Playnation Riviera Playhouse 1536 User Manual

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Riviera Playhouse
Model: 1536
(BOXES: 1518, 1528,
Copyright © 2016 PlayNation Play Systems, Inc.
All Rights Reserved
*52-3036-W*
52-3036-W
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
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PLAYNATION WARRANTY 2016
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™, Riviera Playhouse
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.
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.
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PLAYNATION WARRANTY 2016
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. PlayNation Play Systems, Inc. • 190 Etowah Industrial Ct. • Canton, GA 30114 •
770-704-9300 Monday to Friday 9AM-5PM EST. Any warranty claim must include proof of purchase, including the date of purchase. 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.
• TANDEM 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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Warranty registration
- riviera playhouse -
PlayNation™ 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 Registration
on le.
option 1
option 2
option 3
3 Easy Ways To REgisTER
Complete the online registration form at:
http://www.playnation.com/register
Fax this completed form to:
(678) 880-3300
Mail this completed form to:
PlayNation Playsets
190 Etowah Industrial Court
Canton, GA 30114
Where did you buy this product?
Date of Purchase Store Store City Store State
Your registration information:
Name: _______________________________________________________ Email: ______________________________________
Address: __________________________________________________________________________________________________
Street City State Zip
Please select
your age
How old are
your children?
Would you recommend this product to friends & family?
Comments: ________________________________________________________________________________________________
____________________________________________________________________________________________________________
18-30
31-40
2-3
4-5
41-50
51+
6-7
8+
How would
you rate the
quality of this
product?
Yes
    
No
Below Average
Poor
Average
Excellent
Above Average
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
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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.
As your swing set acclimates to its new environment, natural characteristics of the wood can show 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 and is not covered under warranty.
KEEPING YOUR PLAYSET LIKE NEW
MUST DO’s
The following owner responsibilities are crucial to the safety, integrity and aesthetic appeal of your swing set and may affect the warranty if not adhered to.
WITHIN 60 DAYS
Check and tighten Hex Bolts/T-nuts, Carriage Bolts/Lock-nuts, and Lag Screws within the first 60 days and
•
then twice annually – once before each season and then once during the season.
WITHIN 90 DAYS
• Apply a sealant or semi-transparent stain with sealant within the first 90 days of owning the swing set. If applicable state laws allow, an oil based product will penetrate and protect the lumber better than a water based product. Because climate conditions can vary drastically from region to region, we suggest asking the product covering specialists at any number of specialty paint stores or home improvement centers for a product that would work best for your local environment. ** TIP – while the set is new, take a small board from your swing set to the store with you so they can color match the tint of the stain or sealant. Be sure to replace the board when you get home.
SEASONAL REMINDERS
If your area experiences regular snowfall, remove your fabric tarp/canopy to avoid stretching, sagging or
•
tearing of the material. Store it inside, folded up, and it will be as good as new when winter is over.
If your area experiences extremely cold temperatures, remove swing belts and other pliable features to
•
prolong the lifespan of these play activities.
OTHER TIPS
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 repel yellow jackets and wasps, use a cotton ball and dab interior wooden corners underneath the play set
•
deck with a liquid dish soap. Avoid using insecticides.
To speed up the slide wipe the center of slide with wax paper every 2 - 3 weeks.
•
For additional safety and maintenance guidelines, please visit our website.
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IMPORTANT DOCUMENTS
CUSTOMER MUST READ AND RETAIN
Please go to the following links and read important SAFETY information prior to using your new play structure.
http://www.playnation.com/safety-and-maintenance.html
http://www.playnation.com/manuals.html (Click on your specific model)
http://www.playnation.com/warranty.html
NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings reduces the likelihood of serious injury. 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.
PlayNation Play Systems, Inc.
190 Etowah Industrial Court
Canton, GA. 30114
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Model: 1536
(BOXES: 1518, 1528,
1529, 1536 & ACCESSORY
BOX)
REV: 11.17.2016
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TABLE OF CONTENTS
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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 ......Pages 9-12
Site Plan, Required Tool List and Kit Contents………..………...….................Pages 13-14
Hardware, Lumber and Accessory Checklists.…………………………..….....Pages 15-28
Framing the Playhouse……………………....……………….…………...….......... Steps 1-9
Wood Roof Assembly……………………………...…..……..……...….……....... Steps10-15
Front Gable Assembly .……………………..……................................................... Step 16
Bottom Wall Board………….……………………..……........................................… Step 17
Attaching Front Gable.……...……………………….……….................................... Step 18
Wall Panel Supports and Roof Finishers………………………….................... Steps 19-20
Roof Battens………………...…………………………….…..................................... Step 21
Wall Panel Boards and Roof Gable Boards……………….............................. Steps 22-23
Dormer Assembly and Installation……………….…….……................................... Step 24
Wall Boards-Left, Rear and Right Sides…………………………..……........... Steps 25-33
Panel Slats…...…........................................................................................... Steps 34-35
Drilling for Front Accent pieces and Installating them………………………...... Step 36-37
Solar Wall Lights.................................................................................................... Step 38
Lemonade Stand sign…………....……………………..................................... Steps 39-40
Logo Plate…………………….....…..…………..….…………................................... Step 41
Appendix............................................................................................................... Page 70
PLEASE READ OWNER’S MANUAL CAREFULLY
BEFORE STARTING ASSEMBLY!
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Safety and Maintenance Tips for Your New Play Set:
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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 4-6 occupants.
• On-site adult supervision is required.
• Teach children not to use the equipment in a manner other than intended.
• 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 on the playhouse railings, serving window, window or roof.
• 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 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.
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Safety and Maintenance Tips for Your New Play Set:
4
(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 hardware often due to wood expansion and contraction. It is particularly important that this procedure be followed at the beginning of each season.
• 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.
• 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:
5
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.
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2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential
6
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)
= Area to be scored and channeled for levelness
The diagonal measure­ments should be the same from corner post to corner post. If not, adjust corner posts so that the distance is equal.
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General Info to Review Before Installation
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• 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.
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This page is a list of denitions and explanations used throughout our
8
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.
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Common Installation Practice Installing T-nuts
9
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.
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
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.
FACE OF THE WOOD
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HOW A T-NUT WORKS
10
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
A
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
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BOARD IDENTIFICATION
11
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.
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
3
" WIDTH
3
8
3
"
1
8
THICKNESS
TAG
2-4-3600-BPB
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PRE-DRILL LAG SCREW DIRECTIONS
Pre-drilling holes for lag screws will make it easier to drive the screws in by hand.
12
"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
7
16
2
" 3
16
Corner Post
5
"
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
4 x 4 board
Corner Post
15
4 "
16
2
13 16
"
Page 23
Malibu Playhouse - Site Plan
MORE TEXT
13
Please familiarize yourself with the manual, parts/components and general
construction process of your new playset before getting started.
SITE PLAN:
1
" 53
2
7
"
76
8
3
"
4
291"
8
3
"
72
4
8215"
16
297"
8
13
29 "
16
Playset height:83”
Interior Dimensions:
Width-68-1/2” Depth-45-3/4” Height at front/rear-55-1/2” Height at center (roof peak) 75-1/2”
Other dimensions (rounded off): Door Opening-21-1/2”W x 39-3/4” H Serving Window Opening-29-3/4”W x 12-3/4”H(at center) Serving Window Top Height- 29-3/4” Front Wall Height to top of railing-29”
50
16
7
"
39
8
5
"
5
"
21
8
Approximate assembly time: 12 to 16 hours
(6) foot unobstructed safety perimeter around playset recommended
Page 24
REQUIRED TOOL LIST:
14
___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/16”, 1/8”, 3/8”, 9/64” ___ ½” Wrench and Socket ___ ½” Deep Well Socket
___ Level
___ Tape Measure ___ Extension Cord (if using standard drill or jigsaw)
___ Hammer
___ Pencil ___ You may need a Saw (handsaw or jigsaw) See Step 20 ___ Pliers and/or Locking Pliers (Vise Grips) ___ Carpenter’s Square ___ Shovel (if installing outdoors)
KIT CONTENTS
Swings, Slides, Accessories:
___ (Qty ) Description ___ (2) Plastic Sunburst ___ (1) Plastic Front Arch ___ (2) Plastic Dormer Window ___ (2) Solar Wall Light
___ (1) Logo Plate ___ (1) Plastic Window with shutters ___ (1) Lemonade Stand Sign
Hardware:
see following pages
Wood Components:
see following pages
Page 25
#8 X 1-1/4"
15
WOOD SCREW
QTY: 58
#8 X 1-3/4"
WOOD SCREW
QTY: 118
#8 X 2"
WOOD SCREW
QTY: 28
11-0054
1518 HARDWARE
PAGE 1 OF 1
REV C: 3/24/2014 JH.
9
8
7
6
5/16 x 3-1/2" LAG SCREW
QTY: 12
3/8" x 1-1/8"
BLACK PLASTIC
PLUG
QTY: 2
5
#2 SQUARE
DRIVE TIP
QTY:1
4
3
5/16" TEE NUT
QTY: 2
2
1
5/16" WASHER
5/16 X 4-1/2"
HEX BOLT
QTY: 4
QTY: 16
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
1528 HARDWARE
16
PAGE 1 OF 1
1/16/2015 SO.
#8 X 1"
WOOD SCREW
QTY: 2
#8 X 1-1/4"
WOOD SCREW
QTY: 25
#8 X 1-1/2"
WOOD SCREW
QTY: 110
#8 X 2"
WOOD SCREW
QTY: 25
#8 X 2-1/2"
WOOD SCREW
QTY: 12
9
8
7
6
5/16" X 4-1/2"
HEX BOLT
QTY: 4
5/16" X 2-1/2"
HEX BOLT
QTY: 2
5/16" x 3-1/2"
LAG SCREW
QTY: 6
#2 SQUARE
DRIVE BIT
QTY:1
5/16" WASHER
QTY: 12
5/16" TEE NUT
QTY: 6
5
4
3
2
1
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 27
1529 HARDWARE
17
PAGE 1 OF 1
1/16/2015 S.O.
#8 X 1-1/4"
WOOD SCREW
QTY: 22
#8 X 1-1/2"
WOOD SCREW
QTY: 34
#8 X 1-3/4"
WOOD SCREW
QTY: 8
#8 X 2"
WOOD SCREW
QTY: 6
#8 X 2-1/2"
WOOD SCREW
QTY: 4
9
8
7
6
#2 SQUARE
DRIVE BIT
QTY:1
5
4
3
2
1
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 28
1536 HARDWARE
18
11-0086 11/10/2016 JH
#8 x 1"
WOOD SCREW
QTY: 2
#8 x 1-1/4"
WOOD SCREW
QTY: 5
#8 x 1-3/4"
WOOD SCREW
QTY: 22
#8 x 2"
WOOD SCREW
QTY: 33
#10 x 3-1/2"
WOOD SCREW
QTY: 4
9
8
7
6
5/16" T-NUT
5/16" X 4-1/2"
HEX BOLT
QTY: 6
5
4
QTY: 6
3
2
1
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 29
1528
19
1 X 2 X 32"
ROOF BATTEN
1-2-3200-RB
1 X 4 X 8-3/4"
WALL PANEL
BOARD
1-4-0875-WPB
1 X 4 X 12-1/4"
WALL PANEL
BOARD
1-4-1225-WPB
QTY.PICTURE DESCRIPTION
2
2
2
1 X 4 X 15-3/4"
WALL PANEL
BOARD
1-4-1575-WPB
1 X 4 X 19-5/16"
WALL PANEL
BOARD
1-4-1931-WPB
1 X 4 X 29-1/4" ROOF FINISHER
FRONT LEFT
1-4-2929-RFFL
2
2
1
1 X 4 X 29-1/4" ROOF FINISHER
FRONT RIGHT
1-4-2929-RFFR
1
Page 30
PICTURE DESCRIPTION QTY.
20
1 X 4 X 76-7/8" ROOF FINISHER
REAR
1-4-7688-RFR
1
4.00
3.25
1 X 4 X 76-7/8" ROOF STARTER
FRONT
1-4-7688-RSF
1 X 4 X 76-7/8" ROOF STARTER
REAR
1-4-7688-RSR
1 X 5 X 76-7/8"
ROOF BOARD
1-5-7688-RB
1
1
14
NOT USED
2 X 4 X 22-3/4"
WALL PANEL
SUPPORT LEFT
2-4-2275-WPSL
2 X 4 X 22-3/4"
WALL PANEL
SUPPORT RIGHT 1
2-4-2275-WPSR
2 X 4 X 28-9/16"
CENTER POST
2-4-2856-CPFR
1
2
Page 31
DESCRIPTIONPICTURE QTY.
21
2 X 4 X 35-3/16" ROOF SUPPORT
LEFT
2-4-3515-RSL
2 X 4 X 35-3/16" ROOF SUPPORT
RIGHT
2-4-3515-RSR
2 X 4 X 69-3/4"
ROOF FINISHER
SUPPORT
2-4-6975-RFS
2
2
1
5/4 X 6 X 10"
ROOF PEAK
SUPPORT
125-6-1000-RPS
5/4 X 5 X 10-7/8"
ROOF PANEL
PEAK SUPPORT
125-5-1081-RPPS
5 X 11 X 46-15/16" ROOF PANEL LEFT
ASSEMBLY
5-11-4697-RPLA
2
1
1
5 X 11 X 46-15/16"
ROOF PANEL
RIGHT ASSEMBLY
5-11-4697-RPRA
1
Page 32
1518
22
1 X 3 X 18"
WINDOW TOP
BOARD
1-3-1800-WTB
1 X 3 X 29-7/8"
OPEN WINDOW
OUTSIDE
SUPPORT
1-3-2988-OWOS
1 X 3 X 34-3/4"
WINDOW
BOTTOM
BOARD
1-3-3475-WBB
QTY.PICTURE DESCRIPTION
1
1
1
1 X 3 X 40-1/2" PANEL BOARD
BRACE
1-3-4050-PBB
1 X 4 X 9"
TOP BOARD
WINDOW
1-4-0900-TBW
1 X 4 X 10"
OPEN WINDOW
TOP BOARD 3
1-4-0998-OWTB3
2
3
2
1 X 4 X 27-3/4"
BOTTOM
WINDOW
BOARD
1-4-2775-BWB
5
Page 33
DESCRIPTIONPICTURE QTY.
23
1 X 4 X 29-1/2"
OPEN WINDOW
BOARD
1-4-2950-OWB
1 X 4 X 51"
WALL BOARD
1-4-5100-WB
1 X 6 X 8-7/16"
TOP BOARD
DOOR 2
1-6-0843-TBD2
1
6
2
1 X 6 X 10-3/16"
TOP BOARD
DOOR 1
1-6-1020-TBD1
1 X 6 X 11-3/16"
OPEN WINDOW
TOP BOARD 2
1-6-1118-OWTB2
1 X 6 X 13-5/8"
OPEN WINDOW
TOP BOARD 1
1-6-1360-OWTB1
2
2
2
1 X 6 X 27"
ARCH TOP
BOARD DOOR
1-6-2700-ATBD
1
Page 34
PICTURE DESCRIPTION QTY.
24
1 X 6 X 27-3/4"
BOTTOM
BOARD OPEN
WINDOW
1-6-2775-BBOW
1 X 6 X 34"
TOP BOARD
WINDOW
1-6-3400-TBW
1 X 6 X 51"
WALL BOARD
1-6-5100-WB
4
1
11
NOT USED
1 IS NOT USED
2 X 4 X 47-1/2"
TOP PANEL
BOARD
2-4-4750-TPB
2 X 4 X 70"
BOTTOM WALL
BOARD
2-4-7000-BWB
2 X 6 X 70"
BOTTOM PANEL
BOARD DOOR
2-6-7000-BPBD
1
2
1
5/4 X 6 X 28-1/4"
PANEL SLAT
125-6-2825-PS
7
Page 35
1536
25
PICTURE DESCRIPTION QTY.
5/4 X 4 X 20-3/4"
VERTICAL
ACCENT
125-4-2075-VA
5/4 X 4 X 28-3/8"
DIAGONAL
ACCENT
125-4-2838-DA
2 X 6 X 42"
ROOF GABLE
BOARD
2-6-4200-RGB
1
2
2
2 X 5 X 47-1/2"
BOTTOM PANEL
BOARD
2-5-4750-BPB
2 X 5 X 70"
SANDBOX
BOARD
2-5-7000-SB
4 X 4 X 51-1/4"
FRONT CORNER
POST
4-4-5125-FCP
2
1
2
4 X 4 X 51-1/4"
REAR CORNER
POST
4-4-5125-RCP
2
Page 36
PICTURE DESCRIPTION QTY.
26
5/4 X 3 X 28-1/4"
PANEL SLAT
125-3-2825-PS
8
Page 37
PICTURE DESCRIPTION QTY.
27
PLASTIC
SUNBURST
07-0028-G
PLASTIC
FRONT ARCH
07-0027-G
PLASTIC
DORMER
WINDOW
07-0029-G
2
1
2
SOLAR WALL
LIGHT
09-2003
MANUFACTURER (NOT SHOWN)
LOGO PLATE
UNASSEMBLED
DORMER
(1529 BOX)
2
1
2
UNASSEMBLED
CHIMNEY
(1529 BOX)
1
Page 38
PICTURE DESCRIPTION QTY.
28
PLASTIC
WINDOW
07-0013
LEMONADE
STAND
SIGN
07-0024
1
1
1528, 1518, 1536
(NOT SHOWN)
HARDWARE
KITS
TOUCH UP
STAIN
(LITTLE BOTTLE
THAT IS
BAGGED)
1EA
1
Page 39
STEP 1: RIGHT SIDE
29
1: HAMMER T-NUTS INTO THE CORNER POSTS HOLES THAT ARE 3" OFF THE BOTTOM. TIP: USE A SCREWDRIVER OR A 4-1/2" HEX BOLT TO CLEAN OUT THE HOLES IF SAWDUST IS PRESENT. IF THE HOLES ARE SLIGHTLY SMALL THEN REAM THEM OUT WITH A 3/8" DRILL BIT.
2: FASTEN THE 2 X 5 X 47-1/2" BOTTOM PANEL BOARD (OFFSET DOWN) TO THE CORNER POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
4 X 4 X 51-1/4" REAR CORNER POST
4 X 4 X 51-1/4" FRONT CORNER POST
5/16" T-NUT
EXTRA HOLE IN FRONT POST
3"
5/16" T-NUT
5/16" X 4-1/2" HEX BOLT
5/16" WASHER
2 X 5 X 47-1/2" BOTTOM PANEL BOARD (OFFSET DOWN)
Page 40
STEP 2: FRONT SIDE
30
1: HAMMER T-NUTS INTO THE CORNER POSTS HOLES THAT ARE 3-3/4" OFF THE BOTTOM. 2: FASTEN THE 2 X 5 X 70" SANDBOX BOARD (OFFSET UP) TO THE CORNER POSTS WITH 5/16" X 4-
1/2" HEX BOLTS AND 5/16" WASHERS.
4 X 4 X 51-1/4" FRONT CORNER POST
5/16" T-NUT
3
EXTRA HOLE
RIGHT SIDE
5/16" WASHER
5/16" T-NUT
5/16" X 4-1/2" HEX BOLT
3
"
4
2 X 5 X 70" SANDBOX BOARD (OFFSET UP)
Page 41
STEP 3: LEFT SIDE
31
1: HAMMER T-NUTS INTO THE CORNER POSTS HOLES THAT ARE 3" OFF THE BOTTOM. 2: FASTEN THE 2 X 5 X 47-1/2" BOTTOM PANEL BOARD (OFFSET DOWN) TO THE CORNER POSTS
WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
4 X 4 X 51-1/4" REAR CORNER POST
RIGHT SIDE
5/16" T-NUT
3"
5/16" WASHER
5/16" X 4-1/2" HEX BOLT
FRONT SIDE
5/16" T-NUT
2 X 5 X 47-1/2" BOTTOM PANEL BOARD (OFFSET DOWN)
Page 42
STEP 4: BACK SIDE
32
1: HAMMER T-NUTS INTO THE CORNER POSTS HOLES THAT ARE 4-1/2" OFF THE BOTTOM. 2: FASTEN THE 2 X 6 X 70" BOTTOM PANEL BOARD DOOR (OFFSET UP) TO THE CORNER
POSTS WITH 5/16" X 4-1/2" HEX BOLTS AND 5/16" WASHERS.
RIGHT SIDE
4
FRONT SIDE
5/16" T-NUT
1
"
2
5/16" X 4-1/2" HEX BOLT
5/16" WASHER
5/16" T-NUT
LEFT SIDE
2 X 6 X 70" BOTTOM PANEL BOARD DOOR (OFFSET UP)
Page 43
STEP 5: ROOF SUPPORT
33
1: PLACE THE 2 X 4 X 35.15 ROOF SUPPORTS ON A FLAT SURFACE AS SHOWN. THE COUNTERBORES SHOULD BE FACING THE GROUND (FLAT SURFACE).
2: USE A CARPENTER'S SQUARE TO ENSURE THE PARTS ARE SQUARE TO ONE ANOTHER. 3: PLACE THE 5/4 X 6 X 10" ROOF PEAK SUPPORT ON TOP OF THE ROOF SUPPORTS. THE
EDGES OF THE ROOF PEAK SUPPORT SHOULD BE EVEN OR SLIGHTLY BELOW THE EDGES OF THE ROOF SUPPORTS.
4: ATTACH THE ROOF PEAK SUPPORT TO THE ROOF SUPPORTS WITH #8 X 2" WOOD SCREWS.
5: REPEAT SUBSTEPS 1THROUGH 4 TO MAKE ANOTHER ROOF SUPPORT ASSEMBLY.
5/4 X 6 X 10" #8 X 2" WOOD SCREW
ROOF PEAK SUPPORT
(TRIANGLE)
CARPENTER'S SQUARE
2 X 4 X 35.15 ROOF SUPPORT RIGHT SIDE
COUNTERBORES SHOULD BE FACING THE FLAT SURFACE THE PARTS ARE RESTING ON.
THE TRIANGLE EDGE SHOULD BE EVEN OR BELOW THE ROOF SUPPORT EDGE ON BOTH SIDES.
2 X 4 X 35.15 ROOF SUPPORT LEFT SIDE
Page 44
STEP 6: PLASTIC SUNBURSTS
34
1: PLACE THE PLASTIC SUNBURST OVER THE ROOF SUPPORTS. 2: MAKE SURE THE ROOF SUPPORTS ARE STILL SQUARE TO ONE ANOTHER WITH THE CARPENTER'S
SQUARE. 3: THE TOP SURFACES OF THE SUNBURST SHOULD BE FLUSH OR SLIGHTLY BELOW THE TOP
SURFACES OF THE ROOF SUPPORTS. 4: FASTEN THE SUNBURST TO THE ROOF SUPPORTS WITH TWO #8 X 2-1/2" WOOD SCREWS AT THE
TOP TRIANGLE SECTION AND SIX #8 X 2" WOOD SCREWS ON THE SIDES. 5: REPEAT SUBSTEPS 1 THROUGH 4 FOR THE OTHER ROOF SUPPORT ASSEMBLY.
CARPENTER'S SQUARE
NOTE: COUNTERBORES
#8 X 2-1/2" WOOD SCREW (2 THROUGH TRIANGLE PORTION OF PLASTIC)
#8 X 2" WOOD SCREW (6 ON SIDES)
PLASTIC SUNBURST
THIS SURFACE OF THE PLASTIC MUST BE EVEN OR SLIGHTLY BELOW THE SURFACE OF THE WOOD ROOF SUPPORT. THIS IS SO THE WOOD ROOF CAN BE ATTACHED PROPERLY TO THE WOOD ROOF SUPPORTS.
Page 45
STEP 7: ROOF SUPPORT ASSEMBLIES
35
1: HAMMER A T-NUT INTO THE TOP HOLE ON THE INSIDE OF EACH CORNER POSTS. 2: FASTEN THE ROOF SUPPORT ASSEMBLY TO THE LEFT SIDE WITH 5/16" X 4-1/2" HEX BOLTS
AND 5/16" WASHERS. 3: REPEAT SUBSTEPS 1 THROUGH 2 FOR THE OTHER ROOF SUPPORT ASSEMBLY.
ROOF SUPPORT ASSEMBLY
T-NUT
ROOF SUPPORT
T-NUT
ASSEMBLY
RIGHT SIDE
T-NUT
T-NUT
5/16" WASHER
5/16" X 4-1/2" HEX BOLT
LEFT SIDE
Page 46
STEP 8: LEVEL AND SQUARE
36
1: NOW IS THE TIME TO LEVEL AND SQUARE UP THE FRAME. 2: MAKE SURE THE BOARDS AT THE BOTTOM ARE ALL LEVEL. MAKE SURE ALL THE POSTS
ARE SQUARE TO THE BOARDS AT THE BOTTOM. 3: COMPARE MEASUREMENTS AT THE BOTTOM AND AT THE TOP OF THE POSTS. THE POSTS
NEED TO BE PARALLEL TO ONE ANOTHER. IF THEY ARE NOT PARALLEL THEN LOOSEN THE HEX BOLTS AND MAKE THEM PARALLEL.
COMPARE DIAGONAL DIMENSIONS. WHEN THEY ARE THE SAME THE BASE SHOULD BE CLOSE TO BEING SQUARE. DOUBLE CHECK IT WITH THE CARPENTER'S SQUARE ON THE CORNERS. (DIAGONAL MEASUREMENTS SHOWN ARE FOR REFERENCE ONLY. YOURS MAY VARY.)
75
75
3
16
3
16
"
"
47
1 2
"
1
"
47
2
SQUARE
LEVEL
SQUARE
70"
SQUARE
LEVEL
70"
Page 47
STEP 9: LAG SCREWS
37
1: THE FRAME SHOULD BE LEVEL AND SQUARE AT THIS POINT. THE POSTS SHOULD BE PARALLEL TO ONE ANOTHER ALSO.
2: USE A 9/64" DRILL BIT TO DRILL A PILOT HOLE AT EACH LOCATION SHOWN. (SEE PRE­DRILL LAG SCREW DIRECTIONS AT FRONT OF THE MANUAL FOR 5/16" X 3-1/2" LAG SCREWS.)
3: INSTALL A 5/16" X 3-1/2" LAG SCREW WITH 5/16" WASHER AT EACH LOCATION. 4: VERIFY THE POSTS ARE STILL PARALLEL TO ONE ANOTHER.
5/16" WASHER
5/16" X 3-1/2" LAG SCREW
Page 48
STEP 10: ROOF STARTER REAR
38
IT MAY BE HELPFUL TO TEMPORARILY INSTALL A ROOF BOARD AT THE BOTTOM OF THE ROOF SUPPORTS. THAT WAY YOU CAN POSITION THE REAR ROOF STARTER AND MAKE ADJUSTMENTS EASILY IN STEP 11.
1: FASTEN THE ROOF BOARD AT THE END OF THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS. 2: MEASURE THE DISTANCE ACROSS THE SET AT THE TOP OF THE POSTS. THAT DISTANCE SHOULD MATCH THE
BOTTOM OF THE POSTS. IF THAT DISTANCE IS NOT THE SAME THEN LOOSEN THE WOOD SCREWS IN THE ROOF BOARD AND REPOSITION ON ONE SIDE UNTIL THE DISTANCES MATCH.
THE ROOF SUPPORT ASSEMBLIES SHOULD BE VERTICAL. IF THEY ARE NOT THEN YOU WILL BE ABLE TO ADJUST THEM SOME IN THE NEXT STEP.
ROOF SUPPORT ASSEMBLY SHOULD BE VERTICAL (NOT LEANING IN OR OUT)
REAR STARTER WILL BE INSTALLED IN THE NEXT STEP.
#8 X 1-1/2" WOOD SCREWS 2 PER SIDE
70"
90.00°
1 X 5 X 76-7/8" ROOF BOARD
90.00°
ROOF SUPPORT ASSEMBLY SHOULD BE VERTICAL (NOT LEANING IN OR OUT)
70"
Page 49
STEP 11: ROOF STARTER REAR
39
1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER REAR BOARD AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER SHOULD BE PLACED FLUSH TO THE PEAK OF THE ROOF SUPPORTS.
2: FASTEN THE ROOF STARTER REAR TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS. WHEN ATTACHING THE ROOF STARTER DIM B AT THE ROOF PEAK SHOULD MATCH DIM A. THIS WILL MAKE THE ROOF SUPPORTS PARALLEL TO EACH OTHER. DUE TO WOOD MILLING VARIATIONS YOUR HOLES IN THE ROOF STARTER WILL EITHER BE CENTERED ON THE ROOF SUPPORTS OR THEY WILL BE OFFSET TOWARDS THE INSIDE OF THE ROOF SUPPORTS SLIGHTLY. SUBTRACT DIM A FROM 76-7/8" AND THEN DIVIDE THIS NUMBER BY 2. THIS WILL GIVE YOU THE OVERHANG FOR EACH SIDE. USE THE OVERHANG NUMBER ON EACH SIDE TO KEEP YOUR ROOF SUPPORTS PARALLEL.
DIM B
ROOF STARTER
7
" ROOF STARTER LENGTH
76
8
TOP OF ROOF SUPPORT AT THE PEAK OF THE ROOF.
OVERHANG
#8 X 1-1/2" WOOD SCREW
EXAMPLE: 76-7/8" MINUS 72-3/4" EQUALS 4-1/8". 4-1/8" DIVIDED BY 2 EQUALS 2-1/16" OVERHANG PER SIDE.
BOTTOM OF ROOF SUPPORT ATTACHED
3
" EXAMPLE DIMENSION 72
4
DIM A
1 X 4 X 76-7/8" ROOF STARTER REAR 1-4-7688-RSR (3-1/4" WIDE)
1
"
3
4
TO CORNER POST
OVERHANG
FLUSH
Page 50
STEP 12: ROOF REAR SECTION AND CHIMNEY
40
ROOF BOARD INSTALLATION TIPS:
*INSTALL TWO ROOF BOARDS AND THEN REMOVE THE ROOF BOARD AT THE BOTTOM YOU ATTACHED TEMPORARILY.
*BEFORE FITTING ROOF BOARDS INTO ONE ANOTHER SIGHT DOWN THE BOARD TO SEE IF IT HAS A BOW TO IT. IF THE BOARD IS BOWED THEN PLACE THE "BOW SIDE UP". IT IS EASIER TO PUSH A BOW DOWN THAN TO PULL A BOW UP.
*SOMETIMES IT IS EASIER TO FIT BOARDS TOGETHER IF THE BOTTOM TWO SCREWS ARE LEFT OUT. INSTALL THE TWO SCREWS NEAR THE TOP OF THE ROOF BOARD AND LEAVE THE BOTTOM TWO HOLES EMPTY. THEN INSTALL THE NEXT ROOF BOARD BELOW IT AND ONLY INSTALL THE TWO TOP SCREWS IN THAT BOARD. GO BACK TO THE PRIOR BOARD AND INSTALL THE TWO BOTTOM SCREWS.
*USE A SCRAP BLOCK OF WOOD WITH A HAMMER TO HAMMER AGAINST ANY ROOF BOARDS THAT ARE DIFFICULT TO FIT. THIS SHOULD PREVENT DAMAGE TO THE ROOF BOARD.
1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER REAR. THIS SIDE OF THE ROOF GETS SEVEN ROOF BOARDS.
2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. 3: PLACE THE 1 X 4 X 76-7/8" ROOF FINISHER AT THE END OF THE ROOF ASSEMBLY, AND FASTEN WITH 1-
1/2" WOOD SCREWS. 4: MOUNT THE 2 X 4 X 69-3/4" ROOF FINISHER SUPPORT UNDERNEATH THE ROOF UP AGAINST THE ROOF
FINISHER REAR AND ATTACH TO THE REAR CORNER POST USING 5/16" LAG SCREWS AND 5/16" WASHERS.
TIP: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE CHIMNEY. INSTALL THREE ROOF BOARDS AND INSTALL THE CHIMNEY ACCORDING TO THE CHIMNEY INSTRUCTIONS.
CHIMNEY
1 X 5 X 76-7/8" ROOF BOARD
1-1/2" WOOD SCREW
(FIRST ONE)
ROOF STARTER REAR
5/16" X 3-1/2" LAG SCREW
5/16" WASHER
ROOF BOARD (SEVENTH ONE)
1 X 4 X 76-7/8" ROOF FINISHER
2 X 4 X 69-3/4" ROOF FINISHER SUPPORT
Page 51
STEP 13: ROOF STARTER FRONT
41
IT MAY BE HELPFUL TO TEMPORARILY INSTALL A ROOF BOARD AT THE BOTTOM OF THE ROOF SUPPORTS. THAT WAY YOU CAN MAKE SURE THE FRONT CORNER POSTS STAY PARALLEL.
1: FASTEN THE ROOF BOARD AT THE END OF THE ROOF SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS.
2: MEASURE THE DISTANCE ACROSS THE SET AT THE TOP OF THE POSTS. THAT DISTANCE SHOULD MATCH THE BOTTOM OF THE POSTS. IF THAT DISTANCE IS NOT THE SAME THEN LOOSEN THE SCREWS IN THE ROOF BOARD AND REPOSITION ON ONE SIDE UNTIL THE DISTANCES MATCH.
ROOF SUPPORT ASSEMBLY SHOULD BE VERTICAL (NOT LEANING IN OR OUT)
#8 X 1-1/2" WOOD SCREWS 2 PER SIDE
FRONT STARTER WILL BE INSTALLED IN THE NEXT STEP
ROOF SUPPORT ASSEMBLY SHOULD BE VERTICAL (NOT LEANING IN OR OUT)
70"
1 X 5 X 76-7/8" ROOF BOARD
90.00° 90.00°
70"
Page 52
STEP 14: ROOF STARTER FRONT
42
1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF. THE HOLES IN THE ROOF STARTER SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE FRONT (4") ROOF STARTER SHOULD OVERLAP THE OTHER REAR (3-1/4")ROOF STARTER.
2: FASTEN THE ROOF STARTER FRONT TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS. MEASURE DIM A ACROSS THE BOTTOM OF THE ROOF SUPPORTS NEAR THE CORNER POSTS. WHEN
ATTACHING THE ROOF STARTER DIM B AT THE ROOF PEAK SHOULD MATCH DIM A. THIS WILL MAKE THE ROOF SUPPORTS PARALLEL TO EACH OTHER. DUE TO WOOD MILLING VARIATIONS YOUR HOLES IN THE ROOF STARTER WILL EITHER BE CENTERED ON THE ROOF SUPPORTS OR THEY WILL BE OFFSET TOWARDS THE INSIDE OF THE ROOF SUPPORTS SLIGHTLY. SUBTRACT DIM A FROM 76-7/8" AND THEN DIVIDE THIS NUMBER BY 2. THIS WILL GIVE YOU THE OVERHANG FOR EACH SIDE. USE THE OVERHANG NUMBER ON EACH SIDE TO KEEP YOUR ROOF SUPPORTS PARALLEL.
TOP OF ROOF SUPPORT AT THE PEAK OF THE ROOF.
DIM B
ROOF STARTER
OVERLAP
1 X 4 X 76-7/8" ROOF STARTER FRONT (4" WIDE)
OVERHANG
FLUSH
7
" ROOF STARTER LENGTH
76
8
EXAMPLE: 76-7/8" MINUS 72-3/4 EQUALS 4-1/8". 4-1/8" DIVIDED BY 2 EQUALS 2-1/16" OVERHANG PER SIDE.
72
1 X 4 X 76-7/8" ROOF STARTER REAR (3-1/4" WIDE)
3
" EXAMPLE DIMENSION
4
DIM A
#8 X 1-1/2" WOOD SCREW
BOTTOM OF ROOF SUPPORT ATTACHED TO CORNER POST
OVERHANG
1 X 4 X 76-7/8" ROOF STARTER FRONT 1-4-7688-RSF (4" WIDE)
Page 53
STEP 15: ROOF FRONT SECTION
43
1: PLACE THE 1 X 5 X 76-7/8" ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE GROOVE END OF THE ROOF STARTER FRONT. THIS SIDE GETS SEVEN ROOF BOARDS.
2: FASTEN THE ROOF BOARDS TO THE ROOF SUPPORTS WITH 1-1/2" WOOD SCREWS.
1 X 5 X 76-7/8" ROOF BOARD
#8 X 1-1/2" WOOD SCREW
ROOF BOARD (FIRST ONE)
1 X 4 X 76-7/8" ROOF STARTER FRONT
ROOF BOARD (SEVENTH ONE)
Page 54
STEP 16: FRONT GABLE ASSEMBLY
44
1: FIND ONE 5 X 11 X 46.97" ROOF PANEL LEFT ASSEMBLY, ONE 5 X 11 X 46.97" ROOF PANEL RIGHT ASSEMBLY, ONE 5/4 X 5 X 10.81 ROOF PANEL PEAK SUPPORT AND A FRONT PLASTIC ARCH.
2: PLACE THE ROOF PANEL ASSEMBLIES ON A FLAT SURFACE WITH THE COUNTERSUNK HOLES FACING UP. ALIGN THE ANGLED ENDS OF THE ROOF PANEL ASSEMBLIES FLUSH AT THE PEAK LEAVING A GAP AT THE BOTTOM OF THE SEAM, THIS PROVIDES YOU FREEDOM FOR ADJUSTABILITY.
FLUSH (AT THE PEAK)
ROOF PANEL LEFT ASSEMBLY
3: PLACE THE FRONT PLASTIC ARCH ON TOP OF THE ROOF SUPPORTS. MAKE SURE TO KEEP THE ROOF PANEL ASSEMBLIES TIGHT AT THE PEAK AND THE FRONT PLASTIC ARCH FLUSH TO THE ROOF OVERHANG ON BOTH SIDES. FASTEN USING #8 X 1-1/4" WOOD SCREWS. THE FINAL ASSEMBLY SHOULD MEASURE 69-7/8" AT THE BOTTOM.
#8 X 1-1/4" WOOD SCREW
5 x 11 x 46.97
FLUSH TO
ROOF OVERHANG
GAP (AT THE BOTTOM)
COUNTERSUNK HOLES
FACING UP
KEEP TIGHT AT THE PEAK
FLUSH TO ROOF OVERHANG
5 x 11 x 46.97 ROOF PANEL RIGHT ASSEMBLY
FRONT PLASTIC ARCH
7
69
"
8
125-5-1081-RPPS ROOF PANEL PEAK SUPPORT
4: PLACE THE ROOF PANEL PEAK SUPPORT ON TOP OF THE TWO PANELS AND FLUSH TO THE SIDES OF THE ROOF BOARD BATTENS. FASTEN THE ROOF PANEL PEAK SUPPORT TO THE ROOF PANELS USING 2" WOOD SCREWS.
ROOF PANEL RIGHT ASSEMBLY
ROOF PANEL LEFT ASSEMBLY
2" WOOD SCREW
FLUSH TO ROOF BOARD BATTENS
Page 55
STEP 17: BOTTOM WALL BOARD
45
1: HAMMER A T-NUT INTO EACH HOLE IN THE FRONT CORNER POSTS. 2: FASTEN THE 2 X 4 X 70" BOTTOM WALL BOARD TO THE FRONT CORNER POSTS WITH 5/16" X 4-
1/2" HEX BOLTS AND 5/16" WASHERS.
5/16" WASHER
5/16" X 4-1/2" HEX BOLT
2 X 4 X 70" BOTTOM WALL BOARD
T-NUT
T-NUT
Page 56
STEP 18: ATTACHING THE FRONT GABLE
46
MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE BOTTOM WALL BOARD. MAKE SURE THE GABLE ASSEMBLY IS FLUSH AGAINST THE FRONT CORNER POSTS. THE GABLE ROOF PEAK SHOULD BE RESTING ON TOP OF THE ROOF FRONT SECTION.
TIP: MAKE SURE THE DISTANCE BETWEEN THE GABLE ASSEMBLY AND THE ROOF OVERHANG IS EQUAL ON BOTH SIDES. IT IS RECOMMENDED TO TEST FIT THE 1 X 4 X 29.29" ROOF FINISHERS FRONT LEFT AND RIGHT TO ASSURE THIS EQUAL DISTANCE (DO NOT FASTEN). IF NECESSARY SLIDE THE GABLE ASSEMBLY LEFT OR RIGHT UNTIL FINAL POSITION IS ACCOMPLISHED.
2: THE GABLE ASSEMBLY BOTTOM COUNTERSUNK HOLES WILL REMAIN EMPTY FOR NOW.
GABLE ASSEMBLY
ROOF OVERHANG
EQUAL
ROOF OVERHANG
1 X 4 X 29.29" ROOF FINISHER LEFT (TEST FIT ONLY)
33
EQUAL
T
GH
I
R
OR
T
F
LE
E
D
I
L
S
EMPTY
3: AFTER THE GABLE ASSEMBLY IS IN ITS FINAL POSITION GO INSIDE ON TOP OF THE DECK AND PULL THE GABLE ASSEMBLY TOWARDS YOU MAKING SURE IT IS FLUSH TO THE OUTSIDE OF THE ROOF AND INSERT TWO 1-1/2" WOOD SCREWS
33-7/8"
7
"
8
6
7
"
8
FROM UNDERNEATH THE ROOF INTO THE GABLE ASSEMBLY ROOF PEAK. USE THE DIMENSIONS SHOWN IN THE DIAGRAM TO THE LEFT TO INSERT THE WOOD SCREWS IN THE CORRECT LOCATION. REMOVE THE ROOF FINISHERS,
THESE WILL BE USED IN A LATER STEP.
BOTTOM WALL BOARD
1 X 4 X 29.29" ROOF FINISHER RIGHT (TEST FIT ONLY)
EMPTY
NOTE: CORNER POST REMOVED FOR CLARITY
PULL TOWARDS
YOU
Page 57
STEP 19: WALL PANEL SUPPORTS
47
SINCE ALL INSTALLATIONS VARY THE 15-13/16" DIMENSION SHOWN MAY NOT BE CORRECT. FOLLOW THE PROCEDURE BELOW TO POSITION THE WALL PANEL BOARDS PROPERLY.
1: SLIDE THE LEFT ROOF FINISHER (NOT SHOWN) AGAINST THE ROOF BOARD TEMPORARILY. THEN PUSH THE WALL PANEL SUPPORT UNDER IT. THE TOP OF THE FINISHER NEEDS TO BE FLUSH TO THE TOP OF THE ROOF BOARD ABOVE IT.
2: SLIDE THE FINISHER OUT AND THEN MAKE A MARK AT THE END OF THE TIP OF THE WALL PANEL BOARD. 3: ALIGN THE BACK OF THE WALL PANEL SUPPORT FLUSH TO THE BACK OF THE GABLE ASSEMBLY. ALIGN THE TIP OF THE WALL
PANEL BOARD WITH THE MARK. USE THE HOLE IN THE WALL PANEL BOARD TO DRILL A 1/8" PILOT HOLE THROUGH THE SHORT ROOF BOARD IN THE GABLE ASSEMBLY. INSTALL A 2-1/2" WOOD SCREW IN THE HOLE.
4: MAKE THE WALL PANEL SUPPORT PARALLEL TO THE ROOF BOARD. INSTALL A 5/16" X 3-1/2" LAG SCREW WITH 5/16" WASHER IN THE COUNTERBORED HOLE.
5: REPEAT SUBSTEPS 1 THROUGH 4 FOR THE RIGHT WALL PANEL SUPPORT.
2 X 4 X 22-3/4" WALL PANEL SUPPORT LEFT
2-1/2" WOOD SCREW
LEFT ROOF FINISHER (NOT SHOWN)
MAKE A MARK HERE AT THE TIP.
15 13/16"
ROOF BOARD
GABLE ASSEMBLY
INSTALL 5/16" X 3-1/2" LAG SCREW WITH 5/16" WASHER IN THE COUNTERBORED HOLE.
2 X 4 X 22-3/4" WALL PANEL SUPPORT RIGHT
Page 58
STEP 20: ROOF FINISHERS FRONT
48
1: PLACE THE RIGHT ROOF FINISHER INTO THE GROOVE OF THE ROOF BOARD. 2: SLIDE THE FINISHER OVER UNTIL IT HITS THE GABLE ASSEMBLY ROOF. IF THE FINISHER STICKS OUT BEYOND THE END
OF THE ROOF BOARD ABOVE IT THEN YOU WILL HAVE TO TRIM IT. MARK THE END OF THE FINISHER AND CUT IT TO LENGTH.
(IF THE FINISHER IS FLUSH TO THE END OF THE ROOF BOARD ABOVE IT THEN ALL YOU NEED TO DO IS TO ATTACH IT WITH THREE #8 X 1-1/2" WOOD SCREWS)
3: RESTAIN THE TRIMMED END OF THE FINISHER IF YOU CUT IT WITH THE STAIN PROVIDED. 4: AT THIS POINT YOU MAY NOTICE THAT THE TWO SMALL HOLES MAY NOT BE CENTERED OVER THE ROOF
SUPPORT. IF THAT IS THE CASE THEN DRILL TWO SMALL HOLES THAT ARE CENTERED OVER THE ROOF SUPPORT AND INSTALL TWO #8 X 1-1/2" WOOD SCREWS.
REPEAT SUBSTEPS 1 THROUGH 4 FOR THE LEFT ROOF FINISHER
1 X 4 X 29.29" ROOF FINISHER FRONT LEFT
IDEAL IF ENDS ARE FLUSH
#8 X 1-1/2" WOOD SCREWS (3 PER SIDE)
ROOF BOARD
GABLE ASSEMBLY ROOF
1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT
A
IF THE FINISHER OVERHANGS THEN TRIM IT.
DETAIL A
SCALE 1 : 4
IF THESE HOLES ARE NOT CENTERED OVER THE ROOF SUPPORT THEN DRILL NEW HOLES BESIDE THEM.
NEW HOLES
Page 59
STEP 21: ROOF BATTEN
49
1: PLACE THE 1 X 2 X 32" ROOF BATTEN UP AGAINST THE ROOF PANEL, CENTERED BETWEEN THE ROOF SUPPORTS. FLUSH THE BOTTOM EDGE OF THE ROOF BATTEN TO THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD. MAKE SURE IT IS PARALLEL TO THE ROOF SUPPORTS. INSERT 1-1/4" SCREWS THROUGH THE PREDRILLED HOLES ALONG THE BATTEN AND SECURE THE BATTEN TO THE ROOF BOARDS. DO NOT OVERTIGHTEN THE SCREWS OR THE BATTEN COULD SPLIT.
2: REPEAT THIS PROCESS FOR THE SECOND ROOF BATTEN ON THE OTHER SIDE.
#8 X 1-1/4" WOOD SCREWS
1 X 2 X 32" ROOF BATTEN
ROOF SUPPORT
1 X 2 X 32" ROOF BATTEN
EDGE OF SEVENTH ROOF BOARD
FLUSH
ROOF SUPPORT
Page 60
STEP 22: WALL PANEL BOARDS
50
1: START MOUNTING THE 1 X 4 X 19.31" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT. THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE FRONT LEFT CORNER POST. THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1" FROM THE SIDE EDGE OF THE GABLE ROOF SUPPORT. FASTEN THE WALL PANEL BOARD WITH FOUR 1-1/2" WOOD SCREWS.
2: MOUNT THE 1 X 4 X 15.75" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT. THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE PREVIOUS WALL PANEL BOARD. THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1" FROM THE SIDE EDGE OF THE GABLE ROOF SUPPORT. FASTEN THE WALL PANEL BOARD WITH FOUR 1-1/2" WOOD SCREWS.
3: MOUNT THE 1 X 4 X 12.25" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT. THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE PREVIOUS WALL PANEL BOARD. THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1" FROM THE SIDE EDGE OF THE GABLE ROOF SUPPORT. FASTEN THE WALL PANEL BOARD WITH FOUR 1-1/2" WOOD SCREWS.
4: MOUNT THE 1 X 4 X 8.75" WALL PANEL BOARD AGAINST THE GABLE LEFT ROOF SUPPORT AND THE WALL PANEL SUPPORT LEFT. THE SIDE EDGE OF THE WALL PANEL BOARD MUST BE PARALLEL AND 1/4" FROM THE SIDE EDGE OF THE PREVIOUS WALL PANEL BOARD. THE WALL PANEL BOARD BOTTOM ANGLED END SHOULD BE PARALLEL AND 1" FROM THE SIDE EDGE OF THE GABLE ROOF SUPPORT. FASTEN THE WALL PANEL BOARD WITH FOUR 1-1/2" WOOD SCREWS.
5: REPEAT SUB-STEP 1 TO 4 FOR THE OTHER SIDE. ROOF BOARDS REMOVED FROM VIEW FOR CLARITY
WALL PANEL SUPPORTS
GABLE ROOF SUPPORTS
1
"
4
CORNER POST
1/4"
1"
4
1"
1 4
1-1/2"
"
WOOD SCREW
1 X 4 X 8.75" WALL PANEL BOARD
1 X 4 X 12.25" WALL PANEL BOARD
CORNER POST
1 X 4 X 15.75" WALL PANEL BOARD
1 X 4 X 19.31" WALL PANEL BOARD
Page 61
STEP 23: GABLE BOARDS
51
1: PLACE THE 2 X 6 X 42" ROOF GABLE BOARD DIRECTLY UNDERNEATH THE ROOF SUPPORTS. 2: SECURE THE ROOF GABLE BOARD TO THE ROOF SUPPORTS WITH TWO #10 X 3-1/2" WOOD
SCREWS. 3: REPEAT SUBSTEPS 1 THROUGH 2 FOR THE OTHER SIDE OF THE ROOF.
2 X 6 X 42" ROOF GABLE BOARD
ROOF SUPPORT
FLUSH
#10 X 3-1/2" WOOD SCREW
FLUSH
Page 62
STEP 24: DORMERS
52
1: ASSEMBLE THE DORMERS AS SHOWN IN THE APPENDIX. 2: MAKE MARKS ON THE ROOF WITH A PENCIL AT THE DIMENSIONS SHOWN. NOTE THE
DIMENSIONS START FROM THE JOINT OF THE SEVENTH ROOF BOARD AND THE FINISHERS. 3: INSTALL THE DORMER MOUNTING BLOCKS WITH TWO #8 X 2" WOOD SCREWS. 4: MOUNT THE DORMER 4-1/2" FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD. THE
DORMER MOUNTING BLOCK WILL FIT BETWEEN THE SIDES OF THE DORMER. 5: ATTACH THE DORMER TO THE DORMER MOUNTING BLOCK WITH #8 X 2-1/2" WOOD
SCREWS 6: INSTALL TWO 2" WOOD SCREWS FROM UNDERNEATH THE ROOF INTO THE DORMER
MOUNTING BLOCKS.
DORMER
2" WOOD SCREW
DORMER
#8 X 2-1/2" WOOD SCREW
DORMER MOUNTING BLOCK
41"
2
3 4
15"
EDGE OF SEVENTH ROOF BOARD
" 9
Page 63
STEP 25: WALL BOARDS LEFT SIDE
53
1: FIND SIX 1 X 6 X 51" WALL BOARDS AND TWO 1 X 4 X 51" WALL BOARDS WITH PRE-DRILLED HOLES.
2: PLACE WALL BOARDS ON THE LEFT SIDE OF THE FORT AGAINST THE ROOF GABLE BOARD AND THE SANDBOX BOARD AS SHOWN BELOW. THE BOTTOM OF THE WALL BOARDS SHOULD BE 1­3/8" ABOVE THE BOTTOM OF THE SANDBOX BOARD.
3: USE A #8 X 1-3/4" WOOD SCREWS TO ATTACH THE BOARDS. LEAVE 1/4" SPACES BETWEEN THE WALL BOARDS AS WELL AS THE CORNER POSTS.
LEFT SIDE VIEW (INSIDE)
SANDBOX BOARD
1 X 4 X 51" WALL BOARD (TWO BOARDS)
1/4" GAPS APPROXIMATELY
1
3
"
8
LEFT SIDE VIEW (OUTSIDE)
#8 X 1-3/4" WOOD SCREW
ROOF GABLE BOARD
1 X 6 X 51" WALL BOARD (SIX BOARDS)
SANDBOX BOARD
Page 64
STEP 26: ATTACHING PANEL BOARD BRACE
54
1: PLACE THE 1 X 3 X 40-1/2" PANEL BOARD BRACE AT THE CENTER OF THE WALL BOARDS YOU ATTACHED TO THE SWING BEAM SIDE. FASTEN IT TO THE WALL BOARDS WITH #8 X 1-1/4" WOOD SCREWS.
1 X 3 X 40-1/2" PANEL BOARD BRACE
13
"
26
16
WOOD SCREW
1 X 3 X 40-1/2"#8 X 1-1/4" PANEL BOARD BRACE
LEFT WALL INSIDE VIEW
Page 65
STEP 27: REAR WALL BOARDS
55
1: PLACE WALL BOARDS ON THE REAR SIDE OF THE FORT AGAINST THE BOTTOM PANEL BOARD AND THE ROOF FINISHER SUPPORT AS SHOWN BELOW. THE BOTTOM OF THE WALL PANEL BOARDS SHOULD BE FLUSH TO THE BOTTOM OF THE BOTTOM PANEL BOARD DOOR. THE OPENING DIMENSIONS FOR ATTACHING THE WINDOW IN THE NEXT STEP ARE SHOWN BELOW.
2: USE #8 X 1-3/4" WOOD SCREWS TO ATTACH THE WALL BOARDS. LEAVING 1/4" SPACES BETWEEN THE WALL BOARDS AS WELL AS THE CORNER POSTS.
BOTTOM PANEL BOARD DOOR
#8 X 1-3/4" WOOD SCREW
1 X 6 X 8-3/8" TOP BOARD DOOR 2 (TWO BOARDS)
FLUSH
1 X 6 X 10" TOP BOARD DOOR1 (TWO BOARDS)
1 X 4 X 9" TOP BOARD
(THREE BOARDS)
11
1 X 4 X 51" WALL BOARD (FOUR BOARDS)WINDOW
2 X 4 X 69-3/4" ROOF FINISHER
1
"
2
1
" 14
2
SUPPORT 1 X 6 X 51"
WALL BOARD (THREE BOARDS)
1 X 4 X 27-3/4" BOTTOM WINDOW BOARD (THREE BOARDS)
Page 66
STEP 28: INSTALL WINDOW
56
1: FIND THE PLASTIC WINDOW. PLACE WINDOW AT THE REAR OF THE PLAYHOUSE IN THE OPENING. THE 1" WIDE SECTION OF THE WINDOW FRAME SHOULD BE AT THE TOP.
2: ATTACH THE WINDOW WITH FOUR #8 X 1-1/4" WOOD SCREWS.
#8 X 1-1/4" WOOD SCREWS
1" WIDE
SECTION
AT TOP.
Page 67
STEP 29: WINDOW BOARD AND DOOR BOARD
57
1: PLACE THE 1 X 3 X 34-3/4" WINDOW BOTTOM BOARD FLUSH WITH THE BOTTOM OF THE WINDOW. THIS BOARD TIES THE BOARDS TOGETHER.
2: FASTEN THE WINDOW BOTTOM BOARD WITH #8 X 1-1/4" WOOD SCREWS. 3: PLACE THE 1 X 3 X 18" WINDOW TOP BOARD FLUSH WITH THE TOP OF THE WINDOW. THIS BOARD TIES THE
BOARDS TOGETHER. 4: FASTEN THE WINDOW TOP BOARD WITH #8 X 1-1/4" WOOD SCREWS. 5: PLACE THE 1 X 6 X 27" ARCH TOP BOARD DOOR FLUSH WITH THE BOTTOM OF THE TOP DOOR BOARD 2 AND
TOP DOOR BOARD 1 PIECES. 6: FASTEN THE ARCH TOP BOARD DOOR PIECE WITH #8 X 1-1/4" WOOD SCREWS.
1 X 6 X 27" ARCH TOP BOARD DOOR
#8 X 1-1/4" WOOD SCREW
1 X 3 X 18" WINDOW TOP BOARD
#8 X 1-1/4" WOOD SCREW
FLUSH
1 X 3 X 34-3/4" WINDOW BOTTOM BOARD
#8 X 1-1/4" WOOD SCREW
Page 68
STEP 30: RIGHT SIDE WALL BOARDS
58
1 PLACE WALL BOARDS ON THE RIGHT SIDE OF THE PLAYSET AGAINST THE ROOF GABLE BOARD AND THE SANDBOX BOARD AS SHOWN BELOW. THE BOTTOM OF THE WALL BOARDS SHOULD BE 1-3/8" ABOVE THE BOTTOM OF THE SANDBOX BOARD. FASTEN THE BOARDS WITH #8 X 1-3/4" WOOD SCREWS. LEAVE A 1/4" GAP BETWEEN THE BOARDS AS WELL AS THE CORNER POSTS.
1 X 6 X 11-3/16" OPEN WINDOW
1 X 6 X 13-5/8" OPEN WINDOW TOP BOARD 3 (TWO BOARDS)
1 X 6 X 51" WALL BOARD (TWO BOARDS)
TOP BOARD 2 (TWO BOARDS)
1 X 4 X 10" OPEN WINDOW TOP BOARD 3 (TWO BOARDS)
ROOF GABLE BOARD
BOARDS FLUSH ACROSS THE TOP
1
#8 X 1-3/4"
3
WOOD SCREW
"
8
1 X 6 X 27-3/4" BOTTOM BOARD OPEN WINDOW (FOUR BOARDS)
1 X 4 X 27-3/4" BOTTOM WINDOW BOARD (TWO BOARDS)
1
SANDBOX BOARD
3
"
8
Page 69
STEP 31: PANEL BOARD BRACE AND TOP BOARD WINDOW
59
1: PLACE THE 1 X 3 X 40-1/2" PANEL BOARD BRACE FLUSH OR SLIGHTLY ABOVE THE BOTTOM BOARD OPEN WINDOW PIECES.
2: FASTEN WITH #8 X 1-1/4" WOOD SCREWS. 3: PLACE THE 1 X 6 X 34" TOP BOARD WINDOW FLUSH WITH THE OPEN WINDOW TOP BOARDS. 4: FASTEN WITH #8 X 1-1/4" WOOD SCREWS.
FLUSH
FLUSH OR SLIGHTLY ABOVE
BOTTOM BOARD OPEN WINDOW PIECES
OPEN WINDOW TOP BOARDS
1 X 6 X 34" TOP BOARD WINDOW
#8 X 1-1/4" WOOD SCREW
1 X 3 X 40-1/2" PANEL BOARD BRACE
Page 70
STEP 32: OPEN WINDOW OUTSIDE SUPPORT
60
1: PLACE THE 1 X 3 X 29-7/8" OPEN WINDOW OUTSIDE SUPPORT ON THE OUTSIDE OF THE RIGHT WALL BOARDS. MAKE THE TOP OF THE BOARD FLUSH TO THE TOP OF THE PANEL BOARD BRACE ON THE INSIDE.
2: FASTEN THE OPEN WINDOW OUTSIDE SUPPORT WITH #8 X 1-1/4" WOOD SCREWS.
1 X 3 X 29-7/8" OPEN WINDOW OUTSIDE SUPPORT
PANEL BOARD BRACE ON INSIDE.
A
#8 X 1-1/4" WOOD SCREW
MAKE THE TOP OF THE OPEN WINDOW OUTSIDE SUPPORT FLUSH TO THE TOP OF THE PANEL BOARD BRACE.
PANEL BOARD BRACE ON INSIDE.
1 X 3 X 29-7/8" OPEN WINDOW OUTSIDE SUPPORT
DETAIL A
SCALE 1 : 8
Page 71
STEP 33: OPEN WINDOW BOARD
61
1: PLACE THE 1 X 4 X 29-1/2" OPEN WINDOW BOARD ON TOP OF THE BOARDS IN THE WINDOW OPENING. THE BACK OF THE OPEN WINDOW BOARD SHOULD BE FLUSH TO THE INSIDE OF THE PANEL BOARD BRACE.
2: FASTEN THE OPEN WINDOW BOARD WITH #8 X 1-3/4" WOOD SCREWS.
#8 X 1-3/4" WOOD SCREW
1 X 4 X 29-1/2" OPEN WINDOW BOARD
OUTSIDE VIEW
PANEL BOARD BRACE
ROUNDED CORNERS GO ON THE OUTSIDE
INSIDE VIEW
BACK OF OPEN WINDOW BOARD IS FLUSH TO THE SURFACE OF THE PANEL BOARD BRACE.
Page 72
STEP 34: PANEL SLATS
62
1: FIND SEVEN 5/4 X 6 X 28-1/4" PANEL SLATS. 2: INSTALL THE PANEL SLATS WITH EQUAL SPACING. SEE DETAILS BELOW FOR MEASUREMENTS. 3: ATTACH THE PANEL SLATS TO THE PLAYHOUSE WITH #8 X 2" WOOD SCREWS.
3
"
3
16
SPACING FOR
ALL SPACES.
5/4 X 6 X 28-1/4" PANEL SLAT
FLUSH TO TOP
#8 X 2" WOOD SCREWS
Page 73
STEP 35: PANEL SLATS
63
1: PLACE THE 5/4 X 3 X 28-1/4" PANEL SLATS IN BETWEEN THE SLATS INSTALLED IN THE PREVIOUS STEP.
2: ATTACH THE PANEL SLATS TO THE PLAYHOUSE WITH #8 X 2" WOOD SCREWS.
5/4 X 3 X 28-1/4" PANEL SLAT (EIGHT)
FLUSH
#8 X 2" WOOD SCREW
Page 74
STEP 36: DRILLING HOLES FOR FRONT ACCENT PIECES
64
1: USE THE DIMENSIONS ON THE LEFT TO MAKE CENTER MARKS FOR THE DIAGONAL ACCENT. THEN MEASURE 1" ABOVE AND BELOW EACH CENTER MARK TO MAKE THE SCREW HOLE MARKS. DRILL 1/8" HOLES AT THE SCREW HOLE MARKS. REPEAT THIS PROCESS AGAIN FOR THE BOARD ON THE OPPOSITE SIDE.
SCREW HOLE MARKS
1"
DETAIL A
SCALE 1 : 4
1"
CENTER MARK
19
1
16
15
"
9
16
1
"
14
2
"
5
3
"
8
2: USE THE DIMENSIONS ON THE RIGHT TO MAKE CENTER MARKS FOR THE SCREW HOLES FOR THE VERTICAL ACCENT BOARD AT THE CENTER. DRILL 1/8" HOLES AT EACH MARK.
3
" 35
4
341"
4
1
1"
2
1
" 10
2
19
1
"
2
18"
22
A
1
"
4
1
26
"
2
3
"
30
4
Page 75
STEP 37: FRONT ACCENTS
65
1: PLACE THE 5/4 X 4 X 20-3/4" VERTICAL ACCENT CENTERED ON THE FRONT OF THE PLAYHOUSE. LET THE BOTTOM EDGE REST ON THE 2 X 5 X 70. FASTEN THE VERTICAL ACCENT FROM INSIDE GOING THROUGH THE SLAT INTO THE BACK SIDE OF THE VERTICAL ACCENT. USE #8 X 1-3/4" WOOD SCREWS TO SECURE THE VERTICAL ACCENT.
2: PLACE THE LEFT 5/4 X 4 X 28-3/8" DIAGONAL ACCENT FLUSH TO THE LEFT SIDE OF THE VERTICAL ACCENT AND LET THE TIP REST ON TOP OF THE 2 X 5 X 70. IF THE BOARD DOES NOT LOOK RIGHT THEN FLIP IT END FOR END AND PUT IT BACK INTO POSITION. FASTEN THE DIAGONAL ACCENT FROM THE INSIDE GOING THROUGH THE SLATS INTO THE BACK SIDE OF THE DIAGONAL ACCENT. USE #8 X 1-3/4" WOOD SCREWS TO SECURE THE DIAGONAL ACCENT.
3: PLACE THE RIGHT 5/4 X 4 X 28-3/8" DIAGONAL ACCENT FLUSH TO THE RIGHT SIDE OF THE VERTICAL ACCENT AND LET THE TIP REST ON TOP OF THE 2 X 5 X 70. IF THE BOARD DOES NOT LOOK RIGHT THEN FLIP IT END FOR END AND PUT IT BACK INTO POSITION. FASTEN THE DIAGONAL ACCENT FROM THE INSIDE GOING THROUGH THE SLATS INTO THE BACK SIDE OF THE DIAGONAL ACCENT. USE #8 X 1-3/4" WOOD SCREWS TO SECURE THE DIAGONAL ACCENT.
#8 X 1-3/4" WOOD SCREWS DRIVEN IN FROM THE INSIDE OF THE PLAYHOUSE GOING OUTWARDS.
THERE WILL BE A SMALL 1/4" GAP HERE AND THAT IS NORMAL.
5/4 X 4 X 20-3/4" VERTICAL ACCENT ACCENT (1 PIECE)
5/4 X 4 X 28-3/8" DIAGONAL
(2 PIECES)
2 X 5 X 70
Page 76
STEP 38: SOLAR WALL LIGHTS
66
1: WITH A PENCIL MAKE A CENTER MARK ON THE OUTSIDE FACE OF THE 1 X 4 X 19.31 WALL PANEL BOARD. MEASURE 4-7/8" HORIZONTALLY FROM THE OUTSIDE EDGE OF THE CORNER POST TOWARDS THE CENTER OF THE WALL PANEL BOARD AND 2-3/8" FROM THE BOTTOM EDGE OF THE WALL PANEL SUPPORT TOWARDS THE CENTER OF THE WALL PANEL BOARD AS SHOWN IN THE DIAGRAM BELOW.
2: PARTIALLY INSERT A #8 X 1" WOOD SCREW INTO THE WALL PANEL BOARD CENTER MARK FROM THE PREVIOUS SUB-STEP. MAKE SURE THE HEAD OF THE SCREW IS STICKING OUT ABOUT 3/8" FROM THE OUTSIDE FACE OF THE WALL PANEL BOARD.
3: MOUNT THE SOLAR WALL LIGHT ONTO THE WALL USING THE HEAD OF THE WOOD SCREW AS A HANGER INTO THE SLOT LOCATED IN THE BACK OF THE SOLAR WALL LIGHT. THE ON/OFF SWITCH IS LOCATED IN THE BOTTOM REAR OF THE SOLAR WALL LIGHT. YOU CAN ACCESS THIS SWITCH BY SWINGING THE SOLAR WALL LIGHT TOWARDS THE OUTSIDE OF THE CORNER POST.
4: REPEAT SUBSTEPS 1 TO 3 FOR THE OTHER SOLAR WALL LIGHT.
WALL PANEL SUPPORT
4 7/8"
2 3/8"
CORNER POST
#8 X 1" WOOD SCREW
1 X 4 X 19.31
SOLAR WALL LIGHT WALL PANEL BOARD
ON/OFF SWITCH
SWING THE SOLAR WALL LIGHT TOWARDS THE OUTSIDE.
Page 77
STEP 39: LEMONADE SIGN HOOKS
67
1: MEASURE 16-1/4" FROM THE EACH END OF THE ROOF GABLE BOARD AND MAKE A MARK ON THE BOTTOM OF IT. CENTER THE MARK.
2: PREDRILL A SMALL 1/16" HOLE AT EACH MARK. 3: INSTALL A HOOK IN EACH HOLE.
HOOKS
ROOF GABLE BOARD
16 1/4" 16 1/4"
A
ROOF GABLE BOARD
HOOKS
ROOF GABLE BOARD
HOOKS
HOOK END FACES OUT
DETAIL A
SCALE 1 : 4
Page 78
STEP 40: LEMONADE STAND SIGN
68
1: CUT TWO LENGTHS OF CHAIN TO 3-1/4" FROM THE PIECES PROVIDED. 2: HANG ONE END OF THE CHAIN ON THE END OF THE HOOK. PLACE THE OTHER END
THROUGH THE HOLE ON THE LEMONADE STAND SIGN. PLACE THE END OF THE CHAIN ON THE HOOK. CLOSE THE HOOK WITH A PAIR OF PLIERS.
3: REPEAT SUBSTEP 2 FOR THE OTHER CHAIN.
CLOSE HOOK WITH PLIERS AFTER CHAIN IS INSTALLED.
A
CUT CHAIN TO 3-1/4" LONG
DETAIL A
SCALE 1 : 4
Page 79
STEP 41: LOGO PLATE
69
1: PLACE THE MANUFACTURER LOGO PLATE ON THE 2 X 6 ROOF GABLE BOARD. 2: FASTEN THE LOGO PLATE TO THE BOARD WITH #8 X 1" WOOD SCREWS.
LOGO PLATE
Page 80
APPENDIX
70
Page 81
1529 HARDWARE
PAGE 1 OF 1
1/16/2015 S.O.
#8 X 1-1/4"
WOOD SCREW
QTY: 22
#8 X 1-1/2"
WOOD SCREW
QTY: 34
#8 X 1-3/4"
WOOD SCREW
QTY: 8
#8 X 2"
WOOD SCREW
QTY: 6
#8 X 2-1/2"
WOOD SCREW
QTY: 4
9
8
7
6
#2 SQUARE
DRIVE BIT
QTY:1
5
4
3
2
1
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 82
DESCRIPTIONPICTURE QTY.
DORMER SUNRAY
ASSEMBLY
2-10-1355-DS
DORMER ROOF
PANEL ASSEMBLY
2-13-1828-DRPA
DORMER SIDE
RIGHT ASSEMBLY
4
4
2
2-17-1850-DSRA
DORMER SIDE LEFT
ASSEMBLY
2-17-1850-DSLA
DORMER MOUNT
2-3-1150-DM
2
2
CHIMNEY FRONT
ASSEMBLY
2-8-1500-CFA
CHIMNEY RIGHT
SIDE ASSEMBLY 1
2-10-1500-CRS
1
Page 83
PICTURE DESCRIPTION QTY.
CHIMNEY LEFT
SIDE ASSEMBLY
2-10-1500-CLS
CHIMNEY REAR
ASSEMBLY
2-8-0700-CRA
CHIMNEY
MOUNTING
BLOCK
1
1
1
2-3-0675-CMB
Page 84
STEP 1: DORMER SUNRAYS AND SIDES
1: FIND ONE DORMER SIDE LEFT ASSEMBLY AND ONE DORMER SIDE RIGHT ASSEMBLY. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE TWO DORMER SUNRAY ASSEMBLIES BETWEEN THE DORMER SIDE LEFT
ASSEMBLY AND DORMER SIDE RIGHT ASSEMBLY. ONE DORMER SUNRAY ASSEMBLY FLUSH TO THE FRONT FLAT END OF THE DORMER SIDE ASSEMBLIES AND THE OTHER DORMER SUNRAY ASSEMBLY FLUSH TO THE REAR FLAT END OF THE DORMER SIDE ASSEMBLIES AS SHOWN BELOW.
4: ATTACH THE DORMER SIDE ASSEMBLIES TO THE DORMER SUNRAY ASSEMBLIES WITH #8 X 1-1/2" WOOD.
DORMER SUNRAY ASSEMBLY
1-1/2" WOOD SCREW
DORMER SIDE LEFT ASSEMBLY
DORMER SUNRAY
ASSEMBLY
DORMER SIDE RIGHT ASSEMBLY
Page 85
STEP 2: DORMER WINDOW
1: MOUNT THE DORMER WINDOW IN THE FRONT OF THE DORMER, THE WINDOW SHOULD FIT IN BETWEEN THE DORMER SIDES AND THE DORMER SUNRAY. THE BACK FACE OF THE WINDOW MUST BE RESTING AGAINST THE DORMER SIDES BATTENS.
2: MAKE SURE THE HOLES ON THE DORMER WINDOW ARE CENTERED WITH THE DORMER SIDES BATTENS AND THE DORMER SIDES ARE FLUSH TO THE SIDE EDGES OF THE DORMER WINDOW AND FASTEN WITH #8 X 1-1/2" WOOD SCREWS.
DORMER SIDE
DORMER SUNRAY
DORMER SIDE
DORMER SIDE BATTEN
FLUSH
DORMER WINDOW
1-1/2" WOOD SCREW
FLUSH
DORMER SIDE
FLUSH
Page 86
STEP 3: DORMER ROOF PANELS
1: FIND TWO DORMER ROOF PANEL ASSEMBLIES. 2: PLACE ONE DORMER ROOF PANEL ASSEMBLY ON TOP OF THE DORMER SUNRAY
ASSEMBLIES, THE ROOF PANEL BOARDS MUST OVERHANG EQUALLY OFF THE FRONT AND BACK, MAKE SURE THE PRE-DRILLED HOLES ON THE ROOF PANEL ARE CENTERED WITH THE TOP FACE OF THE DORMER SUNRAY ASSEMBLES. FASTEN WITH #8 X 1-1/2" WOOD SCREWS.
3: REPEAT THE PREVIOUS SUB-STEP FOR THE OTHER SIDE.
1-1/2" WOOD SCREW
DORMER ROOF PANEL ASSEMBLY
1-1/2" WOOD SCREW
DORMER ROOF PANEL ASSEMBLY
DORMER SUNRAY ASSEMBLY
Page 87
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 LEFT SIDE
CHIMNEY FRONT
1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY. 2: ATTACH THE REAR AND RIGHT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW.
USE A 2" WOOD SCREW IN THIS LOCATION
CHIMNEY REAR
CHIMNEY RIGHT SIDE
Page 88
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 89
STEP 6: CHIMNEY
1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.
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.
3: FASTEN THE CHIMNEY TO THE CHIMNEY MOUNTING BLOCK WITH A 1-1/2" WOOD SCREW IN EACH SIDE.
1-1/2" WOOD SCREW
5/4 X 3 X 6-3/4"
CHIMNEY MOUNTING BLOCK
1-1/2" WOOD SCREW
ABOVE UNIT MAY NOT BE YOUR EXACT PLAYSET.
SHOWN FOR ILLUSTRATION PURPOSES ONLY.
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