Playnation 2300 User Manual

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Page 1

Fresh Squeeze

Model: 2300

(BOXES: 2300-1, 2300-2,

2300-3, (110 or 1513),

Glider Box & Slide Box

190 Etowah Industrial Court

Canton, GA 30114

www.playnation.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 use our “Quick Response Center” located at:

www.playnation.com/support

DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECTLY. THE RETAILER DOES NOT STOCK COMPONENTS.

PLEASE RETAIN ALL INSTRUCTIONS FOR FUTURE REFERENCE. KEEP THEM IN A SAFE PLACE WHERE YOU CAN REFER TO THEM AS NEEDED. CHECK FOR REVISED INSTRUCTIONS AT:

http://www.playnation.com/manuals.html

Page 3

PLAYNATION WARRANTY

MANUFACTURER'S LIMITED LIFETIME WARRANTY

PlayNation Play Systems, Inc. warrants its Lifetime™ series of swing sets to be free from defects in

workmanship and materials, under normal use and conditions, for the lifetime of the product for above ground structural wood components and for two years for all other components (e.g., swings, hardware,

plastics, tarps, rope ladder, etc.) except PlayNation's Super Scoop Slides™ and Super Tube Spiral Slides™.

PlayNation warrants its Super Scoop Slides™ and Super Tube Spiral Slides™ to be free from defects in

workmanship and materials, under normal use and conditions, for the lifetime of the product.

PlayNation warrants its Regal™, Imperial™, and Empire™ series swing sets to be free from defects in workmanship and materials, under normal use and conditions, for a period of 15 years for above ground structural wood components and for two years for all other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).

PlayNation warrants all remaining products, including but not limited to its Free Standing Swing Set, Free Standing Tire Swing, See-Saw, Children's Picnic Table with Umbrella, Play-Zee-Bo™ and spring riders to be free from defects in workmanship and materials, under normal use and conditions, for a period of 1 year. All accessories purchased separate from those included with one of our swing set packages have a one year limited warranty.

The Krazy Clubhouse is warranted for a period of 6 months.

Cosmetic imperfections and natural tendencies of wood such as peeling, splintering, warping, seasonal checking or cracking, knots or knot holes, etc. are normal characteristics of all outdoor wooden play equipment and are not covered by this warranty. Checks or cracks in wood components that do not affect the intended function of the part, piece or overall swing set are not covered under this warranty.

Wood rot or decay that develops because the product was installed in an area with poor drainage is not covered under this warranty. Lumber that has been damaged by wood boring bees, or conditions that develop as a result of faulty or improper installation of the product, are not covered by this warranty. Fading of stain, discoloration or mold on any wood part or accessory is not covered by this warranty. Cracks in plastic components, surface rust on hardware and chips on powder coated materials are not considered defects in material as long as they do not affect the functionality or structural integrity of the part or component.

It is the owner's responsibility to maintain the swing set. This includes but is not limited to staining and sealing the lumber as needed and regular inspection to be sure all hardware is tight. Instructions for proper maintenance can be found on PlayNation's website. Imperfections or conditions that develop because of a failure to properly maintain the swing set are not covered by this warranty.

PlayNation will , at its discretion, replace any above ground part within the stated warranty period that is defective in workmanship or materials. This decision is subject to verification of the defect, which, at PlayNation's discretion, may be accomplished by submitting photographs or by delivery of the defective part to PlayNation. Any warranty claim must include proof of purchase, including the date of purchase.

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PLAYNATION WARRANTY

In addition, within the first 30 days from the date of purchase, PlayNation will replace any parts discovered to be missing from or damaged in the original packaging.

This warranty is valid only if the product is used for the purpose for which it was designed and installed at a residential, single-family dwelling. This warranty is void if the product is used in a commercial, institutional or multi-family setting. This warranty does not cover normal wear and tear or (a) products that have been damaged by acts of God and/or nature, negligence, misuse or accident; (b) products that have been modified or repaired by unauthorized persons; (c) the cost of labor; or (d) the cost of shipping any replacement product or part.

PLAYNATION DISCLAIMS ALL OTHER REPRESENTATIONS AND WARRANTIES OF ANY KIND, EXPRESSED, IMPLIED, STATUTORY OR OTHERWISE, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. PLAYNATION WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty is non-transferable and does not extend to the owners of the product subsequent to the original purchaser. Some states do not allow limitations on implied warranties or exclusion of incidental or consequential damages, so these restrictions may not be applicable to you. This warranty gives you specific legal rights. You may also have other rights which vary from state to state.

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IMPORTANT SAFETY GUIDELINES

This product is recommended for use by children ages 3-11. This product is intended for residential use only and not intended for use in any public setting. A safety surface such as mulch or recycled tire should be used under the play set to prevent injury from falls. Also a 6 foot safety zone should be used around the entire play set.

As with any home project, good judgment and respect for power tools will greatly reduce the risk of injury. PlayNation recommends you follow all tool manufacturers’ safety guidelines. Always wear eye protection and safety gloves to prevent injury. In several phases of construction two people may be required for lifting and securing of lumber. While the play set is being constructed, please keep children off the equipment until the project is complete. Bolts and screw heads should be checked regularly for tightness. The ground ladder, rope ladder, slide, swings and other areas where children spend a majority of their playtime should be checked more frequently.

PlayNation shall not be liable for incidental, indirect or consequential damages or injuries that result from the building and/or playing on our play sets. Adult supervision is recommended anytime a play set is being used.

WEIGHT LIMITS FOR PLAYNATION PLAYSETS

• FORT PLATFORMS: 800 LBS. TOTAL WEIGHT

• SWING BELT: 225 LBS.

• GLIDER SWINGS: 70 LBS. PER CHILD. UP TO 140 LBS TOTAL WEIGHT.

• TRAPEZE: 125 LBS.

• FULL BUCKET SWING/ HALF BUCKET SWING: 50 LBS.

• HEAVY DUTY TODDLER BUCKET SWING: 85 LBS.

• INFANT SWING: 35 LBS.

• TIRE SWING: 125 LBS. TOTAL WEIGHT

• ROPE LADDER: 75 LBS.

• ROCK WALL: 150 LBS.

• CLIMBING RAMP: 150 LBS.

• MONKEY BARS: 175 LBS.

• ALL SLIDES: 150 LBS.

PlayNation recommends that the weight limits for all components must not be exceeded. Failure to

adhere to these and other safety guidelines could result in damage to the play set and injury to the users.

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IMPORTANT – PLEASE READ

As fresh lumber acclimates to its new environment, the natural tendencies of the tree can show itself in the form of checks, or “cracks” in the lumber. In almost all cases this is normal and it will not affect the structural integrity of your play set.

Cosmetic defects that do not affect the structural integrity of the product, or natural defects of wood such as warping, checking or any other physical properties of wood that do not present a safety hazard, are not covered by this warranty. Defects that develop because the product is exposed to extreme climate conditions or woodboring insects are not covered by this warranty. Defects that develop as a result of faulty or improper installation of the product are also not covered by this warranty.

Most cracks are not warrantable, however if you believe that the integrity of your play set is compromised by this natural occurrence, please follow the warranty claim procedure found at http://www.playnation.com/warranty. Click on the “Warranty” tab and follow the instructions.

KEEPING YOUR PLAYSET LIKE NEW

LUBRICATE:

• Spray swing hangers with Pam, Mazola or olive oil to stop squeaking.

• Do not use petroleum based products such as WD-40 or motor oil.

• To speed up the slide wipe center of slide ONLY with wax paper every 2 - 3 weeks.

TIGHTEN:

• Check and tighten hex/carriage bolts within rst 60 days and then twice annually.

• Check lag screws for tightness before each season and then once during the season for

tightness. Tighten lag screws as required.

SEAL:

• Apply an oil based sealer or preservative within 90 days, then every 2 - 3 years. You may

need to power wash the unit before sealer application on year two.

INSECTS:

• To repel yellow jackets and wasps, using a cloth, coat all interior 90 degree corners with liquid

dish soap underneath the play set deck. This will make wasps sick when they attempt to build a nest. Avoid using insecticides.

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WARRANTY REGISTRATION

- FRESH SQUEEZE -

PlayNaon manufactures the nest quality products that are designed for outstanding strength and durability. We back our products with an unparalleled warranty. In the unlikely event that you will need to contact us about covered repairs, we must have a valid Warranty Registraon on le.

Where did you buy this product?:

Store Store City Store StateDate of

Purchase

OPTION 1

OPTION 2

OPTION 3

3 EASY WAYS TO REGISTER

Fax this completed form to:

(800) 880-3300

Complete the online registraon form at:

hp://www.playnaon.com/register

Scan this QR Code

with your smart

phone to complete

the form using your

phone

Mail this completed form to:

PlayNaon Playsets

190 Etowah Industrial Court

Canton, GA 30114

Your registraon informaon:

Name: Email:

Address:

Street City State Zip

Please select your age?

18-30

31-40

41-50

51+

How would

you rate the

quality of

this product?

How old are your children?

2-3

4-5

6-7

Would you recommend this product to friends & family?

Comments:

Excellent

Above Average

Average

Below Average

Poor

Yes No

Page 9

Model: 2300

(BOXES: 2300-1, 2300-2,

2300-3, (110 OR 1513) Glider

Box & Slide Box)

REV: 4.28.2014

Page 10

TABLE OF CONTENTS

Safety Guidelines……………………………………….......……...........................Pages 3-6

Leveling Fort, General Information and Denitions………………………............Pages 6-8

How to Install T-nuts, Board Identication, 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 16-36

Arranging Corner Posts and adding T-nuts to Corner Posts…………...…......... Steps 1-2

Framing the Fort……………………...…..……..……...….…….......................... Steps 3-10

Attaching Deck Spacers, Center Deck Support and Deck Boards…….......... Steps 11-13

Framing for Lower Level clubhouse ……….……………………..……........… Steps 14-15

Rock Wall assembly and installation.……...……………………….………...... Steps 16-20

Ladder assembly and installation.……………………………………………..... Steps 21-22

Angle Supports……………...…………………………….…..................................... Step 23

Picnic Table Wall Assembly……………………………………….....………...... Steps 24-26

Lower Level Clubhouse Walls………………….…….……............................... Steps 27-33

Panel Slats…………………………………………..…….......................................... Step 34

Swing Beam Assembly…...…......................................................................... Steps 35-42

Upper and Lower Roof Assembly……………………………........................... Steps 43-54

Lower and Upper Sun Supports and Sun Rays…………....…………............. Steps 55-61

Upper Wall Panels and Windows…………….....…..…………..….…………... Steps 62-66

Rock Wall Rope and Steering Wheel............................................................. Steps 67-68

Tic Tac Toe Assembly and Installation............................................................ Steps 69-70

Telescope, Flag Kits, Plastic Sun (Crown), Slide, Safety Handles................. Steps 71-75

Picnic Table Assembly and Installation........................................................... Steps 76-81

Dinner Bell, Phone, Sign and Umbrella Installation........................................ Steps 82-85

Ground Stakes, Name Plate and Hanging Swings......................................... Steps 86-87

PLEASE READ OWNER’S MANUAL CAREFULLY BEFORE STARTING ASSEMBLY!

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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.

• This play set is designed for the use of 4 occupants who have a combined weight not exceeding 800 pounds on the elevated oor, 3 occupants who have a combined weight of 425 pounds on the swing area, for a total Unit capacity of 7 occupants who have a combined weight of 1225. (This weight does not include any picnic table area(s).)

• On-site adult supervision is required.

• Teach children not to walk close to, in front of, behind, or between moving swings or other moving playground equipment.

• Teach children to sit in and never stand on swings

• Teach children not to twist the chains and ropes and not to loop them over the swing beam, since this may reduce the strength of the chain or rope.

• Teach children not to jump from swings or other playground equipment in motion.

• Teach children not to push empty seats. The seat may hit them and cause serious injury.

• Teach children to sit in the center of the swings with their full weight on the seats.

• Teach children not to use the equipment in a manner other than intended.

• Teach children to always go down slides feet rst. Never slide headrst.

• Teach children to look before they slide to make sure no one is at the bottom.

• Teach children to never run up a slide, as this increases their chances of falling.

• The parents should have the children dress appropriately with well-tting shoes. Loose clothing such as scarves and ponchos should not be worn. Always take off, tie up or tuck in cords and drawstrings on children’s clothing. These things can get caught on playground equipment and strangle a child.

• Teach children not to climb when the equipment is wet.

• Teach children to never jump from a fort deck. They should always use the ladder,

ramp or slide.

• Teach children to never crawl or walk across the top of monkey bars or swing beam.

• Teach children to never crawl on top of a fort roof or on the outside of a tube slide.

• Verify that any suspended climbing ropes, chains, or cables are secured at both ends and that they cannot be looped around an adult hand.

• Teach children not to attach items to the playground equipment that are not specically designed for use with the equipment, such as, but not limited to, jump ropes, clothesline, pet leashes, cables and chain as they may cause a strangulation hazard.

• Teach children to never wrap their legs around swing chain.

• Teach children to never slide down the swing chain.

• Teach children to remove their bike or other sports helmet before playing on the

playgound equipment.

• Teach children to NEVER look at the sun or other bright light through any accessory such as but not limited to a telescope, periscope or binoculars.

WARNING: Children must NOT use this play set until it has been completely assembled and inspected by an adult to insure it has been properly installed and the swing beam legs are anchored.

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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.

• Exposed equipment footings.

• Scattered debris, litter, rocks, or tree roots.

• Splinters, large cracks, and decayed wood components.

• Deterioration and corrosion on structural components, which connect to the ground.

• Missing or damaged equipment components, such as handholds, guardrails, swing seats.

• Check all nuts and bolts twice monthly during the usage season and tighten as required. (But not so tight that you crack the wood) We recommend you check the swing beam and hardware often due to wood expansion and contraction. It is particularly important that this procedure be followed at the beginning of each season.

• Remove plastic swing seats and take indoors or do not use when the temperature drops below 32°F. Reinstall swings and other swing equipment at the beginning of the usage season.

• Oil all metallic moving parts monthly during the usage period.

• Check all coverings for bolts and sharp edges twice monthly during usage season to be certain they are in place. Replace when necessary. It is especially important to do this at the beginning of each new season.

• Check swing seats, ropes, cables and chains monthly during usage season for evidence of deterioration. Replacement should be made of any swing seat that has developed cracks in the plastic seats. Ropes, cables and chains should be removed and replaced if excessive wear is found. Contact us for warranted replacement parts.

• Swing chains, rings, ropes, etcetera should always be fastened to a rotating swing hanger. NEVER attach a chain, ring, rope, etcetera to a stationary hanger such as but not limited to an eye bolt. Severe wear could occur leading to an injury.

• For rusted areas on metallic members such as monkey bars, hand supports brackets, etc.; sand and repaint, using a non lead-based paint meeting the requirements of Title 16 C.F.R. Part

1303. These requirements are available at: http://www.cpsc.gov/

• Inspect wood parts monthly. The grain of the wood sometimes will lift in the dry season causing splinters to appear. Light sanding may be necessary to maintain a safe playing environment. If you are treating your play set with stain regularly, it will help prevent severe checking/splitting and other weather damage.

• Once or twice a year, depending on your climate conditions, you must apply some type of protection (sealant) to the wood of your unit. Prior to the application of sealant, lightly sand any “rough” spots on your set. Please note this is a requirement of your warranty.

• Creating and maintaining the play set on a level location is very important. As your children play, your play set will slowly dig its way into the soil, and it is very important that it settles evenly. Make sure the play set is level and true once each year or at the beginning of each play

season.

• Twice a month during the usage season rake the playground protective surfacing materials to prevent compaction and maintain appropriate depths. Replace the protective surfacing materials

as required.

• Disposal Instructions: When the play set is no longer desired, it should be disassembled and disposed of in such away that no unreasonable hazards will exist at the time the play set is

discarded.

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Play Set Surfacing Recommendations:

Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf

1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective surfacing under and around all playground equipment is the most critical safety factor on playgrounds.

Certain manufactured synthetic surfaces also are acceptable; however, test data on shock absorbing performance should be requested from the manufacturer.

Asphalt and concrete are unacceptable. They do not have any shock absorbing properties. Similarly, grass and turf should not be used. Their ability to absorb shock during a fall can be reduced considerably through wear and environmental conditions.

Certain loose-ll surfacing materials are acceptable. Surfacing materials are acceptable, such as the types and depths shown in the table.

Fall Heights and Materials

Type Of Material 6 in. depth 9 in. depth 12 in. depth

Double-Shredded bark mulch 6’ Fall Height 10’ Fall Height 11’ Fall Height

Wood Chips 6’ Fall Height 7’ Fall Height 12’ Fall Height

Fine Sand 5’ Fall Height 5’ Fall Height 9’ Fall Height

Shredded Tires* 10-12’ Fall Height N/A N/A

Fine Gravel 6’ Fall Height 7’ Fall Height 10’ Fall Height

*This data is from tests conducted by independent testing laboratories on a 6-inch depth of uncompressed shredded tire samples produced by four manufacturers. The tests reported critical heights, which varied from 10 feet to greater than 12 feet. It is recommended that persons seeking to install shredded tires as a protective surface request test data from the supplier showing the critical height of the material when it was tested in accordance with ASTM F1292.

It should be recognized that all injuries due to falls cannot be prevented no matter what surfacing material is used.

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’ in all directions from the perimeter of the equipment.

Swings should have a fall zone extending a minimum of 6’ from the outer edge of the support structure on each side. The fall zone in front and back of the swing should extend out a minimum distance of twice the height of the swing as measured from the ground to the top of the swing support structure.

LEVELING YOUR FORT DURING ASSEMBLY

• Complete the steps which will be the basic frame of the fort. {i.e. four corner posts with base (sand box boards) and deck supports}

• Position in the most level area chosen for the play set, keeping in mind the location and size of the swing beam, ladder, slides, etc. that extend off the fort.

• Once the frame is in the nal position, check for vertical and horizontal levelness to determine which side(s) will need to be dug into the ground to level the play set.

• With a shovel, score the ground around the outside edges of the sandbox boards on the ‘high’ side of the fort. This is the area that will be dug in. Make sure to score deep enough; the scored lines will be your digging template.

• Push the frame off and away from the scored area, far enough to dig and remove dirt to reach the appropriate depth.

• Dig a channel along the scored line(s) for the base of the fort (corner post and sandbox boards) to rest into. Dig the channel(s) to the same level depth. The bottom of the channel(s) should be level to each other so your frame doesn’t teeter or rock because the channel(s) are uneven.

• Once you have removed enough grass and dirt, slide/push the frame into the channel(s). Place a level on the vertical and horizontal boards of the frame to determine if enough soil, or too much, was removed.

• Repeat this process until the basic frame is plumb and level and in its nal position before completing the rest of the assembly.

• Measure to make sure fort is square.

Important: if you require a channel depth of more than 6”, then we recommend you have your play set area professionally graded before completing assembly.

Example Play area:

Side View of Playset Frame

(Grade is the

Slanted Line)

The diagonal measurements should be the same from corner post to corner post. If not, adjust corner posts so that the distance is equal.

= Area to be scored and channeled for levelness

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.

• Identify all of the parts for your play set. Empty each box and lay out boards so you can see each part. Your instruction book will have detailed drawings that will make it easy for you to recognize individual parts. Keep all hardware and metal parts separate from wooden pieces.

• After everything is laid out, check carefully to ensure all parts are present. Make sure there are no broken boards.

• Find an area to sort your hardware. It is best to open the hardware on a solid surface so that you do not lose any pieces in the grass. This will save time and familiarize you with all the different pieces in the hardware bag.

• Important note: Wood has some natural defects such as knots, surface cracks, etc… We reject parts that are structurally defective. We use a high quality lumber in our structures; however, you should inspect each part for splinters or rough spots and sand them smooth to prevent injury.

• After familiarizing yourself with all of the components, read all instructions thoroughly. Reading instructions after you have studied the parts will help you understand the installation process, and help to eliminate unnecessary mistakes.

• Pay close attention to the diameter and length of each bolt and screw.

• Never tighten hardware completely at rst. It helps to have some adjustment for bolt alignment while you are attaching parts together. After everything is square, tighten each joint.

• After the main unit is assembled it is critical that the oor is level and square. If the main frame is not level, the walls and oor will be out of square.

• After you complete installation, make sure every bolt, screw, and nut is tight, and every board is secure. Wood will expand and contract with the seasons.

• Place the set on level ground, not less than 6 feet from any structure or obstruction such as a fence, garage, house, overhanging branches, laundry lines, or electrical

wires.

Page 16

This page is a list of denitions 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. In the procedures you will be instructed to attach the boards with the holes offset up or with the holes offset down. This refers to which side of the board the hole/holes should be closer to. Offset holes up= hole/holes will be closer to the top of the board. Offset holes down= hole/holes will be closer to the bottom of the board. Note: some parts do not have offset holes, but instead the holes are on center. Therefore there will not be any reference on how to offset these parts.

EXAMPLE OF OFFSET HOLES UP

EXAMPLE OF OFFSET HOLES DOWN

Counter-sunk holes - Many of the parts that will be used have counter-sunk holes. A

counter-sunk hole is one that surrounds one side of a through hole, but does not extend through the wood it’s self. When using a counter-sunk hole the bolt will be inserted through the through hole and either the head of the bolt and washer or nut and washer will occupy the counter sunk hole.

Counter-Sunk Hole

Through Hole

Lag Screws- Lag screws are used in the construction of our play sets to enhance the structural integrity of the unit. There will not be predrilled holes in the post for lag screw installation. Lag screws are self-tapping, though if you are using a manual socket wrench it may be advantageous to pre-drill a hole rst. Instructions for this are provided on a separate page in the front of the manual. Be sure to tighten the lags completely when driving them in by hand. Power tools such as a heavy duty impact driver or large power drill should have enough torque to drive in the lag screws, but make sure not to over tighten as this can cause the threads to “strip out” in the post.

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 ush 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 ush to the wood.

This picture shows the T-nut inserted and installed ush to the wood.

Flush (Correct)

Cross Section end view, you are looking at an X-ray view of the post and T-nut. The barrel of the T-nut is in the corner post the line is the face of the wood.

This picture shows an end view of the T-nut installed ush to the wood.

WARNING: DO NOT EMBED THE TOP

OF THE T-NUT INTO THE

FACE OF 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.

THE T-NUT HAS A BARREL SHAPED END WHICH GOES INTO THE HOLE IN THE CORNER POST. THE T-NUT ALSO HAS AN FLANGE SHAPED END WITH TEETH. THE TEETH PENETRATE INTO THE CORNER POST WOOD TO PREVENT THE T-NUT FROM SPINNING WHEN YOU TIGHTEN THE HEX HEAD BOLT.

SHOWN BELOW YOU WILL SEE THE T-NUT IS HAMMERED INTO THE CORNER POST ON THE BACK SIDE. THE BOARD IS BEING ATTACHED ON THE FRONT SIDE OF THE CORNER POST.

CORNER POST

BOARD YOU ARE ATTACHING TO CORNER POST.

HEX HEAD BOLT

T-NUT FLANGE IS HERE.

WASHER

BOARD YOU ARE ATTACHING TO CORNER POST.

CORNER POST

HEX HEAD BOLT

FRONT SIDE OF CORNER POST

T-NUT

WASHER

BACK SIDE OF CORNER POST

TEETH

CROSS SECTION VIEW OF BOARD, CORNER POST AND FASTENERS.

T-NUT DETAILS

FLANGE SHAPED END WITH TEETH

THREADS ON INSIDE OF BARREL .

BARREL SHAPED END GOES INTO HOLE IN CORNER POST.

DETAIL A

SCALE 2 : 1

Page 19

BOARD IDENTIFICATION

1. On the end of each board there should be a small white tag that is stapled into place.

2. This white identifcation tag displays the thickness, width, length and an abbreviated description of the part.

Example: a tag reads "2-4-3600-BPB"

The 2 is the thickness of the board. "Nominal Lumber" at a home center will measure 1-• 1/2" for the thickness. We "remill" that lumber to 1-3/8" thick.

The 4 is the width of the board. "Nominal Lumber" at a home center will measure 3-• 1/2" for the width. We "remill" that lumber to 3-3/8" wide. Note: sometimes the width will be smaller than 3-3/8" because: A) We need the width of the part to fit into a certain area of the play set. B) We need the designation to be simple.

The 3600 is the length of the board. It means the board is 36 inches long. If the code • were 3625 then the board is 36-1/4" in length.

The "BPB" abbreviation stands for "Bottom Panel Board". The wood part bill of materials • in the instructions has a description which will match the abbreviation closely.

In the event that there is no tag on a wood part measure the part then:• A)Use the measurements and compare them to the wood list at the front of the instructions to identify it. B)Look at the holes on the wood part and compare them to the pictures in the wood list. C)Look to see if the holes are centered or if they are offset up or offset down. This should help you identify any parts that have missing tags. In the event that you cannot identify a board please email us for assistance.

36" LENGTH

THICKNESS

" WIDTH

TAG

2-4-3600-BPB

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.

Pay attention to the DIAMETER of the lag screw you are installing. Your playset may come with two different diameter lag screws. Each diameter will require a different size drill bit. When installing lag screws DO NOT OVERTIGHTEN.

LAG SCREW DIAMETER DRILL BIT SIZE

" 3

Corner Post

5/16" DIAMETER 9/64"

3/8" DIAMETER 11/64"

Example: 3/8" diameter x 3-1/2" lag screw

This would be like the 2 x 4 board installation shown below. Place the board into position. Spot Drill through the holes in the 2 x 4 board into the corner posts with an 11/64" drill bit. Remove the 2 x 4 board. Continue to drill the holes to a total depth of 2-5/16" as shown at the right. Install the 2 x 4 board.

Example 5/16" diameter x 3-1/2" lag screw

This would be like the 2 x 4 board installation shown below. Place the board into position. Spot Drill through the holes in the 2 x 4 board into the corner posts with an 9/64" drill bit. Remove the 2 x 4 board. Continue to drill the holes to a total depth of 2-5/16" as shown at the right. Install the 2 x 4 board.

2 x 4 board

Example 3/8" diameter x 5" lag screw

This would be like the 4 x 4 board installation shown below. Place the board into position. Spot drill through the holes in the 4 x 4 board into the corner posts with an 11/64" drill bit. Remove the 4 x 4 board. Continue to drill the holes to a total depth of 2-13/16" as shown at the right. Install the 4 x 4 board.

Corner Post

Corner post

2 x 4 board

4 x 4 board

Corner Post

4 "

13 16

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.

2) The maximum allowable swinging weight at the Trapeze position is 125 lbs.

3) The MAXIMUM SWING BEAM LOAD IS 425 lbs.

MAXIMUM SWING BEAM LOAD IS 425 LBS.

THIS END OF SWING BEAM IS ATTACHED TO PLAY SET.

SWINGING WEIGHT

125 LBS MAX150 LBS MAX

SWINGING WEIGHT

TRAPEZE BAR

150 LBS MAX

SWINGING WEIGHT

SWING BELT SWING BELT

Page 22

Please familiarize yourself with the manual, parts/components and general

construction process of your new playset before getting started.

SITE PLAN:

20'-7 7/8"

8'-0"

9'-9

1'-6

3'-1

Ladder

10'-0"

Glider Swing Trapeze SwingSwing Belt

3'-11

3'-2"

14'-3

Bench with

Umbrella and Serving

Rock

7 8

Wall

" 1'-11

7'-2

15 16

Window

Wave Slide

Playset height: 11 feet - 4-3/4 inches Deck height: 5 feet Deck Size: 4 feet x 6 feet Enclosed bottom - Playhouse Area: 4 feet x 3 feet Swing Beam height: 7 feet - 7-1/4 inches

Approximate assembly time:16 to 24 hours

(6) foot unobstructed safety perimeter around playset recommended

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) ___ Hammer

___ Pencil ___ Locking Pliers (Vise Grips) ___ Shovel

KIT CONTENTS

Swings, Slides, Accessories:

___ (Qty ) Description ___ (1) Swingbelt w/ Chains ___ (1) Trapeze w/ Chains ___ (1) Glider w/Chains ___ (1) Wave Slide ___ (1) Telescope

___ (1) Green Crown ___ (2) Flag Kit

___ (1) Ground Stakes (pair) ___ (10) Climbing Rocks ___ (1) Tic Tac Toe ___ (1) Steering Wheel

___ (2) Safety Handles ___ (1) Telephone ___ (1) Dinner Bell ___ (1) Lemonade Stand Sign ___ (4) Window ___ (1) Umbrella

Fort Hardware:

see following pages

Swing Beam Hardware:

see following pages

Wood Components:

see following pages

Page 24

#8 X 1-1/4"

WOOD SCREW

QTY: 84

#8 X 1-1/2"

WOOD SCREW

QTY: 116

#8 X 1-3/4"

WOOD SCREW

QTY: 162

#8 X 2"

WOOD SCREW

QTY: 330

#8 X 2-1/2"

WOOD SCREW

QTY: 52

#8 X 3"

WOOD SCREW

QTY: 16

11-0055

2300 HARDWARE

PAGE 1 OF 2

REV C: 4/11/2014 JH

5/16" X 5/8" L TEE NUT

QTY: 48

TORQUE WASHER

QTY: 17

3/8" LOCK NUT

QTY: 19

3/8" WASHER

QTY: 31

5/16" WASHER

QTY: 91

5/16 X 4-1/2"

HEX BOLT

QTY: 40

5/16 X 1-1/2"

HEX BOLT

QTY: 8

#14 X 1-1/4"

PAN HEAD SCREW

QTY: 4

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 25

11-0055

2300 HARDWARE

PAGE 2 OF 2

REV C: 4/11/2014 JH

3/8 x 3-1/2"

LAG SCREW

QTY: 12

5/16 x 3-1/2" LAG SCREW

QTY: 40

3/8 x 9"

CARRIAGE BOLT

QTY: 1

3/8 x 7"

CARRIAGE BOLT

3/8 x 6-1/2"

CARRIAGE BOLT

QTY: 2

3/8 x 3-1/2"

CARRIAGE BOLT

QTY: 2QTY: 14

#2 SQUARE

DRIVE TIP

QTY:1

PLASTIC

BOLT CAP

QTY: 19

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 26

DESCRIPTIONPICTURE QTY.

5/4 X 2 X 9"

LOWER ROOF

RAY SUN

125-2-0900-LRRS

5/4 X 2 X 10"

UPPER SMALL

RAY

125-2-1000-USR

5/4 X 2 X 15"

LOWER ROOF

RAY SUN

125-2-1500-LRRS

5/4 X 2 X 16"

UPPER LARGE

RAY

125-2-1600-ULR

5/4 X 3 X 17-1/2"

TIC TAC TOE

125-3-1750-TTTM

5/4 X 3 X 18-3/4"

LADDER BACK

125-3-1875-LB

2 MOUNT

5/4 X 3 X 23-7/8"

ROCK WALL CAP

125-3-2376-RWC

Page 27

DESCRIPTIONPICTURE QTY.

5/4 X 3 X 42"

UPPER SUN

SUPPORT

125-3-4200-USS

5/4 X 4 X 38-1/2"

LOWER ROOF

SUN SUPPORT

125-4-3850-LRSS

5/4 X 4 X 40-3/8"

DECK SPACER

125-4-4038-DS

5/4 X 5 X 40-3/8"

DECK BOARD

MIDDLE

125-5-4038-DBM

5/4 X 5 X 47-1/8"

DECK BOARD

125-5-4713-DB

5/4 X 6 X 10" ROOF PEAK

SUPPORT

125-6-1000-RPS

5/4 X 6 X 14"

PICNIC TABLE

LEG BRACE

125-6-1400-PTLB

Page 28

DESCRIPTIONPICTURE QTY.

5/4 X 6 X 23-7/8"

BOTTOM ROCK

WALL BOARD

125-6-2388-BRWB

5/4 X 6 X 23-7/8"

ROCK WALL

BOARD

125-6-2388-RWB

5/4 X 6 X 28-1/2"

PANEL SLAT

125-6-2850-PS

5/4 X 6 X 47-3/8"

PICNIC TABLE

TOP BOARD

125-6-4738-PTTB

5/4 X 6 X 47-1/2"

PICNIC TABLE

WALL BOTTOM

125-6-4750-PTWB

5/4 X 6 X 47-1/2"

PICNIC TABLE

WALL TOP

125-6-4750-PTWT

5/4 X 6 X 50"

PICNIC TABLE

SEAT

125-6-5000-PTS

Page 29

DESCRIPTIONPICTURE QTY.

1 X 3 X 10"

DOOR SUPPORT

1-3-1000-DS

1 X 3 X 18"

WALL PANEL

BRACE

1-3-1800-WPB

1 X 3 X 29-1/2"

WALL PANEL

2BRACE

1-3-2950-WPB

1 X 3 X 40"

WALL PANEL

BRACE

1-3-4000-WPB

1 X 4 X 11-1/2"

UPPER WALL

PANEL BOARD

1-4-1150-UWPB

1 X 4 X 36-5/8"

UPPER ROOF

FINISHER

1-4-3663-URF

1 X 4 X 36-5/8"

UPPER ROOF

STARTER

1-4-3663-URS

Page 30

DESCRIPTIONPICTURE QTY.

1 X 4 X 38"

LOWER ROOF

STARTER

1-4-3800-LRS

1 X 4 X 51-1/2"

WALL PANEL

2BOARD

1-4-5150-WPB

1 X 5 X 25"

UPPER WALL

PANEL BOARD

1-5-2500-UWPB

1 X 5 X 36-5/8"

UPPER ROOF

PEAK

1-5-3663-URP

1 X 5 X 38"

LOWER ROOF

PEAK

1-5-3800-LRP

1 X 5 X 51-1/2"

WALL PANEL

BOARD

1-5-5150-WPB

1 X 6 X 6"

WALL PANEL

BOARD DOOR 2

1-6-0600-WPBD2

Page 31

DESCRIPTIONPICTURE QTY.

1 X 6 X 7"

WALL PANEL

BOARD

1-6-0700-WPB

1 X 6 X 7"

WALL PANEL

BOARD DOOR 1

1-6-0700-WPBD1

1 X 6 X 11-1/2"

UPPER WALL

PANEL BOARD

1-6-1150-UWPB

1 X 6 X 25"

ARCH DOOR

BOARD

1-6-2500-ADB

1 X 6 X 29-5/8"

WALL PANEL

BOARD

1-6-2963-WPB

1 X 6 X 36-5/8"

UPPER ROOF

BOARD

1-6-3663-URB

1 X 6 X 38"

LOWER ROOF

BOARD 8

1-6-3800-LRB

Page 32

DESCRIPTIONPICTURE QTY.

1 X 6 X 38"

LOWER ROOF

FINISHER

1-6-3800-LRF

1 X 6 X 51-1/2"

WALL PANEL

BOARD DOOR

1-6-5150-WPBD

1 X 6 X 51-1/2"

WALL PANEL

BOARD

1-6-5150-WPB

2 X 4 X 11" PICNIC TABLE SEAT SUPPORT

2-4-1100-PTSS

2 X 4 X 15"

PICNIC TABLE SEAT

ANGLE SUPPORT

2-4-1500-PTSAS

2 X 4 X 17"

LADDER STEP

2-4-1700-LS

2 X 4 X 17-1/2" PICNIC TABLE

UMBRELLA

SUPPORT

2-4-1750-PTUS

Page 33

DESCRIPTIONPICTURE QTY.

2 X 4 X 18"

ANGLE SUPPORT

2-4-1800-AS

2 X 4 X 18-1/2"

PICNIC TABLE LEG

2-4-1850-PTL

2 X 4 X 25"

VERTICAL LOWER

2ROOF SUPPORT

2-4-2500-VLRS

2 X 4 X 30-1/8"

LOWER ROOF

2-4-3013-LRS

2 X 4 X 35-1/4"

UPPER ROOF

SUPPORT LEFT

2-4-3524-URSL

2 X 4 X 35-1/4"

UPPER ROOF

SUPPORT RIGHT

4SUPPORT

2-4-3524-RSR

2 X 4 X 36-1/2"

WALL PANEL

BOARD

2-4-3650-WPB

Page 34

DESCRIPTIONPICTURE QTY.

2 X 4 X 36-5/8" LOWER ROOF

SUPPORT LEFT

2-4-3663-LRSL

2 X 4 X 36-5/8"

LOWER ROOF

SUPPORT RIGHT

2-4-3663-LRSR

2 X 4 X 47-1/4"

BOTTOM PANEL

BOARD DOOR

2-4-4725-BPBD

2 X 4 X 47-1/2"

TOP WALL

PANEL BOARD

2-4-4750-TWPB

2 X 4 X 47-1/2"

BOTTOM BOARD

2-4-4750-BB

2 X 4 X 58"

SWING CROSS

MEMBER

2-4-5800-SCM

2 X 4 X 66"

LADDER LEFT

SIDE

2-4-6600-LLS

Page 35

DESCRIPTIONPICTURE QTY.

2 X 4 X 66"

LADDER

RIGHT SIDE

2-4-6600-LRS

2 X 4 X 66"

ROCK WALL

SIDE

2-4-6600-RWS

2 X 4 X 70"

CENTER DECK

SUPPORT

2-4-7000-CDS

2 X 4 X 70"

DECK SUPPORT

2-4-7000-DS

2 X 4 X 96" SANDBOX

BOARD LEFT

2-4-9600-SBL

2 X 4 X 96"

SANDBOX

BOARD RIGHT

2-4-9600-SBR

2 X 5 X 5-3/8"

PICNIC TABLE

SUPPORT

2-5-0538-PTS

Page 36

DESCRIPTIONPICTURE QTY.

2 X 6 X 16"

SUN

2-6-1600-S

2 X 6 X 43-1/8"

UNDER SUN

SUPPORT

2-6-4313-USS

2 X 6 X 47-1/4"

BOTTOM

SANDBOX

BOARD

2-6-4725-BSB

2 X 6 X 47-1/2"

END SANDBOX/

PANEL BOARD

2-6-4750-ESPB

2 X 6 X 70"

BACK TOP

PANEL BOARD

2-6-7000-BTPB

2 X 6 X 70"

BACK FACE

BOARD

2-6-7000-BFB

2 X 6 X 70"

FRONT FACE

BOARD

2-6-7000-FFB

Page 37

DESCRIPTIONPICTURE QTY.

2 X 6 X 70"

FRONT TOP

1PANEL BOARD

2-6-7000-FTPB

4 X 4 X 47-1/2"

SWING BEAM

MOUNT

4-4-4750-SBM

4 X 4 X 86-1/8"

CORNER POST

RIGHT

4-4-8613-CPR

4 X 4 X 108"

SWING LEGS

4-4-10800-SL

4 X 4 X 110"

CORNER POST

LEFT

4-4-11000-CPL

4 X 4 X 110"

CORNER POST

MIDDLE

4-4-11000-CPM

4 X 6 X 120"

SWING BEAM

4-6-12000-SB

Page 38

DESCRIPTIONPICTURE QTY.

WAVE

SLIDE

03-0013

GLIDER

04-0020

TELESCOPE

07-0001

CROWN

07-0019

90 GREEN

BRACKET

11-5013

Page 39

DESCRIPTIONPICTURE QTY.

SPRING

CLIP

11-4003

IRON

DUCTILE

SWING

HANGER

11-4012

FLAG KIT

09-1014

GROUND

STAKE (2

STAKES

ARE IN

ONE BAG)

07-0016

Page 40

DESCRIPTIONPICTURE QTY.

UNASSEMBLED

DORMER

(110 BOX OR

1513 BOX)

UNASSEMBLED

CHIMNEY

1513 BOX)

SWING

W/CHAINS

04-0002

1(110 BOX OR

TRAPEZE

BAR

W/CHAINS

04-0006

Page 41

DESCRIPTIONPICTURE QTY.

SWING

PLATE

11-5002

CLIMBING

ROCK

(5 ROCKS

ARE IN

ONE

BAG)

07-0008

ROCKS

HARDWARE BOX: 2300

A-FRAME

SWING

LEG

BRACKET

11-5010

HARDWARE

BOX

11-0055

Page 42

(NOT SHOWN)

DESCRIPTIONPICTURE QTY.

MANUFACTURER

LOGO PLATE

TIC TAC TOE

1(UNASSEMBLED)

07-0010

STEERING

WHEEL

07-0004

SAFETY

HANDLE

(2 HANDLES

ARE IN

ONE BAG)

07-0005

TELEPHONE

07-0014

Page 43

DESCRIPTIONPICTURE QTY.

DINNER BELL

09-0001

LEMONADE

STAND

SIGN

07-0024

WINDOW

07-0013

10'

ROCK

WALL

ROPE

Page 44

DESCRIPTIONPICTURE QTY.

UMBRELLA

09-0013

Page 45

STEP 1: CORNER POST LAYOUT

1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO DIS-ASSEMBLE AND THE RE-ASSEMBLE TO MAKE YOUR CORRECTIONS.

2: LAY OUT EACH OF THE 4 X 4 X 86-1/8" CORNER POST RIGHT, 4 X 4 X 110" CORNER POST MIDDLE AND 4 X 4 X 110" CORNER POST LEFT IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE PLAYSET.

3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POST SHOULD FACE.

NOTE: THE SLIDE SIDE IS CONSIDERED THE FRONT OF THE PLAYSET WITH THE SWINGBEAM EXTENDING OFF THE LEFT SIDE.

4 X 4 X 110" CORNER POST LEFT

FRONT OF PLAYSET

4 X 4 X 110"

CORNER POST

MIDDLE

4 X 4 X 86-1/8" CORNER POST

RIGHT

Page 46

STEP 2: INSERTING T-NUTS INTO CORNER POSTS

1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH TO

THE CORNER POSTS.

NO T-NUT IN THESE HOLES

T-NUT

4 X 4 X 110"

CORNER POST

LEFT

FRONT OF FORT

4 X 4 X 110"

CORNER POST

MIDDLE

4 X 4 X 86-1/8"

CORNER POST

RIGHT

Page 47

STEP 3: ASSEMBLING THE RIGHT SIDE FRAME

1: LAY THE 2 X 6 X 47-1/4" BOTTOM SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST 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 THET-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.

3: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN.

4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM HOLES OF THE BOTTOM PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE TOP HOLES WILL BE USED LATER.

5: LAY THE 2 X 6 X 47-1/2" TOP PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS. THE HOLES IN THE TOP PANEL BOARD MUST BE OFFSET DOWN.

6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE TOP PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.

7: DO NOT INSTALL LAG SCREWS AT THIS TIME.

2 X 6 X 47-1/2" TOP PANEL BOARD (OFFSET DOWN)

5/16" WASHER

4 X 4 X 86-1/8" CORNER POST RIGHT

5/16" X 4-1/2"HEX BOLT

2 X 6 X 47-1/2" BOTTOM PANEL BOARD (OFFSET DOWN)

FRONT OF FORT

2 X 6 X 47-1/4" BOTTOM SANDBOX BOARD (OFFSET DOWN)

Page 48

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 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF

THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN. 3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD

TO THET-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER. 4: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS IN THE MIDDLE

OF THE CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN. 5: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM HOLES OF THE BOTTOM PANEL

BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE TOP HOLES WILL BE USED LATER. 6: LAY THE 4 X 4 X 47-1/2" SWING BEAM MOUNT ON TOP OF THE LEFT SIDE CORNER POSTS. THE THREE

COUNTER-SUNK HOLES IN THE MIDDLE OF THE SWING BEAM SUPPORT MUST FACE DOWNWARD. 7: FIND TWO TORQUE WASHERS. PLACE A 6-1/2" CARRIAGE BOLT THROUGH THE TORQUE WASHER,

MAKING SURE THAT THE TEETH ARE FACING IN THE SAME DIRECTION AS THE THREADS OF THE CARRIAGE BOLT. PLACE THE TORQUE WASHER/CARRIAGE BOLT ASSEMBLY INTO THE CORNER POST HOLES SO THAT THE HEAD OF THE CARRIAGE BOLT FACES WHAT WILL BE THE INSIDE OF THE FORT. USE A HAMMER TO SET THE TORQUE WASHER INTO THE CORNER POST.

8: ATTACH THE SWING BEAM SUPPORT AS SHOWN IN DETAIL A.

4 X 4 X 47-1/2" SWING BEAM MOUNT

DETAIL A

SCALE 2 : 19

TORQUE WASHER

6-1/2" CARRIAGE BOLT

3/8" WASHER

3/8" NUT

BOLT CAP

2 X 6 X 47-1/2" BOTTOM PANEL BOARD (OFFSET DOWN)

5/16 X 4-1/2" HEX BOLT

5/16" WASHER

2 X 6 X 47-1/2" SANDBOX BOARD (OFFSET DOWN)

4 X 4 X 110" CORNER POST LEFT

THE THREE COUNTER-SUNK HOLES ON THE SWING BEAM SUPPORT WILL FACE DOWN WHEN PROPERLY INSTALLED.

FRONT OF FORT

Page 49

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" WASHERS FROM THE INSIDE OF THE FORT

5/16" WASHER

5/16 X 4-1/2" HEX BOLT

2 X 4 X 70" DECK SUPPORT COUNTER-SUNKHOLES ON CENTER

Page 50

STEP 6: MIDDLE CORNER POST

1: PLACE THE 4 X 4 X 110" CORNER POST MIDDLE BETWEEN THE LEFT AND RIGHT SIDE FRAMES . 2: USE A 5/16 X 4-1/2" HEX BOLT AND A 5/16" WASHER THROUGH THE DECK SUPPORT AND

POSTS HOLE INTO THE T-NUT TO ATTACH THEM.

5/16" WASHER

5/16 X 4-1/2" HEX BOLT

LEFT SIDE OF THE SET

T-NUT

RIGHT SIDE OF THE SET

4 X 4 X 110" CORNER POST MIDDLE

FRONT OF FORT

Page 51

STEP 7: FRONT FRAME ASSEMBLY

1: PLACE THE 2 X 4 X 96" SANDBOX BOARD LEFT ON THE FRONT OF THE CORNER POSTS. THE CENTER HOLE IN THE SANDBOX BOARD LEFT SHOULD BE OFFSET UP.

2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE HOLES OF THE SANDBOX BOARD LEFT TO THE T-NUTS INSTALLED ON THE CORNER POSTS.

3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT FACE BOARD SHOULD BE OFFSET UP.

4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE FRONT FACE BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.

5: PLACE THE 2 X 6 X 70" FRONT TOP PANEL BOARD ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE FRONT TOP PANEL BOARD SHOULD BE OFFSET UP.

6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE FRONT TOP PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.

2 X 6 X 70" FRONT TOP PANEL BOARD

2 X 6 X 70" FRONT FACE BOARD

5/16 X 4-1/2" HEX BOLT

5/16" WASHER

2 X 4 X 96" SANDBOX BOARD LEFT

5/16" WASHER

5/16 X 4-1/2" HEX BOLT

Page 52

STEP 8: REAR FRAME ASSEMBLY

1: PLACE THE 2 X4 X 96" SANDBOX BOARD RIGHT ON THE BOTTOM REAR OF THE CORNER POSTS. THE CENTER HOLE IN THE SANDBOX BOARD RIGHT MUST BE OFFSET UP.

2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE HOLES OF THE SANDBOX BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.

3: PLACE THE 2 X 6 X 70" BACK FACE BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN THE BACK FACE BOARD MUST BE OFFSET UP.

4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE BOTTOM PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.

5: PLACE THE 2 X 6 X 70" BACK TOP PANEL BOARD NEAR THE TOP OF THE REAR CORNER POSTS. THE HOLES IN THE BACK TOP PANEL BOARD MUST BE OFFSET UP.

6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE HOLES OF THE BACK TOP PANEL BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS.

2 X 6 X 70" BACK TOP PANEL BOARD

2 X 6 X 70" BACK FACE BOARD

5/16" WASHER

5/16 X 4-1/2" HEX BOLT

2 X 4 X 96" SANDBOX BOARD RIGHT

REAR OF FORT

5/16 X 4-1/2" HEX BOLT

RIGHT SIDE OF FORT

5/16" WASHER

Page 53

STEP 9: 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. THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS.

2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU LIFT THE FRAME AS REQUIRED. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE FRAME HAS BEEN LEVELED AND SQUARED.

3: ONCE THE FRAME IS LEVEL, SQUARE AND SET INTO POSITION; GO BACK AND INSERT THE 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS IN ALL OF THE REMAINING HOLES OF THE 2 X 6 PARTS ON THE FRONT, SIDES AND REAR OF THE PLAY SET. NOTE: THERE WILL NOT BE ANY PREDRILLED HOLES IN THE CORNER POSTS FOR THE LAG SCREWS.

***IMPORTANT*** SQUARE BOARDS TO POSTS;THEN INSTALL LAG SCREWS AND WASHERS ONLY IN THESE FOUR 2 X 6 BOARDS FIRST. THEN LEVEL/SQUARE THE FRAME. FINALLY, INSTALL LAG SCREWS IN THE REMAINING 2 X 6 BOARDS.

5/16" WASHER

5/16 X 3-1/2" LAG SCREW

Page 54

STEP 10: BOTTOM BOARDS

1: PLACE THE 2 X 4 X 47-1/2" BOTTOM BOARDS ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP ON RIGHT AND LEFT SIDE OF THE SET, FASTEN TO THE CORNER POSTS WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.

2 X 4 X 47-1/2" BOTTOM BOARD (OFFSET HOLES UP)

5/16" WASHER

5/16" X 3-1/2" LAG SCREW

FRONT OF FORT

Page 55

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 AND INTO THE DECK SUPPORT BELOW. NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER.

5/4 X 4 X 40-3/8" DECK SPACER

2" WOOD SCREW

FRONT OF FORT

NOTE: THE RIGHT BOTTOM BOARD IS REMOVED FOR CLARITY.

RIGHT SIDE OF FORT

Page 56

STEP 12: CENTER DECK SUPPORT

1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES. 2: PLACE THE CENTER DECK SUPPORT UNDER 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.

3: CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT ON THE LINE AND PUSH THE CENTER DECK SUPPORT FLUSH TO THE BOTTOM SIDE OF THE DECK SPACERS. USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT.

4: USING TWO 2-1/2" WOOD SCREWS, ATTACH THE 2 X 4 X 70" CENTER DECK SUPPORT THROUGH THE OUTSIDE OF THE 2 X 6, AND INTO THE END OF THE CENTER DECK SUPPORT. REPEAT THIS STEP ON THE OPPOSITE END OF THE FORT.

2 X 4 X 70" CENTER DECK SUPPORT

2" WOOD SCREW

USE 2-1/2" WOOD SCREWS IN THESE LOCATIONS ON EACH SIDE.

DRAW CENTER LINE HERE USING THE MIDDLE DECK SPACER HOLE AS AGUIDE.

NOTE:THE RIGHT 2 X 4 BOTTOM BOARD IS REMOVED FOR CLARITY.

Page 57

STEP 13: DECK BOARDS

1: START WITH A 5/4 X 5 X 47-1/8" DECK BOARD AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE FRONT FACE BOARD AND THE REAR BOTTOM BOARD AND PLACE 5/4 X 5 X 40-3/8" DECK BOARD MIDDLE BETWEEN THE CORNER POST MIDDLE AND ATTACH THE DECK BOARDS WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES AND INTO THE DECK SUPPORT BELOW. LEAVE A UNIFORM (APPROX. 1/8") SPACE BETWEEN THE DECK BOARDS. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK BOARDS.

LAY ALL DECK BOARDS ACROSS THE DECK SUPPORTS BEFORE SECURING THEM TO THE FORT. THIS WILL ENSURE THAT YOU HAVE EQUAL SPACING ACROSS THE DECK.

5/4 X 5 X 40-3/8" DECK BOARD MIDDLE

5/4 X 5 X 47-1/8" DECK BOARD

2" WOOD SCREW

Page 58

STEP 14: BOTTOM PANEL BOARD DOOR

1: FASTEN THE 2 X 4 X 47-1/4" BOTTOM PANEL BOARD DOOR (OFFSET DOWN) TO THE CORNER POSTS MIDDLE. USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM PANEL BOARD DOOR.

FRONT OF FORT

5/16" WASHER

5/16 X 4-1/2" HEX BOLT

2 X 4 X 47-1/4" BOTTOM PANEL BOARD DOOR (OFFSET DOWN)

Page 59

STEP 15: WALL PANEL BOARDS

1: PLACE THE 2 X 4 X 36-1/2" WALL PANEL BOARDS UNDER OF THE 2 X 6 X 70" FRONT FACE BOARD AND 2 X 6 X 70" BACK FACE BOARD. FASTEN TO THE CORNER POSTS LEFT AND CORNER POSTS MIDDLE WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.

2: PLACE THE 2 X 4 X 47-1/2" TOP WALL PANEL BOARDS UNDER THE 2 X 6 X 47-1/2" PANEL BOARD AND 2 X 4 X 70" DECK SUPPORTS. FASTEN TO THE CORNER POSTS LEFT AND CORNER POSTS MIDDLE WITH 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS.

2 X 4 X 36-1/2" WALL PANEL BOARD

5/16" WASHER

5/16 X 3-1/2" LAG SCREW

2 X 4 X 47-1/2" TOP WALL PANEL BOARD

Page 60

STEP 16: 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

DETAIL A

SCALE 1 : 3

2 X 4 X 66"

ROCK WALL

SIDES

Page 61

STEP 17: 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" WOOD SCREWS IN EACH SIDE.

3: CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS, FASTENING EACH BOARD WITH TWO 2" WOOD SCREWS ON EACH END.

4: THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE. ATTACH WITH TWO 2" WOOD SCREWS PER SIDE.

5: IN SOME CASES, THERE WILL BE EXCESS LENGTH ON THE ROCK WALL SIDES. THIS IS DUE TO MILLING VARIATIONS, AND IS ALSO USED TO HELP LEVEL THE ROCK WALL SIDES ON UNEVEN GROUND.

6: ROCK WALL SIDES MAY NOT BE EVEN WITH THE BOTTOM ROCK WALL BOARD DUE TO MILLING VARIATIONS AND WOOD SHRINKAGE.

5/4 X 6 X 23-7/8" ROCK WALL BOARD

TOP IS FLUSH TO ENDS OF SIDES.

2" WOOD SCREW

5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD

Page 62

STEP 18: 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.

90 GREEN BRACKET

5/16" WASHER

5/16" X 1-1/2"

HEX BOLT

DETAIL A

SCALE 1 : 4

Page 63

STEP 19: ROCK WALL

1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS. 2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE

PAN HEAD SCREWS AND WASHERS WILL SECURE EACH ROCK TO THE WALL. NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE

ROCK WALL. YOUR ACTUAL CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT. BE CREATIVE!

1-1/4" PAN HEAD SCREW

WASHER

CLIMBING ROCKS

3: PLACE THE 5/4 X 3 X 23-7/8" ROCK WALL TOP CAP ON TOP OF THE ROCK WALL SIDES. FASTEN THE ROCK WALL TOP CAP TO THE ROCK WALL SIDES WITH 2" WOOD SCREWS.

2" WOOD SCREW

5/4 X 3 X 23-7/8" ROCK WALL TOP CAP

Page 64

STEP 20: ATTACHING THE ROCK WALL

1: PLACE THE ROCK WALL INTO POSITION CENTERED ON THE FRONT - LEFT CUT OUT AREA OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE FRONT FACE BOARD.

2: GO UNDERNEATH THE DECK TO INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE FRONT FACE BOARD.

3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS. 4: WHEN THE BRACKETS ARE SECURE, AND THE ROCK WALL IS IN ITS FINAL POSITION; TIGHTEN THE

5/16 X 1-1/2” BOLTS ON THE ROCK WALL SIDES.

ROCK WALL (CENTER IT IN THE CUT OUT AREA OF THE FRONT FACE BOARD.)

5/16" WASHER

5/16" X 1-1/2" HEX BOLT

T-NUT

Page 65

STEP 21: LADDER

1: FIND TWO 2 X 4 X 66" LADDER SIDES. 2: POSITION THE LADDER SIDES SO THAT THE

SLOTS IN THE BOARDS ARE FACING EACH OTHER AND ARE PARALLEL.

3: INSERT T-NUTS INTO THE

OUTSIDE

OF THE

LADDER SIDES AND SET WITH A HAMMER.

2" WOOD SCREW

2 X 4 X 17" LADDER STEP

2 X 4 X 66" LADDER SIDE

T-NUT

4: FIND FIVE 2 X 4 X 17" LADDER STEPS. 5: PLACE THE STEPS INTO THE SLOTS ON THE

LADDER SIDES, AND FASTEN WITH 2" WOOD SCREWS.

5/16 X 1-1/2" HEX BOLT

5/16" WASHER

90 ANGLE BRACKET

8: INSTALL THE 5/4 X 3 X 18-3/4" LADDER BACK ABOVE THE TOP STEP OF THE LADDER WITH TWO 2" WOOD SCREWS PER SIDE.

6: CAREFULLY TURN THE LADDER OVER AND PUT THE SCREWS INTO THE OTHER SIDE.

7: INSTALL THE 90 INSIDE OF THE LADDER RAILS WITH 5/16 X 1-1/2" BOLTS, 5/16 WASHERS, INTO THE 5/16" T-NUTS.

2" WOODSCREW

ANGLE BRACKETS TO THE

5/4 X 3 X 18-3/4" LADDER BACK

Page 66

STEP 22: LADDER TO FORT

1: PLACE THE LADDER INTO POSITION CENTERED ON THE REAR - LEFT CUT OUT AREA OF THE FORT AS SHOWN BELOW. THE GREEN BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE BACK FACE BOARD. USING THE 90 GREEN BRACKETS AS A TEMPLATE; DRILL A 3/8" HOLE THROUGH THE FRONT FACE BOARD.

2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACK SIDE OF THE 3/8" HOLES IN THE BACK FACE BOARD.

3: ATTACH THE LADDER WITH 5/16" X 1-1/2" HEX BOLTS AND 5/16" WASHERS. 4: WHEN THE BRACKETS ARE SECURE AND THE LADDER IS IN ITS FINAL POSITION, TIGHTEN THE

5/16" X 1-1/2" BOLTS ON THE LADDER SIDES.

BRACKET

5/16" WASHER

5/16 X 1-1/2 HEX BOLT

BACK FACE BOARD

Page 67

STEP 23: ANGLE SUPPORTS

1: TWO 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE RIGHT SIDE OF THE PLAY SET TO THE 2 X 6 PANEL BOARD. THE TOP OF THE ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT

2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE ANGLE SUPPORTS INTO THE PANEL BOARD. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE CORNER POST.

2 X 6 X 47-1/2" PANEL BOARD

2-1/2" WOOD SCREW

2 X 4 X 18" ANGLE SUPPORT

3" WOOD SCREW

2" WOOD SCREW

ANGLE SUPPORT

FRONT OF THE FORT

RIGHT SIDE OF THE FORT

Page 68

STEP 24: ATTACHING PICNIC TABLE WALL BOARD

1: PLACE THREE 5/4 X 6 X 47-1/2" PICNIC TABLE WALL BOTTOM (WITH FOUR HOLES)ON TOP OF THE 2 X 6 BOTTOM SANDBOX BOARD ON THE RIGHT SIDE OF THE FORT. FASTEN TO THE CORNER POSTS RIGHT WITH #8 X 2" WOOD SCREWS AS SHOWN BELOW.

2: PLACE THE 5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP (WITH TEN HOLES)ON TOP OF THE 5/4 X 6 X 47-1/2" PICNIC TABLE WALL BOTTOM. FASTEN TO THE CORNER POSTS RIGHT WITH #8 X 2" WOOD SCREWS AS SHOWN BELOW.

5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP (WITH TEN HOLES)

2" WOOD SCREW

5/4 X 6 X 47-1/2" PICNIC TABLE WALL BOTTOM

2 X 6 X 47-1/2" BOTTOM SANDBOX BOARD

Page 69

STEP 25: PICNIC TABLE TOP BOARD

1: PLACE THE 5/4 X 6 X 47-3/8" PICNIC TABLE TOP BOARD (WITH NINE HOLES)HORIZONTALLY ON TOP OF THE 5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP. FASTEN TO THE 5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP WITH THREE #8 X 2" WOOD SCREWS. AS SHOWN BELOW.

#8 X 2" WOOD SCREW

5/4 X 6 X 47-3/8" PICNIC TABLE TOP BOARD

5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP

Page 70

STEP 26: PICNIC TABLE SUPPORT

1: PLACE THREE 2 X 5 X 6" PICNIC TABLE SUPPORTS AGAINST THE 5/4 X 6 X 47-3/8" PICNIC TABLE TOP BOARD AND THE 5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP. THE ANGLE SUPPORTS SHOULD BE CENTERED UNDER/BEHIND THE PRE-DRILLED HOLES . FASTEN THE 2 X 5 X 6" PICNIC TABLE SUPPORTS WITH #8 X 2" WOOD SCREWS.

5/4 X 6 X 47-3/8" PICNIC TABLE TOP BOARD

5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP

2 X 5 X 6" PICNIC TABLE SUPPORT

5/4 X 6 X 47-3/8" PICNIC TABLE TOP BOARD

2 X 5 X 6" PICNIC TABLE SUPPORT

5/4 X 6 X 47-1/2" PICNIC TABLE WALL TOP

#8 X 2" WOOD SCREW

Page 71

STEP 27: LEFT SIDE WALL BOARDS

1: FIND SIX 1 X 6 X 51-1/2" WALL PANEL BOARDS AND TWO 1 X 4 X 51-1/2" WALL PANEL BOARDS WITH PRE-DRILL HOLES.

2: PLACE WALL PANEL BOARDS ON THE LEFT SIDE OF THE FORT AGAINST THE TOP WALL PANEL BOARD AND SANDBOX BOARD AS SHOWN BELOW. THE BOTTOM OF THE WALL PANEL BOARDS SHOULD BE 1-1/8 " ABOVE THE BOTTOM OF THE SANDBOX BOARD.

3: ATTACH TO THE WALL PANEL BOARD AND SANDBOX BOARD USING #8 X 1-3/4" WOOD SCREWS LEAVING 1/4" SPACES BETWEEN THE BOARDS.

2 X 4 X 47-1/2" TOP WALL PANEL BOARD

1 X 4 X 51-1/2" WALL PANEL BOARD (TWO BOARDS)

1 X 6 X 51-1/2" WALL PANEL BOARD (SIX BOARDS)

#8 X 1-3/4" WOOD SCREW

DETAIL A

2 X 6 X 47-1/2" SANDBOX BOARD

NOTE: ROCK WALL REMOVED FOR CLARITY.

Page 72

STEP 28: ATTACHING WALL PANEL BRACE

1: PLACE THE 1 X 3 X 40" WALL PANEL BRACE AT CENTER OF THE WALL PANEL BOARDS. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS.

WALL BOARDS

# 8 X 1-1/4" WOOD SCREW

1 X 3 X 40" WALL PANEL BRACE

Page 73

STEP 29: FRONT AND REAR WALL PANEL BOARD

1: FIND FOUR 1 X 5 X 51-1/2" WALL PANEL BOARDS, TWO 1 X 6 X 29-5/8" WALL PANEL BOARDS AND TWO 1 X 6 X 7" WALL PANEL BOARDS WITH PRE-DRILLED HOLES.

2: PLACE WALL BOARDS INSIDE THE REAR OF THE FORT AGAINST THE WALL PANEL BOARD AND SANDBOX BOARD RIGHT AS SHOWN BELOW. THE BOTTOM OF THE WALL PANEL BOARDS SHOULD BE 1-1/8 " ABOVE THE BOTTOM OF THE SANDBOX BOARD RIGHT. THE DIMENSIONS FOR ATTACHING THE WINDOWS ARE SHOWN BELOW.

3: ATTACH THE WALL PANEL BOARDS USING #8 X 1-3/4" WOOD SCREWS LEAVING 1/4" SPACES BETWEEN THE BOARDS.

4: REPEAT SUBSTEPS 1-3 FOR THE FRONT SIDE OF THE FORT.

1 X 6 X 7" WALL PANEL BOARD

2 X 4 X 36-1/2" WALL PANEL BOARD

1 X 5 X 51-1/2"

WALL PANEL BOARD (FOUR BOARDS)

1 X 6 X 29-5/8" WALL PANEL BOARD

#8 X 1-3/4" WOOD SCREW

2 X 4 X 96" SANDBOX BOARD RIGHT

NOTE: ROCK WALL AND FRONT CORNER POST MIDDLE REMOVED FOR CLARITY.

DETAIL A

SCALE 1 : 17

Page 74

STEP 30: INSTALL WINDOWS

1: FIND TWO PLASTIC WINDOWS. PLACE EACH WINDOW ON THE FRONT AND REAR OF THE FORT IN THE OPENING WITH THE 1" WIDE SECTION OF THE WINDOW FRAME AT THE TOP. ATTACH EACH WINDOW WITH FOUR 1-1/4" WOOD SCREWS.

WINDOW

WIDE SECTION

IS THE TOP

Page 75

STEP 31: ATTACHING WALL PANEL BRACE

1: PLACE THE 1 X 3 X 29-1/2" WALL PANEL BRACE FLUSH WITH THE BOTTOM OF THE WINDOWS. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS.

2: PLACE THE 1 X 3 X 18" WALL PANEL BRACE FLUSH WITH THE TOP OF THE WINDOWS. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS.

3: REPEAT SUBSTEPS 1-2 FOR THE FRONT SIDE OF THE FORT.

1 X 3 X 18"

WINDOWS

WALL PANEL BOARD REAR SIDE OF THE FORT

WALL PANEL BRACE

1 X 3 X 29-1/2" WALL PANEL BRACE

# 8 X 1-1/4" WOOD SCREW

NOTE: ROCK WALL, FRONT CORNER POST MIDDLE AND FRONT WALL REMOVED FOR CLARITY.

Page 76

STEP 32: RIGHT SIDE WALL PANEL BOARD

1: FIND FOUR 1 X 6 X 51-1/2" WALL PANEL BOARDS, TWO 1 X 6 X 7" WALL PANEL BOARD DOOR 1 AND TWO 1 X 6 X 6" WALL PANEL BOARD DOOR 2 WITH PRE-DRILLED HOLES.

2: PLACE WALL BOARD BETWEEN THE CORNER POST MIDDLE AGAINST THE WALL PANEL BOARD AND 2 X 4 X 47-1/4" BOTTOM PANEL BOARD DOOR AS SHOWN BELOW. THE BOTTOM OF THE WALL PANEL BOARD SHOULD BE 1-1/8 " ABOVE THE BOTTOM OF THE 2 X 4 X 47-1/4" BOTTOM PANEL BOARD DOOR . USE #8 X 1-3/4" WOOD SCREWS .

3: PLACE WALL BOARD DOOR BETWEEN THE WALL BOARDS AGAINST THE WALL PANEL BOARD AS SHOWN BELOW. THE TOP OF THE WALL BOARD DOOR SHOULD BE FLUSH WITH TOP OF THE WALL BOARDS. USE #8 X 1-3/4" WOOD SCREWS LEAVING A 1/4" SPACE BETWEEN THE BOARDS.

1 X 6 X 7" WALL PANEL BOARD DOOR 1 (TWO BOARDS)

1 X 6 X 6" WALL PANEL BOARD DOOR 2 (TWO BOARDS)

1 X 6 X 51-1/2" WALL PANEL BOARD DOOR (FOUR BOARDS)

#8 X 1-3/4" WOOD SCREW

2 X 4 X 47-1/2" WALL PANEL BOARD

2 X 4 X 47-1/4" BOTTOM PANEL BOARD DOOR

NOTE: LEFT WALL AND FRONT WALL REMOVED FOR CLARITY.

Page 77

STEP 33: ATTACHING DOOR SUPPORTS

1: PLACE THE 1 X 3 X 10" DOOR SUPPORT CENTERED ON THE WALL PANEL BOARDS. FASTEN WITH #8 X 1-1/4" WOOD SCREWS.

2: PLACE THE 1 X 6 X 25" ARCH DOOR BOARD FLUSH WITH ARCH WALL PANEL BOARD DOOR. FASTEN WITH # 8 X 1-1/4" WOOD SCREWS.

1 X 6 X 25"

# 8 X 1-1/4" WOOD SCREW

ARCH DOOR BOARD

1 X 3 X 10" DOOR SUPPORT (TWO BOARDS)

# 8 X 1-1/4" WOOD SCREW

NOTE: LEFT WALL AND FRONT WALL REMOVED FOR CLARITY.

Page 78

STEP 34: PANEL SLATS

1: FIND THIRTEEN 5/4 X 6 X 28-1/2" 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.

5/4 X 6 X 28-1/2"

REAR SIDE OF THE FORT

SWING BEAM SIDE

PANEL SLAT

2" WOOD SCREW

RIGHT SIDE OF THE FORT

SWING BEAM SIDE

PANEL SLAT DIMENSIONS

(VIEW FROM OUTSIDE THE PLAY SET)

14"

12 "

RIGHT SIDE OF THE FORT

WALL PANEL SLAT DIMENSIONS

3 8

REAR SIDE OF THE FORT

WALL PANEL SLAT DIMENSIONS

" "

SPACING

Page 79

STEP 35: 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 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH, IN THE COUNTER-SUNK HOLES OF THE SWING BEAM MOUNT. USE BOLT CAPS TO COVER ANY EXPOSED THREADS.

3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER. 4: IF NECESSARY USE LOCKING PLIERS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.

3/8" x 3-1/2" CARRIAGE BOLT

SWING BEAM PLATE

3/8" WASHER

3/8" NUT

BOLT CAP

Page 80

STEP 36: 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" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS.

3: PLACE BOLT CAPS OVER EXPOSED THREADS.

DETAIL A

SCALE 2 : 15

IRON DUCTILE SWING HANGER

7" CARRIAGE BOLT

TORQUE WASHER

3/8" WASHER 3/8" LOCK NUT

BOLT CAP

SWING BEAM

Page 81

STEP 37: 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

SWING LEG BRACKET

4 X 4 X 108" SWING LEG

3/8 X 3-1/2" LAG SCREW

3/8" WASHER

Page 82

STEP 38: REST SWING BEAM ON FORT

AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: REST THE SWING BEAM ON TOP OF THE FORT RAILINGS. THE END OF THE SWING BEAM WITH

TWO EMPTY HOLES SHOULD OVERHANG THE SIDE OF THE FORT WITH THE TRIANGULAR SWING BEAM PLATE.

2: SIT THE SWING BEAM LEGS UPRIGHT UNDER THE TWO EMPTY HOLES IN THE END OF THE SWING BEAM.

THESE TWO HOLE LOCATIONS WILL BE EMPTY ON YOUR SWING BEAM. LINE THEM UP WITH THE HOLES IN THE SWING LEG BRACKET UNDER THE SWING BEAM.

Page 83

STEP 39: 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" LAG SCREW WITH 3/8" WASHER FOR THE HOLE IN THE CENTER OF THE SWING BEAM BRACKET.

3: PLACE A BOLT CAP OVER ANY EXPOSED THREADS.

7" CARRIAGE BOLT

TORQUE WASHER

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

3/8 X 3-1/2" LAG SCREW

Page 84

STEP 40: MOUNT SWING BEAM ON FORT

AN EXTRA PERSON IS NEEDED FOR THIS STEP. 1: HAVE ONE PERSON WALK THE SWING BEAM OUT TO THE END OF THE FORT FROM INSIDE THE

FORT WHILE THE OTHER PERSON CARRIES IT BY THE LEGS. 2: LINE UP THE PILOT HOLE AT THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE

SWING BEAM PLATE. 3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM SUPPORT USING A

9" CARRIAGE BOLT WITH A TORQUE WASHER ON TOP AND A 3/8" LOCK NUT AND WASHER ON THE BOTTOM. PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.

4: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE FROM UNDERNEATH WITH A 3/8 X 31/2" LAG SCREW AND 3/8" WASHER.

5: IF NECESSARY USE VISE GRIPS TO HOLD CARRIAGE BOLTS IN PLACE WHEN INSTALLING.

9" CARRIAGE BOLT

TORQUE WASHER

3/8" WASHER

3/8 X 3-1/2" LAG SCREW

3/8" WASHER

3/8" NUT

BOLT CAP

3/8" NUT

BOLT CAP

Page 85

STEP 41: 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.

LEVEL

IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). THE LEGS ARE LONGER THAN REQUIRED. IF YOUR GROUND IS RELATIVELY LEVEL, YOU MAY EITHER:

A) DIG IN BOTH LEGS WHERE THEY MEET THE GROUND

OR B) BEND THE LEGS OUT SLIGHTLY TO

MATCH YOUR GRADE.

OUT

Page 86

STEP 42: 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.

LEVEL

2 X 4 X 58" CROSS-MEMBER

3/8 X 3-1/2" LAG SCREW

3/8" WASHER

Page 87

STEP 43: ROOF SUPPORT ASSEMBLIES

1: LOCATE TWO 2 X 4 X 35-1/4" ROOF SUPPORT (LEFT), TWO 2 X 4 X 35-1/4" 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. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORTS FLUSH WITH ONE ANOTHER. PLACE A ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.

3: USE FOUR #8 X 2" WOOD SCREWS TO ATTACH THE ROOF PEAK SUPPORT TO THE ROOF SUPPORTS AS SHOWN BELOW.

4: MAKE ONE MORE ROOF SUPPORT ASSEMBLY BY REPEATING 2 AND 3.

COUNTERSUNK HOLE FACES DOWN

2 X 4 X 35-1/4" UPPER ROOF SUPPORT RIGHT

#8 X 2" WOOD SCREW

2 X 4 X 35-1/4" UPPER ROOF SUPPORT LEFT

5/4 X 6 X 10" ROOF PEAK SUPPORT

COMPLETED ROOF SUPPORT ASSEMBLY (MAKE ONE MORE)

FLUSH

DETAIL A

FLUSH

Page 88

STEP 44: ROOF SUPPORTS

1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES AT THE CORNER POSTS LEFT AND CORNER POST MIDDLE

2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE POSTS WITH 5/16" X 4-1/2" HEX BOLTS WITH

5/16" WASHERS.

ROOF SUPPORT ASSEMBLY

ROOF PEAK SUPPORT (TRIANGLE) ON OUTSIDE.

5/16 X 4-1/2" HEX BOLT

5/16" WASHER

Page 89

STEP 45: LOWER ROOF SUPPORTS

1: LOCATE TWO 2 X 4 X 25" VERTICAL ROOF SUPPORTS, A 2 X 4 X 36-5/8" LOWER ROOF SUPPORT RIGHT AND A 2 X 4 X 36-5/8" LOWER ROOF SUPPORT LEFT.

2: FIND A FLAT SURFACE TO WORK ON. LAY THE VERTICAL ROOF SUPPORT DOWN AND LOWER ROOF SUPPORT RIGHT ON THE FLAT SURFACE. ALIGN THE ANGLED ENDS OF THE ROOF SUPPORT RIGHT AND VERTICAL ROOF SUPPORT FLUSH WITH ONE ANOTHER. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.

3: USE A #8 X 2" WOOD SCREW AND #8 X 3" WOOD SCREW TO ATTACH THE ROOF SUPPORTS AS SHOWN BELOW.

4: MAKE A LEFT ROOF SUPPORT ASSEMBLY BY REPEATING 2 AND 3.

FLUSH

#8 X 2" WOOD SCREW

2 X 4 X 25" VERTICAL ROOF

#8 X 3" WOOD SCREW

2 X 4 X 36-5/8" LOWER ROOF SUPPORT RIGHTSUPPORT

Page 90

STEP 46: LOWER ROOF SUPPORT ASSEMBLIES

1: PLACE THE LOWER ROOF SUPPORT RIGHT ASSEMBLY ON THE REAR OF THE FORT . THE TOP SHOULD BE 2" FROM THE TOP OF THE CORNER POST MIDDLE .

2: ATTACH LOWER ROOF SUPPORT RIGHT ASSEMBLY TO THE CORNER POST MIDDLE WITH A 5/16" X 31/2" LAG SCREW AND A 5/16" WASHER. ATTACH THE VERTICAL ROOF SUPPORT TO THE CORNER POST RIGHT WITH 3" WOOD SCREWS.

3: PLACE THE LOWER ROOF SUPPORT LEFT ASSEMBLY ON THE FRONT OF THE FORT. THE TOP SHOULD BE 2" FROM THE TOP OF THE CORNER POST MIDDLE.

4: ATTACH LOWER ROOF SUPPORT LEFT ASSEMBLY TO THE CORNER POST MIDDLE WITH A 5/16" X 3-1/2" LAG SCREW AND A 5/16" WASHER. ATTACH THE VERTICAL ROOF SUPPORT TO THE CORNER POST RIGHT WITH 3" WOOD SCREWS.

CORNER POST MIDDLE

VERTICAL ROOF SUPPORT

LOWER ROOF SUPPORT RIGHT

CORNER POST RIGHT

3" WOOD SCREW

5/16" WASHER

DETAIL A

5/16" X 3-1/2" LAG SCREW

SQUARE

DETAIL B

LOWER ROOF SUPPORT RIGHT

LOWER ROOF SUPPORT LEFT

SQUARE

Page 91

STEP 47: LOWER ROOF SUPPORT ASSEMBLIES

1: LOCATE FOUR 2 X 4 X 30-1/8" LOWER ROOF SUPPORT, AND TWO 5/4 X 6 X 10" ROOF PEAK SUPPORT PIECES.

2: FIND A FLAT SURFACE TO WORK ON. LAY THE LOWER ROOF SUPPORTS DOWN ON THE FLAT SURFACE WITH TWO HOLES ON TOP. ALIGN THE ANGLED ENDS WITH TWO HOLES OF THE LOWER ROOF SUPPORTS FLUSH WITH ONE ANOTHER.

3: USE A #8 X 3" WOOD SCREW AND A #8 X 2" WOOD SCREW TO ATTACH THE LOWER ROOF SUPPORTS TOGETHER.

4: PLACE A ROOF PEAK SUPPORT ON TOP OF THE LOWER ROOF SUPPORTS AS SHOWN. THE EDGES SHOULD BE FLUSH WHERE SHOWN BELOW.

5: USE FOUR #8 X 2" WOOD SCREWS TO ATTACH THE ROOF PEAK SUPPORT TO THE ROOF SUPPORTS AS SHOWN BELOW.

6: MAKE ONE MORE LOWER ROOF SUPPORT ASSEMBLY BY REPEATING 2 THROUGH 5.

2 X 4 X 30-1/8" LOWER ROOF SUPPORT

5/4 X 6 X 10" ROOF PEAK SUPPORT

FLUSH

3" WOOD SCREW

2" WOOD SCREW

FLUSH

Page 92

STEP 48: LOWER ROOF SUPPORTS

1: PLACE TWO OF THE ROOF SUPPORT ASSEMBLIES INSIDE THE LOWER ROOF SUPPORTS. 2: THE (TRIANGLE) ROOF PEAK SUPPORT SHOULD FACE THE OUTSIDE. 3: ATTACH EACH ROOF SUPPORT ASSEMBLY TO THE LOWER ROOF SUPPORT

WITH A #8 X 2-1/2" WOOD SCREW ON TOP AND A #8 X 2" WOOD SCREW ON THE BOTTOM.

LOWER ROOF SUPPORT LEFT

#8 X 2-1/2" WOOD SCREW

DETAIL A

SCALE 1 : 6

#8 X 2" WOOD SCREW

VERTICAL LOWER ROOF SUPPORT

#8 X 2-1/2" WOOD SCREW

#8 X 2" WOOD SCREW

CORNER POST MIDDLE

DETAIL B

SCALE 2 : 15

ROOF PEAK SUPPORT

FLUSH

LOWER ROOF SUPPORT

ROOF PEAK SUPPORT

FLUSH

Page 93

STEP 49: LOWER ROOF STARTER

1: PLACE THE 1 X 4 X 38" GROOVE-ONLY LOWER ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTERS SHOULD BE CENTERED ON THE LOWER ROOF SUPPORTS. THE SMOOTH ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.

2: FASTEN THE LOWER ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.

1 X 4 X 38" LOWER ROOF STARTER

1-1/2" WOOD SCREW

DETAIL A

Page 94

STEP 50: LOWER ROOF PEAK

1: PLACE THE 1 X 5 X 38" LOWER ROOF PEAK ON TOP OF THE LOWER ROOF STARTER BOARDS. 2: FASTEN THE LOWER ROOF PEAK TO THE LOWER ROOF STARTER BOARDS WITH #8 X 1-1/4"

WOOD SCREWS.

1 X 5 X 38" LOWER ROOF PEAK

#8 X 1-1/4" WOOD SCREW

Page 95

STEP 51: UPPER LEVEL ROOF

1: PLACE A 1 X 6 X 38" LOWER ROOF BOARD ON TOP OF THE LOWER ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER. EACH SIDE OF THE ROOF GETS FOUR ROOF BOARDS.

2: FASTEN THE LOWER ROOF BOARDS TO THE LOWER ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.

3: PLACE A 1 X 5 X 38" LOWER ROOF FINISHER ON THE ENDS OF THE LOWER ROOF ASSEMBLY AND FASTEN WITH #8 X 1-1/2" WOOD SCREWS.

TIP: USE THE INSTRUCTIONS PROVIDED WITH THE CHIMNEY TO BUILD IT. INSTALL THREE ROOF BOARDS AND INSTALL THE CHIMNEY ACCORDING TO THE CHIMNEY INSTRUCTIONS.

CHIMNEY

#8 X 1-1/2" WOOD SCREW

1 X 6 X 38" LOWER ROOF FINISHER

1 X 6 X 38" LOWER ROOF BOARD

ROOF BOARD (THIRD ONE)

Page 96

STEP 52: UPPER ROOF STARTER

1: PLACE THE 1 X 4 X 36-5/8" GROOVE-ONLY UPPER ROOF STARTER BOARDS AT THE PEAK OF THE ROOF. THE HOLES IN THE UPPER ROOF STARTERS SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE SMOOTH ENDS OF THE ROOF STARTERS SHOULD BE PLACED AS CLOSE TO EACH OTHER AS POSSIBLE WITHOUT THE BOARDS OVERLAPPING.

2: FASTEN THE ROOF STARTER BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.

1-1/2" WOOD SCREW

1 X 4 X 36-5/8" UPPER ROOF STARTER

Page 97

STEP 53: UPPER ROOF PEAK

1: PLACE THE 1 X 5 X 36-5/8" UPPER ROOF PEAK ON TOP OF THE UPPER ROOF STARTER BOARDS. 2: FASTEN THE UPPER ROOF PEAK TO THE UPPER ROOF STARTER BOARDS WITH #8 X 1-1/4"

WOOD SCREWS.

1 X 5 X 36-5/8" UPPER ROOF PEAK

#8 X 1-1/4" WOOD SCREW

Page 98

STEP 54: UPPER ROOF BOARDS

1: PLACE A 1 X 6 X 36-5/8" UPPER ROOF BOARD ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER. EACH SIDE OF THE ROOF GETS SIX ROOF BOARDS.

2: FASTEN THE UPPER ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE A 1 X 4 X 36-5/8" UPPER ROOF FINISHER ON THE ENDS OF THE ROOF ASSEMBLY AND

FASTEN WITH 1-1/2" WOOD SCREWS. TIP: USE THE INSTRUCTIONS PROVIDED WITH THE DORMER TO BUILD IT. INSTALL THE FIFTH ROOF

BOARD AND INSTALL THE DORMER ACCORDING TO THE DORMER INSTRUCTIONS. THEN FINISH INSTALLING THE REMAINING ROOF BOARDS AND FINISHER. ALSO NOTE THAT THERE IS ONE DORMER ON EACH SIDE OF THE ROOF.

DORMER (ONE EACH SIDE OF THE ROOF)

1 X 6 X 36-5/8" UPPER ROOF BOARD

1-1/2" WOOD SCREW

ROOF BOARD (FIFTH ONE)

1 X 4 X 36-5/8" UPPER ROOF FINISHER

Page 99

STEP 55: LOWER SUN SUPPORT ASSEMBLY

1: CENTER A 2 X 6 X 16" SUN ON TOP OF A 5/4 X 4 X 38-1/2" LOWER SUN SUPPORT. THE BOTTOM OF THE SUN SHOULD BE 1" BELOW THE TOP OF THE LOWER ROOF SUN SUPPORT.

2 X 6 X 16" SUN

5/4 X 4 X 38-1/2"

LOWER ROOF SUN SUPPORT

2: FASTEN THE SUN TO THE LOWER SUN SUPPORT WITH #8 X 2" WOOD SCREWS.

2 X 6 X 16" SUN

5/4 X 4 X 38-1/2" LOWER ROOF SUN SUPPORT

#8 X 2" WOOD SCREWS

Page 100

STEP 56: LOWER SUN SUPPORT

1: PLACE THE ASSEMBLY MADE IN THE PREVIOUS STEP UNDERNEATH THE LOWER ROOF BOARDS ON THE INSIDE OF THE ROOF SUPPORTS. THE SUN SHOULD BE ON THE OUTSIDE. MAKE SURE THE ASSEMBLY IS LEVEL BEFORE PROCEEDING TO THE NEXT STEP.

2: FASTEN THE LOWER SUN SUPPORT ASSEMBLY TO THE FORT WITH #8 X 2" WOOD SCREWS FROM THE INSIDE INTO THE ROOF SUPPORTS.

ATTACH WITH #8 X 2" WOOD SCREWS ON EACH SIDE ON THE INSIDE OF THE ROOF SUPPORTS

SUN ON OUTSIDE