fig. 6.5 Hardware Other Parts 1 x Door Handle 16 x #6 x 5/8” Pan Screw 1 x Small Window 2 x Door Hinge ...

  • Page 29: Step 7: Roof Assembly

    Step 7: Roof Assembly Part 1 A: Attach 1 (2394) Roof Support to another at the peak using 1 (S4) #8 x 3” Wood Screw. Do this twice so you have 2 Roof Support Assemblies. (fig. 7.1) B: Attach 1 (2417) Joist to another at the peak using 1 (S4) #8 x 3” Wood Screw. (fig. 7.1) Fig. 7.1 2394 2394 2394 2394 2417 2394 Wood Parts Hardware Roof Support 2 x 3 x 34-1/4” #8 x 3” Wood Screw 2394 Joist 2 x 2 x 33-1/2” 2417 support@solowavedesign.com...
  • Page 30 Step 7: Roof Assembly Part 2 C: Starting at the top of the Roof Support Assembly attach 1 (2421) Cedar Roofing on each side of the Roof Support Assemblies with 3 (S0) #8 x 7/8” Truss Screws per board. (fig. 7.2) Be sure to overlap the top of the boards so there are no gaps. (fig. 7.2 and 7.3) D: Drill a hole 1-1/2” up from the bottom of the 2 bottom (2421) Cedar Roofing (for bottom row only). Attach 1 (2421) Cedar Roofing at the bottom of the Roof Support Assembly on each side, making sure they are flush to each (2394) Roof Support with 3 (S0) #8 x 7/8” Truss Screws per board. (fig. 7.2 and 7.4) E: On one side of the assembly evenly space and attach 8 (2421) Cedar Roofing, leaving no gaps, with 3 (S0) #8 x 7/8” Truss Screws per board. There should be 10 (2421) Cedar Roofing on this side. (fig. 7.2) F: On the other side of the assembly evenly space and attach 8 (2421) Cedar Roofing, leaving no gaps, with 3 (S0) #8 x 7/8” Truss Screws per board. (fig. 7.2) Fig. 7.2 S0 x 60 x 20 2421 2394 2161 (hidden) 1-1/2” Fig. 7.3 Fig. 7.4 2421 Overlap cedar roofing Flush to edge 1-1/2” Roof Supports removed for clarity Wood Parts Hardware 20 x...
  • Page 31 Step 8: Access Wall Assembly Note: Pre-drill all holes using a 1/8” drill bit before installing the Lag Screws. A: On the ground lay flat 2 (2383) Posts then loosely attach (0348) SL Ground with 4 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut); (2371) Floor End (in the top holes) and (1502) Wall Support with 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut) per board, as shown in fig. 8.1. Keep bolts loose. B: Make sure assembly is square and then fasten (2371) Floor End to (2383) Posts with 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer). (fig. 8.1) C: Tighten all bolts. D: Install one 1/4” T-nut into (2371) Floor End as shown in fig.8.1. 1502 Fig. 8.1 1/4” flat 1/4” lock washer 1/4” t-nut washer 2383 1/4” t-nut 2371 Notice the hole locations 1/4” flat washer...
  • Page 32 Step 9: Cafe Wall Assembly Note: Pre-drill all holes using a 1/8” drill bit before installing the Lag Screws. A: On the ground lay flat 2 (2383) Posts then loosely attach (0348) SL Ground with 4 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut); (2371) Floor End (in the top holes) and (2387) Side Arch (in the top holes) with 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut) per board, as shown in fig. 9.1. Keep bolts loose. B: Make sure assembly is square and then fasten (2371) Floor End to (2383) Posts with 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer) and (2387) Side Arch to posts with 2 (S2) #8 x 1-1/2” Wood Screws. (fig. 9.1) C: Tighten all bolts. 2387 1/4” flat washer 1/4” t-nut Fig. 9.1 2383 1/4” lock washer 2371 Notice the hole locations 1/4” flat washer...
  • Page 33 Step 10: Front Wall Assembly A: With both the Access and Cafe Walls facing each other loosely attach (2372) Fig. 10.1 Front Ground to (2383) Posts with 2 (H4) 2380 Notice hole towards top. 1/4 x 4” Hex Bolts (with lock washer, flat 1/4” washer and t-nut). Notice the extended t-nut 2383 end is on the Cafe Wall side. (fig. 10.1) 1/4” flat washer B: Loosely attach (2350) Front Floor to 1/4” lock both (2383) Posts with 2 (H5) 1/4 x 4-1/2” washer Hex Bolts (with lock washer, flat washer and t-nut), the arch should be on the right side of the wall, and (2380) Middle Front 2383 to both posts with 4 (H4) 1/4 x 4” Hex Bolts (with lock washer, flat washer and 2350 t-nut). (fig. 10.1) 2366 C: Check that assembly is square then attach (2372) Front Ground to both (2383) Posts with 2 (S7) #12 x 2” Pan Notice Arch Screws (with flat washer). (fig. 10.1)
  • Page 34 Step 11: Swing Wall Assembly A: Loosely attach (2395) SW Ground using 2 (H4) 1/4 x 4” Hex Bolts (with lock washer, flat washer and t-nut) in the top holes, (2370) Floor Back using 2 (H5) 1/4 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut) in the bottom holes and (2389) SW Back using 4 (H5) 1/4 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut) to both (2383) Posts. (fig. 11.1) B: Loosely attach (2390) SW Mount to (2370) Floor Back and (2389) SW Back with 2 (G5) 5/16 x 4-1/2” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 11.1) Note: Pre-drill all holes using a 1/8” drill bit before installing the Lag Screws. C: Make sure the assembly is square then tighten all Hex Bolts from this step. Attach (2370) Floor Back to each (2383) Post with 2 (LS3) 1/4 x 3” Lag Screw (with flat washer) and (2395) SW Ground to each (2383) Posts with 2 (S7) #12 x 2” Pan Screws (with flat washer). (fig. 11.1) D: Tight to the bottom of (2370) Floor Back and bevelled edges flush to outside edge of (2383) Posts, attach 1 (2113) Gussett II to each side using 2 (LS3) 1/4 x 3” Lag Screws (with flat washer) per gusset. (fig. 11.1) 2389 Notice holes towards top. Fig. 11.1 2383 2383 5/16” t-nut (hidden) 2390...
  • Page 35 Step 12: Floor Assembly Part 1 A: 5/8” down from the top of both (2371) Floor Ends attach (0790) Floor Joist with 2 (S4) #8 x 3” Wood Screws per end. (fig. 12.1 and 12.3) B: On the Swing Wall attach (0795) Side Joist to the inside of (2370) Floor Back with 2 (H3) 1/4 x 2-1/2” Hex Bolts (with lock washer, flat washer and t-nut) and 2 (S7) #12 x 2” Pan Screws from outside the assemby, as shown in fig. 12.1. C: On the Front Wall, on the Access Wall side, place (2375) Long Joist on the inside of (2350) Front Floor and (2379) Mid Joist on the outside of (2350) Front Floor, with the long edge flat to the board and the angled end towards the middle. Attach both joists to (2350) Front Floor with 2 (H4) 1/4 x 4” Hex Bolts (with lock washer, flat washer and t-nut) and 1 (S4) #8 x 3” Wood Screw, as shown in fig. 12.1 and 12.2. D: On the Front Wall, on the Cafe Wall side place (2386) Short Joist on the inside of (2350) Front Floor and attach with 2 (H3) 1/4 x 2-1/2” Hex Bolts (with lock washer, flat washer and t-nut) from outside the assembly. (fig. 12.1 and 12.2) Cafe Wall 0790 Fig. 12.1 Fig. 12.3 Swing Wall 2371 2370 0790 5/8” 2386 2350 2371 Side View 0795 0790 Notice angled end Fig.
  • Page 36 Step 12: Floor Assembly Part 2 E: Place 1 (1853) Cedar Gap Board at each end of the assembly. Then starting on the Access Wall side place 3 (1851) Cedar Floor Boards, 3 (2415) Cedar Floor Boards, 1 (2416) Cedar Gap Board so the gap in the board fits around (2366) Centre Post, 1 more (2415) Cedar Floor Board and 1 (2414) Cedar Floor Board. Make sure all boards are evenly spaced. (fig. 12.4) F: Attach boards to (0795) Side Joist, (0790) Floor Joist, (2375) Long Joist and (2386) Short Joist with 5 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 12.4) 1851 2366 Fig. 12.4 Cafe Wall 2416 1853 1853 0795 (hidden) 2386 (hidden) 2414 0790 (hidden) x 5 per 2415 board 2375 (hidden) Access Wall Wood Parts Hardware Cedar Gap Board 1 x 5 x 38-3/4” 1853 55 x #8 x 1-1/2”...
  • Page 37 Step 13: Attach Ground Stakes MOVE FORT TO FINAL LOCATION. FINAL LOCATION MUST BE LEVEL GROUND. WARNING: To prevent tipping and avoid potential injury, stakes must be driven 10-1/2” into ground. Digging or driving stakes can be dangerous if you do not check first for underground wiring, cables or gas lines. A: Drive 2 (0318) Ground Stakes 10-1/2” into the ground at each (2383) Post on the Swing Wall side tight to each post, as shown in fig. 13.1. Attach using 2 (S3) #8 x 2-1/2” Wood Screws per ground stake. (fig. 13.2) Swing Side...

  • Page 38: Step 14: Roof Frame Assembly

    Step 14: Roof Frame Assembly Part 1 A: Place 1 (2384) Post Support tight to top of (1502) Wall Support on Access Wall side at each (2383) Post and 1 (2384) Post Support tight to top of (2837) Side Arch on Cafe Wall side at each (2383) Post. Each (2384) Post Support must be flush to the inside edge of each post. Attach each (2384) Post Support to posts with 3 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 14.1 and 14.2) B: Tight to the top and flush to the inside edge of each (2383) Post attach 1 (2364) Block to each (2384) Post Support with 4 (S2) #8 x 1-1/2” Wood Screws per board. Notice the hole orientation on each board. (fig. 14.1 and 14.2) Fig. 14.1 2383 2837 Fig. 14.2 Notice hole orientation. 1502 2383 2364 2383 2384 Flush and Tight x 7 per Access Wall board 2383 Flush 1502 Wood Parts Hardware Block 2 x 4 x 13”...
  • Page 39 Step 14: Roof Frame Assembly Part 2 C: On the Cafe Wall and Access Wall sides place 1 (0348) SL Ground tight to top of each (2384) Post Support and flush to the outside edges of each (2364) Block. Attach to each (2364) Block with 4 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut) per board. (fig. 14.3 and 14.4) D: On the Front Wall and Swing Wall sides place 1 (2391) Top Front Back flush to the top and outside edge of each (2364) Block. Attach to each (2364) Block with 2 (H4) 1/4 x 4” Hex Bolts (with lock washer, flat washer and t-nut) in the top holes and 2 (S2) #8 x 1-1/2” Wood Screws in the bottom holes, per board. (fig. 14.3 and 14.4) Swing Wall Cafe Wall Fig. 14.3 0348 2391 0348 Fig. 14.4 0348 1/4” t-nut 2391 1/4” flat washer Front Wall Access Wall 1/4” flat washer 1/4” lock washer 1/4” lock washer 2384 2364...
  • Page 40 Step 15: Attach Roof to Fort Part 1 A: Attach 1 (2420) Bottom Gable to each end of the Roof Assembly from Step 7 with 1 (S2) #8 x 1-1/2” Wood Screw and 1 (S4) #8 x 3” Wood Screw per corner. (fig. 15.1 and 15.2) B: Attach 2 Corner Braces to each (2420) Bottom Gable with 2 (S5) #8 x 1/2” Pan Screws per brace. The Corner Braces should be centred over the outside arches as shown in fig 15.1 and 15.2. 2394 Fig. 15.1 2394 Roof Assembly 2394 2420 Fig. 15.2 2420 Corner Brace x 2 per Corner Brace Wood Parts Hardware Other Parts #8 x 1/2” Pan Screw 4 x Corner Brace Bottom Gable 2 x 4 x 41”...
  • Page 41 Step 15: Attach Roof to Fort Part 2 C: With two helpers place the Roof Assembly on the fort as shown in fig. 15.3. All four Corner Braces should sit on the outside face of each (0348) SL Ground. (fig. 15.3 and 15.4) D: Attach each Corner Brace to the (0348) SL Grounds with 1 (S5) #8 x 1/2” Pan Screw per brace. (fig. 15.4) Fig. 15.3 Access Wall 0348 0348 Cafe Wall Corner Brace x 4 Fig. 15.4 0348 x 1 per Corner Brace Hardware #8 x 1/2” Pan Screw support@solowavedesign.com...
  • Page 42 Step 16: Attach Gable to Roof A: Along each (2394) Roof Support measure 8” up from the top of (2420) Bottom Gables then tight to the underside of the Roof, on each Roof Support Assembly, attach 2 (2419) Gable Sides, at the measured spot, to (2394) Roof Supports and (2420) Bottom Gable with 2 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 16.1) B: Tight to the underside of the Roof, at the peak of each Roof Support Assembly, attach 1 (2418) Gable Top to the (2394) Roof Supports with 4 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 16.1) Repeat for opposite side. 2418 Fig. 16.1 2394 8” 2419 x 16 Inside View 2420 Notice board orientation. Wood Parts Hardware 16 x #8 x 1-1/2” Wood Screw Gable Top 1 x 6 x 19” 2418 Gable Side 1 x 4 x 13-23/32”...
  • Page 43 Step 17: Upper Swing Wall Assembly A: In between both (2383) Posts on Swing Wall side attach 7 (5265) Cedar Walls to (2370) Floor Back and (2389) SW Back using 4 (S2) #8 x 1-1/2” Wood Screws per board. Make sure the bottom of the boards are tight against the floor boards and the bevelled ends are at the top and facing out. Evenly space boards as shown below. Spacing must not exceed 3” in between all boards. (fig. 17.1 and 17.2) Fig. 17.1 Swing Wall 2389 Not to 2383 exceed 3” Bevelled edges facing out. 2370 2383 x 4 per board 5265 Fig. 17.2 Wood Parts Hardware Cedar Wall 1 x 4 x 28” 28 x #8 x 1-1/2”...
  • Page 44 Step 18: Attach Access Ladder to Fort Pre-drill all holes using a 3/16” drill bit before installing the Lag Screws A: Place the Access Ladder in the opening of the Access Wall, flush to the outside edge of (2371) Floor End on the Swing Wall. Attach (2410) Right Access to (2371) Floor End with 1 (H12) 1/4 x 3” Hex Bolt (with lock washer and flat washer and previously installed t-nut). (fig. 18.1 and 18.2) B: Attach (2374) Left Access to (2371) Floor End with 1 (LS4) 1/4 x 4” Lag Screw (with flat washer). (fig. 18.1 and 18.2) C: Attach (2395) SW Ground to (2374) Left Access with 2 (S2) #8 x 1-1/2” Wood Screws. (fig. 18.1 and 18.3) 1/4” flat washer Fig. 18.2 Fig. 18.1 1/4” t-nut 1/4” lock (previously washer installed) 1/4” flat 2371 washer 2371 2410 2374...
  • Page 45 Step 19: Upper Access Wall Assembly A: On the Access Wall side, tight to (2410) Right Access and centred between (1502) Wall Support and (2371) Floor End attach 1 (0304) CE Floor Board with 4 (S1) #8 x 1-1/8” Wood Screws. (fig. 19.1 and 19.2) B: Evenly space and attach 2 more (0304) CE Floor Boards to (1502) Wall Support and (2371) Floor End with 4 (S1) #8 x 1-1/8” Wood Screws per board. The space between boards should be 1-7/8”, not exceeding 2-1/8” (fig. 19.1 and 19.2) Fig. 19.1 1502 Evenly space 2371 2410 Fig. 19.2 0304 Access Wall 2371 x 4 per board Wood Parts Hardware 12 x #8 x 1-1/8” Wood Screw CE Floor Board 1 x 4 x 32-1/2” 0304 support@solowavedesign.com...
  • Page 46 Step 20: Upper Front Wall Assembly Part 1 A: On the Front Wall, tight to the floor boards, (2366) Centre Post and (2383) Post and 3/8” back from the outside face of (2383) Post and (2366) Centre Post attach 1 (2407) Wall Joist to each post with 3 (S3) #8 x 2-1/2” Wood Screws per board. (fig. 20.1, 20.2 and 20.3) Fig. 20.1 Fig. 20.2 2380 2407 x 3 per board Front Wall 3/8” 2407 Fig. 20.3 2407 2383 2383 2366 2366 2350 2350 Side View Wood Parts Hardware #8 x 2-1/2” Wood Screw Wall Joist 2 x 2 x 28-1/2”...
  • Page 47 Step 20: Upper Front Wall Assembly Part 2 B: Between (2366) Centre Post and (2383) Post and tight to the top of the floor boards attach 3 (2412) CE Siding to both (2407) Wall Joists with 2 (S0) #8 x 7/8” Truss Screws per board. Make sure there are no gaps between boards (fig. 20.4 and 20.5) C: Install (2430) Clock Siding followed by 4 more (2412) CE Siding making sure there are no gaps between boards. Attach to both (2407) Wall Joists with 2 (S0) #8 x 7/8” Truss Screws per board. The top of the last (2412) CE Siding should be to the bottom of (2380) Middle Front. (fig. 20.5) Fig. 20.4 Fig. 20.5 2407 (hidden) 2380 2383 2366 2412 2430 Front Wall x 2 per board 2412 Wood Parts Hardware CE Siding 3/8 x 3-1/2 x 12-1/8” 2412 16 x #8 x 7/8”...
  • Page 48 Step 21: Front Window Wall Assembly Part 1 A: On the Front Wall place 1 (2406) Wall Board tight to (2364) Block on Cafe Wall and tight to top of (2407) Wall Joist then attach to (2391) Top Front Back and (2380) Middle Front with 4 (S1) #8 x 1-1/8” Wood Screws. (fig. 21.1 and 21.2) B: Tight to (2364) Block on the Access Wall and 2” up from the bottom of (2380) Middle Front attach a second (2406) Wall Board to (2391) Top Front Back and (2380) Middle Front with 4 (S1) #8 x 1-1/8” Wood Screws. (fig. 21.1 and 21.2) C: In the centre of the opening measure 2” up from the bottom of (2380) Middle Front and attach 2 (0606) CE Access Boards to (2391) Top Front Back and (2380) Middle Front with 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 21.1 and 21.2) Centre in opening Fig. 21.1 Roof removed for clarity. 2391 Fig. 21.2 2406 2380 2391 0606 Flush 2407 2406 2364 2383 Access Wall 2383 2380 2”...
  • Page 49 Step 21: Front Window Wall Assembly Part 2 D: Flush to the inside edge of each (2406) Wall Boards attach 1 (2409) Window Trim with 2 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 21.3 and 21.4) E: Flush to the outside edge of each (0606) CE Access Board attach 1 (2409) Window Trim with 2 (S1) #8 x 1-1/8” Wood Screw per board. (fig. 21.4) Fig. 21.4 Flush 2406 2406 2409 2380 0606 Outside View x 2 per board Fig. 21.3 Front Wall Wood Parts Hardware Window Trim 1 x 2 x 13-3/8” #8 x 1-1/8” Wood Screw 2409 support@solowavedesign.com...
  • Page 50 Step 22: Cafe Window Wall Assembly A: In the centre of the Cafe Wall opening measure 3” down from the top of (0348) SL Ground and attach 2 (0850) CE Wall Boards to (0348) SL Ground and (2387) Side Arch with 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 22.1 and 22.2) B: Flush to the outside edge of each (0850) CE Wall Board attach 1 (2409) Window Trim with 2 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 22.3 and 22.4) Fig. 22.1 Centre in opening Cafe Wall Fig. 22.2 Inside View 0348 3” Parts removed for clarity. 0850 Bevelled edge towards bottom and facing in. 2387 Fig. 22.3 x 4 per board Flush Fig.
  • Page 51 Step 23: Lower Swing Wall Assembly Part 1 A: Tight to the top of (2395) SW Ground and flush to the outside edges of both (2383) Posts on the Swing Wall side attach 6 (2413) CE Siding to each post with 2 (S0) #8 x 7/8” Truss Screws per board, as shown in fig. 23.1 and 23.2. Make sure there are no gaps between boards. B: Tight to the top (2413) CE Siding and flush to outside edges of both (2383) Posts attach (2422) Lower Back to each post with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 23.2) Fig. 23.1 Fig. 23.2 2383 2422 Swing Wall 2413 2383 x 2 per board 2395 Wood Parts Hardware CE Siding 3/8 x 3-1/2 x 46-5/8” 2413 #8 x 1-1/2” Wood Screw Lower Back 1 x 4 x 46-1/2”...
  • Page 52 Step 23: Lower Swing Wall Assembly Part 2 C: From inside the assembly measure 1-1/4” down from the top of (2422) Lower Back then place 2 (1858) Short Wall Supports over the pilot holes of the (2413) CE Siding then attach to (2422) Lower Back and (2395) SW Ground with 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 23.3 and 23.4) D: From outside of the assembly attach (1858) Short Wall Supports to each (2413) CE Siding with 2 (S0) #8 x 7/8” Truss Screws per siding. (fig. 23.5) Fig. 23.4 Fig. 23.3 2422 1-1/4” x 4 per board 2413 1858 2395 Inside View 1858 Fig. 23.5 (hidden) 2413 x 2 per board Wood Parts Hardware Short Wall Support 1 x 4 x 24-1/4” 1858 #8 x 1-1/8”...
  • Page 53 Step 24: Lower Access Wall Assembly Part 1 A: Flush to the outside edge of (2383) Post and tight to the top of (0348) SL Ground attach (1808) Short Trim to (2383) Post with 3 (S2) #8 x 1-1/2” Wood Screws. (fig. 24.1 and 24.2) B: Tight to top of (0348) SL Ground and tight to (1808) Short Trim attach 6 (1852) CE Siding to both (2383) Posts with 2 (S0) #8 x 7/8” Truss Screws per board. Make sure there are no gaps between boards. (fig. 24.1 and 24.2) C: Tight to (1852) CE Siding and top of (0348) SL Ground attach 1 (1870) Trim Short to (2383) Post with 3 (S2) #8 x 1-1/2” Wood Screws. (fig 24.2) Fig. 24.1 2383 2383 1852 Fig. 24.2 Flush 2383 1870 2383 Access Wall 1808 Tight 0348 x 2 per board Tight Wood Parts Hardware 12 x #8 x 7/8” Truss Screw Trim Short 1 x 2-1/2 x 19-5/8”...
  • Page 54 Step 24: Lower Access Wall Assembly Part 2 D: Place (1868) Table Support flush to the angled edge of (0376) Table Top, as shown in fig. 24.3. The overhang should measure Fig. 24.4 3-3/8” on each side. Attach using 5 (S7) #12 x 2” Pan Screws. E: Place Table Top Assembly tight to the top of (1852) CE Siding, (1808) Short Trim and (1870) Trim Short. Make sure (1868) Table Support is flush to the outside edges of both (2383) Posts then attach (1868) Table Support to each post with 2 (S3) #8 x 2-1/2” Wood Screws per post. (fig. 24.4 and 24.5) Flush Fig. 24.3 Front Wall 0376 1868 Flush Fig. 24.5 3-3/8” 1868 2383 1870 1852 1808 Wood Parts Hardware #8 x 2-1/2” Wood Screw Table Top 5/4 x 6 x 32”...
  • Page 55 Step 24: Lower Access Wall Assembly Part 3 F: From inside the assembly tight to the bottom of (0376) Table Top place 2 (1858) Short Wall Supports over the pilot holes of the (1852) CE Siding then attach to (1868) Table Support and (0348) SL Ground with 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 24.6 and 24.7) G: From outside of the assembly attach (1858) Short Wall Supports to each (1852) CE Siding with 2 (S0) #8 x 7/8” Truss Screws per siding. (fig. 24.8) 0376 Fig. 24.6 1868 Fig. 24.7 Flush x 4 per board 1858 1852 Access Wall 0348 1868 1858 (hidden) Fig. 24.8 1852 x 2 per board Wood Parts Hardware #8 x 1-1/8” Wood Screw Short Wall Support 1 x 4 x 24-1/4”...
  • Page 56 Step 24: Lower Access Wall Assembly Part 4 Note: Pre-drill all holes using a 1/8” drill bit before installing the lag screws. H: Tight to the bottom of (2371) Floor End, place (2387) Side Arch flush to the outside edges of each (2383) Post then attach with 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer) in the top holes. (fig. 24.9 and 24.10) I: Attach (2387) Side Arch to (2383) Posts in the bottom holes with 2 (S2) #8 x 1-1/2” Wood Screws. (fig. 24.10) Fig. 24.9 2371 2387 2383 2383 Fig. 24.10 with 1/4” flat washer 2371 2383 2387 Flush 2383 Wood Parts Hardware Side Arch 1 x 5 x 38-1/4”...

  • Page 57: Step 25: Bench Assembly

    Step 25: Bench Assembly A: Attach (2144) Lower Bench flush to the top and outside edges of 2 (2105) Bench Posts with 4 (S2) #8 x 1-1/2” Wood Screws, as shown in fig. 25.2. Notice the bolt holes in (2105) Bench Posts are at the bottom of the boards. B: Centre (2363) Bench on top of (2105) Bench Posts and attach with 4 (S15) #8 x 1-3/4” Wood Screws. The posts should measure 1” from the edges and sides. (fig. 25.1 and 25.2) Fig. 25.1 1” 2105 1” 2105 1” 2363 Fig. 25.2 2363 2105 2144 2105 Notice bolt holes Flush towards bottom of boards Wood Parts Hardware Bench 5/4 x 6 x 41” 2363 #8 x 1-1/2” Wood Screw Lower Bench 1 x 4 x 38-7/8”...
  • Page 58 Step 26: Attach Bench Assembly to Fort A: With (2144) Lower Bench facing away from the fort, attach (2372) Front Ground and (2395) SW Ground to (2105) Bench Posts with 2 (H1) 1/4 x 1-1/2” Hex Bolts (with lock washer, flat washer and t-nut) and 1 (S2) #8 x 1-1/2” Wood Screw per post. (fig. 26.1 and 26.2) Fig. 26.1 2395 Fig. 26.2 2372 2144 (hidden) 2105 1/4” Flat Washer 2395 1/4” 1/4” Lock T-Nut Washer 2372 Hardware 1/4 x 1-1/2” Hex Bolt (1/4” lock washer, 1/4” flat washer, 1/4” t-nut) #8 x 1-1/2”...
  • Page 59 Step 27: Lower Front Wall Assembly Part 1 A: On the Front Wall measure 20-3/8” up from (2372) Front Ground then place (2378) Lower Window flush to outside edge of (2383) Post at measured location. Attach (2378) Lower Window to (2383) Post and (2377) Lower Post with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 27.1 and 27.2) B: Tight to the top of (2372) Front Ground and flush to the outside edge of (2383) Post evenly space and attach 5 (2376) CE Siding to each post with 2 (S0) #8 x 7/8” Truss Screws per board, as shown in fig. 27.1 and 27.2. Make sure there are no gaps between boards. Fig. 27.1 2377 Front Wall 2383 Fig. 27.2 2378 2376 2377 Flush 2383 20-3/8” 2372 x 2 per board Wood Parts Hardware #8 x 1-1/2” Wood Screw Lower Window 1 x 4 x 27” 2378 10 x #8 x 7/8”...
  • Page 60 Step 27: Lower Front Wall Assembly Part 2 C: Tight to the bottom of (2350) Front Floor and flush to the outside edge of (2383) Post attach 2 (2376) CE Siding to (2383) Post and (2377) Lower Post with 2 (S0) #8 x 7/8” Truss Screws per board, as shown in fig. 27.3 and 27.4. Make sure there are no gaps between boards. D: Tight to the bottom and flush to the outside edge of (2376) CE Siding and flush to outside edge of (2383) Post evenly space and attach 5 (2411) CE Siding to each (2383) Post and (2377) Lower Post with 1 (S0) #8 x 7/8” Truss Screw per board. (fig. 27.4) Fig. 27.3 Fig. 27.4 2350 2376 Front Wall 2383 Flush 2411 x 10 Flush 2377 2378 x 14 Wood Parts Hardware CE Siding 3/8 x 3-1/2 x 27” 14 x #8 x 7/8”...
  • Page 61 Step 27: Lower Front Wall Assembly Part 3 E: From inside the assembly flush to the bottom of (2372) Front Ground place 2 (2408) Wall Supports over the pilot holes of the siding and flush to the inside edges of (2411) CE Siding then attach to (2350) Front Floor and (2372) Front Ground with 4 (S1) #8 x 1-1/8” Wood Screws per board. (fig. 27.5 and 27.6) F: From outside of the assembly attach (2408) Wall Supports to each (2376) CE Siding with 2 (S0) #8 x 7/8” Truss Screws per siding and to (2411) CE Siding with 1 (S0) #8 x 7/8” Truss Screw per siding. (fig. 27.7) Fig. 27.5 Parts removed for clarity. Fig. 27.6 x 4 per board 2350 2411 2376 (hidden) 2408 Fig. 27.7 Flush 2411 2376 2408 2411 2376 Inside View 2372 x 2 per board Flush Wood Parts Hardware #8 x 1-1/8”...
  • Page 62 Step 27: Lower Front Wall Assembly Part 4 G: From inside the fort flush to the bottom of (2383) Post and 1-3/8” from front of (2383) Post attach (2367) Door Stop to (2383) Post with 4 (S15) #8 x 1-3/4” Wood Screws. (fig. 27.8 and 27.9) H: In the notched out opening of (2367) Door Stop attach the Magnetic Catch using 2 (S18) #6 x 1” Wood Screws. (fig. 27.10) Important: Use a hand held screw driver and DO NOT over tighten. Fig. 27.8 Fig. 27.9 Flush 2386 2383 2367 2367 Fig. 27.10 Magnetic Catch Inside View 2372 Flush 1-3/8” Wood Parts Hardware Other Parts...
  • Page 63 Step 27: Lower Front Wall Assembly Part 5 I: In the opening for the door between (2383) Post and (2377) Lower Post, measure 5/8” up from the top of (2372) Front Ground then attach remaining side of the Door Hinges on the Door Assembly from Step 6 to (2377) Lower Post with 3 (S13) #6 x 5/8” Pan Screws per hinge. (fig. 27.11 and 27.12) Fig. 27.11 2383 2377 Fig. 27.12 5/8” 2372 Hardware #6 x 5/8” Pan Screw support@solowavedesign.com...
  • Page 64 Step 28: Attach Windows and Hand Grips Part 1 Pre-drill all holes using a 1/8” drill bit before installing the Pan Screws. Make sure pre-drill goes into siding only. A: On the outside of the assembly place 1 Bay Window in the window gap. On the inside of the assembly place 1 (2365) Bottom Top Trim against the Bay Window on the top and bottom, as shown in fig. 28.2. Attach Bay Window to fort through both (2365) Bottom Top Trims and both (2408) Wall Supports with 10 (S16) #6 x 1” Pan Screws. (fig. 28.1, 28.2 and 28.3) Fig. 28.1 Front Wall Fig. 28.3 2408 Fig.
  • Page 65 Step 28: Attach Windows and Hand Grips Part 2 Pre-drill all holes using a 1/8” drill bit before installing the Lag Screws. B: Measure 3” up from the top of (2371) Floor End on (2383) Post on the Access Wall then attach 1 Hand Grip with 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer). (fig. 28.4 and 28.5) Fig. 28.4 2383 1/4” flat Fig. 28.5 washer Hand Grip 3” Access Wall 2371 Hardware Other Parts 1 x Hand Grip 1/4 x 1-1/2”...
  • Page 66 Step 28: Attach Windows and Hand Grips Part 3 C: On the outside of the assembly measure 3/4” down from the top of (2387) Side Arch and (2380) Middle Front then place 4 6-Pane Arch Top Windows in the window gaps on the Front and Cafe Walls and attach with 8 (S13) #6 x 5/8” Pan Screws per window. (fig. 28.6 and 28.7) Fig. 28.6 Fig. 28.7 2380 2387 x 8 per Window 6-Pane Arch Top Window 3/4” 2387 Front Wall Cafe Wall Hardware Other Parts 4 x 6-Pane Arch Top Window 32 x #6 x 5/8” Pan Screw support@solowavedesign.com...
  • Page 67 Step 28: Attach Windows and Hand Grips Part 4 D: Place Clock Face on the Front Wall lining the hole in the clock to the hole in (2430) Clock Siding, making sure the clock is snug to the siding. Attach to (2430) Clock Siding and (2412) CE Siding with 4 (S10) #8 x 1” Pan Screws. (fig. 28.8 and 28.9) E: From inside the assembly insert Clock Knob in the hole in (2430) Clock Siding, then with 1 person inside the fort and 1 outside place Hour Hand over Clock Knob making sure they are lined up properly. Finally, press Minute Hand over Hour Hand. (fig. 28.9, 28.10, and 28.11) Fig. 28.9 Hour Hand Fig. 28.8 2430 2412 Clock Hole in Clock Minute Hand Siding lines up to hole in Clock. Fig. 28.10 2430 Fig. 28.11 Front Wall Hour Hand Knob connects to Inside View minute/hour hands. Minute Hand Knob Clock Hardware...
  • Page 68 Step 29: A Frame MK Wall Assembly Part 1 A: Loosely attach 2 (2361) A Frame Uprights to 1 (2353) A Frame Floor Support with 2 (H11) 1/4 x 2-3/4” Hex Bolts (with lock washer, flat washer and t-nut) and to 1 (2359) A Frame Top Side with 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut), as shown in fig. 29.1. B: Loosely attach (2352) A Frame Access R and 1 (2356) A Frame Post to (2353) A Frame Floor Support with 1 (H11) 1/4 x 2-3/4” Hex Bolt (with lock washer, flat washer and t-nut) per board and to each (2361) A Frame Upright with 1 (G21) 5/16 x 3-3/4” Hex Bolt (with lock washer, flat washer and t-nut) per board. (fig. 29.1) 2359 Notice bolt hole towards bottom 1/4” T-Nut Fig. 29.1 2361 1/4” Flat 1/4” Lock Washer Washer 516” T-Nut 5/16” Lock 2361 Washer 5/16” Flat Washer 1/4” 2353 T-Nut 1/4” Flat Washer...
  • Page 69 Step 29: A Frame MK Wall Assembly Part 2 C: Install 1 5/16” T-Nut into (2381) MK Mount. (fig. 29.2) D: Loosely attach (2381) MK Mount to (2353) A Frame Floor Support with 1 (H11) 1/4 x 2-3/4” Hex Bolt (with lock washer, flat washer and t-nut) and to (2359) A Frame Top Side with 1 (H2) 1/4 x 2” Hex Bolt (with lock washer, flat washer and t-nut), as shown in fig. 29.3. Notice the direction the 5/16” T-Nut installed in Step C is facing. E: Loosely attach (2355) A Frame Lower Side B to (2356) A Frame Post and (2352) A Frame Access R with 2 (H3) 1/4 x 2-1/2” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 29.3) F: Make sure the assembly is square then attach (2355) A Frame Lower Side B to (2356) A Frame Post and (2352) A Frame Access R with 2 (S7) #12 x 2” Pan Screws. (fig. 29.3) G: Tighen all bolts. 2359 Notice board location. 1/4” Flat Washer 1/4” T-Nut Fig. 29.3 1/4” Lock Washer Fig. 29.2 Notice t-nut location. 2353 2381 5/16”...
  • Page 70 Step 30: A Frame Access Wall Assembly Part 1 A: Loosely attach 2 (2361) A Frame Uprights to 1 (2353) A Frame Floor Support with 2 (H11) 1/4 x 2-3/4” Hex Bolts (with lock washer, flat washer and t-nut) and to 1 (2359) A Frame Top Side with 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut), as shown in fig. 30.1. B: Loosely attach (2351) A Frame Access L and 1 (2356) A Frame Post to (2353) A Frame Floor Support with 1 (H11) 1/4 x 2-3/4” Hex Bolt (with lock washer, flat washer and t-nut) per board and to each (2361) A Frame Upright with 1 (G21) 5/16 x 3-3/4” Hex Bolt (with lock washer, flat washer and t-nut) per board. (fig. 30.1) 1/4” Flat 1/4” Washer 1/4” Lock T-Nut Washer Notice bolt hole towards bottom Fig. 30.1 2359 2361 516” T-Nut 5/16” Flat Washer 5/16” Lock Washer 2353 1/4” T-Nut 1/4” Lock 1/4” Flat 2356...
  • Page 71 Step 30: A Frame Access Wall Assembly Part 2 C: Loosely attach (2354) A Frame Lower Side to (2356) A Frame Post and (2351) A Frame Access L with 2 (H2) 1/4 x 2” Hex Bolts (with lock washer, flat washer and t-nut). (fig. 30.2) D: Make sure the assembly is square then attach (2354) A Frame Lower Side to (2356) A Frame Post and (2351) A Frame Access L with 2 (S2) #8 x 1-1/2” Wood Screws. (fig. 30.2) E: Tighten all bolts. Fig. 30.2 1/4” T-Nut 2354 2356 1/4” Flat Washer 1/4” Lock Washer 2351 Wood Parts Hardware 1/4 x 2” Hex Bolt (1/4” lock washer, 1/4” flat washer, 1/4” t-nut) A Frame Lower Side 1 x 4 x 48-5/16”...
  • Page 72 Step 31: A Frame Floor Assembly A: Have a helper hold up the A Frame MK Wall and A Frame Access Wall then measure 3/4” in from the edge of (2353) A Frame Floor Support on the Rock Wall side and tight to the posts attach 1 (2368) A Frame Floor to (2353) A Frame Floor Supports with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 30.1 and 30.2) B: Measure 1” in from the edge of (2353) A Frame Floor Support on the Access Ladder Wall side and tight to the posts attach 1 (2368) A Frame Floor to (2353) A Frame Floor Supports with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 30.1 and 30.3) Rock Wall Fig. 31.2 2368 Fig. 31.1 3/4” 2353 Tight 2368 2353 2356 2353 2356 2356 2352 2351 Access Ladder Tight Wall Fig. 31.3 2353 2368 2351 1”...
  • Page 73 Step 32: A Frame Access Ladder A: In between (2351) A Frame Access L and (2352) A Frame Access R insert 4 (2360) A Frame Treads into the grooves so they sit tight to each board. (fig. 32.1 and 32.2) B: Attach (2360) A Frame Tread to (2351) A Frame Access L and (2352) A Frame Access R with 4 (S3) #8 x 2-1/2” Wood Screws per tread. (fig. 32.1 and 32.2) Fig. 32.1 2352 2351 Fig. 32.2 2360 2351 2360 X 4 Tight Wood Parts Hardware 16 x #8 x 2-1/2” Wood Screw A Frame Tread 5/4 x 4 x 22-1/8” 2360 support@solowavedesign.com...
  • Page 74 Step 33: Rock Wall Assembly Part 1 A: Flush to the top of (2368) A Frame Floor and flush to the outside edges of each (2356) A Frame Post attach (0702) CE Wall Board with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 33.1 and 33.2) B: Tight to the bottom of (0702) CE Wall Board and flush to the outside edges of (2356) A Frame Posts attach 4 (2330) Rock Board A and 5 (2257) Rock Board B, placing them as shown in fig. 33.1, this will prevent rocks from forming a straight line. Secure boards with 4 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 33.2) Fig. 33.1 Fig. 33.2 Flush 2368 x 4 per board 0702 2368 0702 2330 2257 2356 Hardware Wood Parts CE Wall Board 1 x 6 x 23-1/2” 40 x #8 x 1-1/2”...
  • Page 75 Step 33: Rock Wall Assembly Part 2 C: Alternating colours and shapes, attach 1 rock to each rock board using 1 (PB2) 1/4 x 1-1/4” Pan Bolt (with lock washer, flat washer and barrel nut) and 1 (S10) #8 x 1” Pan Screw per rock. (fig. 33.3 and 33.4) The Pan Screw is placed in the hole beneath the Pan Bolt. (fig. 33.4) Note: Make sure all hardware is used to secure each rock properly. Fig. 33.4 1/4” Barrel (hidden) Fig. 33.3 1/4” Lock Washer 1/4” Flat Washer 2330 Rock Rock 2257 Other Parts Hardware 5 x Rocks (3 green/2 yellow) #8 x 1”...
  • Page 76 Step 34: A Frame Roof Assembly Part 1 A: Attach one (2358) A Frame Roof End to each end of (2359) A Frame Top Sides with 4 (S2) #8 x 1-1/2” Wood Screws per board. The holes in (2358) A Frame Roof End should be centred on each (2359) A Frame Top Side. (fig. 34.1) B: At all four corners attach 1 Corner Brace using 3 (S5) #8 x 1/2” Pan Screws per Corner Brace as shown in fig. 34.1 and 34.2. The Corner Brace should be centred on (2358) A Frame Roof End and (2359) A Frame Top Side. 2359 Fig. 34.1 2358 2358 Fig. 34.2 2359 2358 x 3 per brace Hardware Other Parts Wood Parts 4 x Corner Brace #8 x 1-1/2” Wood Screw A Frame Roof End 1 x 4 x 27-3/4”...
  • Page 77 Step 34: A Frame Roof Assembly Part 2 C: From inside the assembly, attach 1 (2385) Roof Upright to each (2359) A Frame Top Side with 1 (H2) 1/4 x 2” Hex Bolt (with lock washer, flat washer and t-nut) in the bottom hole and 1 (S2) #8 x 1-1/2” Wood Screw in the top hole. The bolt and screw are installed from the outside of the assembly. (fig. 34.3 and 34.4) D: Attach (2357) A Frame Ridge to tops of (2385) Roof Uprights with 2 (S4) # 8 x 3” Wood Screws, so each end has an overhang of 2-1/8”. (fig. 34.3 and 34.5) Fig. 34.5 Fig. 34.4 2385 2357 1/4” T-Nut 2385 2-1/8” 2359 1/4” Lock Fig. 34.3 Washer 1/4” Flat Washer 2385 2359 2359 Wood Parts Hardware A Frame Ridge 2 x 2 x 27-3/4” 2357 #8 x 3”...
  • Page 78 Step 34: A Frame Roof Assembly Part 3 E: Place Canopy over (2357) A Frame Ridge making sure the bottom edges of tarp are even on both sides of the assembly. (fig. 34.6) F: Secure one side of the Canopy by attaching to (2358) A Frame Roof End with 4 (S5) #8 x 1/2” Pan Screws (with #8 flat washer). (fig. 34.6 and 34.7) G: Make sure the Canopy is smooth and tight then secure to the remaining (2358) A Frame Roof End with 4 (S5) #8 x 1/2” Pan Screws (with #8 flat washer). (fig. 34.6 and 34.7) H: Attach Canopy to each end of (2357) A Frame Ridge with 2 (S5) #8 x 1/2” Pan Screws (with #8 flat washer). Install screws 1/2” from each edge. (fig. 34.6 and 34.8) #8 Flat Washer 1/2” Fig. 34.8 Fig. 34.6 2357 Fig. 34.7 2358 2358 #8 Flat x 4 per side Washer Hardware Other Parts 1 x Canopy 10 x #8 x 1/2” Wood Screw (#8 flat washer) support@solowavedesign.com...
  • Page 79 Step 35: Attach Hand Grips to A Frame Pre-drill all holes using a 1/8” drill bit before installing the Lag Screws A: Measure 1-1/2” up from the top of (2351) A Frame Access L and (2352) A Frame Access R then attach 1 Hand Grip to each (2361) A Frame Upright with 2 (LS1) 1/4 x 1-1/2” Lag Screws (with flat washer) per hand grip. (fig. 35.1) Fig. 35.1 Fig. 35.2 1/4” flat washer 2361 2361 Hand Grip 1-1/2” 2352 2351 Hardware Other Parts 2 x Hand Grip 1/4 x 1-1/2”...
  • Page 80 Step 36: A Frame Floor Assembly A: Measure 22-5/8” up from top of (2353) A Frame Floor Support on A Frame Access Wall and attach (2398) Tunnel Left End flush to the outside edge of each (2361) A Frame Upright with 4 (S15) #8 x 1-3/4” Wood Screws. (fig 36.1) B: Centred between (2398) Tunnel Left End and (2359) A Frame Top Side attach (2405) Wall Board to each (2361) A Frame Upright with 4 (S2) #8 x 1-1/2” Wood Screws. (fig. 36.1) 2405 Fig. 36.1 Note: (2398) Tunnel Left End must be flush to the 2359 2361 outside edge of each (2361) A Frame Upright. DO NOT OVER HANG. 2398 22-5/8”...
  • Page 81 Step 37: A Frame/Tunnel Floor Board Assembly A: Tight to (2361) A Frame Upright on the Rock Wall side and flush to the outside edge of (2353) A Frame Floor Support attach (2393) A Frame Floor A to each (2353) A Frame Floor Support with 4 (S2) #8 x 1-1/2” Wood Screws. (fig 37.1) B: Tight to (2361) A Frame Upright on the Ladder side and flush to the outside edge of (2353) A Frame Floor Support attach (2423) A Frame Floor D to each (2353) A Frame Floor Support with 4 (S2) #8 x 1-1/2” Wood Screws. (fig 37.1) C: Place and evenly space (2425) A Frame Floor B and (2424) A Frame Floor C between the first 2 floor boards, flush to the outside edge of (2353) A Frame Floor Support, then each floor board to both (2353) A Frame Floor Supports with 4 (S2) #8 x 1-1/2” Wood Screws per floor board. (fig 37.1) Notice the ends of the floor boards, make sure they are flush and angled as shown below. Fig. 37.1 2361 2361 2368 Tight 2393...
  • Page 82 Step 38: Connect A Frame to Fort Part 1 A: With at least one helper move A Frame so the floor boards centre on (2379) Mid Joist and are tight to (2350) Front Floor. Make sure (2393) A Frame Floor A is flush with the top of (2350) Front Floor. (fig 38.1, 38.2 and 38.3) B: Place (2373) Front Tunnel Support tight to the bottom of (2393) A Frame Floor A, tight to inside edge of (2361) A Frame Upright on the A Frame and (2379) Mid Joist on the main fort. Attach (2373) Front Tunnel Support to (2361) A Frame Upright from inside the fort with 2 (S4) #8 x 3” Wood Screws. Notice bolt hole location on (2373) Front Tunnel Support. (fig 38.1, 38.3 and 38.4) C: Make sure top of (2373) Front Tunnel Support remains tight to the bottom of (2393) A Frame Floor A and tight to (2379) Mid Joist then attach to (2350) Front Floor from outside the fort with 2 (S7) #12 x 2” Pan Screws. (fig. 38.3) Fig. 38.1 Fig. 38.4 2373 2373 2361 View from under the A Frame Main Fort A Frame Note: Attach this end first. 2393 Fig.
  • Page 83 Step 38: Connect A Frame to Fort Part 2 D: Place (2362) Back Tunnel Support tight to bottom of (2423) A Frame Floor D, tight to inside edge of (2361) A Frame Upright on the A Frame and (2379) Mid Joist on the main fort. (fig. 38.5, 38.6, 38.7 and 38.8) Attach (2362) Back Tunnel Support to (2361) A Frame Upright from inside the fort with 2 (S4) #8 x 3” Wood Screws. (fig 38.9) E: Make sure top of (2362) Back Tunnel Support remains tight to bottom of (2423) A Frame Floor D and tight to (2379) Mid Joist then attach to (2350) Front Floor from inside the fort with 2 (S7) #12 x 2” Pan Screws. (fig. 38.9) Fig. 38.6 Fig. 38.5 A Frame 2373 2362 Main Fort View from Underneath 2361 Fig. 38.8 Fig. 38.7 2350 Tight Fig. 38.9 Flush 2379 Outside View...
  • Page 84 Step 38: Connect A Frame to Fort Part 3 F: Place (2397) Tunnel Joist tight to underside of the floor boards, covering the pilot holes, between (2362) Back Tunnel Support and (2373) Front Tunnel Support. Attach (2397) Tunnel Joist to both supports with 2 (S3) #8 x 2-1/2” Wood Screws per support. (fig 38.10 and 38.11) G: Attach floor boards to (2397) Tunnel Joist and (2379) Mid Joist with 4 (S2) #8 x 1-1/2” Wood Screws per board. (fig. 38.12 and 38.13) 2362 Fig. 38.11 Fig. 38.10 View from Underneath 2397 2373 Fig. 38.12 x 2 per side Fig. 38.13 x 16 Floor Boards 2379 (hidden) 2397 (hidden) 2373 Wood Parts Hardware Tunnel Joist 2 x 3 x 18-1/4”...
  • Page 85 Step 39: Tunnel Assembly Part 1 A: Bend all 4 Tunnel panels in the 2 places shown in fig 39.1. B: Match 2 Tunnel panels together by making a slight “V” with the pieces so the peak of the “V” faces away from you. Make sure connector tabs are coupled then straighten the 2 panels. Push down on one panel and up on the other until you hear the connector tabs click together and the bottom edges are flush. You may have to knock panels on a hard surface to align properly. (fig. 39.2 and 39.3) C: Press nodules through the connector tab holes to hold Tunnel panels in place. (fig. 39.3) D: Repeat Steps A-C to create a second Tunnel side. Fig. 39.2 Fig. 39.1 Bend Here Tunnel Fig. 39.3 Connector Tabs Nodule Other Parts 4 x Tunnel Panels support@solowavedesign.com...
  • Page 86 Step 39: Tunnel Assembly Part 2 E: Centre (2404) Tunnel Top Cross in the notch of (2403) Tunnel Top and attach with 1 (S2) #8 x 1-1/2” Wood Screw. (fig. 39.4) F: With a helper place 2 Tunnel panels together, make sure they are centred on (2403) Tunnel Top, leaving a 1” overhang on each end. Attach Tunnel assembly with 4 (S10) #8 x 1” Pan Screws in each side of (2404) Tunnel Top Cross and 8 (S10) #8 x 1” Pan Screws in (2403) Tunnel Top. (fig. 39.5, 39.6 and 39.7) G: Turn assembly over and place (2392) Tunnel Arch centred on top of (2403) Tunnel Top then attach with 2 (S3) #8 x 2-1/2” Wood Screws. (fig. 39.7) Fig. 39.5 2403 Fig. 39.4 2404 2404 (hidden) 2403 Fig. 39.6 Fig. 39.7 1” 2392 2403 2403 Notice holes in end panel not used here Wood Parts Hardware Tunnel Top Cross 5/4 x 3 x 16-1/2”...
  • Page 87 Step 40: Attach Tunnel Assembly to Fort Part 1 A: With helper place Tunnel Assembly over floor boards. Make sure (2403) Tunnel Top is centred over the pilot holes in (2398) Tunnel Left End and the bottoms of both boards are flush to each other. Ends of the Tunnel Assembly should sit tight against both (2361) A Frame Uprights. Attach (2398) Tunnel Left End to (2403) Tunnel Top with 2 (S3) #8 x 2-1/2” Wood Screws. (fig. 40.1 and 40.2) B: Make sure the bottom of the Tunnel sits 1-1/2” up from the bottom of both (2362) Back Tunnel Support and (2373) Front Tunnel Support then install 1 (S10) #8 x 1” Pan Screw to each support in the holes closes to the A Frame. (fig. 40.3) C: Maintaining the 1-1/2” measurement on each (2362) Back Tunnel Support and (2373) Front Tunnel Support install 6 (S10) #8 x 1” Pan Screws in each support working from A Frame towards the main fort. (fig. 40.3) Fig. 40.2 2403 2398 Fig. 40.1 Flush Fig. 40.3 A Frame 2362 2373 2361 x 6 per 1-1/2” Main Fort side Hardware #8 x 2-1/2”...
  • Page 88 Step 40: Attach Tunnel Assembly to Fort Part 2 D: Attach 1 side of Tunnel Assembly to 1 (2361) A Frame Upright with 4 (S10) #8 x 1” Pan Screws in the connector tab holes. (fig. 40.4 and 40.5) E: Attach top of Tunnel Asssembly to bottom of (2398) Tunnel Left End with 4 (S10) #8 x 1” Pan Screws. (fig. 40.5) F: Attach remaining side of Tunnel Assembly to second (2361) A Frame Upright with 4 (S10) #8 x 1” Pan Screws in the connector tab holes. (fig. 40.5) Fig. 40.4 Fig. 40.5 2398 2361 2361 x 4 per side Hardware 12 x #8 x 1” Pan Screw support@solowavedesign.com...
  • Page 89 Step 40: Attach Tunnel Assembly to Fort Part 3 G: With the bevelled edge facing the Tunnel Assembly slide (2396) Tunnel Corner Support in between Tunnel Assembly and (2384) Post on Access Wall, making sure (2396) Tunnel Corner Support sits tight to the floor boards. Attach Tunnel Assembly to (2396) Tunnel Corner Support with 4 (S10) #8 x 1” Pan Screws in the connector tab holes. (fig. 40.6 and 40.7) H: Attach (2396) Tunnel Corner Support to (2384) post with 5 (S3) #8 x 2-1/2” Wood Screws. (fig. 40.7) Fig. 40.6 Fig. 40.7 2384 (hidden) 2396 Bevelled edge on this side. Tunnel Assembly Wood Parts Hardware Tunnel Corner Support 2 x 4 x 26-1/2” 2396 #8 x 2-1/2” Wood Screw #8 x 1”...
  • Page 90 Step 40: Attach Tunnel Assembly to Fort Part 4 I: Place (2401) Tunnel Right End tight to top of the Tunnel Assembly and centred pilot holes over (2403) Tunnel Top. Make sure the distance between top of (2350) Front Floor and bottom of (2401) Tunnel Right End measures 22”. Notice the bolt hole location. (fig. 40.8, 40.9 and 40.10) J: Attach (2401) Tunnel Right End to (2403) Tunnel Top with 2 (S3) #8 x 2-1/2” Wood Screws. (fig. 40.10) K: Make sure (2401) Tunnel Right End is flush to the bevelled edge of (2396) Tunnel Corner Support and attach with 2 (S15) #8 x 1-3/4” Wood Screws. (fig. 40.9 and 40.10) Fig. 40.8 Notice bolt hole location Flush Note: (2401) Tunnel Right End must be flush to the Fig. 40.9 outside edge of (2396) 2401 Tunnel Corner Support. DO NOT OVER HANG.
  • Page 91 Step 40: Attach Tunnel Assembly to Fort Part 5 L: Loosely attach (2399) Tunnel Post to (2401) Tunnel Right End with 1 (H3) 1/4 x 2-1/2” Hex Bolt (with lock washer, flat washer and t-nut) and to (2373) Front Tunnel Support with 1 (H11) 1/4 x 2-3/4” Hex Bolt (with lock washer, flat washer and t-nut). Keep bolts loose. (fig. 40.11 and 40.12) M: Loosely attach (2400) Tunnel Rail to (2380) Middle Front with 1 (PB2) 1/4 x 1-1/4” Pan Bolt (with lock washer, flat washer and t-nut) and to (2399) Tunnel Post with 1 (H3) 1/4 x 2-1/2” Hex Bolt (with lock washer, flat washer and t-nut). Keep bolts loose. (fig. 40.13 and 40.14) Note: (2401) Tunnel Right End must be flush to the outside edge Fig. 40.12 of (2399) Tunnel Post. DO NOT Fig. 40.11 OVER HANG. 2401 2399 1/4” flat...
  • Page 92 Step 40: Attach Tunnel Assembly to Fort Part 6 N: Pull Tunnel Assembly tight to (2399) Tunnel Post then attach with 4 (S10) #8 x 1” Pan Screws. (fig. 40.15 and 40.16) O: Attach top of Tunnel Assembly to bottom of (2401) Tunnel Right End with 4 (S10) #8 x 1” Pan Screws. (fig. 40.16) P: Attach (2401) Tunnel Right End to (2399) Tunnel Post with 1 (S7) #12 x 2” Pan Screw. (fig. 40.17) Q: Tighten all 4 bolts from Step 40, Part 5. R: From inside the main fort attach (2380) Middle Front to (2400) Tunnel Rail with 1 (S2) #8 x 1-1/2” Wood Screw. (fig. 40.17 and 40.18) Fig. 40.16 Fig. 40.15 2401 2399 Fig. 40.17 Fig. 40.18 2380 2400 2401 2399 2380 Inside View Outside View Hardware #8 x 1-1/2”...
  • Page 93 Step 40: Attach Tunnel Assembly to Fort Part 7 S: Using the pilot holes in (2400) Tunnel Rail as a guide place 4 (2402) Tunnel Spindles against and flush to the bottom of (2373) Front Tunnel Support then attach with 1 (S7) #12 x 2” Pan Screws per spindle. (fig. 40.19 and 40.20) T: Attach each (2402) Tunnel Spindle to (2373) Front Tunnel Support with 1 (S3) #8 x 2-1/2” Wood Screw per spindle. (fig. 40.20) Fig. 40.19 2400 Fig. 40.20 2402 2373 Flush Wood Parts Hardware Tunnel Spindle 2 x 2 x 33-1/8” #8 x 2-1/2” Wood Screw 2402 #12 x 2”...
  • Page 94 Step 41: Attach A Frame Ground Stakes A: Drive 1 (0318) Ground Stake 10-1/2” into the ground at (2352) A Frame Access R and (2356) A Frame Post on the outside of the assembly and attach with 2 (S3) #8 x 2-1/2” Wood Screws per ground stake. (fig. 41.1 and 41.2) WARNING: To prevent tipping and avoid potential injury, stakes must be driven 10-1/2” into ground. Digging or driving stakes can be dangerous if you do not check first for under- ground wiring, cables or gas lines. Fig.
  • Page 95 Step 42: Monkey Rail Assembly Pre-drill all pilot holes using a 1/8” drill bit before installing wood screws. A: Insert 3 (578) 1-1/8 x 15-7/8” Dowels into both (1565) MK Rail Shorts as shown in fig. 42.1. Note the pilot holes in one of the (1565) MK Rail Short are on the bottom of the board. 1” 1565 Note: Pilot holes at Fig. 42.1 bottom of this rail 1” 1-1/4” 1-1/4” 1” 1565 1565 B: Make sure shoulder of dowel is against each rail before pre-drilling pilot holes. Drill Fig. 42.2 1/8” pilot holes through the rails and into the dowels to prevent splitting. (fig. 42.2) Fig. 42.3 1565 C: Attach (578) 1-1/8 x 15-7/8” Dowels to both rails with 2 (S3) #8 x 2-1/2” Wood Screws per dowel. (fig. 42.3) Wood Parts...
  • Page 96 Step 43: Monkey Ladder Assembly Note: Pre-drill all holes using a 1/8” drill bit before installing the Lag Screws and Wood Screws. A: Insert 2 (858) 1-1/8 x 18-5/8” Dowels into 2 (2382) MK Posts as shown in fig. 43.1. Fig. 43.1 Note: Pilot holes at bottom of this rail 2382 Note: Pilot holes at Fig. 43.2 top of this rail B: Make sure shoulder of dowel is against each post before pre-drilling pilot holes. Drill 1/8” pilot holes through the posts and into the dowel to prevent splitting. (fig. 43.2 and 43.3) 2382 C: Attach (858) 1-1/8 x 18-5/8” Dowel to both posts with 2 (S2) #8 x 1-1/2” Wood Screws. Two screws are installed from top of the rails and the others from the bottom as shown in fig. 43.3. D: At bottom of (2382) MK Posts attach (0353) MK Ground with 2 (H12) 1/4 x 3” Hex Bolts (with lock washer, flat washer and t-nut). Be sure to keep the bolts loose. (fig. 43.3) E: Make sure the assembly is square and then attach 1 (0369) Lower Diagonal to each end of (0353) MK...
  • Page 97 Step 44: Connect Monkey Bar Assemblies Note: Pre-drill all holes using a 1/8” drill bit before installing the pan screws. A: Using a Monkey Bracket connect both (1565) MK Rail Shorts to each (2382) MK Post with 1 (G10) 5/16 x 3” Hex Bolt (with lock washer, flat washer and t-nut) and Monkey Bracket to the rails using 2 (S6) #12 x 1” Pan Screws per rail as shown in fig. 44.1 and 44.2. Be sure to attach the correct end, using the 1-1/4” measurement shown in fig. 44.2 as your guide. B: Attach Monkey Bracket to both (2382) MK Posts with 2 (S6) #12 x 1” Pan Screws per bracket. (fig. 44.2) 1565 90° Fig. 44.2 1565 Monkey Bracket 1-1/4” 5/16” Flat Washer 5/16” T-Nut 2382 Fig. 44.1 5/16” Lock Washer 1367...
  • Page 98 Step 45: Connect Monkey Bar Assembly to Fort Part 1 Pre-drill all pilot holes using a 1/8” drill bit before installing the lag screws. A: Using a MB Mount Strap attach 1 (1565) MK Rail Short to (2381) MK Mount with 1 (G4) 5/16 x 4” Hex Bolt (with lock washer, flat washer and previously installed t-nut) in the centre hole and 2 (S6) #12 x 1” Pan Screws in the 2 end holes as shown in fig. 45.1 and 45.2. B: Make sure the Monkey Bar Assembly is level then using a MB Mount Strap attach (1565) MK Rail Short to (2361) A Frame Upright with 1 (LS3) 1/4 x 3” Lag Screw (with flat washer) in the centre hole and 2 (S6) #12 x 1” Pan Screws in the 2 end holes as shown in fig. 45.2. Fig. 45.1 5/16” Flat MB Mount Fig. 45.2 Washer Strap 1565 2381 1/4” Flat 5/16”...
  • Page 99 Step 45: Connect Monkey Bar Assembly to Fort Part 2 C: Drive 1 (0318) Ground Stake 10-1/2” into the ground at one (2382) MK Post on the inside of the assembly and attach with 2 (S3) #8 x 2-1/2” Wood Screws. (fig. 45.3 and 45.4) WARNING: To prevent tipping and avoid potential injury, stakes must be driven 10-1/2” into ground. Digging or driving stakes can be dangerous if you do not check first for underground wiring, cables or gas lines. Fig.
  • Page 100 Step 46: Assemble Spiral Wave Slide A: Assemble the top and bottom sections using the tongue and groove as a guide. Push together until snaps engage. (fig. 46.1, 46.2 and 46.3) B: Complete sub-assembly by securing sections with 2 (S8) #12 x 3/4” Pan Screws in the middle holes and 2 (S6) #12 x 1” Pan Screws in the outside holes. See fig. 46.2 for accurate screw placement. Fig. 46.1 Bottom Section Top Section Snaps Fig. 46.2 Fig. 46.3 Hardware Other Parts #12 x 3/4” Pan Screw Top Section Bottom Section #12 x 1” Pan Screw 100 support@solowavedesign.com...
  • Page 101 Step 47: Slide Support Assembly Part 1 A: Place 1 (4909) SW Block centred on (2388) SL Upright and attach using 2 (S3) #8 x 2-1/2” Wood Screws. Notice the bolt hole should be towards the bottom of the board. (fig. 47.1) Fig. 47.1 2388 Notice hole location 4909 Wood Parts Hardware SL Upright 2 x 3 x 48-1/2” #8 x 2-1/2” Wood Screw 2388 SW Block 5/4 x 4 x 3-1/2” 4909 101 support@solowavedesign.com...
  • Page 102 Step 47: Slide Support Assembly Part 2 WARNING: Digging can be Fig. 47.2 dangerous if you do not check first for underground wiring, cables or gas lines. B: At the end of (2372) Front Ground dig one, flat bottom, 8” wide by 6” deep hole as shown in fig. 47.3. Place (2388) SL Upright in the hole, making sure that it is plumb. (fig. 47.3) C: Place (2140) Short Upright beside (2388) SL Upright on the opposite side of (2372) Front Ground making sure that it is plumb. Notice the angled edge slopes away from (2372) Front Ground. (fig. 47.2 and 47.3) D: Loosely attach (2140) Short Upright and (2388) SL Upright to (2372) Front Ground with 1 (H12) 1/4 x 3” Hex Bolt (with lock washer, flat washer and t-nut) per board.
  • Page 103 Step 47: Slide Support Assembly Part 3 G: Place Slide in the centre between (2383) Posts on the Cafe Wall. (fig. 47.4 and 47.5) H: Place 2 (0620) SL Braces tight to the underside of (1853) Cedar Gap Board and each tight to (0790) Floor Joist and (2387) Side Arch. Attach slide through (1853) Cedar Gap Board and into each (0620) SL Brace with 4 (S7) #12 x 2” Pan Screws. (fig. 47.5 and 47.6) Fig. 47.4 Fig. 47.6 1853 Tight 0790 Tight 2387 0620 View from under fort Uprights Fig. 47.5 Note: Slide must be centred in opening 2383 2383 2371 Slide Wood Parts Hardware #12 x 2”...
  • Page 104 Step 47: Slide Support Assembly Part 4 I: See fig. 47.11 for Spiral Wave Bracket example. Bend bracket to fit as necessary. J: Align (2388) SL Upright between holes on underside of Bottom Section of the slide and attach using 1 Spiral Wave Bracket with 2 (S6) #12 x 1” Pan Screws as shown in fig. 47.7, 47.8 and 47.9. K: Attach Spiral Wave Bracket to (2140) Short Upright with 2 (S6) #12 x 1” Pan Screw and to the Bottom Section of the slide with 1 (S8) #12 x 3/4” Pan Screw as shown in fig. 47.7, 47.8 and 47.10. Fig. 47.11 Spiral Wave Fig. 47.7 Bracket Fig. 47.8 View from under fort 2388 Bottom Section Fig. 47.10 Bottom Fig. 47.9 Section Bottom Section Spiral Wave 2388 Bracket 2140 Hardware Other Parts...
  • Page 105 Step 48: Attach Swing Assembly to Fort A: Attach Swing Assembly from Step 5 to (2390) SW Mount with 1 (G5) 5/16 x 4-1/2” Hex Bolt (with lock washer, flat washer and t-nut) and 1 (G8) 5/16 x 2” Hex Bolt (with 2 flat washers and 1 lock nut) as shown in fig. 48.1 and 48.2. Fig. 48.1 Fig. 48.2 2390 5/16” Flat Washer 5/16” T- Nut 5/16” Lock Washer 5/16” Lock nut 5/16” Flat Washer Hardware 5/16 x 4-1/2” Hex Bolt (5/16” lock washer, 5/16” flat washer, 5/16” t-nut) 5/16 x 2”...
  • Page 106 Step 49: Attach Swing Ground Stakes A: Drive 1 (0318) Ground Stake 10-1/2” into the ground at each (1863) SW Post and attach with 2 (S3) #8 x 2-1/2” Wood Screws per ground stake. (fig. 49.1 and 49.2) WARNING: To prevent tipping and avoid potential injury, stakes must be driven 10-1/2” into ground. Digging or driving stakes can be dangerous if you do not check first for underground wiring, cables or gas lines. Fig.
  • Page 107 Step 50: Glider Assembly A: Attach 1 Glider End to the Glider Seat using 1 (Z) 5/16 x 6” Hex Bolt (with 2 flat washers and 1 lock nut). Repeat for the second Glider End. (fig. 50.1) B: Install 2 Glider Rope with Chains into each Glider End using 2 - 5/16” Flat Washers and 1 Lock Nut per rope. (fig. 50.1) Glider Rope and Chain Fig. 50.1 5/16 Flat Washer-Zinc 5/16 Flat Washer-Zinc 5/16 Lock 5/16 Lock 5/16 x 6” Hex Bolt 5/16 Flat Washers 5/16 Lock Nuts Glider Seat Glider End WARNING: Bolt must not exceed 1/2 thread past the nut Hardware...
  • Page 108 Step 51: Attach Glider and Swings If Bolt protrudes WARNING: beyond T-Nut Check entire play centre for bolts protruding beyond T-Nuts. Use Use an extra extra washers to eliminate this condition. Flat W asher A: Connect the assembled Glider to the Glider Hangers previously installed. (fig. 51.1) B: Attach 2 Belt Swings to the Bolt-Thru Swing Hangers. (fig. 51.1) Fig. 51.1 Belt Swings Glider Other Parts...
  • Page 109 Final Step: Attach I.D. Plaque STEP # STEP NAME ATTACH THIS WARNING & I.D. PLAQUE TO A PROMINENT LOCATION ON YOUR PLAY EQUIPMENT! (Fort or Swing Post) This provides warnings concerning safety and important contact information. A Tracking Number is provided to allow you to get critical information or order replacement parts for this specific model Attach with screws provided to a location...
  • Page 110 NOTES 110 support@solowavedesign.com...
  • Page 111 NOTES 111 support@solowavedesign.com...
  • Page 112 MAIL TO: Fill out your registration card online at Solowave Design www.bigbackyard.com/ownerslounge 375 Sligo Road W. Mount Forest, Ontario, Canada Big Backyard would like to say Thank You for N0G 2L0 your time and feedback. Attention: Customer Service REVISION: 11/28/12...