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Gorilla Playsets Everest Elite Manual

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*51-1091-W*
51-1091
Everest Elite
Model: 1500MWC
(BOXES: 1501, 1504, 1506,
1509N, 1509W, 1514, 1528,
1529, 1535N-1, 1535N-2, 1537,
1539, 1540, 7' Turbo Tube Slide
Box, & Slide Box)
Copyright © 2020 Gorilla Playsets
All Rights Reserved
166 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
™
™
playsets
playsets
™
™
playse ts
playse ts
Stained Post Option
BOXES: 1533, 1534,
1522, 1541
REV: 2-14-2020

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  • Page 1 (BOXES: 1501, 1504, 1506, 1522, 1541 1509N, 1509W, 1514, 1528, 1529, 1535N-1, 1535N-2, 1537, 1539, 1540, 7’ Turbo Tube Slide Box, & Slide Box) Copyright © 2020 Gorilla Playsets All Rights Reserved *51-1091-W* 166 Etowah Industrial Court Canton, GA 30114 REV: 2-14-2020 www.gorillaplaysets.com...
  • Page 2 Please inspect and inventory all parts immediately upon accepting delivery. Use the inventory pages in the manual to make sure you have received all necessary parts. The quickest method to get any parts that are missing or damaged is to use our “Quick Response Center”...
  • Page 3 This decision is subject to verification of the defect, which, at Gorilla’s discretion, may be accomplished by submitting photographs or by delivery of the defective part to Gorilla Playsets • 166 Etowah Industrial Ct. • Canton, GA 30114 • 1-800-882-0272 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase.
  • Page 4 Gorilla shall not be liable for incidental, indirect or consequential damages or injuries that result from building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used. WEIGHT LIMITS FOR GORILLA PLAYSETS • FORT PLATFORMS: 800 LBS. TOTAL WEIGHT • SWING BELT: 225 LBS.
  • Page 5 PRODUCT REGISTRATION - EVEREST ELITE - Gorilla Playsets manufactures ™ 3 EASY WAYS TO REGISTER the finest quality products that are designed for outstanding Complete the online registration form at: OPTION 1 http://www.gorillaplaysets.com/register strength and durability. We back our products with unparalleled...
  • Page 6 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 7 IMPORTANT – PLEASE READ Congratulations! You have just purchase one of the finest residential wooden swing sets available today. As with any wooden product that spends its entire life outside, in varying elements, it is important to know what to expect with your new swing set so that your family can enjoy it for many years.
  • Page 8 WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to ensure it has been properly installed. Gorilla Playsets 166 Etowah Industrial Court Canton, GA. 30114...
  • Page 9 Model: 1500MWC Stained Post Option BOXES: 1533, 1534, (BOXES: 1501, 1504, 1506, 1522, 1541 1509N, 1509W, 1514, 1528, 1529, 1535N-1, 1535N-2, 1537, 7’ Turbo Tube Slide Box, & Slide Box) REV: 2.14.2020...
  • Page 10 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 4-7 Leveling Fort, General Information and Definitions..........Pages 7-9 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 10-14 Site Plan, Safety Zone, Required Tool List and Kit Contents ……....Pages 15-17 Hardware, Lumber and Accessory Checklists……………………………..Pages 18-64 Adding T-Nuts to Corner Posts (Middle Level Deck)...………..………...…....

  • Page 11: Table Of Contents

    TABLE OF CONTENTS Upper Level Wood Roof Assembly.………………………..……....Steps 66-70 Middle Level Wood Roof Assembly..............Steps 71-76 Lower Level Wood Roof Assembly..............Steps 77-84 Wall Panel Boards....................Step 85 Plastic Sunburst..................... Step 86 Sandbox Seats and Name Plate................Step 87 Picnic Table....................
  • Page 12 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 13 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 14 Play Set Surfacing Recommendations: Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/PageFiles/122149/325.pdf 1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
  • Page 15 2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around equipment where a child might fall. This area should be free of other equipment and obstacles onto which a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum of 6’...
  • Page 16 General Info to Review Before Installation • Depending on your experience, assembly of the playset can take as little as 6 hours up to 24 hours, depending on size, after inventory of parts; therefore, we recommend you set aside a full two days for assembly. •...
  • Page 17 This page is a list of definitions and explanations used throughout our instructions to aid you in the assembly of your play set. Offset Holes- Throughout the installation procedures we will refer to parts with offset holes. This refers to the orientation of the holes on the board. An offset hole is one that is closer to one side than it is the other or in other words, it is not centered on the board.
  • Page 18 Common Installation Practice Installing T-nuts When installing T-nuts into the wood, use a smooth faced hammer to set the face of the T-nut flush into the wood. Corner Post T-nut Insert the barrel of the T-nut into the predrilled hole. Using a smooth faced hammer, drive the T-nut until the face of the T-nut is flush to the wood.
  • Page 19 HOW A T-NUT WORKS THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN THE CORNER POSTS.
  • Page 20 BOARD IDENTIFICATION 1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed. 2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part.
  • Page 21 PRE-DRILL LAG SCREW DIRECTIONS Pre-drilling holes for lag screws will make it easier to drive the screws in by hand. "Jobber" length drill bits are available in sizes that are longer than standard drill bits and those are ideal for the job. When using the drill bit you will have to "spot" drill the post and then remove the board you are attaching to finish drilling the hole.
  • Page 22 SWING BEAM LOADING Weight Limits for Accessories: The weight limit for a Swing Belt is 225 lbs. (Although 150lbs is the maximum recommended swinging weight capacity for the swing position.) The weight limit for a Trapeze Bar is 125 lbs. Maximum Allowable swinging weight for a three position swing: 1) The maximum allowable swinging weight at each Swing Belt position is 150 lbs.
  • Page 23 Everest Elite - 2020 (Gorilla) Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: 9'-10 8 " Swing Belts (2) Trapeze (1) 10'-1 8 " Clatter Bridge 3'-11 2 "...
  • Page 24 EVEREST ELITE SAFETY ZONE SAFETY ZONE 34'-7 2 " 6'-0" 6'-0" 34'-10 " 6'-0" 6'-0" (6) foot unobstructed safety perimeter around playset recommended...
  • Page 25 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64” and a 1” Paddle style bit. ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16”...
  • Page 26 1501 HARDWARE PAGE: 1 OF 2 REV A: 9/10/2014 JH #8 X 1" WOOD SCREW QTY: 2 #14 X 1-1/4" #8 X 1-3/4" PAN HEAD SCREW WOOD SCREW QTY: 4 QTY: 4 #8 X 2" WOOD SCREW QTY: 189 #8 X 2-1/2" WOOD SCREW QTY: 52 #8 X 3"...
  • Page 27 5/16" X 3-1/2" 3/8 X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 12 QTY: 12 1501 HARDWARE PAGE: 2 OF 2 REV A: 9/10/2014 JH #2 SQUARE DRIVE BIT QTY: 1 3/8 x 7" 3/8 x 6-1/2" 3/8 x 3-1/2" 3/8 x 9"...
  • Page 28 1504 HARDWARE PAGE: 1 OF 1 PRELIMINARY 9/18/2012 J.H. #8 X 2" WOOD SCREW QTY: 71 #8 X 2-1/2" WOOD SCREW QTY: 12 #8 X 3" WOOD SCREW QTY: 5 #10 x 3-1/2" WOOD SCREW #14 x 3" QTY: 2 PAN HEAD SCREW QTY: 3 5/16"...
  • Page 29 1506N HARDWARE #8 X 1-1/4" PAGE: 1 OF 1 WOOD SCREW QTY: 6 REV B: 8/18/2015 J.H. #8 X 1-1/2" WOOD SCREW QTY: 104 #8 X 2" WOOD SCREW QTY: 28 #8 X 2-1/2" WOOD SCREW QTY: 10 #8 X 3" WOOD SCREW QTY: 2 5/16"...
  • Page 30 11-0071 1509N HARDWARE PAGE: 1 OF 1 REV A: 9/19/2014 JH #8 X 2" WOOD SCREW QTY: 94 #8 X 2-1/2" #14 x 1-1/4" WOOD SCREW PAN HEAD SCREW QTY: 18 QTY: 6 #8 X 3" WOOD SCREW QTY: 5 3/8"...
  • Page 31 1509W HARDWARE #8 X 1-1/4" WOOD SCREW PAGE 1 OF 1 QTY: 8 9/11/2014 JH #8 X 1-1/2" WOOD SCREW QTY: 60 #8 X 2" WOOD SCREW QTY: 8 5/16" x 3-1/2" HEX LAG SCREW QTY: 4 5/16" WASHER QTY: 4 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
  • Page 32 1514 HARDWARE PAGE: 1 OF 1 PRELIMINARY 9/19/2012 J.H. END OF SCREW #10 X 2" SELF LOOKS SPLIT DRILLING SCREW SIMILAR TO A QTY: 18 DRILL BIT. #14 x 1-1/4" PAN HEAD SCREW QTY: 4 5/16" TEE NUT QTY: 8 3/8"...
  • Page 33 1528 HARDWARE #8 X 1" PAGE 1 OF 1 WOOD SCREW QTY: 2 1/16/2015 SO. #8 X 1-1/4" WOOD SCREW QTY: 25 #8 X 1-1/2" WOOD SCREW QTY: 110 #8 X 2" WOOD SCREW QTY: 25 #8 X 2-1/2" WOOD SCREW QTY: 12 #2 SQUARE DRIVE BIT...
  • Page 34 1529 HARDWARE #8 X 1-1/4" PAGE 1 OF 1 WOOD SCREW QTY: 22 1/16/2015 S.O. #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 #2 SQUARE DRIVE BIT...
  • Page 35 11-0087 #8 X 3" 1535 Hardware WOOD SCREW QTY: 3 PAGE 1 OF 1 REV: E 1/31/2020 JH #8 X 2-1/2" WOOD SCREW QTY: 2 #8 X 2" WOOD SCREW QTY: 84 3/8" WASHER #8 X 1-1/2" QTY: 4 WOOD SCREW QTY: 130 #8 X 1-1/4"...
  • Page 36 11-0091 780/1540 HARDWARE KIT 3/12/2018 JH 5/16" X 2-3/4" 5/16" X 3-1/2" HEX HEAD BOLT LAG SCREW QTY: 2 QTY: 2 5/16" WASHER 5/16" QTY: 4 T-NUT QTY: 2 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS. PICTURE VIEWS SHOWN ABOVE ARE 1:1 SCALE AND CAN BE USED TO MATCH BOLT AND SCREW SIZES.
  • Page 37 PICTURE DESCRIPTION QTY. 1501 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 14-3/4" PICNIC TABLE TOP SUPPORT 2-4-1475-PTTS NOT USED 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 18" ANGLE SUPPORT 2-4-1800-AS NOT USED 2 X 4 X 24"...
  • Page 38 PICTURE DESCRIPTION QTY. 2 X 4 X 47-1/2" SAFETY/END PANEL BOARD 2-4-4750-SBEP 2 X 4 X 58" SWING BEAM CROSS MEMBER 2-4-5800-CM NOT USED 2 X 4 X 66" LADDER RIGHT SIDE 2-4-6600-LRS NOT USED 2 X 4 X 66" LADDER LEFT SIDE 2-4-6600-LLS...
  • Page 39 PICTURE DESCRIPTION QTY. 2 x 4 x 70" REAR TOP PANEL BOARD 2-4-7000-RTPB 2 x 6 x 47-1/2" END SANDBOX/ BOTTOM PANEL BOARD 2-6-4750-ESPB 2 x 6 x 70" FRONT FACE BOARD 2-6-7000-FFB 2 x 6 x 70" SANDBOX BOARD 2-6-7000-SB 4 x 4 x 47-1/2"...
  • Page 40 PICTURE DESCRIPTION QTY. NOT USED 5/4 X 3 X 18-3/4" LADDER BACK 125-3-1875-LB 5/4 X 3 X 23-7/8" ROCK WALL 125-3-2387-RWC 2 NOT USED 5/4 X 3 X 28-1/4" PANEL SLATS 125-3-2825-PS 5/4 X 4 X 40-3/8" DECK SPACER 125-4-4038-DS 5/4 X 6 X 22"...
  • Page 41 PICTURE DESCRIPTION QTY. 5/4 X 6 X 43" PICNIC TABLE & SEAT BOARD 125-6-4300-PTTS 5/4 X 6 X 47-3/8" DECK BOARD 125-6-4737-DB...
  • Page 42 PICTURE DESCRIPTION QTY. 1504 2 X 4 X 18" ANGLE SUPPORT- UPPER LEVEL RAD RIDE SIDE 2-4-1800-ULRDAS 2 X 4 X 18" ANGLE SUPPORT- UPPER LEVEL REAR 2-4-1800-ULRAS 2 X 4 X 21-1/2" ANGLE SUPPORT- UPPER LEVEL SWING SIDE 2-4-2150-ULSAS 2 X 4 X 30-7/16"...
  • Page 43 PICTURE DESCRIPTION QTY. 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD 2-6-3043-SBPB 2 X 6 X 42-1/2" REAR BOTTOM PANEL BOARD 2-6-4250-RBPB 2 X 6 X 70" BACK PANEL BOARD 2-6-7000-BPB5 4 X 4 X 23-1/2" SLIDE BLOCK 4-4-2350-SB 4 X 4 X 30-1/2"...
  • Page 44 PICTURE DESCRIPTION QTY. 5/4 X 3 X 34-1/2" PANEL SLAT 125-3-3450-PS 5/4 X 4 X 25" RAD RIDE DECK SPACER 125-4-2500-RRDS 5/4 X 4 X 29-1/2" UPPER DECK SPACER 125-4-2950-UDS 5/4 X 4 X 35-1/2" REAR DECK SPACER 125-4-3550-RDS 5/4 X 4 X 63" UPPER DECK SPACER 125-4-6300-UDS...
  • Page 45 PICTURE DESCRIPTION QTY. 1506 1 X 4 X 30-1/2" ROOF FINISHER 1-4-3050-RF 1 X 4 X 30-1/2" ROOF STARTER 1-4-3050-RS 1 X 5 X 30-1/2" ROOF BOARD 1-5-3050-RB 1 X 6 X 30-1/2" ROOF PEAK 1-6-3050-RP NOT USED 2 X 4 X 18" CLOSE OUT BOARD 2-4-1800-COB...
  • Page 46 PICTURE DESCRIPTION QTY. 2 X 4 X 51-1/8" ROOF SUPPORT RIGHT 2-4-5113-RSR 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST 4-4-3331-ULCP 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST 4-4-5950-LLCP 4 X 4 X 60-1/4" LAG POST WOOD ROOF LEFT 4-4-6025-LPWL RIGHT HAS...
  • Page 47 PICTURE DESCRIPTION QTY. 1509N 2 X 4 X 29" BRIDGE DECK 2-4-2900-BD 2 X 4 X 36-3/4" SAFETY BOARD WITH CHAIN HOLES 2-4-3675-SBH 2 X 4 X 36-3/4" SAFETY BOARD 2-4-3675-SB 2 X 4 X 66" RAIL 2-4-6600-R 2 X 6 X 36-3/4" BOTTOM PANEL BOARD/SANDBOX BOARD...
  • Page 48 PICTURE DESCRIPTION QTY. 5/4 X 3 X 28-1/2" PANEL SLAT 125-3-2850-PS 5/4 X 4 X 29-3/8" DECK SPACER 125-4-2937-DS 5/4 X 4 X 36-1/2" DECK BOARD 125-4-3650-DB...
  • Page 49 PICTURE DESCRIPTION QTY. 1509W 1 X 3 X 36-3/4" ROOF PEAK BOARD 2 1-3-3675-RPB2 1 X 4 X 36-3/4" ROOF PEAK BOARD 1 1-4-3675-RPB1 1 X 5 X 36-3/4" ROOF BOARD 1-5-3675-RB 1 X 4 X 36-3/4" ROOF FINISHER 1-4-3675-RF 1 X 4 X 36-3/4"...
  • Page 50 PICTURE DESCRIPTION QTY. 1514 4 X 4 X 70" MONKEY BAR RUNNER-LEFT 4-4-7000-MBRL 4 X 4 X 70" MONKEY BAR RUNNER-RIGHT 4-4-7000-MBRR 4 X 4 X 86-1/4" MONKEY BAR LADDER 4-4-8650-MBL 4 X 4 X 70" LOWER LEVEL UNDER DECK SUPPORT 4-4-7000-MBS...
  • Page 51 PICTURE DESCRIPTION QTY. 1528 1 X 4 X 29.29" LEFT ROOF FINISHER FRONT 1-4-2929-RFFL 1-4-2929-RFFR RIGHT 1 X 4 X 76-7/8" ROOF STARTER REAR 1-4-7688-RSR 1 X 4 X 76-7/8" ROOF STARTER FRONT 1-4-7688-RSF 1 X 4 X 76-7/8" ROOF FINISHER REAR 1-4-7688-RFR 3 NOT USED...
  • Page 52 PICTURE DESCRIPTION QTY. 1 X 4 X 12-1/4" WALL PANEL BOARD 1-4-1225-WPB 1 X 4 X 15-3/4" WALL PANEL BOARD 1-4-1575-WPB 1 X 4 X 19-5/16" WALL PANEL BOARD 1-4-1931-WPB 5/4 X 5 X 10.81" ROOF PANEL PEAK SUPPORT 125-5-1081-RPPS 5/4 X 6 X 10"...
  • Page 53 PICTURE DESCRIPTION QTY. 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT (1 HOLE ON ON CENTER) 2-4-2275-WPSL RIGHT 2-4-2275-WPSR 2 X 4 X 35.15" LEFT ROOF SUPPORT (1 HOLE OFFSET) 2-4-3515-RSL 2-4-3515-RSR RIGHT NOT USED 2 X 4 X 69.75" ROOF FINISHER SUPPORT (2 HOLES ON...
  • Page 54 PICTURE DESCRIPTION QTY. 1535 1 X 2 X 10" WINDOW BATTEN 1-2-1000-WB 1 X 2 X 17-1/2" WINDOW BATTEN 1-2-1750-WB 1 X 4 X 10-1/4" WINDOW PANEL BOARD 1-4-1025-WPB 1 X 4 X 11-1/8" WINDOW PANEL BOARD 1-4-1113-WPB 1 X 4 X 16-1/2" WINDOW PANEL BOARD 1-4-1650-WPB...
  • Page 55 PICTURE DESCRIPTION QTY. 1 X 4 X 26" WINDOW PANEL BOARD 1 X 4 X 2600-WPB 1 X 4 X 27" WINDOW PANEL BOARD 1-4-2700-WPB 1 X 4 X 28" WINDOW PANEL BOARD 1-4-2800-WPB 1 X 5 X 38-7/8" ROOF BOARD 1-5-3888-RB 1 X 5 X 38-7/8"...
  • Page 56 PICTURE DESCRIPTION QTY. 5/4 X 4 X 63" DECK SPACER 125 X 4 X 6300-DS 5/4 X 4 X 69-7/8" DECK BOARD 125-4-6988-DB 5/4 X 6 X 12-7/8" ROOF PEAK SUPPORT 125-6-1281-RPS 5/4 X 6 X 69-7/8" DECK BOARD 125-6-6988-DB 2 X 4 X 14"...
  • Page 57 PICTURE DESCRIPTION QTY. 2 X 4 X 29-1/2" SUN SUPPORT 2-4-2950-SS 2 X 4 X 35-1/2" CENTER DECK SUPPORT 2-4-3550-CDS 2 X 4 X 35-1/2" TOP PANEL BOARD 2-4-3550-TPB 2 X 4 X 39" PANEL AND DECK SUPPORT 2-4-3900-PDS 2 X 4 X 46-3/8" REAR ROOF SUPPORT LEFT 2-4-4635-RRSL...
  • Page 58 PICTURE DESCRIPTION QTY. 2 X 4 X 47-7/8" FRONT ROOF SUPPORT RIGHT 2-4-4788-FRSR 2 X 4 X 57" LADDER SIDE LEFT 2-4-5700-LSL 2 X 4 X 57" LADDER SIDE RIGHT 2-4-5700-LSR 2 X 4 X 70" TRANSITION STEP 2-4-7000-DS 2 X 4 X 70" TOP PANEL BOARD 2-4-7000-TPB...
  • Page 59 PICTURE DESCRIPTION QTY. 2 X 6 X 70" FRONT TOP PANEL BOARD 2-6-7000-FTPB 2 X 6 X 70" SANDBOX BOARD 2-6-7000-SB 4 X 4 X 35-1/2" MONKEY BARS MOUNT 4-4-3550-MBM 4 X 4 X 28-1/2" CONNECTOR POST 4-4-2850-CP 4 X 4 X 32" CENTER POST 4-4-3200-CP 4 X 4 X 87-1/2"...
  • Page 60 PICTURE DESCRIPTION QTY. 2 X 13 X 46-1/2" ROOF PANEL RIGHT ASSEMBLY 2-13-4652-RPRA 1535F 2 X 6 X 70" SANDBOX BOARD 2-6-7000-SB 2 X 6 X 78" SIDE SANDBOX BOARD LEFT 2-6-7800-SBL 2 X 6 X 78" SIDE SANDBOX BOARD RIGHT 2-6-7800-SBR...
  • Page 61 PICTURE DESCRIPTION QTY. 1539 FOOTER KIT (SUPPORT BASE) IF YOU PURCHASED A PLAYSET ALL PARTS ON 2 X 4 X 7" THIS PAGE ARE INCLUDED. FOOTER 1 7" 2-4-0700-F1 IF YOU DID NOT PURCHASE A PLAYSET YOU WILL HAVE TO PURCHASE ONE 2 X 4 X 8' PRESSURE TREATED BOARD TO MAKE THESE PARTS.
  • Page 62 PICTURE DESCRIPTION QTY. 1540 KIT PLAYSET PARTS INCLUDED ONLY IF A 1500 SERIES PLAYSET WAS PURCHASED 2 X 4 X 4" (AMBER STAINED) SLIDE BRACKET BLOCK 2-4-0400-SBB 2 X 4 X 70" SLIDE BRACKET SUPPORT 2-4-7000-SBS 780 KIT PLAYSET PARTS INCLUDED ONLY IF A 700 SERIES PLAYSET WAS PURCHASED 2 X 4 X 4"...
  • Page 63 PICTURE DESCRIPTION QTY. 4 X 4 X 108" CORNER POST- FRONT 4 X 4 X 120" CORNER POST- MIDDLE 4 X 4 X 120" CORNER POST- REAR 4 X 4 X 108" SWING LEG 4 X 6 X 120" SWING BEAM 4 X 4 X 96"...
  • Page 64 PICTURE DESCRIPTION QTY. WAVE SLIDE 03-0016-G TURBO TUBE SLIDE 03-0019...
  • Page 65 PICTURE DESCRIPTION QTY. ROCK WALL ROPE SWING W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006 CHANNEL BRACKET 11-5018...
  • Page 66 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCK (5 ROCKS ARE IN BAG) 07-0008 A-FRAME SWING BRACKET 11-5010 HARDWARE BOXES HARDWARE BOXES: 1501,1504, 1506, 1509N, 1509W, 1514, 1528, 1535 INSTRUCTIONS...
  • Page 67 PICTURE DESCRIPTION QTY. 90 GREEN BRACKET 11-5013 SPRING CLIP 11-4003 IRON DUCTILE SWING HANGER 11-4012...
  • Page 68 PICTURE DESCRIPTION QTY. UNASSEMBLED DORMER (1529 BOX) UNASSEMBLED CHIMNEY (1529 BOX) TELESCOPE 07-0040-G/Y...
  • Page 69 PICTURE DESCRIPTION QTY. PLASTIC SUNBURST 07-0028-G FRONT PLASTIC ARCH 07-0027-G DORMER WINDOW 07-0029-G SOLAR WALL LIGHT 09-2003...
  • Page 70 PICTURE DESCRIPTION QTY. MANUFACTURER (NOT SHOWN) LOGO PLATE CLATTER BRIDGE (NOT SHOWN) MESH PANEL (PAIR) 06-2004 SAFETY (NOT SHOWN) WARNING PLATE 11-5023 GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 ACTUAL PRODUCT MAY VARY STEERING WHEEL 07-0004...
  • Page 71 PICTURE DESCRIPTION QTY. SAFETY HANDLE (2 HANDLES ARE IN ONE BAG) 07-0005 PLASTIC DORMER SUNBURST 07-0031-G UNASSEMBLED DORMERS (1537 BOX) BINOCULARS 07-0003 CHALKBOARD 07-0018...
  • Page 72 PICTURE DESCRIPTION QTY. CROWN 07-0019 PLASTIC WINDOW 07-0013-G 8-5/8"W X 6-1/2"H MONKEY BAR PLATE 11-5014 1-5/16" DIA. X 19-3/4L MONKEY 11-5104 16" SAFETY HANDLE 08-0001 96" CHAIN SECTION...
  • Page 73 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 108"...
  • Page 74 STEP 2: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP THE PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT USING 3/8" X 3-1/2" CARRIAGE BOLTS ON TOP AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. USE BOLT CAPS TO COVER ANY EXPOSED THREADS.
  • Page 75 STEP 3: ASSEMBLING THE RIGHT SIDE FRAME 1: LAY THE RIGHT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION. 2: LAY THE 2 X 6 X 78" SIDE SANDBOX BOARD- RIGHT ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 76 STEP 4: 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" SIDE SANDBOX BOARD - LEFT ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS.
  • Page 77 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 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16"...
  • Page 78 STEP 6: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED IN THE CORNER POSTS.
  • Page 79 STEP 7: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED IN THE CORNER POSTS.
  • Page 80 STEP 8: LEVELING THE PLAY SET AND LAGS 1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE FOUR BOARDS TO THE CORNER POSTS AND THEN INSTALL THE LAG SCREWS.
  • Page 81 STEP 9: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS WITH 5/16" WASHERS. 2 X 4 X 14"...
  • Page 82 STEP10: ANGLE SUPPORTS 1: TWO 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE RIGHT SIDE OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 83 STEP 11: DECK SPACERS 1: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE CORNER POSTS AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE DECK SUPPORT BELOW.
  • Page 84 STEP 12: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND DRAW A LINE ON THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE.
  • Page 85 STEP 13: DECK BOARDS 1: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORTS BELOW.
  • Page 86 STEP 14: CONNECTOR POSTS 1: TWO 4 X 4 x 28.5" CONNECTOR POSTS WILL BE USED TO EXTEND THE FRONT CORNER POSTS TO ACCEPT THE LOWER LEVEL PLATFORM. 2: MAKE SURE TO INSTALL THE T-NUTS INTO THE CONNECTOR POSTS SIDE HOLES AS SHOWN IN THE DRAWING BELOW BEFORE MOUNTING IT TO THE FRONT POSTS.
  • Page 87 STEP 15: LOWER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE LOWER LEVEL 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 87-1/2"...
  • Page 88 STEP 16: LOWER LEVEL PANEL BOARDS 1: PLACE THE 2 X 4 X 35.5" TOP PANEL BOARD FLUSH TO THE CONNECTOR POST. ATTACH THE COUNTERSUNK HOLE OF THE TOP PANEL BOARD TO THE T-NUT INSTALLED IN THE CONNECTOR POST USING ONE 5/16" X 4-1/2" HEX BOLT AND ONE 5/16"...
  • Page 89 STEP 16A: DRILL HOLES FOR BRIDGE CHAINS 1: LOCATE ONE 4 X 4 X 70" LOWER LEVEL UNDER 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"...
  • Page 90 STEP 17: LOWER LEVEL FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 70" FRONT TOP PANEL BOARD ON THE FRONT OF THE LOWER LEVEL CORNER POSTS. THE HOLES IN THE FRONT TOP PANEL BOARD SHOULD BE OFFSET UP. 2: USE 5/16 X 4-1/2"...
  • Page 91 STEP 18: LEVELING THE LOWER LEVEL FRAME 1: INSTALL LAG SCREWS ONLY IN THE THREE 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME. SQUARE EACH OF THESE THREE BOARDS TO THE LOWER LEVEL CORNER POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID FOR THE LEVELING AND SQUARING PROCESS.
  • Page 92 STEP 19: LOWER LEVEL DECK SUPPORTS 1: FASTEN THE 2 X 4 X 39" PANEL AND DECK SUPPORTS TO THE HOLES AT 45" WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT. 5/16" WASHER 5/16"...
  • Page 93 STEP 20: LOWER LEVEL UNDER DECK SUPPORTS 1: PLACE THE 4 X 4 X 70" LOWER LEVEL UNDER DECK SUPPORT DIRECTLY UNDERNEATH THE LOWER LEVEL DECK SUPPORTS. MAKE SURE THE CHAIN HOLES ARE OFFSET TO THE RIGHT SIDE OF THE PLAY SET. ATTACH THE UNDER DECK SUPPORT TO THE LOWER LEVEL CORNER POSTS WITH 3/8"...
  • Page 94 STEP 21: LOWER LEVEL DECK SPACER AND DECK BOARD 1: PLACE THE 5/4 X 4 X 63" DECK SPACER AT THE FRONT OF THE LOWER LEVEL FORT. CENTER THE BOARD BETWEEN THE LOWER LEVEL CORNER POSTS AND FLUSH TO THE FRONT FACE BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES INTO THE LOWER LEVEL DECK SUPPORT BELOW.
  • Page 95 STEP 22: CENTER DECK SUPPORT 1: FIND THE 2 X 4 X 35.5" CENTER DECK SUPPORT WITHOUT HOLES. 2: FROM THE UNDERSIDE OF THE DECK SPACER AND DECK BOARD THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK SUPPORT AT THE CENTER OF THE DECK SPACER AND DECK BOARD (USE THE HOLE ON CENTER AS A GUIDE) CENTER THE 2 X 4 X 70"...
  • Page 96 STEP 23: LOWER LEVEL DECK BOARDS 1: START WITH A 5/4 X 6 X 69.875" DECK BOARD AT THE BACK OF THE LOWER LEVEL FORT. CENTER THE BOARD BETWEEN THE BOTTOM PANEL BOARDS AND ATTACH IT WITH #8 X 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES AND INTO THE DECK SUPPORTS BELOW.
  • Page 97 STEP 24: PANEL SUPPORTS 2: PLACE THE 2 X 4 X 39" PANEL AND DECK SUPPORT ON TOP OF THE 2 X 6 BOTTOM 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 98 STEP 25: LADDER ASSEMBLY 1: LAY ONE 2 X 4 X 57” LADDER SIDE ON A FLAT SURFACE WITH CHANNELS FACING DOWN. PLACE THE BARREL OF A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE, AND SECURE WITH A HAMMER.
  • Page 99 STEP 26: LADDER TO FORT 1: PLACE THE LADDER INTO POSITION ON THE FRONT SIDE OF THE LOWER LEVEL FORT AS SHOWN BELOW.CENTER THE LADDER HORIZONTALLY ON THE 2 X 6. CENTER THE 90 BRACKETS VERTICALLY ON THE 2 X 6. USE THE HOLES IN THE LADDER BRACKETS AS A TEMPLATE TO DRILL 3/8"...
  • Page 100 STEP 27: LOWER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" LOWER LEVEL STEP FLUSH WITH THE TOP OF THE MAIN LEVEL DECK BOARDS. LOWER LEVEL STEPS HAVE TWO HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH TWO 5/16" X 3-1/2" LAG SCREWS AND TWO 5/16"...
  • Page 101 STEP 28: MAIN LEVEL CENTER POST 1: LOCATE THE 4 X 4 X 32" CENTER POST AND PLACE IT CENTERED BEHIND THE HOLE IN THE TOP PANEL BOARD. 2: HAMMER A T-NUT INTO THE HOLE IN THE BACK SIDE OF THE CENTER POST. FASTEN THE CENTER POST TO THE TOP PANEL BOARD WITH A 5/16"...
  • Page 102 STEP 29: 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 103 STEP 30: 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 104 STEP 31: 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 105 STEP 32: ROCK WALL 1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL.
  • Page 106 STEP 33: ATTACHING THE ROCK WALL 1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE LEFT SIDE OF THE MAIN LEVEL FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 2-1/4" ABOVE THE BOTTOM OF THE BOTTOM PANEL BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD.
  • Page 107 STEP 33A: ANGLE SUPPORTS 1: TWO 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE ROCK WALL SIDE OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
  • Page 108 STEP 34: UPPER LEVEL CORNER POST T-NUTS 1: THIS STEP IS CRITICAL TO BUILDING THE UPPER LEVEL 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: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT POSTS PROPERLY.
  • Page 109 STEP 35: LAG POSTS 1: TWO 4 X 4 60-1/4" LAG POSTS WILL BE USED TO EXTEND THE MIDDLE CORNER POSTS TO ACCEPT THE UPPER LEVEL ROOF. 2: MAKE SURE TO INSTALL THE T-NUTS INTO THE LAG POSTS TOP HOLES AS SHOWN IN THE DRAWING BELOW BEFORE MOUNTING IT TO THE MIDDLE POSTS.
  • Page 110 STEP 36: REAR CORNER POSTS & DECK SUPPORTS & SIDE TOP PANEL BOARDS TIP: BEFORE YOU INSTALL THESE BOARDS LEAVE THEM ALL A LITTLE LOOSE. WHEN YOU HAVE FASTENERS IN ALL THE BOARDS GO BACK AND TIGHTEN THEM ALL UP. 1: ATTACH THE BOTTOM OF THE REAR CORNER POSTS TO THE SIDE SANDBOX BOARDS WITH 5/16"...
  • Page 111 STEP 37: UPPER LEVEL - RAILING & UNDER DECK SUPPORT 1: PLACE THE 2 X 4 X 70" UPPER LEVEL STEPS/RAILING BOARD (3 HOLES ON CENTER) AT THE TOP OF THE REAR CORNER POSTS. THIS BOARD WILL GET ATTACHED TO THE 2ND HOLE DOWN FROM THE TOP OF THE POSTS.
  • Page 112 STEP 38: LOWER LEVEL REAR CENTER POST 1: HAMMER A T-NUT INTO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST HOLE. 2: ATTACH THE LOWER LEVEL CENTER POST TO THE MIDDLE HOLE OF THE 2 X 6 X 70" BACK PANEL BOARD.
  • Page 113 STEP 39: CENTER DECK SUPPORT ASSEMBLY NOTE: IT IS BEST TO PLACE THESE BOARDS UPON A FLAT SURFACE BEFORE ATTACHING THEM TOGETHER. 1: PLACE ONE 2 X 4 X 34" UPPER LEVEL CENTER DECK SUPPORT (OFFSET UP) ON THE RIGHT SIDE OF THE 4 X 4 X 30-1/2"...
  • Page 114 STEP 40: CENTER DECK SUPPORT ASSEMBLY INSTALLATION AND LAGS 1: PLACE THE CENTER DECK SUPPORT ASSEMBLY ON TOP OF THE 4 X 4 X 70" UPPER LEVEL UNDER DECK SUPPORT. THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST SHOULD FIT INSIDE THE CENTER DECK SUPPORT ASSEMBLY. 2: MAKE THE CENTER DECK SUPPORT ASSEMBLY LEVEL WITH THE CENTER DECK SUPPORTS.
  • Page 115 STEP 41: SLIDE BLOCK 1: PLACE THE 4 X 4 X 23-1/2" SLIDE BLOCK AGAINST THE UPPER DECK SUPPORT ON THE LEFT SIDE (LADDER SIDE) OF THE PLAY SET. THE TOP OF THE BLOCK SHOULD BE FLUSH TO THE TOP OF THE DECK SUPPORT.
  • Page 116 STEP 42: ANGLE SUPPORT - UPPER LEVER REAR 1: PLACE A 2 X 4 X 18" ANGLE SUPPORT -UPPER LEVEL REAR AGAINST THE 4 X 4 X 70 UPPER LEVEL UNDER DECK SUPPORT ON EACH SIDE AT THE REAR OF THE PLAY SET. 2: THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH TO THE TOP OF THE UNDER DECK SUPPORT.
  • Page 117 STEP 43: SIDE REAR ANGLE SUPPORTS 1: (SEE DETAIL A) PLACE THE 2 X 4 X 18" ANGLE SUPPORT UPPER LEVEL RAD RIDE SIDE UNDER THE 4 X 4 X 23-1/2" SLIDE BLOCK ON THE LEFT SIDE OF THE FORT. THE ANGLE SUPPORT SHOULD BE FLUSH TO THE LEFT SIDE OF THE LEFT REAR CORNER POST.
  • Page 118 STEP 44: UPPER LEVEL DECK SPACERS 1: MAKE SURE THE LOWER LEVEL CENTER POST HAS AN EQUAL OPENING ON EACH SIDE. 2: PLACE THE 5/4 X 4 X 29-1/2" UPPER DECK SPACERS BETWEEN THE LOWER LEVEL CENTER POST AND THE MIDDLE CORNER POSTS. ATTACH EACH UPPER DECK SPACER TO THE DECK SUPPORTS WITH #8 X 2"...
  • Page 119 STEP 45: SLIDE POST ASSEMBLY 1: PREDRILL TWO 1/8" PILOT HOLES CENTERED VERTICALLY ON THE NOTCH IN THE 4 X 4 X 43-1/2" RAD RIDE CENTER POST. 2: PLACE ONE END OF THE 5/4 X 4 X 25" RAD RIDE DECK SPACER INTO THE NOTCH IN THE RAD RIDE CENTER POST.
  • Page 120 STEP 46: SLIDE POST INSTALLATION 1: PLACE THE END OF THE DECK SPACER AGAINST THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST. FASTEN THE DECK SPACER TO THE DECK SUPPORT WITH #8 X 2" WOOD SCREWS. 2: MAKE THE DECK SPACER LEVEL WITH THE DECK BOARD BEHIND IT.
  • Page 121 STEP 47: UPPER LEVEL REAR DECK SPACER 1: PLACE THE 5/4 X 4 X 35-1/2" REAR DECK SPACER ON TOP OF THE DECK SUPPORTS. THE END SHOULD BE FLUSH TO THE CORNER POST. THE OUTSIDE OF THE DECK SPACER SHOULD BE FLUSH TO THE OUTSIDE OF THE CORNER POST/CENTER POST.
  • Page 122 STEP 48: UPPER LEVEL DECK BOARDS 1: PLACE FOUR 5/4 X 6 X 69-7/8" UPPER DECK BOARDS ACROSS THE DECK SUPPORTS AS SHOWN. EQUALLY SPACE THE DECK BOARDS 5/16" FROM ONE ANOTHER AND FROM THE DECK SPACER. 2: SECURE EACH UPPER DECK BOARD TO THE DECK SUPPORTS WITH FIVE #8 X 2" WOOD SCREWS.
  • Page 123 STEP 49: UPPER LEVEL CENTER POST 1: PLACE THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST AGAINST THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST. FLUSH THE TOPS AND SIDES OF THE POSTS TOGETHER. 2: ATTACH THE 4 X 4 X 33-5/16" UPPER LEVEL CENTER POST TO THE 4 X 4 X 59-1/2" LOWER LEVEL CENTER POST WITH 3/8"...
  • Page 124 STEP 50: RAILING 1: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD (RAILING) AGAINST THE MIDDLE POSTS, FLUSH WITH THE TOP END OF THE CENTER POST. 2: THE TOP OF THE RAILING SHOULD BE 33" ABOVE THE DECK BOARDS. 3: ATTACH THE RAILING TO THE LAG POSTS AND UPPER LEVEL CENTER POST WITH 5/16"...
  • Page 125 STEP 51: TURBO TUBE SLIDE 1: ASSEMBLE AND INSTALL THE TURBO TUBE SLIDE ACCORDING TO THE DIRECTIONS IN THE APPENDIX OF THIS MANUAL. 2: THIS WILL REQUIRE THE TURBO TUBE SLIDE BOX, THE 1539 WOOD KIT AND THE 1540 WOOD KIT.
  • Page 126 STEP 52: UPPER LEVEL BOTTOM PANEL BOARDS 1: PLACE THE 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD (OFFSET UP) ON THE SWING BEAM SIDE (RIGHT SIDE) OF THE PLAYSET. ATTACH THE TOP HOLES OF THE BOARD TO THE POSTS WITH 5/16"...
  • Page 127 STEP 52A: UPPER LEVEL BOTTOM PANEL BOARDS 1: PLACE THE 2 X 6 X 30-7/16" SIDE BOTTOM PANEL BOARD (OFFSET UP) ON THE THE (LEFT SIDE) OF THE UPPER LEVEL DECK. ATTACH THE TOP HOLE NEAREST THE TUBE SLIDE WITH A 5/16"...
  • Page 128 STEP 53: UPPER LEVEL STEPS 1: PLACE THE TOP OF ONE 2 X 4 X 70" UPPER LEVEL STEP FLUSH WITH THE TOP OF THE UPPER LEVEL DECK SPACERS. UPPER LEVEL STEPS HAVE THREE HOLES THAT ARE CENTERED. 2: ATTACH THE UPPER LEVEL STEP TO THE POSTS WITH THREE 5/16" X 3-1/2" LAG SCREWS AND THREE 5/16"...
  • Page 129 STEP 54: UPPER LEVEL REAR CENTER POST 1: PLACE THE 2 X 4 X 35-5/8" UPPER LEVEL REAR CENTER POST AGAINST THE REAR RAILING ON THE UPPER LEVEL. HAMMER A T-NUT INTO THE TOP HOLE IN THE UPPER LEVEL REAR CENTER POST.
  • Page 130 STEP 55: UPPER LEVEL PANEL SLATS 1: FIND THIRTEEN 5/4 X 3 X 34-1/2" 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. SEE DETAIL BELOW FOR MEASUREMENTS. 4: ATTACH THE PANEL SLATS TO THE FORT WITH 2"...
  • Page 131 STEP 56: MAIN LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FOUR SLATS ON THE LEFT SIDE, SIX SLATS ON THE RIGHT SIDE OF THE MAIN LEVEL. 2: PLACE EACH SLAT AS SHOWN BELOW ON THE INSIDE OF THE PANEL BOARDS AND ATTACH EACH PANEL SLAT TO THE FORT WITH TWO #8 X 2"...
  • Page 132 STEP 57: LOWER LEVEL PANEL SLATS 1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS INTO THE OPENINGS AS SHOWN BELOW. SPACE THE SLATS AS INDICATED BY THE DIMENSIONS SHOWN. THERE ARE FIVE SLATS ON THE LEFT SIDE, FIVE SLATS ON THE RIGHT SIDE AND TWO SLATS ON THE FRONT OF THE LOWER LEVEL.
  • Page 133 STEP 58: IRON DUCTILE SWING HANGERS 1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM. 2: FASTEN EACH SWING HANGER TO THE SWING BEAM USING 7"...
  • Page 134 STEP 59: 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 135 STEP 60: REST SWING BEAM ON FORT 1: REST THE SWING BEAM ASSEMBLY ON TOP OF THE UPPER RAILING BOARDS OF THE FORT. 2: THE END OF THE SWING BEAM WITH 2 HOLES SHOULD OVERHANG THE SWING BEAM SIDE OF THE FORT.
  • Page 136 STEP 61: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM. 2: PLACE THE CHANNEL BRACKET UNDERNEATH THE SWING BEAM BRACKET. 3: FASTEN THE 3/8"...
  • Page 137 STEP 62: MOUNT SWING BEAM TO FORT 1: PLACE A 3/8" X 9" CARRIAGE BOLT THROUGH A TORQUE WASHER. INSERT THE CARRIAGE BOLT INTO THE HOLE AT THE END OF THE SWING BEAM OVER THE SWING BEAM MOUNT. ALIGN THE SQUARE SHANK OF THE CARRIAGE BOLT WITH THE SQUARE HOLE IN THE TORQUE WASHER. HAMMER THE CARRIAGE BOLT TO SET THE TORQUE WASHER INTO THE SWING BEAM.
  • Page 138 STEP 63: 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 139 STEP 64: 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 140 STEP 65: 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 141 STEP 66: ROOF SUPPORT ASSEMBLY 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP.
  • Page 142 STEP 66A: UPPER LEVEL ROOF SUPPORTS 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE UPPER LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LAG POSTS OR REAR CORNER POSTS WITH 5/16"...
  • Page 143 STEP 67: UPPER LEVEL ROOF 1: PLACE THE 1 X 4 X 30-1/2" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE UPPER LEVEL ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH TOP SIDE OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.
  • Page 144 STEP 68: UPPER LEVEL ROOF 1: PLACE THE 1 X 6 X 30-1/2" ROOF PEAK ON TOP OF THE ROOF STARTER BOARDS. 2: FASTEN THE ROOF PEAK TO THE ROOF STARTER BOARDS WITH FOUR #8 X 1-1/4" WOOD SCREWS. #8 X 1-1/4" WOOD SCREW 1 X 6 X 30-1/2"...
  • Page 145 STEP 69: UPPER LEVEL ROOF 1: PLACE THE TONGUE OF A 1 X 5 X 30-1/2" ROOF BOARD INTO THE SLOT OF THE ROOF STARTER. ALIGN THE ENDS OF THE BOARDS. FASTEN THE ROOF BOARD TO THE ROOF SUPPORTS WITH #8 X 1-1/2"...
  • Page 146 STEP 70: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBURST TO THE ROOF SUPPORTS ON THE FRONT AND REAR OF THE ROOF. THE PLASTIC SUNBURST MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBURST TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS ON THE TOP AND SIX #8 X 2"...
  • Page 147 STEP 71: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 35.15" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35.15" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING DOWN.
  • Page 148 STEP 72: ROOF SUPPORTS (MAIN LEVEL) 1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES ON THE MAIN LEVEL DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE MAIN LEVEL CORNER POSTS WITH 5/16 X 4-1/2"...
  • Page 149 STEP 73: ROOF STARTER REAR 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER BOARD AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER SHOULD BE PLACED FLUSH TO THE PEAK OF THE ROOF SUPPORTS. 2: FASTEN THE ROOF STARTER REAR TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 150 STEP 74: ROOF REAR SECTION 1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR. THIS SIDE OF THE ROOF GETS FOUR BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 151 STEP 75: ROOF FRONT SECTION 1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPPING THE ROOF STARTER REAR. THE HOLES IN THE ROOF STARTER FRONT SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER FRONT SHOULD BE PLACED FLUSH TO THE TOP EDGE OF THE ROOF STARTER REAR.
  • Page 152 STEP 76: DORMERS 1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE DORMERS. AFTER INSTALLING THE SEVENTH ROOF BOARD, INSTALL THE DORMER MOUNTING BLOCK 9-3/4" FROM THE SIDE EDGE OF THE ROOF TO THE SIDE EDGE OF THE DORMER MOUNTING BLOCK, AND 15" FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE TOP EDGE OF THE DORMER MOUNTING BLOCK.
  • Page 153 STEP 77: LOWER LEVEL FRONT ROOF SUPPORT ASSEMBLY 1: LOCATE ONE 2 X 4 X 47.88" FRONT ROOF SUPPORT (LEFT), ONE 2 X 4 X 47.88" FRONT ROOF SUPPORT (RIGHT) AND ONE 5/4 X 6 X 12.81" ROOF PEAK SUPPORT. 2: FIND A FLAT SURFACE TO WORK ON.
  • Page 154 STEP 78: LOWER LEVEL REAR ROOF SUPPORT ASSEMBLY 1: LOCATE ONE 2 X 4 X 47.35" REAR ROOF SUPPORT (LEFT), ONE 2 X 4 X 47.35" REAR ROOF SUPPORT (RIGHT) AND ONE 5/4 X 6 X 10.81" ROOF PEAK SUPPORT. 2: FIND A FLAT SURFACE TO WORK ON.
  • Page 155 STEP 79: MOUNTING LOWER LEVEL ROOF SUPPORTS 1: PLACE THE REAR ROOF SUPPORT ASSEMBLY AGAINST THE MAIN LEVEL FRONT CORNER POST AND REST ON TOP OF THE LOWER LEVEL CONNECTOR POSTS. THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE BACK TOWARDS THE MAIN LEVEL ROOF. 2: MAKE SURE THE BOTTOM ENDS OF THE REAR ROOF SUPPORT ASSEMBLY ARE FLUSH TO THE MAIN LEVEL CORNER POSTS SIDE FACES.
  • Page 156 STEP 80: ROOF PANEL ASSEMBLIES TO FORT 1: MOUNT THE ROOF PANEL ASSEMBLY (LEFT) AND ROOF PANEL ASSEMBLY (RIGHT) ON TOP OF THE LOWER LEVEL ROOF SUPPORTS ASSEMBLIES (FRONT & REAR). MAKE SURE EACH ROOF PANEL ASSEMBLY BEVEL END IS FLUSH TO THE MAIN LEVEL ROOF. 2: UNDERNEATH THE ROOF PANEL ASSEMBLIES, THE FRONT AND REAR BATTEN SHOULD BE FLUSH BETWEEN THE ROOF SUPPORT ASSEMBLIES (FRONT AND REAR).
  • Page 157 STEP 81: ROOF 1: PLACE THE 1 X 5 X 38.875" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF PANEL ASSEMBLY. EACH SIDE OF THE ROOF GETS 7 ROOF BOARDS. 2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 158 STEP 82: WALL PANEL SUPPORTS 1: PLACE THE 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE AND THE OPPOSITE END WITH THE COUNTERSUNK HOLE FLUSH AGAINST THE LEFT FRONT CORNER POST. MAKE SURE THE ANGLED END OF THE WALL PANEL SUPPORT IS FLUSH TO THE INSIDE OF THE ROOF PANEL.
  • Page 159 STEP 83: ROOF FINISHERS 1: PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT LEFT ANGLED END ON TOP OF THE ROOF PANEL ASSEMBLY LEFT SIDE. PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT ANGLED END ON TOP OF THE ROOF PANEL ASSEMBLY RIGHT SIDE.
  • Page 160 STEP 84: ROOF BATTEN 1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE FRONT ROOF PANEL, CENTERED BETWEEN THE ROOF SUPPORTS, FLUSH THE BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD, MAKE SURE IS PARALLEL TO THE ROOF SUPPORTS.

  • Page 161: Wall Panel Boards

    STEP 85: WALL PANEL BOARDS 1: START MOUNTING THE 1 X 4 X 19.31" WALL PANEL BOARD AGAINST THE LEFT SIDE OF THE LOWER LEVEL ROOF SUPPORT ASSEMBLY REAR AND THE WALL PANEL SUPPORT LEFT. THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4"...

  • Page 162: Plastic Sunburst

    STEP 86: PLASTIC SUNBURST 1: MOUNT THE PLASTIC SUNBURST TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF, THE PLASTIC SUNBURST MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBURST TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2"...

  • Page 163: Sandbox Seats And Name Plate

    STEP 87: SANDBOX SEATS AND NAME PLATE 1: PLACE THE 5/4 X 6 X 22" SANDBOX SEATS ONTO THE TOP OF THE SANDBOX BOARDS AS SHOWN BELOW. 2: ATTACH THE SANDBOX SEATS TO THE SANDBOX BOARDS WITH #8 X 2" WOOD SCREWS. 3: LOCATE THE NAME PLATE FOR YOUR PLAY SET.

  • Page 164: Picnic Table

    STEP 88: PICNIC TABLE 1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS. 2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4"...
  • Page 165 STEP 88A: PICNIC TABLE 1: MEASURE UP 26-3/8" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8". 2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE LEFT-MIDDLE CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3"...
  • Page 166 STEP 88B: PICNIC TABLE 1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS. 2: CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS. 3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS. 5/4 X 6 X 43"...

  • Page 167: Safety Boards

    STEP 89: SAFETY BOARDS 1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE MAIN FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2"...
  • Page 168 STEP 90: ASSEMBLING THE MONKEY BAR LADDER 1: SEE FRONT SIDE BELOW. START WITH 4 X 4 X 86-1/2"L LADDER SIDES. WITH THE LARGE HOLES FACING YOU INSTALL A TEE NUT INTO THE TWO SMALL HOLES AT THE END OF EACH SIDE. 2: SEE FRONT SIDE BELOW.
  • Page 169 STEP 91: ASSEMBLING THE MONKEY BAR ASSEMBLY 1: PLEASE NOTE: THERE IS A LEFT AND RIGHT MONKEY BAR RUNNER (SEE BOTTOM LEFT PICTURES BELOW). 2: START WITH THE 4 X 4 X 70" MONKEY BAR RUNNERS. WITH THE FIVE LARGE HOLES FACING YOU INSTALL A 5/16"...
  • Page 170 STEP 92: ATTACHING THE LADDER TO THE MONKEY BAR ASSEMBLY 1: LOCATE TWO 8-5/8" W X 6-1/2"H MONKEY BAR PLATES, EIGHT 5/16" X 3-1/2"L HEX BOLTS AND EIGHT 5/16" FLAT WASHER. LOOSELY ATTACH THE LADDER ASSEMBLY TO THE MONKEY BAR ASSEMBLY WITH THE MONKEY BAR PLATES.
  • Page 171 STEP 93: MONKEY BAR MOUNT 1: CENTER THE MONKEY BAR ASSEMBLY ON TOP OF THE 4 X 4 X 35.5" MONKEY BAR MOUNT. THE COUNTERSUNK HOLES IN THE MONKEY BAR ASSEMBLY SHOULD FACE UP. 2: THE END OF THE MONKEY BAR ASSEMBLY SHOULD BE FLUSH AGAINST THE INSIDE FACE OF THE MONKEY BAR MOUNT.
  • Page 172 STEP 94: ATTACHING THE MONKEY BAR FILLER BOARD 1: FIND ONE 2 X 4 X 28" MONKEY BAR FILLER BOARD AND ATTACH IT TO THE MONKEY BAR ASSEMBLY USING 5/16" X 2-1/2" LAG SCREWS AND 5/16" WASHERS THROUGH THE FILLER BOARD COUNTERSUNK HOLES INTO THE MONKEY BAR RUNNERS (LEFT &...
  • Page 173 STEP 95: MOUNTING THE MONKEY BARS TO THE FORT 1: CENTER THE MONKEY BAR ASSEMBLY MONKEY BAR MOUNT BETWEEN THE LOWER LEVEL CORNER POST AND THE CONNECTOR POST. 2: LEVEL THE MONKEY BAR ASSEMBLY TO THE FORT AND VERIFY THE THE MONKEY BAR MOUNT IS PARALLEL TO THE TOP PANEL BOARD FROM UNDERNEATH.
  • Page 174 STEP 95A: MONKEY BAR FILLER BOARD 1: MEASURE THE GAP BETWEEN THE MONKEY BAR MOUNT AND THE TOP PANEL BOARD (RAILING). IF THE DISTANCE IS 3-1/2" OR MORE THEN USE THE 2 X 4 X 35.5" TOP PANEL BOARD (FILLER BOARD) TO CLOSE UP THE OPENING. ATTACH IT TO THE LOWER LEVEL CORNER POST AND CONNECTOR POST WITH 5/16"...
  • Page 175 STEP 96: ATTACHING THE SAFETY HANDLES 1: LOCATE THE TWO GREEN SAFETY HANDLES, FOUR #14 X 1-1/4" PAN HEAD SCREWS AND FOUR 1/4" FLAT WASHERS. 2: ATTACHING EACH SAFETY HANDLE TO THE LADDER SIDE WITH TWO #14 X 1-1/4" PAN HEAD SCREWS AND TWO 1/4"...

  • Page 176: Ground Stakes

    STEP 97: GROUND STAKES 1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE AGAINST THE SWING LEG.
  • Page 177 STEP 98: TIC TAC TOE ASSEMBLY 1: LOCATE THE TIC TAC TOE BOX. 2: FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 3: LOCATE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 4: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS.
  • Page 178 STEP 99: TIC TAC TOE INSTALLATION 1: PLACE THE TIC TAC TOE AGAINST THE PANEL SLATS AT THE RIGHT SIDE OF THE PLAYSET (SWING BEAM SIDE) ON THE INSIDE OF MAIN LEVEL. THE TIC TAC TOE MOUNT SHOULD BE APPROXIMATELY 4" OFF THE DECK. 2: ATTACH THE TIC TAC TOE MOUNTS TO THE PANEL SLATS WITH #8 X 1-3/4"...

  • Page 179: Rock Wall Rope

    STEP 100: INSTALLING THE ROCK WALL ROPE 1: USE A 1" PADDLE BIT TO DRILL A HOLE IN THE CENTER OF THE TOP PANEL BOARD. THIS IS THE ONLY TIME YOU WILL NEED THIS DRILL BIT IN THE ASSEMBLY. YOU MAY PUT IT AWAY AFTER DRILLING THE HOLE.

  • Page 180: Steering Wheel

    STEP 101: STEERING WHEEL 1: GO TO THE REAR CENTER POST ON THE DECK (UPPER LEVEL). 2: DRILL A 3/16" PILOT HOLE 1" BELOW THE CENTER OF THE T-NUT. DRILL THE HOLE 1" DEEP. 3: PLACE THE SPACER INSIDE THE STEERING WHEEL.. 4: USE THE 2-1/2"...

  • Page 181: Lower Level Front Center Post

    STEP 102: LOWER LEVEL FRONT CENTER POST 1: LOCATE THE 4 X 4 X 29" CENTER POST. PLACE THE 4 X 4 X 29" CENTER POST CENTERED BEHIND THE HOLE IN THE FRONT TOP PANEL BOARD. CAREFULLY DRILL A 3/8" HOLE THROUGH THE CENTER POST USING THE HOLE IN THE ROPE LADDER SUPPORT AS A GUIDE.
  • Page 182 STEP 103: SAFETY HANDLES(UPPER/MAIN/LOWER) LEVEL 1: LOCATE THE SAFETY HANDLE BAGS. 2: ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 3: ATTACH EACH SAFETY HANDLE TO THE PANEL SLAT, CENTER POSTS AND CORNER POSTS WITH TWO PAN HEAD SCREWS AND TWO WASHERS PROVIDED WITH THE SAFETY HANDLES.

  • Page 183: Sun Support

    STEP 104: SUN SUPPORT 1: PLACE THE 2 X 4 X 29.5" SUN SUPPORT UNDERNEATH THE LOWER LEVEL FRONT ROOF SUPPORTS. MAKE SURE THE SUN SUPPORT IS LEVEL. ATTACH THE SUN SUPPORT THROUGH THE PRE-DRILLED HOLES IN THE BOTTOM TO THE ROOF SUPPORTS WITH 2-1/2" WOOD SCREWS. 2 X 4 X 29.5"...

  • Page 184: Wall Panel Boards / Windows And Crowns

    STEP 105: WALL PANEL BOARDS 1: MOUNT THE 1 X 4 X 26" WINDOW PANEL BOARD ABOVE THE LOWER LEVEL CENTER POST. THE END WITH TWO PRE- DRILLED HOLES SHOULD BE OFFSET TO THE TOP. MAKE SURE IT IS STRAIGHT VERTICALLY AND FASTEN IT TO THE SUN SUPPORT USING TWO #8 X 1-1/2"...
  • Page 185 STEP 106: WINDOW AND CROWNS 1: PLACE EACH PLASTIC WINDOW INTO THE FRONT OPENINGS, WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. ATTACH EACH WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS. 2: CENTER THE WINDOW CROWN OVER THE TOP OF THE PLASTIC WINDOW AND ATTACH THE CROWN TO THE TOP WINDOW PANEL BOARDS WITH #8 X 1"...
  • Page 186 STEP 107: WALL PANEL BOARDS 1: MOUNT THE 1 X 4 X 24" WINDOW PANEL BOARD NEXT TO THE 1 X 4 X 27" WINDOW PANEL BOARD INSTALLED ON PREVIOUS STEPS. LEAVE A 1/4" GAP BETWEEN THEM. THE ANGLED END MUST BE OFFSET UP AND PARALLEL TO THE ROOF SUPPORT.FASTEN IT USING FOUR #8 X 1-1/2"...

  • Page 187: Solar Wall Lights

    STEP 108: SOLAR WALL LIGHTS 1: WITH A PENCIL MAKE A CENTER MARK ON THE OUTSIDE FACE OF THE 1 X 4 X 21" WINDOW PANEL BOARD, MEASURE 8-5/8" HORIZONTALLY FROM THE OUTSIDE EDGE OF THE CORNER POST TOWARDS THE CENTER OF THE WALL PANEL BOARD AND 10" FROM THE TOP EDGE OF THE FRONT TOP PANEL BOARD UP TOWARDS THE CENTER OF THE WALL PANEL BOARD AS SHOWN IN THE DIAGRAM BELOW.
  • Page 188 PART 2 CLATTER BRIDGE ASSEMBLY...
  • Page 189 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 190 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 191 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 192 STEP 4: DECK SUPPORTS YOU WILL NEED AN EXTRA PERSON FOR THIS STEP. 1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES. 2: FASTEN THE 2 X 4 X 36-3/4" DECK SUPPORTS TO THE HOLES AT 45-5/16" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE CORNER POST.
  • Page 193 STEP 5: FRONT FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 194 STEP 6: REAR FRAME ASSEMBLY 1: PLACE THE 2 X 6 X 36-3/4" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD SHOULD BE OFFSET DOWN. 2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.
  • Page 195 STEP 7: LAG SCREWS 1: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. TO SQUARE AND LEVEL THE DECK OF THE TOWER TO THE DECK OF THE FORT PLACE A DECK BOARD ACROSS THE 2 X 4'S.
  • Page 196 STEP 8: DECK BOARDS 1: PLACE THE 5/4 X 4 X 29-3/8" DECK SPACERS BETWEEN THE CORNER POSTS. MAKE EACH DECK SPACER FLUSH TO THE INSIDE SURFACE OF THE 2 X 6 X 36-3/4" BOTTOM PANEL BOARD OR THE OUTSIDE SURFACE OF THE CORNER POSTS.
  • Page 197 STEP 9: REAR BOTTOM PANEL BOARD 1: PLACE THE 5/4 X 4 X 36-1/2" 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 REAR CORNER POSTS, AND LEVEL THE TOP OF THE BOARD WITH THE TOP OF THE DECK BOARDS.
  • Page 198 STEP 10: DECK 1: INSTALL THE 5/4 X 4 X 36-1/2" DECK BOARDS. LEAVE A UNIFORM (APPROXIMATELY 1/4") SPACE BETWEEN THE DECK BOARDS. ATTACH THE DECK BOARDS TO THE DECK SUPPORTS WITH WITH 2" WOOD SCREWS. #8 X 2" WOOD SCREW 5/4 X 4 X 36-1/2"...
  • Page 199 STEP 11: BOTTOM PANEL BOARDS 1: PLACE THE 2 X 4 X 36-3/4" BOTTOM PANEL BOARD AGAINST THE LEFT SIDE 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" LAG SCREWS WITH 5/16" WASHERS.
  • Page 200 STEP 12: PANEL SLATS 1: INSTALL THE FIRST PANEL SLAT 2-1/2" FROM THE CORNER POST. THEN INSTALL THE REMAINING FOUR PANEL SLATS 2-7/8" APART AS SHOWN. 2: ATTACH THE PANEL SLATS ONTO THE FRONT AND RIGHT SIDES OF THE TOWER WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES.
  • Page 201 STEP 13: 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. FASTEN THE BRIDGE RAIL TO THE CORNER POST WITH 5/16"...
  • Page 202 STEP 14: BRIDGE RAILS TO PLAYSET 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" LAG SCREWS AND 5/16"...
  • Page 203 STEP 15: BRIDGE RAIL SLATS 1: PLACE THE BRIDGE RAIL SLATS 3" FROM THE FACE OF THE CORNER POSTS, AND ATTACH WITH 2" WOOD SCREWS. THE SLATS WILL MOUNT ON THE OUTSIDE OF THE BRIDGE RAILS. 2: ATTACH THE REMAINING SLATS TO THE UNIT WITH 3" SPACING BETWEEN THE SLATS. 2"...
  • Page 204 STEP 16: 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 205 STEP 17: 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 206 STEP 18: 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 207 STEP 19: 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 208 STEP 20: BRIDGE DECK / CHAIN INSTALLATION 1: TWO PEOPLE MAY BE REQUIRED FOR THIS STEP. 2: THERE SHOULD BE AT LEAST A 1" TO 1-3/4" GAP BETWEEN THE BRIDGE DECK BOARD AND THE FRONT FACE BOARD ON THE PLAY SET. THIS MEANS THAT YOU WILL HAVE TO CONNECT THE ENDS OF THE CHAINS IN A MANNER TO ACHIEVE THE CORRECT GAP.
  • Page 209 STEP 21: ROOF SUPPORT ASSEMBLIES 1: LOCATE FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (LEFT), FOUR 2 X 4 X 51-1/8" ROOF SUPPORT (RIGHT) AND FOUR 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP.
  • Page 210 STEP 22: DRILLING CORNER POST HOLES 1: CHECK THE DIMENSION OF THE ROOF SUPPORT ASSEMBLIES AS SHOWN BELOW BEFORE DRILLING HOLES. 2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON THE CORNER POSTS ON THE INSIDE. 3: DRILL A 9/64" HOLE BY 2-1/2" DEEP AT EACH MARK. 4: REPEAT SUB STEPS 2-3 ON THE INSIDE OF THE OTHER POSTS AS POINTED OUT BELOW.
  • Page 211 STEP 23: INSTALLING THE ROOF SUPPORT ASSEMBLIES 1: PLACE TWO ROOF SUPPORT ASSEMBLIES ON THE CLATTER BRIDGE TOWER DECK. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE INSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE HOLES DRILLED ON THE INSIDE OF THE CORNER POSTS WITH TWO 5/16"...
  • Page 212 STEP 24: ROOF STARTERS 1: PLACE THE 1 X 4 X 36-3/4" GROOVE ONLY ROOF STARTERS AT THE PEAK OF THE ROOF. REFER TO THE DIAGRAM BELOW AND MAKE THE OVERHANG THE SAME ON EACH SIDE OF THE STARTER. 2: PLACE THE STARTERS AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THEM OVERLAPPING. 3: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2"...
  • Page 213 STEP 25: ROOF PEAK 1: FASTEN ROOF PEAK BOARD 1 TO ROOF PEAK BOARD 2 WITH FOUR #8 X 1-1/2" WOOD SCREWS TO MAKE A ROOF PEAK ASSEMBLY 2: PLACE THE ROOF PEAK ASSEMBLY ON TOP OF THE ROOF STARTERS. FASTEN THE ROOF PEAK ASSEMBLY TO THE ROOF STARTERS WITH EIGHT #8 X 1-1/4"...
  • Page 214 STEP 26: ROOF BOARDS AND ROOF FINISHERS 1: LOCATE TEN 1 X 5 X 36-3/4" ROOF BOARDS. SLIDE THE TONGUE OF THE ROOF BOARD INTO THE GROOVE OF THE ROOF STARTER. SECURE THE ROOF BOARD TO THE ROOF SUPPORTS WITH FOUR #8 X 1-1/2"...
  • Page 215 STEP 27: PLASTIC SUNBURST 1: LOCATE TWO OF THE PLASTIC DORMER SUNBURST PIECES AS SHOWN. 2: PLACE THE PIECES AGAINST THE UNDERSIDE OF THE CLATTER BRIDGE ROOF OVERHANG. 3: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION 4: INSTALL A #8 X 1/2"...
  • Page 216 STEP 28: 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: PREDRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH THREE #14 X 1-1/4"...
  • Page 217 STEP 29: TELESCOPE 1: FASTEN THE TELESCOPE BASE 10" AWAY FROM THE OUTSIDE OF THE CORNER POST WITH THE SCREW PROVIDED WITH THE TELESCOPE. 2: SNAP THE ENDS OF THE TELESCOPE BASE INTO THE SOCKETS ON THE SIDE OF THE TELESCOPE.

  • Page 218: Appendix

    APPENDIX...
  • Page 219 1529 HARDWARE #8 X 1-1/4" PAGE 1 OF 1 WOOD SCREW QTY: 22 1/16/2015 S.O. #8 X 1-1/2" WOOD SCREW QTY: 34 #8 X 1-3/4" WOOD SCREW QTY: 8 #8 X 2" WOOD SCREW QTY: 6 #8 X 2-1/2" WOOD SCREW QTY: 4 #2 SQUARE DRIVE BIT...
  • Page 220 PICTURE DESCRIPTION QTY. DORMER SUNRAY ASSEMBLY 2-10-1355-DS DORMER ROOF PANEL ASSEMBLY 2-13-1828-DRPA DORMER SIDE RIGHT ASSEMBLY 2-17-1850-DSRA DORMER SIDE LEFT ASSEMBLY 2-17-1850-DSLA DORMER MOUNT 2-3-1150-DM CHIMNEY FRONT ASSEMBLY 2-8-1500-CFA CHIMNEY RIGHT SIDE ASSEMBLY 2-10-1500-CRS...
  • Page 221 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY 2-10-1500-CLS CHIMNEY REAR ASSEMBLY 2-8-0700-CRA CHIMNEY MOUNTING BLOCK 2-3-0675-CMB...
  • Page 222 STEP 1: DORMER SUNRAYS AND SIDES 1: FIND ONE DORMER SIDE LEFT ASSEMBLY AND ONE DORMER SIDE RIGHT ASSEMBLY. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY. ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW.
  • Page 223 STEP 2: DORMER WINDOW 1: MOUNT THE DORMER WINDOW IN THE FRONT OF THE DORMER, THE WINDOW SHOULD FIT IN BETWEEN THE DORMER SIDES AND THE DORMER SUNRAY. THE BACK FACE OF THE WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS. 2: MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DORMER WINDOW AND FASTEN WITH #8 X 1-1/2"...
  • Page 224 STEP 3: DORMER ROOF PANELS 1: FIND TWO DORMER ROOF PANEL ASSEMBLIES. 2: PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY ASSEMBLIES, THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK, MAKE SURE THE PRE-DRILLED HOLES ON THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES.
  • Page 225 STEP 4: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW. USE A 2" WOOD SCREW IN THIS LOCATION CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY.
  • Page 226 STEP 5: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS. USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE) USE 1-1/4" WOOD SCREWS IN THIS LOCATION (EACH SIDE)
  • Page 227 STEP 6: 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 228 Jumbo Binoculars (07-0003) 1: Attach the Binocular Base to the top of the wood railing on your play set. Fasten with one 5/16" x 1-1/4" lag screw and one 8mm washers included with the Binoculars. 2: Place the bottom side of the Binoculars with the hole in it inside the Binocular Base. Line up the holes in the Binocular Base with the hole on the bottom side of the Binoculars.
  • Page 229 Chalkboard (07-0018) 1. Chalkboard may be mounted with the checkerboard "horizontal" or "vertical". 2. Attach Chalkboard to wood slats or plywood with four of the 3/4" (20mm)long pan head screws provided. Please note: Chalkboard comes with a magnetic chalk holder which will stick to the chalkboard.
  • Page 230 (06-2004) Clatter Bridge Mesh Panels Tools Required: Kit Contents: #2 Phillips Bit or screwdriver 2 - Green Mesh Panels 66" x 24" 1/8" drill bit 44 - Phillips Pan Head Screws Pencil 5.5mm x 25.4mm long Drill 44 - Washers 16mm O.D. X 7.1mm I.D. Note: Your mesh panels will be completely green.
  • Page 231 5) It will be very helpful to have an assistant at this stage. We recommend predrilling holes for the screws on the bottom of the deckboards fastened to the chains. Align the edge of the mesh border with the end of the bridge deck boards.
  • Page 232 PICTURE DESCRIPTION QTY. 1537 DORMERS PLASTIC DORMER SUNBURST (07-0031) DORMER RIGHT SIDE ASSEMBLY DORMER LEFT SIDE ASSEMBLY...
  • Page 233 STEP 1: DORMER 1: OVERLAP THE LEFT DORMER SIDE ONTO THE PEAK SUPPORT OF THE RIGHT DORMER SIDE. 2: MAKE SURE THE FRONT ROOF EDGES ARE FLUSH TO ONE ANOTHER 3: FASTEN THE LEFT DORMER SIDE TO THE PEAK SUPPORT WITH #8 X 1-1/2" WOOD SCREWS. REPEAT SUBSTEPS 1-3 TO CONSTRUCT ANOTHER ROOF ASSEMBLY.
  • Page 234 STEP 2: DORMER 1: PLACE THE PLASTIC DORMER SUNBURST AGAINST THE FRONT FACE SUPPORT ON THE LEFT AND RIGHT ROOF SIDES. 2: PREDRILL 7/64" PILOT HOLES BY 1/2" DEEP INTO THE ROOF SIDES AT EACH HOLE LOCATION. 3: INSTALL #8 X 1/2" PAN HEAD SCREWS TO FASTEN THE SUNBURST TO THE ROOF SIDES. REPEAT SUBSTEPS 1 THROUGH 3 TO CONSTRUCT THE SECOND DORMER.
  • Page 235 STEP 3: DORMER 1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 6TH ROOF BOARD AS SHOWN IN YOUR MANUAL ON STEP 81. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF.
  • Page 236 !IMPORTANT PLEASE READ! Notice to Customer: Please throw away the instructions that came in the 7’ Turbo Slide Box. Use these instructions instead. Also disre- gard the placement of the Slide Entrance in your main playset instructions. Instead follow the instructions in this manual regarding mounting the Slide Entrance onto the playset.
  • Page 237 ASSEMbly INSTRUCTIONS 7' Turbo Tube Slide Note: This accessory is designed to fit a 7’ Deck height only. C A U T I O N • Do not climb on the outside of the slide • This slide is designed for home use only, not for Public Playgrounds •...
  • Page 238 Turbo Tube Slide Dimensions 63-7/16'' 58-11/16'' 34-3/4''...
  • Page 239 TOOLS REQUIRED DRIll CIRCUlAR SAW 1/2" SOCKET & WRENCH TAPE MEASURE WRENCH SAFETy GlASSES 1/8" DRIll bIT SQUARE PHIllIPS bIT & DUST MASK HARDWARE INClUDED (12) 5/16'' x 1-1/2'' Lag Bolts (95) 5/16'' x 3/4" Hex Head Bolts (236) (214) 5/16'' Flat Washers (2) 5/16'' x 2-3/4'' Bolts (112) (101) 5/16'' loc nuts...
  • Page 240 SlIDE COMPONENTS (1) Slide Bracket (1) Entrance Section marked no. 1 (1) Entrance Panel (1) Support Bracket (1) Entrance Section marked no.2 (1) Exit Section marked no. 5 (2) 90 Sections w/flange, marked no. 4 (3) 90 Sections w/o flange, marked no. 3 (1) Slide Base marked no.
  • Page 241 Assembly Instructions EntrancE SEction, 90° SEction (2) Fig. 1 and Exit SEction notES: • At least two individuals are needed to assemble the Turbo Tube Slide. • To aid in aligning holes when assembling sections, insert a screwdriver through adjacent holes to maintain hole alignment.
  • Page 242 1. Position the mounting panel as indicated in (Fig. Assembly Instructions Assembly Instructions 4) (The stamped "T" should be at the top). The panel should be placed to the opening so all the bolt holes fully expose a wood surface except Attaching Entrance Panel to Entrance Section those identified with arrows (which should be Mounting PanEl...
  • Page 243 G THE RAD RIDE TO REAR OF THE FORT Assembly Instructions Mounting PanEl Fig. 4 1. Place the Entrance Panel 7/8” 1. Position the mounting panel as indicated in (Fig. NO LAG away from the outside face of the G TO THE INSTRUCTIONS PROVIDED. SEE BELOW FOR PLACEMENT OF 4) (The stamped "T"...
  • Page 244 Assembly Instructions Assembly Instructions tubE aSSEMbly Fig. 7 1. Position the 90 section to the entrance section so Rotate seam the seams line up. Rotate the section two holes two holes to to the right (clockwise) and realign with the holes the right (clockwise) of the entrance section (see Fig.
  • Page 245 Assembly Instructions Assembly Instructions tubE aSSEMbly (cont.) Fig. 9 Position the exit section to the previously attached sections so the seams line up. Rotate the section two holes to the left (counterclockwise) and realign with the holes of the entrance section (see Fig. Insert a 3/4"...
  • Page 246 Assembly Instructions SuPPort and brackEt aSSEMbly Fig. 13 1. Position the slide bracket between the slide and activity center (Fig. 13). Remove appropriate bolts from the slide (the fourth and fifth bolts as indicated), Attach bracket to the underside of the seam using the previously removed exit section hardware (Fig.
  • Page 247 Assembly Instructions 1. Place the 2 x 4 x 70” board on the inside of the rear corner posts as shown below. The bottom of the board should be 16” above the top of the side sandbox board as shown below. 2.
  • Page 248 Assembly Instructions 1. Place the 5/16” x 2-3/4” hex bolts with washers through the holes in the slide bracket and then through the holes in the 2 x 4 x 4” long board with 2 holes in it. Align the top of the 4”...
  • Page 249 Assembly Instructions 1. In order to perform this step you will most likely have to remove the slide bracket from the slide. Please do so now and set aside the bracket and hardware. 2. At the marks left on the 2 x 4 x 70” board drill two 3/8” diameter holes all the way through the board.
  • Page 250 Assembly Instructions 1. Fasten the Slide Bracket back into position onto the slide elbow. 2. Hammer two 5/16” Tee Nuts into the holes you drilled at the inside face of the 2 x 4 x 70” board. Tee Nuts...
  • Page 251 Assembly Instructions 1. Place the 2 x 4 x 4” block back into position between the Slide Bracket and the 2 x 4 x 70 board. 2.Fasten the Slide Bracket to the Tee Nuts with the 5/16” x 2-3/4” hex bolts and 5/16”...

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1500mwc

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