Gorilla Playsets The Five Star II with Monkey Bars 380A Assembly & Installation

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The Five Star II with Monkey Bars

Timber Shield Post Option

BOXES: 380, 1100

*51-0083-W*

51-0083-W

Model: 380A

(BOXES: 380-1, 380-2,

382, 320 & Slide Box)

190 Etowah Industrial Court

Canton, GA 30114

www.gorillaplaysets.com

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Summary of Contents for Gorilla Playsets The Five Star II with Monkey Bars 380A

Page 1 The Five Star II with Monkey Bars Model: 380A Timber Shield Post Option BOXES: 380, 1100 (BOXES: 380-1, 380-2, 382, 320 & Slide Box) Copyright © 2017 Gorilla Playsets All Rights Reserved *51-0083-W* 190 Etowah Industrial Court Canton, GA 30114 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 • 190 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 - the five star ii with monkey bars - 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...
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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 Please review these safety rules regularly with your children. 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 190 Etowah Industrial Court Canton, GA. 30114...
Page 9 Model: 382 Timber Shield Post Option BOXES: 380, 1100 (BOXES: 380-1, 380-2, 320, 382 & SLIDE BOX) REV: 3.20.2017...
Page 10 TABLE OF CONTENTS Safety Guidelines………………………………………..……......Pages 3-6 Leveling Fort, General Information and Definitions..…………………....Pages 6-8 How to Install T-nuts, Board Identification, Predrill Lag Screw Directions and Swing Beam Loading..................Pages 9-13 Site Plan, Required Tool List and Kit Contents..........Pages 14-15 Hardware, Lumber and Accessory Checklists……………………………..Pages 16-30 Adding T-Nuts to Corner Posts and Sandbox Boards...……..………...…...
Page 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22 Please familiarize yourself with the manual, parts/components and general construction process of your new playset before getting started. SITE PLAN: Swing Belts (2) Trapeze Arm (1) 3'-11 " 5'-8 " 16'- " 9'-1 " Wave Slide Monkey Bars 3'-11 " 2'-0"...
Page 23 REQUIRED TOOL LIST: ___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/8”, 9/64”, 11/64”. ___ ½” Wrench and Socket ___ ½” Deep Well Socket ___ 9/16” Deep Well Socket ___ 9/16” Wrench and Socket ___ Level ___ Tape Measure ___ Extension Cord (if using standard drill)
Page 24 11-0083 #14 X 1-1/4" 380 Hardware PAN HEAD PAGE 1 OF 2 SCREW REV: A 10/20/2016 S.O. QTY: 3 #8 X 1-1/4" WOOD SCREW QTY: 15 #8 X 1-1/2" WOOD SCREW QTY: 106 #8 X 2" WOOD SCREW QTY: 191 #8 X 2-1/2"...
Page 25 11-0083 380 Hardware PAGE 2 OF 2 3/8 X 3-1/2" REV: A 10/20/2016 S.O. 5/16" X 3-1/2" HEX LAG HEX LAG SCREW SCREW QTY: 22 QTY: 12 #2 SQUARE DRILL BIT QTY: 1 PLASTIC BOLT CAP QTY: 19 3/8 x 9" 3/8 x 3-1/2"...
Page 26 11-0085 382 HARDWARE PAGE: 1 OF 1 REV:A 10/20/2016 S.O. 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 27 PICTURE DESCRIPTION QTY. 2 X 4 X 12" BOTTOM PANEL BOARD RIGHT 2-4-1200-BPBR 2 X 4 X 12" BOTTOM PANEL BOARD LEFT 2-4-1200-BPBL 2 X 4 X 13" ANGLE SUPPORT 2-4-1300-AS 2 X 4 X 17" LADDER STEP 2-4-1700-LS 2 X 4 X 28-5/8" CENTER POST 2-4-2863-CP 2 X 4 X 35-1/2"...
Page 28 PICTURE DESCRIPTION QTY. 2 X 4 X 39-1/2" SUNBURST FILLER BOARD 2-4-3950-SFB 2 X 4 X 47-3/8" FACE BOARD 2-4-4738-FB 2 X 4 X 47-3/8" PANEL AND DECK SUPPORT 2-4-4738-PDS 2 X 4 X 47-3/8" ROCKWALL SIDE TOP PANEL BOARD 2-4-4738-RWSTPB 2 X 4 X 47-3/8"...
Page 29 PICTURE DESCRIPTION QTY. 2 X 4 X 57" LADDER RIGHT SIDE 2-4-5700-LRS 2 X 4 X 57" ROCK WALL SIDE 2-4-5700-RWS 2 X 4 X 58" SWING LEG CROSS MEMBER 2-4-5800-CM 2 X 6 X 47-3/8" ARCHED SIDE TOP BOARD 2-6-4738-ASTB 2 X 6 X 47-3/8"...
Page 30 PICTURE DESCRIPTION QTY. 4 X 4 X 47-3/8" SWING BEAM MOUNT 4-4-4738-SBM 5/4 X 2-1/4 X 11-1/2" HORIZONTAL WINDOW SUPPORT 125-225-1150-HWS 5/4 X 2-5/8 X 17-1/2" TIC TAC TOE MOUNT 125-3-1750-TTTM 5/4 X 2-5/8 X 28" PANEL SLAT 125-3-2800-PS 5/4 X 3 X 23-7/8" ROCK WALL TOP 125-3-2388-RWTC 5/4 X 3-1/2 X 18-1/2"...
Page 31 PICTURE DESCRIPTION QTY. 5/4 X 5 X 10" ROOF PEAK SUPPORT 125-6-1000-RPS 5/4 X 5-1/8 X 23-7/8" BOTTOM ROCK WALL BOARD 125-5-2388-BRWB 5/4 X 5-1/8 X 23-7/8" ROCK WALL BOARD 125-5-2388-BRWB 5/4 X 5-1/2 X 20" VERTICAL WINDOW SUPPORT 125-6-2000-VWS 5/4 X 5-1/2 X 47-3/8"...
Page 32 PICTURE DESCRIPTION QTY. 1 X 6 X 52" ROOF PEAK 1-6-5200-RP 1 X 4-1/2 X 52" ROOF BOARD 1-5-5200-RB 4 X 4 X 96" CORNER POST LEFT 4-4-9600-CPL 4 X 4 X 96" CORNER POST RIGHT 4-4-9600-CPR 4 X 4 X 96" SWING LEG 4-4-9600-SL 4 X 6 X 108"...
Page 33 PICTURE DESCRIPTION QTY. 8' WIKI WAVE SLIDE 03-0015-G SWINGS W/CHAINS 04-0002 TRAPEZE W/CHAINS 04-0006...
Page 34 PICTURE DESCRIPTION QTY. SWING PLATE 11-5002 CLIMBING ROCKS (07-0008 IS A PACK ROCKS OF 5) A-FRAME SWING BRACKET 11-5010 HARDWARE HARDWARE BOXES: 380...
Page 35 PICTURE DESCRIPTION QTY. IRON DUCTILE SWING HANGERS 11-4012 TELESCOPE 07-0001 ROCK WALL ROPE...
Page 36 PICTURE DESCRIPTION QTY. GREEN BRACKET 11-5013 SPRING CLIP 11-4003 SAFETY HANDLES (PAIR) 07-0005...
Page 37 PICTURE DESCRIPTION QTY. CHALK BOARD 07-0028-G PLASTIC SUNBURST 07-0028-G PLASTIC DORMER WINDOW 07-0029-G FLAG KIT 09-1014 PLASTIC DORMER SUNBURST 07-0031...
Page 38 PICTURE DESCRIPTION QTY. MANUFACTURER (NOT SHOWN) LOGO PLATE GROUND STAKE (PAIR) 07-0016-P TIC TAC TOE (UNASSEMBLED) 07-0010 STEERING WHEEL 07-0004 UNASSEMBLED DORMER (320 BOX) UNASSEMBLED CHIMNEY (320 BOX)
Page 39 STEP 1: LEFT CORNER POST (FRONT POSITION) AND SAND BOX BOARDS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET DOWN) TO THE FRONT SIDE OF THE LEFT CORNER POST USING ONE 5/16"...
Page 40 STEP 2: LEFT CORNER POST (REAR POSITION) AND SAND BOX BOARDS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET UP) TO THE LEFT SIDE OF THE LEFT CORNER POST USING ONE 5/16"...
Page 41 STEP 3: RIGHT CORNER POSTS AND SAND BOX BOARDS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: ATTACH THE 2 X 6 X 47-3/8" END SAND BOX BOARD (HOLES OFFSET DOWN) TO THE FRONT SIDE OF THE RIGHT CORNER POST USING ONE 5/16"...
Page 42 STEP 4: RIGHT SANDBOX BOARD 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE 2 X 6 X 86" OUTRIGGER (HOLES OFFSET UP) ATTACHES TO THE SIDE OF THE RIGHT CORNER POSTS WITH TWO 5/16"...
Page 43 STEP 5: PANEL SUPPORTS AND ROCK WALL SIDE TOP PANEL BOARD 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE 2 X 4 X 47-3/8" PANEL SUPPORTS (OFFSET HOLES UP) ATTACH TO THE SIDES OF THE FRONT AND REAR CORNER POSTS WITH TWO 5/16"...
Page 44 STEP 6: PANEL SUPPORTS AND DECK SUPPORTS 1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE 2 X 4 X 47-3/8" PANEL SUPPORT (OFFSET HOLES DOWN) ATTACHES TO THE REAR OF THE LEFT REAR AND RIGHT REAR CORNER POSTS WITH TWO 5/16"...
Page 45 STEP 7: LEVELING THE PLAY SET AND INSTALLING LAG SCREWS 1: LEVEL YOUR PLAY SET FRAME. LEVEL SIDE TO SIDE AND FRONT TO BACK. CHECK THE DIAGONALS FOR SQUARE. ONCE YOU HAVE A LEVEL AND SQUARE PLAY SET FRAME YOU MAY INSTALL LAG SCREWS.
Page 46 STEP 8: FORT SUPPORTS 1: PLACE A 5/16" T-NUT INTO THE HOLE IN THE FORT SUPPORTS AS SHOWN. 2: FROM THE INSIDE OF THE RIGHT PANEL BOARD LOOSELY ATTACH EACH FORT SUPPORT WITH ONE 5/16" X 2-1/2" HEX BOLT AND ONE 5/16" WASHER. 3: MEASURE 2"...
Page 47 STEP 9: DECK SPACERS 1: PLACE A 5/4 X 4 X 40-1/4" DECK SPACER BETWEEN THE LEFT AND RIGHT CORNER POSTS ON TOP OF THE DECK SUPPORTS AS SHOWN BELOW. 2: THE DECK SPACER SIDE SHOULD BE FLUSH WITH THE INSIDE OF THE PANEL SUPPORT. 3: ATTACH EACH DECK SPACER TO THE DECK SUPPORTS WITH TWO 2"...
Page 48 STEP 10: ROCK WALL 1: LOCATE TWO 2 X 4 X 57 ROCK WALL SIDE BOARDS. LAY THE BOARDS OUT AS SHOWN AND INSERT A 5/16” T-NUT INTO THE HOLE ON THE INSIDE OF EACH BOARD. USE A HAMMER TO SET EACH T-NUT FLUSH WITH THE BOARD.
Page 49 STEP 11: ROCK WALL 1. LOCATE TEN 5/4 X 5 X 23-7/8” ROCK WALL BOARDS AND ONE 5/4 X 5 X 23-7/8” BOTTOM ROCK WALL BOARD WITH ONE BIG HOLE IN IT. 2. PLACE ONE ROCK WALL BOARD AT THE TOP OF THE ROCK WALL SIDES NEAREST THE HOLES WHERE YOU PREVIOUSLY INSTALLED THE TEE NUTS.
Page 50 STEP 12: ROCK WALL 1: LOCATE TWO 90 GREEN BRACKETS, TWO 5/16” WASHERS AND TWO 5/16” X 1-1/2” HEX BOLTS. 2: FASTEN THE TAPERED SIDE OF EACH 90 GREEN BRACKET TO EACH ROCK WALL SIDE WITH A 5/16” X 1-1/2” HEX BOLT AND 5/16” WASHER. 5/16"...
Page 51 STEP 13: ROCK WALL 1: LOCATE TWO BAGS OF CLIMBING ROCKS. INSIDE EACH BAG SHOULD BE FIVE ROCKS, FIFTEEN #14 X 1-1/4” PAN HEAD SCREWS AND FIFTEEN 1/4” FLAT WASHERS. 2: PLACE THE CLIMBING ROCKS IN A STAGGERED PATTERN ON THE ROCK WALL BOARDS. PLACE ONE ROCK ON EACH BOARD EXCEPT FOR THE BOTTOM ROCK WALL BOARD WITH THE HOLE IN IT.
Page 52 STEP 14: ROCK WALL 1: PLACE THE 5/4 X 3 X 23-7/8” ROCK WALL TOP CAP ON TOP OF THE ROCK WALL SIDES FLUSH WITH THE TOP ROCK WALL BOARD. 2: FASTEN THE 5/4 X 3 X 23-7/8” ROCK WALL TOP CAP TO THE ROCK WALL SIDES AND THE TOP ROCK WALL BOARD WITH FOUR 2”...
Page 53 STEP 15: ATTACHING THE ROCKWALL 1: THE ROCKWALL ATTACHES TO THE REAR OF THE PLAY SET, 11 8 " FROM THE OUTSIDE EDGE OF THE REAR-LEFT CORNER POST. 2: MAKE SURE THE ROCKWALL IS LEVEL. THE BOTTOM EDGE OF THE 90 BRACKETS SHOULD BE 3/4"...
Page 54 STEP 16: DECK STRINGER 1: CENTER THE 2 X 4 X 47-3/8" DECK STRINGER UNDERNEATH THE DECK SPACERS. 2: ATTACH THE DECK STRINGER TO THE DECK SPACERS WITH TWO 2" WOOD SCREWS. 2" WOOD SCREW DECK SPACER DECK SPACER 2 X 4 X 47-3/8" DECK STRINGER...
Page 55 STEP 17: ANGLE SUPPORTS 1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDERNEATH THE DECK ON THE LEFT AND RIGHT OF THE FORT. (THESE ARE CALLED OUT BY THE LETTER "X") 2: ATTACH EACH ANGLE SUPPORT (X) TO THE DECK WITH TWO 2-1/2" WOOD SCREWS AT THE TOP GOING THROUGH THE ANGLE SUPPORT (X) INTO THE DECK SUPPORT.
Page 56 STEP 18: 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 57 STEP 19: ATTACHING THE LADDER 1: LAY THE 2 X 4 X 47-3/8" FACE BOARD ON A FLAT SURFACE AND PLACE THE LADDER ON TOP OF IT. MAKE SURE THE LEFT SIDE OF THE LADDER IS 3-1/2" FROM THE LEFT END OF THE FACE BOARD.
Page 58 STEP 20: FACE BOARDS 1: PLACE THE FACE BOARD (WITH LADDER) ONTO THE FRONT OF THE PLAY SET MAKING SURE THE TOP SIDE IS FLUSH WITH THE TOP SIDE OF THE PANEL SUPPORTS. ATTACH IT TO THE CORNER POSTS USING SIX #8 X 2-1/2" WOOD SCREWS. 2: ATTACH THE ANOTHER FACE BOARD TO THE REAR OF THE PLAY SET MAKING SURE THE TOP SIDE IS FLUSH WITH THE TOP SIDE OF THE PANEL SUPPORTS.
Page 59 STEP 21: DECK BOARDS 1: SEVEN 5/4" X 6 X 47-3/8" DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS, FLUSH TO THE FACE BOARDS. THERE WILL BE APPROXIMATELY A 1/4" GAP BETWEEN EACH DECK BOARD. 2: SPACE THE DECK BOARDS EVENLY ACROSS THE SUPPORTS. 3: SECURE EACH DECK BOARD TO THE DECK SUPPORTS AND THE DECK STRINGER WITH FIVE 2"...
Page 60 STEP 22: PANEL BOARDS 1: PLACE THE 2 X 4 X 12" BOTTOM PANEL BOARD - LEFT AND 2 X 4 X 12" BOTTOM PANEL BOARD - RIGHT ON TOP OF THE 2 X 4 AT THE LEFT SIDE OF THE PLAY SET AS SHOWN BELOW WITH OFFSET HOLES UP.
Page 61 STEP 23: PANEL SLATS 1: FIND SEVENTEEN 5/4 X 2-5/8 X 28-1/4" PANEL SLATS. 2: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES.
Page 62 STEP 24: CENTER POST 1: HAMMER A T-NUT INTO THE HOLE OF THE 2 X 4 X 28-5/8" CENTER POST. 2: PLACE THE CENTER POST INSIDE THE FRONT ARCHED BOARD. LINE UP THE HOLES IN THE CENTER POST WITH THE HOLE IN THE FRONT ARCHED BOARD. 3: FASTEN THE CENTER POST TO THE FRONT ARCHED BOARD WITH A 5/16"...
Page 63 STEP 25: 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 ON THE OUTSIDE HOLES USING 3/8" X 3-1/2" CARRIAGE BOLTS FROM THE TOP AND 3/8" WASHERS WITH 3/8" LOCK NUTS ON THE BOTTOM.
Page 64 STEP 26: SWING BEAM MOUNT 1: THE 4 X 4 X 47-3/8" SWING BEAM MOUNT HAS COUNTER-SUNK HOLES IN THE CENTER AND ON THE ENDS. INSTALL THE SWING BEAM MOUNT SO THAT THE COUNTER-SUNK HOLES ON EACH END OF THE BEAM FACE OUT, AND THE COUNTER-SUNK HOLES IN THE CENTER FACE DOWN. 2: FASTEN THE SWING BEAM MOUNT TO THE RIGHT CORNER POST USING 3/8"...
Page 65 STEP 27: 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 66 STEP 28: 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 67 STEP 29: REST SWING BEAM ON FORT *TWO PEOPLE ARE REQUIRED FOR THIS STEP. 1: SIT THE SWING BEAM LEGS UPRIGHT. 2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE FORT AND SWING LEGS. MAKE SURE THE IRON DUCTILES ARE FACING DOWN.
Page 68 STEP 30: MOUNT SWING BEAM TO SWING BEAM LEGS 1: FASTEN THE SWING BEAM TO THE SWING BEAM BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE SWING BEAM, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH. 2: USE A 3/8 X 3-1/2"...
Page 69 STEP 31: SWING BEAM TO FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP. 1: HAVE ONE PERSON LINE UP THE HOLE IN THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE. THE OTHER PERSON MAY HAVE TO CARRY THE OTHER END WHERE THE LEGS ARE LOCATED TO ACCOMPLISH THIS TASK.
Page 70 STEP 32: LEVEL THE SWING BEAM 1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.
Page 71 STEP 33: SWING LEG CROSS-MEMBER 1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING LEGS. 2: LEVEL THE SWING LEG CROSS-MEMBER, AND SECURE TO THE SWING LEGS WITH 3/8" X 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3/8"...
Page 72 STEP 34: ARCHED SIDE TOP BOARD 1: PLACE ONE ARCHED SIDE TOP BOARD ON THE LEFT / RIGHT SIDE OF THE PLAY SET AT THE TOP. 2: ATTACH EACH ARCHED SIDE TOP BOARD THROUGH THE TOP HOLE INTO THE T-NUT IN THE CORNER POST WITH 5/16"...
Page 73 STEP 35: ROOF SUPPORT ASSEMBLIES 1: LOCATE TWO 2 X 4 X 35.50" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35.50" ROOF SUPPORT (RIGHT) AND TWO 5/4 X 6 X 10.50" ROOF PEAK SUPPORT PIECES. 2: FIND A FLAT SURFACE TO WORK ON. LAY THE ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH THE COUNTER-SUNK HOLES FACING DOWN.
Page 74 STEP 36: ROOF SUPPORT ASSEMBLIES 1: ATTACH THE ROOF SUPPORT ASSEMBLIES TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS. ROOF SUPPORT ASSEMBLIES 5/16" WASHER 5/16" X 4-1/2" HEX BOLT T-NUT...
Page 75 STEP 37: ROOF STARTERS / ROOF PEAK 1: PLACE THE 1 X 5 X 52" (GROOVE ONLY) ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS. THE FLAT SIDE OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TOGETHER AS POSSIBLE BEAR THE PEAK WITHOUT THE BOARDS OVERLAPPING.
Page 76 STEP 38: ROOF BOARDS / ROOF FINISHERS CHIMNEY AND DORMERS 1: PLACE THE 1 X 5 X 52" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE INTO THE GROOVE OF THE ROOF STARTER. THE HOLES IN THE ROOF BOARDS SHOULD BE CENTERED OVER THE ROOF SUPPORTS.
Page 77 STEP 39: PLASTIC SUNBURST 1: LOCATE TWO PLASTIC SUNBURST PIECES. 2: PLACE THE SUNBURST UNDER THE ROOF OVERHANG. FIT IT AGAINST THE BOTTOM SIDE OF THE ROOF BOARDS AND AGAINST THE ROOF SUPPORTS. 3: ATTACH THE PLASTIC SUNBURST WITH SIX #8 X 2" WOOD SCREWS ALONG THE SIDES. ATTACH THE TRIANGLE PORTION OF THE SUNBURST PIECE WITH #8 X 2-1/2"...
Page 78 STEP 40: SUNBURST FILLER BOARD 1: PLACE THE 2 X 4 X 39.50" SUNBURST FILLER BOARD IN BETWEEN THE ROOF SUPPORTS. FASTEN USING #8 X 2-1/2" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ON EACH END, MAKE SURE THERE ARE NO GAPS IN BETWEEN THE SUNBURST FILLER BOARD AND THE ROOF SUPPORTS.
Page 79 STEP 41: WINDOW SUPPORTS / WINDOWS IN THIS STEP THE WOOD COMPONENTS TO ATTACH WINDOWS WILL BE INSTALLED ON THE INSIDE OF THE FRONT OF THE PLAY SET. 1: ATTACH THE 5/4 X 6 X 20" VERTICAL WINDOW SUPPORT IN THE CENTER WITH #8 X 2" WOOD SCREWS.
Page 80 STEP 42: SAFETY BOARD THIS BOARD IS MEANT TO BE A VISUAL DETERRENT TO PREVENT CHILDREN FROM RUNNING THROUGH THE BASE OF THE PLAY SET INTO OTHER CHILDREN ON THE SWING SET. 1: MEASURE 17-1/4" FROM THE TOP OF THE RIGHT SANDBOX BOARD AND MAKE A MARK ON THE RIGHT CORNER POSTS.
Page 81 STEP 43: SLIDE 1: PLACE THE SLIDE IN THE OPENING AT THE FRONT-RIGHT OF THE FORT. LAY THE SLIDE ON THE DECK WITH THE LIP EXTENDING ONTO THE DECK. 2: PRE-DRILL 1/8" HOLES INTO THE DECK BOARDS AT THE SCREW LOCATIONS. 3: ATTACH THE SLIDE TO THE DECK BOARDS WITH 1-1/4"...
Page 82 STEP 44: HANGING THE SWINGS 1: CLIP EACH OF THE SPRING CLIPS ONTO THE IRON DUCTILE SWING HANGERS, THEN CLIP ONTO THE SWING CHAINS. 2: USE THE CLIPS TO ADJUST THE HEIGHT OF THE SWING BY CLIPPING ONTO HIGHER OR LOWER LINKS.
Page 83 STEP 45: CLIMBING ROPE 1: THREAD ONE END OF THE ROPE THROUGH THE HOLE IN THE ROCK WALL SIDE TOP PANEL BOARD. 2: TIE A SECURE KNOT ON THE INSIDE OF THE ROCK WALL SIDE TOP PANEL BOARD. 3: THREAD THE OTHER END OF THE ROPE THROUGH THE HOLE IN THE BOTTOM ROCK WALL BOARD.
Page 84 STEP 46: TELESCOPE 1: PLACE ONE OF THE L-SHAPE TELESCOPE MOUNTING BRACKETS CENTERED ON THE PANEL SUPPORT. 2: ATTACH THE L-SHAPED BRACKET WITH TWO SCREWS PROVIDED WITH THE TELESCOPE. 3: PLACE THE BASE OF THE TELESCOPE INTO THE CUT OUT AREA OF THE L-SHAPED BRACKET. 4: ATTACH ANOTHER L-SHAPED TELESCOPE MOUNTING BRACKET DIRECTLY ACROSS FROM THE PREVIOUSLY INSTALLED BRACKET AND SECURE WITH THE PROVIDED HARDWARE.
Page 85 STEP 47: FLAG KIT 1: PLACE THE FLAGS ON THE FRONT SIDE OF THE PLAY SET CENTERED ON THE CORNER POSTS. 2: ATTACH THE PLASTIC BASE OF EACH FLAG TO THE CORNER POST WITH THE 1/2" PHILLIPS HEAD SCREWS PROVIDED WITH THE FLAGS. FLAGS...
Page 86 STEP 48: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: PREDRILL AN 11/64" HOLE ABOUT 2" DEEP INTO THE END OF THE SWING BEAM. USE THE HARDWARE INCLUDE (ONE 3/8 X 2-1/2" LAG SCREW AND ONE 3/8" WASHER) WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE END OF THE SWING BEAM.
Page 87 STEP 49: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES CENTERED ONTO THE PANEL SLATS SBOVE THE LADDER. ADJUST THE SAFETY HANDLES UP OR DOWN TO SUIT THE NEEDS OF YOUR CHILD. 2: ATTACH EACH SAFETY HANDLE WITH TWO 1-1/4" PAN HEAD SCREWS AND TWO 1/4" WASHERS PROVIDED WITH EACH SAFETY HANDLE.
Page 88 STEP 50: TIC TAC TOE ASSEMBLY / INSTALLATION 1: LOCATE THE TIC TAC TOE BOX. FOLLOW THE INSTRUCTIONS IN THE BOX TO ASSEMBLE THE TIC TAC TOE OMITTING STEPS 6 AND 7. 2: LOCATE THE TWO 5/4 X 3 X 17-1/2" TIC TAC TOE MOUNTS. 3: USE THE SCREWS INCLUDED WITH THE TIC TAC TOE TO ATTACH THE GREEN BRACKETS TO THE TIC TAC TOE MOUNTS.
Page 89 STEP 51: GROUND STAKES 1: PLACE THE GROUND STAKES ON THE OUTSIDE OF THE SWING LEGS AS SHOWN BELOW. 2: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO NOT HOLD THE UPPER PORTION OF THE STAKE SFTER THE FIRST COUPLE OF HITS OR IT MAY VIBRATE HARSHLY AGAINST YOUR HAND.
Page 90 STEP 52: NAME PLATE 1: ATTACH THE MANUFACTURER NAME PLATE TO THE MIDDLE OF THE SWING BEAM WITH TWO 2" WOOD SCREWS. MANUFACTURER PLATE...
Page 91 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 92 APPENDIX...
Page 93 Chimney and Dormers Hardware Kit 8/10/2015 JH #8 X 2-1/2" WOOD SCREW QTY: 2 #8 X 2" WOOD SCREW QTY: 4 #8 X 1-1/2" WOOD SCREW QTY: 14 #8 X 1-1/4 WOOD SCREW QTY: 6 #2 SQUARE DRIVE BIT QTY: 1 USE THE RULER TO THE RIGHT TO MEASURE YOUR BOLTS AND SCREWS.
Page 94 PICTURE DESCRIPTION QTY. CHIMNEY LEFT SIDE ASSEMBLY CHIMNEY RIGHT SIDE ASSEMBLY CHIMNEY FRONT ASSEMBLY...
Page 95 PICTURE DESCRIPTION QTY. CHIMNEY REAR ASSEMBLY 5/4X3X6-3/4" CHIMNEY MOUNTING BLOCK DORMER LEFT SIDE ASSEMBLY...
Page 96 PICTURE DESCRIPTION QTY. PLASTIC DORMER SUNBURST (07-0031) DORMER RIGHT SIDE ASSEMBLY...
Page 97 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 98 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 99 STEP 3: DORMER 1: PLACE THE DORMER ASSEMBLY ON THE ROOF AS SHOWN. 2: FOR 1500 SERIES UNITS LINE UP THE BOTTOM EDGE OF THE PLASTIC SUNBURST WITH THE LOWER EDGE OF THE 8TH ROOF BOARD. 3: CENTER THE DORMER FROM SIDE TO SIDE ON TOP OF THE ROOF. 4: ATTACH THE DORMER TO THE ROOF WITH ONE #8 X 2-1/2"...
Page 100 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 101 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 102 STEP 6: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH #8 X 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE FOR A SUGGESTED PLACE TO MOUNT THE CHIMNEY. 2: AFTER INSTALLING THE CHIMNEY MOUNTING BLOCK PLACE THE CHIMNEY ASSEMBLY ON THE ROOF SO THAT THE INSIDE OF THE BACK WALL RESTS AGAINST THE BLOCK.
Page 103 PICTURE DESCRIPTION QTY. 4 X 4 X 47.375" MONKEY BAR SUPPORT 4-4-4738-MBS 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 86.50" MONKEY BAR LADDER 4-4-8650-MBL 1-5/16"...
Page 104 STEP 1: ASSEMBLING THE 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 105 STEP 2: 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 106 STEP 3: 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 107 STEP 4: MONKEY BAR SUPPORT 1: GO TO REAR OF YOUR PLAY SET. 2: MEASURE UP 5" FROM THE BOTTOM OF THE 2 X 4 X 47-3/8" PANEL SUPPORT AND MAKE A MARK ON EACH OF THE REAR CORNER POSTS. 3: PLACE THE BOTTOM OF THE 4 X 4 X 47-3/8"...
Page 108 STEP 5: ATTACHING THE MONKEY BARS 1: CENTER THE MONKEY BAR ASSEMBLY ON TOP OF THE 4 X 4 X 47-3/8" MONKEY BAR SUPPORT. 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 SUPPORT.
Page 109 STEP 6: 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"...

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