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Gorilla Playsets Blue Ridge Mountaineer 2009 Assembly Manual

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Mountaineer 2009
Blue Ridge
ASSEMBLY MANUAL
Copyright © 2009 Gorilla Playsets
All Rights Reserved
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA 30114
(800) 882-0272
5/MAY/2009 – Version 1.4.2

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Summary of Contents for Gorilla Playsets Blue Ridge Mountaineer 2009

  • Page 1 Mountaineer 2009 Blue Ridge ASSEMBLY MANUAL Copyright © 2009 Gorilla Playsets All Rights Reserved Gorilla Playsets 190 Etowah Industrial Court Canton, GA 30114 (800) 882-0272 5/MAY/2009 – Version 1.4.2...
  • Page 2 STOP…PLEASE READ!! 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. THE RETAILER DOES NOT STOCK COMPONENTS.
  • Page 3 Blue Ridge Mountaineer TABLE OF CONTENTS Warranty and Safety Guidelines………………………….……………………….…..4-10 Kit Contents and Tool List…………..……………………….……………………….11-28 Framing the play set...………………………………………...……………..…...steps 1-7 Constructing deck and upper panel boards………………..……………..…..steps 8-10 Constructing rock wall and securing to fort…………………………..…..steps 11-15 Constructing and attaching ladder..….……..………….…………………….steps 16-17 Assembling Tic-Tac-Toe Panel……………………………………………….steps 18-19 Installing panel slats and Tic-Tac-Toe Panel..…..………..…………...…………step 20 Assembling Swing……………………………..………..…..………..…..steps 21-28...
  • Page 4 Yet you’ll appreciate how quick and easy construction really is! Our playset kits are designed for children ages 3 to 11. gorilla playsets® believes every child should have a playset and with our kits they can! You can rest assured your new playset is safe, durable and designed to hold up to the elements.
  • Page 5 This decision is subject to verification of the defect upon delivery of the defective part to gorilla playsets®...
  • Page 6 • ROCK WALL: 150 LBS. • ALL SLIDES: 125 LBS. Gorilla Playsets recommends that the weight limits for all components must not be exceeded. Failure to adhere to these and other safety guidelines could result in damage to the playset and injury to the users.
  • 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 Ropes, cables and chains should be removed and replaced if excessive wear is found. Contact Gorilla Playsets for warranted replacement parts.
  • Page 9 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) Handbook for Public Playground Safety offers from its . 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 LEVELING YOUR FORT DURING ASSEMBLY • Complete the steps which will be the basic frame of the fort {i.e. four corner posts with base (sand box boards) and deck supports} • Position in the most level area chosen for the playset, keeping in mind the location and size of the swing beam, ladder, slides, etc.

  • Page 11: Qty

    Blue Ridge Mountaineer 2009 KIT CONTENTS COMPONENTS Description Check List (Swings, Slides, Accessories) Swingbelts w/ Chains __________ Rope Climber __________ 10’ Radical Wave Slide __________ Rad Ride Slide __________ The Mountaineer Assembly Manual __________ Rockwall Grips (assorted colors) __________ Trapeze Swing w/Chains...
  • Page 12 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 23’ LADDER ROPE LADDER SWING BELTS (2) 13’ TRAPEZE ARM (1) RAD RIDE 10’ WAVE ROCK WALL SLIDE Playset height: 12’ Approximate assembly time: 12-16 Hours { 6 foot unobstructed safety perimeter around playset recommended }...
  • Page 13 Helpful Installation Hints • 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 14 General Info To Review Before Installation This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your playset. 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.
  • Page 15 Common installation practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.

  • Page 16: Table Of Contents

    #8 X 1-1/2" WOOD SCREW QTY: 140 #8 X 2" WOOD SCREW QTY: 196 #8 X 2-1/2" WOOD SCREW QTY: 135 #8 X 3" WOOD SCREW QTY: 8 #14 X 1-1/4" PAN HEAD SCREW QTY: 24 5/16" LOCK NUT 3/8" LOCK NUT 5/16"...

  • Page 17: Qty: 34

    5/16 X 3-1/2" 3/8 X 3-1/2" HEX LAG SCREW HEX LAG SCREW QTY: 34 QTY: 12 #2 SQUARE DRILL BIT QTY: 1 GREEN PLASTIC 3/8 x 3-1/2" 5/16 X 4" 3/8 x 9" 3/8 x 7" BOLT CAP CARIAGE BOLT CARIAGE BOLT CARIAGE BOLT EYEBOLT LAG...

  • Page 18: Qty

    PICTURE DESCRIPTION QTY. 2 X 4 X 21 " BOTTOM PANEL BOARD 2 X 4 X 15" PICNIC TABLE SUPPORT 2 X 4 X 23" PICNIC TABLE BENCH SUPPORT 2 X 4 X 30" PICNIC TABLE VERT. SUPPORT 2 X 4 X 47 "...

  • Page 19: Qty

    PICTURE DESCRIPTION QTY. 2 X 4 X 58" SWING BEAM CROSS MEMBER 2 X 4 X 66" ROCK WALL SIDE 2 X 4 X 70" CENTER DECK SUPPORT 2 X 4 X 70" DECK SUPPORT 2 X 4 X 70" REAR TOP PANEL BOARD 2 X 4 X 78"...

  • Page 20: Qty

    PICTURE DESCRIPTION QTY. 2 X 6 X 47 " END PANEL/ SANDBOX BOARD 2 X 6 X 70" BOTTOM PANEL/ SANDBOX BOARD 2 X 6 X 70" FRONT FACE BOARD 2 X 6 X 70" REAR ENTRY BOARD 2 X 6 X 78" ROPE LADDER RUNNER 4 X 4 X 47...

  • Page 21: Qty

    PICTURE DESCRIPTION QTY. X 3 X 28 " PANEL SLAT X 3 X 33" PANEL SLAT X 3 X 42" SUN SUPPORT X 4 X 40 " DECK SPACER X 4 X 22 " DECK SPACER X 4 X 14 "...

  • Page 22: Qty

    PICTURE DESCRIPTION QTY. X 10" ROOF PEAK SUPPORT X 6 X 51" PICNIC TABLE SEAT AND TOP 1 X 4 X 47 " TONGUE ONLY ROOF FINISHER 1 X 4 X 47 " GROOVE ONLY ROOF STARTER 1 X 6 X 47 "...

  • Page 23: Qty

    PICTURE DESCRIPTION QTY. 2 X 6 X 21 " END PANEL BOARD 4 X 4 X 96" PLASTIC COATED CORNER POST 4 X 4 X 96" PLASTIC COATED SWING LEG 4 X 6 X 120" PLASTIC COATED SWING BEAM 2 X 4 X 17" LADDER STEP LEFT 2 X 4 X 66"...

  • Page 24: Qty

    PICTURE DESCRIPTION QTY. RAD RIDE 5 ROPE LADDER ASSEMBLY SWINGS W/CHAINS TRAPEZE W/CHAINS...
  • Page 25 PICTURE DESCRIPTION QTY. SWING PLATE CLIMBING ROCKS A-FRAME SWING BRACKET HARDWARE NOT SHOWN INSTRUCTIONS...
  • Page 26 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS TIC-TAC-TOE ASSEMBLY 10' ROPE...
  • Page 27 PICTURE DESCRIPTION QTY. " X 1 " GREEN BRACKET SPRING CLAMP SAFETY HANDLE (PAIR)
  • Page 28 PICTURE DESCRIPTION QTY. 10' RADICAL WAVE SLIDE TELESCOPE UNASSEMBLED CHIMNEY UNASSEMBLED DORMER...
  • Page 29 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 30 STEP 2: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE 2 X 6 X 78" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE OFFSET HOLES IN THE ROPE LADDER RUNNER MUST FACE DOWNWARD. 2: USE 5/16 X 4-1/2"...

  • Page 31: 3/8" Washer

    STEP 3: ASSEMBLING THE LEFT SIDE FRAME 1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST FACE DOWNWARD. 2: USE 5/16 X 4-1/2"...

  • Page 32: 5/16" Washer

    STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT 5/16"...
  • Page 33 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 34 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE OFFSET HOLES IN THE SANDBOX BOARD MUST 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 35 STEP 7: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 47-1/2" PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 5/16"...
  • Page 36 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 SPACER TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 21-5/8" ONLY NEEDS TO BE DRILLED ONCE.
  • Page 37 STEP 9: END WALL SLIDE MOUNT POST 1: FIND THE 4 X 4 X 40" END WALL SLIDE MOUNT POST. 2: MEASURE 26" INCHES FROM THE FRONT OF THE FRONT CORNER POST AND MARK THE MEASUREMENT ON THE INSIDE OF THE 2 X 4 X 78" ROPE LADDER SUPPORT. 3: USE THREE 2-1/2"...
  • Page 38 STEP 10: 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. THE HOLE AT 22-1/8" ONLY NEEDS TO BE DRILLED ONCE. 5/4 X 4 X 22-1/2"...
  • Page 39 STEP 11: ROCK WALL 1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES. 2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY. 3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER. T-NUT 2 X 4 X 66"...
  • Page 40 STEP 12: ROCK WALL 1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE). 2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2"...
  • Page 41 STEP 13: ROCK WALL 1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME. GREEN BRACKET 5/16"...
  • Page 42 STEP 14: ROCK WALL 1: FIND TEN ROCKS AND TWENTY 1-1/4" PAN HEAD SCREWS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. TWO PAN HEAD SCREWS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW.
  • Page 43 STEP 15: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE 90 BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE BOTTOM PANEL BOARD.
  • Page 44 STEP 16: LADDER 2 X 4 X 66" 1: FIND TWO 2 X 4 X 66" LADDER SIDES. LADDER SIDE 2: POSITION THE LADDER SIDES SO THAT THE SLOTS IN THE BOARDS ARE FACING EACH T-NUT OTHER AND ARE PARALLEL. 3: INSERT T-NUTS INTO THE OUTSIDE OF THE...
  • Page 45 STEP 17: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE FORT AS SHOWN BELOW. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8” HOLE THROUGH THE REAR ENTRY BOARD. 2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE REAR ENTRY BOARD.
  • Page 46 STEP 18: TIC TAC TOE 1: LOCATE THE GREEN DOWELS AND MATCH THEM AS FOLLOWS: ONE THREADED STUD END, AND ONE THREADED INSERT. 2: SCREW THE STUDS INTO THE INSERTS UNTIL TIGHT. 3: REPEAT STEPS 1 AND 2 WITH THE REMAINING TWO SETS 4: LOCATE ONE OF THE GREEN BRACKETS AND PLACE THE DOWELS IN AS SHOWN.
  • Page 47 STEP 19: TIC TAC TOE 1: LOCATE THE TIC-TAC- TOE TUMBLERS AND PLACE ONE ON EACH DOWEL ABOVE THE COLLARS. 2: CONTINUE PLACING COLLARS AND TUMBLERS ON THE DOWELS UNTIL NONE REMAIN. 3: LOCATE THE GREEN BRACKET AND PLACE ON TOP OF ASSEMBLY. LINE UP THE HOLES IN THE BRACKET WITH THE DOWELS ON THE UNIT.
  • Page 48 STEP 20: PANEL SLATS 1: FIND TWENTY-ONE 5/4 X 3 X 28-1/2" PANEL SLATS. 2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT. 3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES. 5: CENTER THE 1-3/4 X 1-1/2 X 10-3/4"...
  • Page 49 STEP 21: 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 WITH 1/2" WASHERS ON TOP, AND 3/8"...
  • Page 50 STEP 22: 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 6-1/2" OR 7" CARRIAGE BOLTS (SIZE MAY VARY FROM UNIT TO UNIT) WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 51 STEP 23: ATTACH SWING LEGS TO BRACKET 1: PLACE THE 4 X 4 X 96" 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 52 STEP 24: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP 1: LAY THE SWING BEAM ACROSS THE FORT AND POSITION THE LEGS UNDERNEATH THE END OF THE BEAM. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND SWING LEGS.
  • Page 53 STEP 25: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 6-1/2" OR 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2"...
  • Page 54 STEP 26: MOUNT SWING BEAM ON FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: AFTER THE LEGS ARE ATTACHED, HAVE ONE PERSON ON THE GROUND PICK UP THE SWING BEAM BY THE LEGS, AND ANOTHER PERSON PICK UP THE SWING BEAM FROM INSIDE THE FORT AND WALK OUT THE SWING BEAM. 2: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
  • Page 55 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 56 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 CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES. 3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS. 3/8 X 3-1/2"...
  • Page 57 STEP 29: ROOF SUPPORTS 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. USE A 2"...
  • Page 58 STEP 30: ROOF PEAK SUPPORT 1: PRE-DRILL HOLES IN THE 5/4 X 10" ROOF PEAK SUPPORT 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 FLUSH TO THE SIDES. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 1-1/2"...
  • Page 59 STEP 31: ROOF 1: PLACE THE 1 X 4 X 47-1/2" GROOVE-ONLY ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 60 STEP 32: ROOF 1: PLACE THE 47-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH 1-1/2" WOOD SCREWS. 47-1/2" ROOF PEAK...
  • Page 61 STEP 33: ROOF 1: PLACE THE 1 X 6 X 47-1/2" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTERS. EACH SIDE OF THE ROOF GETS NINE ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 62 STEP 34: SUNBURST 1: PRE-DRILL HOLES IN THE 2 X 6 X 16" SUN TO THE PATTERN SHOWN BELOW. 2 X 6 X 16" 4" 4" 2: PLACE THE 2 X 6 X 16" SUN CENTERED AGAINST THE 5/4 X 2-5/8 X 42" SUN SUPPORT. FASTEN THE SUN TO THE SUN SUPPORT WITH 2"...
  • Page 63 STEP 35: SUNBURST 1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP AGAINST THE ANGLED ROOF SUPPORTS, WITH THE ENDS OF THE SUN SUPPORT FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. MAKE SURE THAT THE BOARD IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP.
  • Page 64 STEP 36: SUNBURST 1: PREDRILL HOLES IN ALL RAYS WITH A 1/8" DRILL BIT AT 3/4" ON CENTER. 2: CENTER THE 5/4 X 2 X 16" LARGE RAY ONTO THE HALF SUN AND THE ROOF SUPPORT BOARDS AND FASTEN WITH TWO 1-1/2"...
  • Page 65 STEP 37: 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 66 STEP 38: SAFETY BOARD 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH HOLES ON CENTER TO THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 67 STEP 39: PICNIC TABLE 1: PLACE THE 2 X 4 X 15" PICNIC TABLE SUPPORT ON TOP OF THE 2 X 4 X 30" PICNIC TABLE VERTICAL SUPPORT AND POSITION THE BOARDS AT A RIGHT ANGLE. 2: ENSURE THAT THE PICNIC TABLE SUPPORT AND THE PICNIC TABLE VERTICAL SUPPORT ARE SQUARE AND FASTEN THE PICNIC TABLE SUPPORT TO THE VERTICAL SUPPORT WITH THREE 2 1/2"...
  • Page 68 STEP 40: PICNIC TABLE 1: MEASURE 18” FROM THE GROUND UP AND MARK THIS POINT ON THE CORNERPOST. 2: ATTACH THE SEAT SUPPORT TO THE OUTSIDE OF THE CORNER POST SO THAT THE TOP IS AT 18” FROM THE GROUND. ATTACH IT WITH THREE 2-1/2” WOOD SCREWS IN EACH END, THEN LEVEL SEAT SUPPORT AND ATTACH IT TO THE VERTICAL SUPPORT ON EACH SIDE.
  • Page 69 STEP 41: PICNIC TABLE 1: ATTACH THE PICNIC TABLE SEAT ON THE SEAT SUPPORTS WITH TWO 2” WOOD SCREWS IN EACH END. 2: ATTACH THE PICNIC TABLE TOPS TO THE TABLE SUPPORTS WITH TWO 2” WOOD SCREWS IN EACH END. ROCK WALL REMOVED FOR ASSEMBLY CLARIFICATION 2"...
  • Page 70 STEP 42: ROPE LADDER ASSEMBLY 1: DRILL THREE 1/8" PILOT HOLES 2" DEEP INTO THE BOTTOM OF THE ROPE LADDER SUPPORT (SEE DIMENSIONS BELOW). 2: PLACE THE EYEBOLT LAGS INTO THE HOLES AT THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIGHTEN. 5-1/2"...
  • Page 71 STEP 43: ROPE LADDER ASSEMBLY 1: PLACE THE HOOKS ON THE END OF THE ROPE LADDER ASSEMBLY THROUGH THE EYE OF THE EYBOLT LAG. 2: THREAD THE BOTTOM OF THE ROPE LADDER THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE A SECURE KNOT.
  • Page 72 STEP 44: RAD RIDE 1: LOCATE THE LEFT AND RIGHT ENTRANCE SECTION. 2: FASTEN THE LEFT AND RIGHT SECTIONS TOGETHER ALONG THE RIBS OF THE SLIDE SECTION WITH 5/16 X 3/4" HEX BOLTS, 5/16" WASHERS, AND 5/16" LOCK NUTS. 3: DO NOT FULLY TIGHTEN BOLTS UNTIL THE ENTIRE UNIT HAS BEEN FULLY ASSEMBLED. THIS WILL ALLOW FOR NECESSARY FLEX OF THE SLIDE BODY WHILE ASSEMBLING.
  • Page 73 STEP 45: SLIDE ENTRY ASSEMBLY 1: LOCATE THE SLIDE ENTRY PANEL AND THE SLIDE ENTRANCE SECTION ASSEMBLY. 2: ATTACH THE PANEL TO THE SLIDE ENTRANCE SECTION WITH EIGHT 5/16 X 3/4" HEX BOLTS, SIXTEEN 5/16" WASHERS, AND EIGHT 5/16" LOCK NUTS. SEE BELOW FOR ATTACHMENT LOCATIONS. 3: LIKE THE PREVIOUS STEP, DO NOT FULLY TIGHTEN THE HARDWARE UNTIL THE SLIDE IS FULLY ASSEMBLED AND ATTACHED TO THE FORT.
  • Page 74 STEP 46: ASSEMBLING THE SLIDE SECTIONS 1: LOCATE TWO 90 SLIDE SECTIONS. FASTEN THE TWO PIECES TOGETHER ALONG THE RIBS WITH 5/16 X 3/4" HEX BOLTS, 5/16" WASHERS, AND 5/16" LOCK NUTS. 2: WITH THE REMAINING 90 SLIDE SECTION AND THE 90 EXIT SECTION, YOU WILL ASSEMBLE THE SLIDE EXIT. THE SLIDE EXIT IS ASSEMBLED THE SAME WAY THAT THE OTHER 90 SECTION WAS ASSEMBLED.
  • Page 75 STEP 47: ATTACHING SLIDE SECTIONS 1: TAKE THE TWO SLIDE SECTIONS THAT WERE ASSEMBLED IN THE PREVIOUS STEP AND LINE UP THE RIBS SO THAT IT LOOKS LIKE THE ONE SHOWN BELOW. 2: ATTACH THE SLIDE SECTIONS WITH 5/16 X 3/4" HEX BOLTS, 5/16" WASHERS, AND 5/16" LOCK NUTS. 3: DO NOT FULLY TIGHTEN HARDWARE UNTIL SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT.
  • Page 76 STEP 48: ATTACHING THE FOOT STAND 1: PLACE THE FOOTER SUPPORT ON THE INSIDE OF THE FOOT STAND, NOT BETWEEN THE EXIT SECTION AND THE FOOT STAND. 2: ATTACH THE SLIDE EXIT SECTION TO THE FOOT STAND AND FOOTER SUPPORT WITH 5/16 X 3/4" HEX BOLTS, 5/16" WASHERS, AND 5/16"...
  • Page 77 STEP 49: ATTACHING THE FOOTER STRAPS 1: PLACE ONE END OF THE FOOTER STRAP INSIDE THE SIDE OF THE FOOT STAND AND THE OTHER END INSIDE THE FOOTER SUPPORT. 2: ATTACH USING 5/16 X 3/4" HEX BOLTS, 5/16" WASHERS, AND 5/16" LOCK NUTS. 3: DO NOT FULLY TIGHTEN HARDWARE UNTIL SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT.
  • Page 78 STEP 50: ATTACHING THE SLIDE BODY TO THE SLIDE ENTRY 1: ATTACH THE SLIDE ASSEMBLY TO THE SLIDE ENTRY ASSEMBLY WITH 5/16 X 3/4" HEX BOLTS, 5/16" WASHERS, AND 5/16" LOCK NUTS. 2: DO NOT FULLY TIGHTEN HARDWARE UNTIL SLIDE HAS BEEN FULLY ASSEMBLED AND ATTACHED TO THE FORT. 5/16 X 3/4"...
  • Page 79 STEP 51: ATTACHING THE SLIDE TO THE FORT 1: ATTACH SLIDE ENTRY ASSEMBLY TO THE CORNER POST AND CENTER POST OF THE FORT WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2: DO NOT ATTACH THE BOTTOM RIGHT HOLE OF THE SLIDE ENTRY PLATE AT THIS TIME. 5/16"...
  • Page 80 STEP 52: SLIDE PANEL 1: FIND THE 2 X 4 X 21-1/2" END PANEL BOARD, AND THE 2 X 6 X 21-1/2" END PANEL BOARD. 2: PLACE THE 2 X 6 X 21-1/2" BOTTOM PANEL BOARD AGAINST THE CORNER POST WITH OFFSET HOLES DOWN, AND MOUNT THE BOTTOM RIGHT HOLE WITH A 5/16 X 4-1/2"...
  • Page 81 STEP 53: DORMER 1: FIND TWO LEFT SIDE AND TWO RIGHT SIDE DORMER ROOF ASSEMBLIES. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE LEFT AND RIGHT ROOF ASSEMBLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW. 4: ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1-1/4"...
  • Page 82 STEP 54: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/2" WOOD SCREWS. DORMER ROOF PEAK...
  • Page 83 STEP 55: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE 2" WOOD SCREWS TO FASTEN THE DORMERS TO THE ROOF. USE 2" WOOD SCREWS IN THESE LOCATIONS (EACH SIDE)
  • Page 84 STEP 56: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW. USE A 2" WOOD SCREW IN THIS LOCATION CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY.
  • Page 85 STEP 57: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS. USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE) USE 1-1/4" WOOD SCREWS IN THIS LOCATION (EACH SIDE)
  • Page 86 STEP 58: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.
  • Page 87 STEP 59: ANGLE SUPPORTS 1: THE FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT AND BACK OF THE FORT. 2: USE TWO 2-1/2" WOOD SCREWS THROUGH THE FRONT FACE/REAR ENTRY BOARDS INTO THE TOP OF THE BRACE, AND ONE 2"...
  • Page 88 STEP 60: WAVE SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: THE FLARED END OF THE SLIDE WILL REST ON THE BOTTOM PANEL BOARD. 3: ATTACH THE SLIDE TO THE DECK WITH 1-1/4"...
  • Page 89 STEP 61: INSTALLING THE ROCK WALL ROPE 1: DRILL A 7/8" HOLE THROUGH THE END 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 END PANEL BOARD. 2: THE UNTIED END WILL GO THROUGH THE HOLE OF THE BOTTOM ROCK WALL BOARD.
  • Page 90 STEP 62: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES ON THE UNIT AS SHOWN BELOW AND ATTACH WITH THE PROVIDED HARDWARE.
  • Page 91 STEP 63: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS ONTO THE SWING BEAM MOUNT, BETWEEN THE SWING BEAM AND THE CORNER POST. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4"...
  • Page 92 _______________________________________________________________________ _______________________________________________________________________ _______________________________________________ Thank you for registering with gorilla playsets™! The information you provided will be kept confidential and will ONLY be used to better serve our customers. Remove this page from the manual and mail to the address below.

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