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Gorilla Playsets Woodbridge Assembly Manual

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Woodbridge
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: October 24, 2011

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  • Page 1 ® Woodbridge 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: October 24, 2011...
  • Page 2 TABLE OF CONTENTS Warranty and Safety Guidelines………………………………………..……...Pages 4-11 Kit Contents and Tool List…………..………………………………………..Pages 11-31 Framing the play set………………………………………......…... Steps 1-7 Constructing Deck and Upper Panel Boards…………………..………...…..Steps 8-11 Constructing Rock Wall and securing to fort..………………………….……..Steps 12-16 Constructing and attaching Ladder…………..……………….…………...…... Steps 17-18 Installing Panel Slats………………………...…..……..……...….……....
  • Page 3 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 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.) except Super Scoop Slides...
  • Page 6 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 PLATFORMS: 800 LBS. TOTAL WEIGHT • SWING BELTS: 225 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: 23'10 " 10'1 8 " 5'10" Ladder " " Swing Belts (2) 9'10 " Trapeze Arm (1) 3'11 " 3'2" 4'11"...
  • Page 15 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ 1/8” Drill Bit ___ 3/8” Drill Bit ___ 1” Spade/Paddle Bit ___ ½” Wrench and Socket ___½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16”...
  • Page 16 5/16" X 3-1/2" 5/16 X 4" 3/8 X 3-1/2" HEX LAG EYEBOLT LAG HEX LAG SCREW SCREW QTY: 3 QTY: 24 QTY: 24 #2 SQUARE DRIVE BIT QTY: 1 PLASTIC 3/8 x 9" 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" BOLT CAP CARRIAGE BOLT CARRIAGE BOLT...

  • Page 17: Hex Bolt

    #8 X 1" WOOD SCREW QTY: 8 #8 X 1-1/4" WOOD SCREW QTY: 16 #14 X 1-1/4" #8 X 1-1/2" PAN HEAD SCREW WOOD SCREW QTY: 16 QTY: 390 #8 X 2" WOOD SCREW QTY: 165 #8 X 2-1/2" WOOD SCREW #14 x 1"...
  • Page 18 PICTURE DESCRIPTION QTY. 1 X 4 X 25" PANEL SLAT 1-4-2500-PS 1 X 4 X 26" FRONT PANEL SLAT 1-4-2600-FPS 1 X 4 X 51" REAR PANEL SLAT 1-4-5100-RPS 1 X 5 X 25" PANEL SLAT 1-5-2500-PS 1 X 5 X 55" ROOF FINISHER 1-5-5500-RF 1 X 5 X 55"...
  • Page 19 PICTURE DESCRIPTION QTY. 1 X 6 X 14-1/4" FRONT PANEL SLAT 1-6-1425-FPS 1 X 6 X 16" TIC TAC TOE SUPPORT 1-6-1600-TTTS 1 X 6 X 17" PANEL SLAT 1-6-1700-PS 1 X 6 X 26" FRONT PANEL SLAT 1-6-2600-FPS 1 X 6 X 27-3/4" PANEL SLAT 1-6-2775-PS 1 X 6 X 29-1/2"...
  • Page 20 PICTURE DESCRIPTION QTY. 1 X 6 X 55" ROOF BOARD 1-6-5500-RB 55" ROOF PEAK 1-6-5500-RP 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 15" PICNIC TABLE SUPPORT 2-4-1500-PTS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 18"...
  • Page 21 PICTURE DESCRIPTION QTY. 2 X 4 X 31" BENCH SUPPORT 2-4-3100-BS 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 51" PICNIC TABLE SEATS AND TOP 2-4-5100-PTST 2 X 4 X 51" ROOF SUPPORT LEFT LEFT AND RIGHT 2-4-5100-RSL 2-4-5100-RSR RIGHT...
  • Page 22 PICTURE DESCRIPTION QTY. 2 X 4 X 70" CENTER DECK SUPPORT 2-4-7000-CDS 2 X 4 X 70" DECK SUPPORT 2-4-7000-DS 2 X 4 X 78" PANEL SUPPORT 2-4-7800-PS 2 X 6 X 16" 2-6-1600-S 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD 2-6-4750-ASTB 2 X 6 X 47-1/2"...
  • Page 23 PICTURE DESCRIPTION QTY. 2 X 6 X 67-1/4" SUNBURST BOARD 2-6-6725-SB 2 X 6 X 70" FRONT FACE BOARD 2-6-7000-FFB 2 X 6 X 70" FRONT TOP PANEL BOARD 2-6-7000-FTPB 2 X 6 X 70" REAR FACE BOARD 2-6-7000-RFB 2 X 6 X 70" REAR TOP PANEL BOARD 2-6-7000-RPTB...
  • Page 24 PICTURE DESCRIPTION QTY. 4 X 4 X 47-1/2" SWING BEAM MOUNT 4-4-4750-SBM 4 X 4 X 78" ROPE LADDER SUPPORT 4-4-7800-RLS 5/4 X 2 X 16" SMALL RAY 125-2-1600-SR 5/4 X 2 X 18" SMALL RAY 125-2-1800-SR 5/4 X 2 X 23" LARGE RAY 125-2-2300-LR 5/4 X 3 X 18-3/4"...
  • Page 25 PICTURE DESCRIPTION QTY. 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB 5/4 X 6 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 4 X 4 X 108" PLASTIC COATED CORNER POST 4 X 4 X 108" PLASTIC COATED SWING LEG 4 X 6 X 120" PLASTIC COATED SWING BEAM...
  • Page 26 PICTURE DESCRIPTION QTY. RADICAL RIDE 5 TUBE SLIDE EXTREME WAVE SLIDE ROPE LADDER ASSEMBLY SWINGS W/CHAINS TRAPEZE W/CHAINS...
  • Page 27 PICTURE DESCRIPTION QTY. SWING PLATE CLIMBING ROCKS A-FRAME SWING BRACKET HARDWARE NOT SHOWN INSTRUCTIONS...
  • Page 28 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS TELESCOPE 10' ROPE...
  • Page 29 PICTURE DESCRIPTION QTY. 90 GREEN BRACKET SPRING CLAMP SAFETY HANDLES (PAIR)
  • Page 30 PICTURE DESCRIPTION QTY. UNASSEMBLED CHIMNEY UNASSEMBLED DORMER BOXED TIC-TAC-TOE SPINNER PANEL FLAG KIT...
  • Page 31 PICTURE DESCRIPTION QTY. WINDOW PANEL STEERING WHEEL SUNBURST SCREEN...
  • Page 32 STEP 1: ATTACHING THE T-NUTS TO THE CORNER POSTS 1: THIS STEP IS CRITICAL TO BUILDING THE PLAY SET PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DISASSEMBLE THEN REASSEMBLE TO MAKE YOUR CORRECTIONS. MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS.
  • Page 33 STEP 2: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" ROPE LADDER RUNNER ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.

  • Page 34: Hex Bolt

    STEP 3: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 35 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 36: Hex Bolt

    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"...

  • Page 37: Hex Bolt

    STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD SHOULD FACE UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T- NUTS INSTALLED ON THE CORNER POSTS.
  • Page 38 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE UP. USE 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHER TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 39 STEP 6A: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS. 2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE.
  • Page 40 STEP 7: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 41 STEP 8: DECK SPACERS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-1/2" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-1/4" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 42 STEP 9: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: USE THE HOLE IN THE CENTER OF THE DECK SPACER AS A GUIDE TO DRAW A LINE ON THE OUTSIDE OF THE BOTTOM PANEL BOARD ON EACH SIDE OF THE PLAY SET.
  • Page 43 STEP 10: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES DOWN AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16"...
  • Page 44 STEP 11: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD. 1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. 5/4 X 6 X 47-3/8"...
  • Page 45 STEP 12: 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 46 STEP 13: 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 47 STEP 14: ROCK WALL 1: FASTEN THE 90 BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME. 90 GREEN BRACKET 5/16" WASHER 5/16"...
  • Page 48 STEP 15: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND THIRTY 1/4" WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH THREE WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
  • Page 49 STEP 16: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT SIDE - RIGHT OF THE PLAY SET AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 BRACKETS AS A TEMPLATE;...
  • Page 50 STEP 17: 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 SLOTS IN THE BOARDS ARE FACING EACH T-NUT OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE LADDER SIDES AND SET WITH A HAMMER.
  • Page 51 STEP 18: LADDER TO PLAY SET 1: THE LADDER WILL ATTACH TO THE REAR OF THE PLAY SET. PLACE THE LADDER AGAINST THE BOTTOM PANEL BOARD CENTERED IN THE NOTCHED OUT AREA. 2: THE BOTTOM OF THE 90 BRACKETS SHOULD BE APPROXIMATELY 3/4" FROM THE BOTTOM OF THE BOTTOM PANEL BOARD.
  • Page 52 STEP 19: FRONT PANEL SLATS 1: FIND ONE 1 X 4 X 25" FRONT PANEL SLATS AND ONE 4 X 4 X 26" CENTER POST. 2: PREDRILL THE SLAT 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3: INSTALL THE PANEL SLAT AS SHOWN ON THE FIGURE BELOW AND ATTACH WITH 2"...
  • Page 53 STEP 20: SIDE PANEL SLATS 1: FIND ELEVEN 1 X 6 X 27-3/4" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END WITH TWO EQUALLY SPACED HOLES WITH A 1/8" DRILL BIT. 3. INSTALL THE PANEL SLATS AS SHOWN LEAVING 1/4" GAP BETWEEN EACH PANEL SLAT OR A 1/4" GAP BETWEEN THE CORNER POST AND PANEL SLAT.
  • Page 54 STEP 21: TIC TAC TOE SUPPORT 1:FIND TWO 1 X 6 X 16" TIC TAC TOE SUPPORT SLATS. 2: PRE-DRILL THE SLATS 2" FROM EACH END, AND 4" OVER FROM THE FIRST HOLE AS SHOWN ON THE DIAGRAM USING A 1/8" DRILL BIT. 3: INSTALL THE SLATS IN THE GAP LEFT FROM THE PREVIOUS INSTALLATION LEAVING A 3/4"...
  • Page 55 STEP 22: 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 THE TOP, AND 3/8"...
  • Page 56 STEP 23: IRON DUCTILES 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 57 STEP 24: 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 58 STEP 25: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8"...
  • Page 59 STEP 26: MOUNT SWING BEAM TO FORT AN EXTRA PERSON IS NEEDED 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 HOLES AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLES ON THE SWING BEAM PLATE.
  • Page 60 STEP 27: LEVEL SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL. IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE).
  • Page 61 STEP 28: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS. 2: LEVEL THE 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.
  • Page 62 STEP 29: ROOF SUPPORT 1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 51" ROOF SUPPORTS TO THE FORT WITH 5/16" X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE. 2: DO NOT CONNECT THE ENDS AT THIS TIME.
  • Page 63 STEP 30: ROOF PEAK SUPPORT 1: PRE-DRILL HOLES IN THE TWO 5/4 X 10" ROOF PEAK SUPPORTS TO THE PATTERN SHOWN BELOW. 5/4 X 10" ROOF PEAK SUPPORT 2: PLACE THE 5/4 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS.
  • Page 64 STEP 31: ROOF 1: PLACE THE 1 X 5 X 55" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 65 STEP 32: ROOF PEAK 1: PLACE THE 55" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH EIGHT 1-1/2" WOOD SCREWS. 55" ROOF PEAK...
  • Page 66 STEP 33: ROOF 1: PLACE THE 1 X 6 X 55" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2. FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 5 X 55"...
  • Page 67 STEP 34: SUNBURST BOARD 1: FIND TWO 2 X 6 X 56-1/2" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS.
  • Page 68 STEP 35: BOTTOM SUNBURST BOARD 1: FIND TWO 2 X 6 X 67-1/4" SUNBURST BOARDS. 2: PRE-DRILL A HOLE ON BOTH ENDS OF THE BOARD AT A 45 DEGREE ANGLE THROUGH THE BOARD AT 1-1/4" FROM THE END OF THE BOARD WITH A 1/8" DRILL BIT. 3: PLACE BOARD IN BETWEEN THE ROOF SUPPORTS.
  • Page 69 STEP 36: FRONT TOP PANEL SLATS 1: FIND SIX 1 X 6 X 26" AND TWO 1 X 4 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT THE DIMENSIONS SHOWN ON THE DIAGRAM.
  • Page 70 STEP 37: REAR PANEL SLATS 1: FIND FOUR 1 X 6 X 51" REAR PANEL SLATS AND TWO 1 X 4 X 51" REAR PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END WITH TWO HOLES EQUALLY SPACED WITH A 1/8" DRILL BIT 3.
  • Page 71 STEP 38: FINAL REAR PANEL BOARDS 1: FIND TWO 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS AND TWO 1 X 6 X 26" FRONT PANEL SLATS. 2: PRE-DRILL THE 1 X 6 X 29-1/2" BOTTOM WINDOW SUPPORT BOARDS 3/4" FROM THE BOTTOM END AND 4" FROM THE TOP END WITH TWO HOLES EQUALLY SPACED WITH A 1/8"...
  • Page 72 STEP 39: WINDOW SUPPORTS 1: FIND THE SIX 1 X 6 X 4-1/2" BOTTOM WINDOW SUPPORTS. PRE-DRILL THREE 1/8" HOLES IN THE BOTTOM OF EACH SUPPORT AS SHOWN IN THE DIAGRAM. 2: PLACE TWO SUPPORTS IN EACH OF THE TWO OPENINGS IN THE FRONT OF THE FORT, AND THE FINAL TWO SUPPORTS IN THE OPENING AT THE REAR OF THE FORT.
  • Page 73 STEP 40: INSTALL WINDOWS 1: FIND FOUR WINDOW PANELS AND FOUR SUN PIECES. PLACE EACH WINDOW IN THE OPENING WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. TEST FIT THE SUN PIECES ABOVE THE WINDOW FRAME (THESE WILL BE INSTALLED LATER).
  • Page 74 STEP 41: INSTALL PANEL SLATS AND SUN PIECES 1: FIND EIGHT 1 X 6 X 14-1/4" FRONT PANEL SLATS AND EIGHT SUN PIECES. 2: PRE-DRILL EACH SLAT WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOW BELOW. 3: ATTACH THE PANEL SLATS AS SHOWN BELOW WITH THE BOTTOM OF THE SLAT RESTING UPON THE INSIDE FLANGE OF THE WINDOW FRAME.
  • Page 75 STEP 42: TIC TAC TOE PANEL 1: ASSEMBLE THE TIC TAC TOE PANEL ACCORDING TO THE INSTRUCTIONS IN THE BOX. DISREGARD STEPS 6 & 7. 2: CENTER THE TIC TAC TOE PANEL BETWEEN THE SUPPORTS ON THE SIDE WALL AND ATTACH WITH EIGHT 1" WOOD SCREWS PROVIDED IN THE TIC TAC TOE BOX.
  • Page 76 STEP 43: SUNBURST 1: PRE-DRILL TWO 1/8" HOLES IN EACH SUN. THE HOLES WILL BE DRILLED NEAR THE OUTER EDGE ON EACH SIDE GOING STRAIGHT DOWN. 2: CENTER SUN ON THE PANEL BOARD AND ATTACH USING TWO 2" WOOD SCREWS. 3: REPEAT FOR OTHER SIDE OF FORT.
  • Page 77 STEP 44: SUNBURST 1: LOCATE TWO 5/4 X 2 X 23" LARGE RAYS, TWO 5/4 X 2 X 16" SMALL RAYS AND TWO 5/4 X 2 X 18" SMALL RAYS. 2: PRE-DRILL ALL SMALL RAYS AT 3/4" ON CENTER FROM EACH END WITH A 1/8" DRILL BIT. PRE-DRILL ALL LARGE RAYS 3/4"...
  • Page 78 STEP 45: SUNBURST 1: INSTALL SUNBURST SCREENS AS SHOWN BELOW, SO THAT IT IS FLUSH TO THE ROOF SUPPORTS. FASTEN EACH SCREEN WITH SIX 1-1/4" PAN HEAD SCREWS INTO THE GROMMETS IN THE SCREEN.
  • Page 79 STEP 46: PANEL SUPPORT 1: MEASURE 17-3/4" FROM THE BOTTOM OF THE SANDBOX BOARD ON THE FRONT FACE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. LINE UP THE TOP OF THE 2 X 4 X 78" PANEL SUPPORT WITH THE MARKS.
  • Page 80 STEP 47: SAFETY BOARD 1: MEASURE 17-3/4" FROM BOTTOM OF THE SANDBOX BOARD ON THE RIGHT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. 2: ALIGN THE TOP OF THE SAFETY PANEL BOARD WITH THE MARKS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH "OFFSET HOLES DOWN"...
  • Page 81 STEP 48: PICNIC TABLE 1: PLACE EACH OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORTS 15" OVER FROM THE CORNER POSTS. (SEE REAR VIEW) 2: MAKE SURE THE PICNIC TABLE VERTICAL SUPPORTS ARE SQUARE TO THE SANDBOX BOARDS. ATTACH THEM TO THE SANDBOX BOARDS FROM THE INSIDE USING TWO 2-1/2"...
  • Page 82 STEP 49: PICNIC TABLE 1: FIND TWO 2 X 4 X 15" PICNIC TABLE SUPPORTS. 2: ATTACH EACH PICNIC TABLE SUPPORT TO THE TOP OF THE PICNIC TABLE VERTICAL SUPPORT AND TO THE CORNER POSTS. 3: ATTACH EACH PICNIC TABLE SUPPORT TO THE PICNIC TABLE VERTICAL SUPPORT AND THE CORNER POST USING SIX 2-1/2"...
  • Page 83 STEP 50: PICNIC TABLE 1: FIND SEVEN 2 X 4 X 51" PICNIC TABLE SEATS AND PICNIC TABLE TOP BOARDS. 2: ATTACH EACH BOARD WITH FOUR 2-1/2" WOOD SCREWS AS SHOWN BELOW TO CREATE THE PICNIC TABLE SEATS AND TOP. NOTE: LADDER AND ROCK WALL REMOVED FOR CLARITY.

  • Page 84: Bottom Panel Slats

    STEP 51: BOTTOM PANEL SLATS 1: FIND FIFTEEN 1 X 6 X 17" PANEL SLATS. 2: PRE-DRILL SLATS WITH TWO EQUALLY SPACED HOLES 1" FROM EACH END WITH A 1/8" DRILL BIT. 3: ATTACH PANEL SLATS ALONG THE SAFETY BOARD AND PANEL BOARD EQUALLY SPACED. 4: ATTACH EACH PANEL SLAT USING FOUR 1-1/ 2"...
  • Page 85 STEP 52: ARCHED SIDE TOP BOARDS 1: PLACE THE 2 X 6 X 47-1/2" ARCHED SIDE TOP BOARD UP AGAINST THE TOP OF THE CORNER POSTS ON THE SIDE OF THE FORT. 2: ATTACH THE ARCHED SIDE TOP BOARD WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3: ATTACH ANOTHER ARCHED SIDE TOP BOARD ON THE OPPOSITE SIDE OF FORT.
  • Page 86 STEP53: CHIMNEY/DORMER 1: USE THE INSTRUCTIONS PROVIDED TO ASSEMBLE AND INSTALL THE CHIMNEY AND DORMERS. TIP: WHEN INSTALLING THE ROOF BOARDS ONLY INSTALL A FEW ROOF BOARDS THEN ASSEMBLE AND INSTALL THE CHIMNEY. AFTERWARDS INSTALL MORE ROOF BOARDS THEN ASSEMBLE ANDINSTALL THE DORMER. FINALLY INSTALL THE REMAINING ROOF BOARDS AND ROOF FINISHER.
  • Page 87 STEP 54: INSTALLING THE CLIMBING ROPE 1:DRILL A 7/8" HOLE THROUGH THE FRONT TOP PANEL BOARD (ABOVE THE ROCK WALL) FOR THE CLIMBING ROPE. 2: TIE A KNOT AT ONE END OF THE 10' ROPE AND THREAD IT THROUGH THE HOLE IN THE FRONT TOP PANEL BOARD. 3: YOU CAN TIE A FEW (NO MORE THAN THREE) KNOTS IN THE ROPE TO AID IN CLIMBING APPROXIMATELY 18"...
  • Page 88 STEP 55: PLASTIC FLAGS 1: FIND THE PLASTIC FLAG KIT. 2: ATTACH THE FLAGS TO THE FRONT CORNER POSTS AS SHOWN BELOW. 3: ATTACH EACH FLAG TO THE CORNER POST THROUGH THE PRE-DRILLED HOLES USING 1/2" PHILLIPS HEAD WOOD SCREWS PROVIDED WITH THE FLAG KIT. PLASTIC FLAG KIT PLASTIC FLAG KIT...
  • Page 89 STEP 56: MOUNTING TELESCOPE 1: PLACE THE TELESCOPE ASSEMBLY ON THE ROPE LADDER SUPPORT ABOVE THE TIC TAC TOE PANEL. USING THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE ROUND TELESCOPE BRACKETS TO THE ROPE LADDER SUPPORT. 2: PLACE THE TELESCOPE STAND INTO THE SLOT OF THE TELESCOPE BRACKET.
  • Page 90 STEP 57: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE SWING BEAM. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN. 3: PLACE THE STEERING WHEEL CAP OVER THE CENTER OF THE STEERING WHEEL.
  • Page 91 STEP 58: ATTACHING THE SAFETY HANDLES 1: LOCATE TWO SAFETY HANDLES PROVIDED WITH YOUR PLAYSET. 2: LOCATE THE HARDWARE PROVIDED IN THE BAG WITH THE HANDLES. **DO NOT USE THE SCREWS PROVIDED IN THE BAG WITH THE HANDLES** 3: LOCATE FOUR #14 X 1" LONG PAN HEAD SCREWS IN YOUR MAIN HARDWARE PACKAGE. USE THE 1/4" FLAT WASHERS PROVIDED IN THE BAG WITH THE HANDLES.
  • Page 92 STEP 59: 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 93 STEP 60: ROPE LADDER ASSEMBLY 1: DRILL THREE 1/8" PILOT HOLES 2" DEEP INTO THE BOTTOM OF THE ROPE LADDER SUPPORT. (SEE DIMENSIONS BELOW) 2: SCREW THE EYEBOLT LAG SCREWS INTO THE HOLES AT THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIGHTEN.
  • Page 94 STEP 61: ROPE LADDER ASSEMBLY 1: PLACE THE HOOKS ON THE END OF THE ROPE LADDER ASSEMBLY THROUGH THE EYE OF THE EYEBOLT LAGS. 2: THREAD THE BOTTOM ROPE ENDS OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE A SECURE KNOT IN THE END OF EACH ROPE.
  • Page 95 PART II CLATTER BRIDGE WITH TARP FOR WOODBRIDGE PLAY SET...
  • Page 96 NOTE: THIS SHEET IS A COMBINATION OF 5/16" X 3-1/2" 3/8 X 5" 11-1920 AND 11-0026 HARDWARE. HEX LAG HEX LAG SCREW SCREW QTY: 4 QTY: 34 CHAIN QUICK LINK QTY: 2 #14 X 1-1/4" PAN HEAD SCREW QTY: 7 #8 X 2"...
  • Page 97 PICTURE DESCRIPTION QTY. NOTE: THIS LIST IS A COMBINATION 4 x 4 x 96" OF THE 106 CORNER POST AND 802 WOOD KITS. 2 X 6 X 36-3/4" SANDBOX BOARDS 2 X 4 X 36-3/4" TOP PANEL/DECK SUPPORT/BOTTOM PANEL BOARD 29"...
  • Page 98 PICTURE DESCRIPTION QTY. 2 X 4 X 29" BRIDGE DECK BOARD 5/4 X 2-5/8" X 28-1/2" PANEL SLAT 5/4 X 2-5/8" X 16" BRIDGE SLAT 5/4 x 2-5/8" x 25" PANEL SLAT LEFT 2 X 4 X 33" VERTICAL TARP SUPPORT 2 X 4 X 36-3/4"...
  • Page 99 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 100: Washer

    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 101 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 102 STEP 4: DRILLING CHAIN HOLES 1: LOCATE TWO 2 X 4 X 36-3/4" BOTTOM PANEL/DECK SUPPORT BOARDS. 2: PLACE ONE OF THE BOARDS WITH THE COUNTERSUNK HOLES FACING UP OVER A SCRAP 2 X 4 BOARD. THE SCRAP BOARD WILL HELP PREVENT THE PADDLE BIT FROM SPLINTERING OUT THE BACK SIDE OF THE BOARD.
  • Page 103 STEP 5: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 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 104 STEP 6: 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 105 STEP 7: 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 106 STEP 8: 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 107 STEP 9: DECK BOARDS THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD 1: PRE-DRILL THE ENDS OF THE DECK SPACERS AND DECKBOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT USING THE DIMENSIONS SHOWN BELOW. 8 "...
  • Page 108 STEP 10: FRONT FACE BOARD 1: PLACE THE 5/4 X 6 X 36-11/16" DECK BOARDS ON TOP OF THE DECK SUPPORTS. DO NOT FASTEN THE DECK BOARDS AT THIS TIME. 2: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE FRONT CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
  • Page 109 STEP 11: DECK 1: INSTALL THE 5/4 X 6 X 36-11/16" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 5/16") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS. 2" WOOD SCREWS 5/4 X 6 X 36-11/16" DECK BOARD FRONT OF TOWER...
  • Page 110 STEP 12: REAR BOTTOM PANEL BOARD 1: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD (WITH HOLES YOU DRILLED) AGAINST THE REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS. 2: FASTEN THE BOTTOM PANEL BOARD TO THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 111 STEP 13: PANEL SLATS 1: FIND FIVE 5/4 X 3 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE PANEL SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. (SEE TOP LEFT PICTURE BELOW) 3: INSTALL THE FIRST PANEL SLAT 2-1/2" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8"...
  • Page 112 STEP 14: 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 113 STEP 15: BRIDGE RAILS TO PLAY SET 1: PLACE THE BRIDGE RAILS AGAINST THE GREEN CORNER POST AND CENTER CORNER POST ON THE PLAY SET. 2: LEVEL EACH TOP BRIDGE RAIL AND ATTACH THEM TO THE CORNER POSTS WITH 5/16" X 3- 1/2"...
  • Page 114 STEP 16: BRIDGE RAIL SLATS 1. PRE-DRILL THE 5/4 X 3 X 16" BRIDGE RAIL SLATS ON EACH END WITH A 1/8" DRILL BIT. (SEE TOP IMAGE BELOW) 2. PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS.
  • Page 115 STEP 17: 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 116 STEP 18: 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 117 STEP 19: 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 118 STEP 20: 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 119 STEP 21: LAG POSTS 1: LOCATE TWO 4 X 4 X 32" LAG POSTS. 2: PLACE THE LAG POSTS ON THE INSIDE OF CORNER POSTS A AND B AS SHOWN. THE COUNTERSUNK HOLE THAT IS 4" FROM THE END SHOULD BE AT THE TOP. 3: ATTACH EACH LAG POST TO THE CORNER POST WITH 3/8"...
  • Page 120 STEP 22: VERTICAL TARP SUPPORTS 1: PLACE THE 2 X 4 X 33" VERTICAL TARP SUPPORTS ON THE INSIDE OF THE TOP PANEL BOARDS. THE END OF EACH VERTICAL TARP SUPPORT SHOULD BE FLUSH TO THE BOTTOM OF THE TOP PANEL BOARD. CENTER EACH VERTICAL TARP SUPPORT WITH THE CENTER OF THE TOP PANEL BOARD.
  • Page 121 STEP 23: TARP BOARDS 1: LOCATE THREE 2 X 4 X 36-3/4" TARP BOARDS. 2: PLACE ONE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. THE END OF THE TARP BOARD SHOULD BE FLUSH WITH THE SIDES OF THE VERTICAL TARPS SUPPORTS. 3: ATTACH THE TARP BOARD TO THE VERTICAL TARP SUPPORTS WITH 2-1/2"...
  • Page 122 STEP 24: CLATTER BRIDGE TARP 1: LOCATE THE 34-1/4" X 57-1/2" CLATTER BRIDGE TARP. 2: PLACE THE TARP OVER THE TOP OF THE TARP BOARD ON TOP OF THE VERTICAL TARP SUPPORTS. 3: THE TARP WILL OVERLAP THE SIDE OF THE TARP BOARDS ON TOP OF THE CORNER POSTS. 4: ATTACH THE TARP THROUGH THE GROMMETS TO THE TARP BOARDS WITH #14 X 1-1/4"...
  • Page 123 STEP 25: BOARD REMOVAL 1: REMOVE THE 2 X 4 AT THE TOP LEFT AS SHOWN BELOW. 2: REMOVE THE 2 X 6 AT THE MIDDLE LEFT AS SHOWN BELOW. 3: USE A 5/16" X 3-1/2" HEX BOLT AND A 5/16" WASHER TO FILL THE FOUR HOLES WHERE THE 2 X 4 AND 2 X 6 WERE ATTACHED.
  • Page 124 STEP 26: DRILLING RADICAL RIDE ENTRY PLATE 1: LOCATE THE RADICAL RIDE ENTRY PLATE IN THE RADICAL RIDE SLIDE BOX. 2: DRILL FOUR HOLES WHERE INDICATED BELOW WITH A 3/8" DRILL BIT. 3: THE BOTTOM TWO MOUNTING HOLES SHOWN BELOW ARE NOT USED WHEN MOUNTING THE FACE PLATE TO THE LAG POSTS.
  • Page 125 STEP 27: ATTACHING RADICAL RIDE SLIDE 1: ASSEMBLE THE RADICAL RIDE 5 TUBE SLIDE FOLLOWING THE DIRECTIONS THAT CAME WITH THE SLIDE. WHEN YOU GET TO STEP 3 IN THE RADICAL RIDE 5 INSTRUCTIONS **STOP** AND USE THIS STEP INSTEAD TO MOUNT THE ENTRY PLATE AND ENTRY ASSEMBLY TO THE CLATTER BRIDGE TOWER.
  • Page 126 STEP 28: ATTACHING 2 X 4 AND 2 X 6 PANEL BOARDS 1: LOCATE THE 2 X 4 X 36-3/4" TOP PANEL BOARD AND THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD THAT YOU REMOVED IN STEP 25. 2: PLACE THE BOTTOM OF THE 2 X 4 FLUSH TO THE TOP OF THE ENTRY PLATE. ATTACH THE 2 X 4 TO THE CORNER POSTS WITH 5/16"...
  • Page 127 STEP 29: ATTACHING WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING OF THE CLATTER BRIDGE TOWER AS SHOWN WITH THE LIP OF THE SLIDE RESTING ON TOP OF THE DECK BOARDS. 2: ATTACH THE SLIDE TO THE DECK BOARDS WITH FOUR #14 X 1-1/4" PAN HEAD SCREWS **DO NOT OVER TIGHTEN** 1-1/4"...
  • Page 128 STEP 30: FINAL PANEL SLAT 1: LOCATE THE 5/4 X 2-5/8" X 25" PANEL SLAT. 2: THIS SLAT WILL GO INSIDE THE PLAY SET ON TOP OF THE DECK ON THE LEFT HAND SIDE. IT WILL BE FLUSH AGAINST THE BRIDGE RAILS AS SHOWN IN DETAIL A BELOW. 3: ATTACH THE PANEL SLAT TO THE INSIDE OF THE 2 X 6 X 70 FRONT FACE BOARD AND INSIDE OF THE 2 X 6 X 70 TOP PANEL BOARD WITH TWO 2"...
  • Page 129 STEP 31: NAME PLATE 1: ATTACH THE Gorilla NAME PLATE CENTERED ON THE FRONT OF YOUR SWING BEAM WITH TWO 2-1/2" WOOD SCREWS. 2: YOUR PLAYSET IS FINISHED! ENJOY YOUR PLAYSET!
  • Page 130 WARRANTY REGISTRATION - WOODBRIDGE - Gorilla Playsets manufactures 3 EASY WAYS TO REGISTER the finest quality products that Mail this completed form to: are designed for outstanding Fax this completed form to: Gorilla Playsets strength and durability. OPTION 1 (678) 880-3329...