PlayNation Play Systems 1500CWR User Manual

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Page 1

Laguna Riviera Roof

Timber Shield Post Option BOXES: X1, 120

*52-2079-W*

52-2079-W

Model: 1500CWR

(BOXES: 1501, 1512, 1528,

1529, Extreme Tube Slide Box,

& Slide Box)

190 Etowah Industrial Court

Canton, GA 30114

www.playnation.com

Amber Post Option BOXES: 1533-2bx, 1522

REV A: 6/20/2017

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 2017

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.

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 2017

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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product registration

- Laguna riviera roof -

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 Product 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?

Number of

children

Would you recommend this product to friends & family?

May we add you to our mailing list?

May we use your comments on websites or other marketing materials?

Comments: ________________________________________________________________________________________________

18-30

31-40

2-3

4-5

41-50

51+

6-7

Yes No

How would

you rate the

quality of this

product?

Yes

    

Below Average

Poor

Yes No

Excellent

Above Average

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

Page 11

Model 1500CWR shown. See cover of manual for the image of your model when it is completed.

Timber Shield Post Option BOXES: X1, 120

Models: 1500CWR

1500CWCR

(BOXES: 1501, 1512, 1518*,

1528, 1529, Extreme Tube Slide

Box,

& Slide Box)

*1518 only included with

1500CWCR Clubhouse model

REV A: 6.20.2017

Amber Post Option BOXES: 1533-2bx, 1522

Page 12

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 16-35

Adding T-Nuts to Corner Posts...…………………………………..………...…........... Step 1

Framing Fort……………………………………..…………………………..……..... Steps 2-9

Mounting Deck…………………………....……………….…………...…................... Step 10

Rock Wall Assembly/Installation…………………...…..……..……...….…….... Steps 11-15

Ladder Assembly/Installation………………..……........................................... Steps 16-17

Center Post and Panel Slat Installation.......................................................... Steps 18-19

Swing Beam Assembly…………….……………………..……........….............. Steps 20-27

Roof Assembly...................................……...……………………….………...... Steps 28-33

Front Gable Assembly and Installation........................................................... Steps 34-35

Front Wall Assembly and Completion of Main Roof....................................... Steps 36-40

Hanging Swings and Safety Board…………………………………………….... Steps 41-42

Picnic Table Assembly and Installation..…………………………......….…....... Steps 43-45

Rope Ladder Assembly/Installation…………………………….....…….........…....... Step 46

Extreme Tube Slide, Side Panel Slats, Right Side Angle Supports…...…….. Steps 47-48

Slide, Rock Wall Rope, Safety Handles and Telescope................................. Steps 49-52

Tic Tac Toe Assembly/Installation………………………………..……............... Steps 53-54

Sandbox Seats/Name Plate, Solar Wall Lights and Steering Wheel.............. Steps 55-57

Ground Stakes....................................................................................................... Step 58

Leftover Parts List............................................................................................... Page 101

Appendix: Chimney and Dormer Instructions, etc.............................................. Page 102

PLEASE READ OWNER’S MANUAL CAREFULLYBEFORE 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.

Page 14

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.

Page 15

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 16

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 17

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 18

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 19

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 20

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 21

BOARD IDENTIFICATION

1. On the end of each board there should be a small white tag that is stapled or stuck into place. Remove the staples and/or tag after the board is installed.

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

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

" WIDTH

THICKNESS

TAG

2-4-3600-BPB

Page 22

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 23

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 24

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

construction process of your new playset before getting started.

SITE PLAN:

20'-10

10'-1

3'-1

5'-10"

2'-8"

4'-11

Rope Ladder

Swing Belt (2)

3'-11

Trapeze (1)

" 14'-4

Extreme Tube Slide

7'-3

Rock Wall

Playset height: 12 feet

Swing Beam height: 7 feet - 7-1/2 inches

Deck height: 5 feet

Approximate assembly time: 12-16 hours

(6) foot unobstructed safety perimeter around playset recommended

Wave Slide

Page 25

REQUIRED TOOL LIST:

___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided) ___ Drill Bits 1/8”, 3/16”, 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 ___ Marker or Tape (Step 46)

KIT CONTENTS

Swings, Slides, Accessories: ___ (Qty ) Description ___ (2) Swingbelt w/ Chains ___ (1) Trapeze Swing w/Chains ___ (1) Wave Slide ___ (10) Rock Wall Grips (assorted colors) ___ (1) Telescope ___ (1) Safety Handles (pair) ___ (2) Solar Wall Light ___ (1) Front Plastic Arch 07-0027-G ___ (2) Plastic Sunburst 07-0028-G ___ (2) Plastic Dormer Window 07-0029-G ___ (1) Logo Plate ___ (1) Ground Stakes (pair) ___ (1) Tic Tac Toe ___ (1) Steering Wheel ___ (1) Extreme Tube Slide

Fort Hardware:

see following pages

Swing Beam Hardware:

see following pages

Wood Components:

see following pages

Page 26

1501 HARDWARE

PAGE: 1 OF 2

#14 X 1-1/4"

PAN HEAD SCREW

QTY: 4

3/8" X 1-1/8"

BLACK PLASTIC

PLUG

QTY: 6

#8 X 1"

WOOD SCREW

QTY: 2

#8 X 1-3/4"

WOOD SCREW

QTY: 4

#8 X 2"

WOOD SCREW

QTY: 189

#8 X 2-1/2"

WOOD SCREW

QTY: 52

#8 X 3"

WOOD SCREW

QTY: 20

REV A: 9/10/2014 JH

5/16" TEE NUT

QTY: 22

TORQUE WASHER

QTY: 17

3/8" LOCK NUT QTY: 19

3/8" WASHER

QTY: 31

5/16 X 4-1/2"

HEX BOLT

QTY: 14

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.

5/16 X 1-1/2"

HEX BOLT

QTY: 8

5/16" WASHER

QTY: 34

Page 27

1501 HARDWARE

5/16" X 3-1/2"

HEX LAG

SCREW

QTY: 12

3/8 X 3-1/2"

HEX LAG SCREW

QTY: 12

PAGE: 2 OF 2

REV A: 9/10/2014 JH

3/8 x 9"

CARRIAGE BOLT

QTY: 1

3/8 x 7"

CARRIAGE BOLT

QTY: 14

3/8 x 6-1/2"

CARRIAGE BOLT

QTY: 2

3/8 x 3-1/2"

CARRIAGE BOLT

QTY: 2

#2 SQUARE

DRIVE BIT

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 28

#8 X 2"

WOOD SCREW

QTY: 35

1512 HARDWARE

PAGE: 1 OF 1

9/19/2012 J.H.

#8 X 2-1/2"

WOOD SCREW

QTY: 6

#8 X 3"

WOOD SCREW

QTY: 3

5/16" TEE NUT

QTY: 10

5/16 X 4-1/2"

HEX BOLT

QTY: 10

5/16" X 3-1/2"

LAG SCREW

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.

QTY: 14

5/16" WASHER

QTY: 24

Page 29

1528 HARDWARE

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

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

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 30

PICTURE DESCRIPTION QTY.

2 X 4 X 13" ANGLE SUPPORT

2-4-1300-AS

2 X 4 X 18" ANGLE SUPPORT

2-4-1800-AS

2 X 4 X 14-3/4" PICNIC TABLE TOP SUPPORT

2-4-1475-PTTS

2 X 4 X 17" LADDER STEP

2-4-1700-LS

2 X 4 X 21-1/2" END PANEL BOARD

2-4-2150-EPB

2 X 4 X 22.75" WALL PANEL SUPPORT (1 HOLES ON CENTER)

2-4-2275-WPSL 2-4-2275-WPSR

2 X 4 X 24" ROPE LADDER STEP

2-4-2400-RLST

LEFT

RIGHT

2 X 4 X 27-1/2" PICNIC TABLE SEAT SUPPORT

2-4-2750-PTTS

Page 31

PICTURE DESCRIPTION QTY.

2 X 4 X 28-9/16" CENTER POST FRONT/REAR

2-4-2856-CPFR

2 X 4 X 32-1/2" PICNIC TABLE LEG

2-4-3250-PTL

2 X 4 X 35.15" ROOF SUPPORT (1 HOLE OFFSET)

2-4-3515-RSL 2-4-3515-RSR

2 LEFT

RIGHT

2 X 4 X 47 BOTTOM PANEL/

SAFETY BOARD (2 HOLES OFFSET)

2-4-4750-SBEP

2 X 4 X 58" SWING BEAM CROSS MEMBER (2 HOLES ON CENTER)

2-4-5800-CM

2 X 4 X 66" LADDER SIDE

2-4-6600-LLS 2-4-6600-LRS

LEFT

1 RIGHT

2 X 4 X 66" ROCK WALL SIDE (1 HOLE ON CENTER)

2-4-6600-RWS

Page 32

PICTURE DESCRIPTION QTY.

2 X 4 X 70" DECK SUPPORT (2 HOLES ON CENTER)

2-4-7000-DS

2 X 4 X 70" REAR TOP PANEL BOARD (2 HOLES OFFSET/ 1 CENTERED)

2-4-7000-RTPB

2 X 4 X 69-3/4" ROOF FINISHER SUPPORT (2 HOLES ON CENTER)

2-4-6975-RFS

2 X 4 X 70" CENTER DECK SUPPORT

2-4-7000-CDS

2 X 6 X 21 END PANEL

BOARD (4 HOLES OFFSET)

2-6-2150-EPB

2 X 6 X 47 BOTTOM PANEL

AND SANDBOX BOARD (4 HOLES OFFSET)

2-6-4750-ESPB

2 X 6 X 70" FRONT FACE BOARD (4 HOLES OFFSET)

2-6-7000-FFB

Page 33

PICTURE DESCRIPTION QTY.

2 X 6 X 70" BOTTOM PANEL AND SANDBOX BOARD (4 HOLES OFFSET)

2-6-7000-SB

2 X 6 X 70" FRONT TOP PANEL BOARD (4 HOLES OFFSET, 1 CENTER)

2-6-7000-FTPB

2 X 6 X 70" REAR FACE BOARD (4 HOLES OFFSET)

2-6-7000-RFB

2 X 6 X 79-1/2" ROPE LADDER SUPPORT (4 HOLES OFFSET, 3 HOLES ON CENTER)

2-6-7950-RLS

2 X 6 X 79-1/2" ROPE LADDER RUNNER(4 HOLES OFFSET, 3 HOLES ON CENTER)

2-6-7950-RLR

4 X 4 X 47 SWING BEAM

MOUNT

4-4-4750-SBM

5 X 11 X 46.97" ROOF PANEL ASSEMBLY

5-11-4697-RPLA 5-11-4697-RPRA

LEFT

1 RIGHT

Page 34

PICTURE DESCRIPTION QTY.

X 2

PICNIC TABLE SLAT

125-3-1325-PTS

X 2

TIC TAC TOE MOUNT

125-3-1750-TTTM

X 2

PANEL SLAT

125-3-2825-PS

X 13

X 17

X 28

X 2

X 33"

PANEL SLAT

125-3-3300-PS

X 4 X 14

DECK SPACER

125-4-1450-DS

X 4 X 22

DECK SPACER

125-4-2250-DS

X 3 X 18

LADDER BACK

125-3-1875-LB

Page 35

PICTURE DESCRIPTION QTY.

X 3 X 23

ROCK WALL CAP

125-3-2387-RWC

X 4 X 40

DECK SPACER

125-4-4038-DS

X 6 X 10"

ROOF PEAK SUPPORT

125-6-1000-RPS

X 5 X 10.81"

ROOF PANEL PEAK SUPPORT

125-5-1081-RPPS

X 6 X 22"

SANDBOX SEAT

125-6-2200-SS

X 6 X 23

BOTTOM ROCK WALL BOARD

125-6-2387-BRW

X 6 X 23

ROCK WALL BOARD

125-6-2387-RWB

Page 36

PICTURE DESCRIPTION QTY.

X 6 X 43"

PICNIC TABLE TOP AND SEATS

125-6-4300-PTTS

X 6 X 47

DECK BOARD

125-6-4737-DB

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

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

Page 37

PICTURE DESCRIPTION QTY.

1 X 4 X 29.29" TONGUE-ONLY ROOF FINISHER FRONT

1-4-2929-RFF

1 X 4 X 76-7/8" GROOVE-ONLY ROOF STARTER REAR

1-4-7688-RSR

1 X 4 X 76-7/8" GROOVE-ONLY ROOF STARTER FRONT

1-4-7688-RSF

1 LEFT

1 RIGHT

1 X 4 X 76-7/8" TONGUE-ONLY ROOF FINISHER REAR

1-4-7688-RFR

1 X 5 X 76-7/8" TONGUE-ANDGROOVE ROOF BOARD

1-5-7688-RB

PLASTIC COATED 4 X 4 X 108" SWING BEAM LEG

SL-1

PLASTIC COATED 4 X 4 X 108" CORNER POST

Page 38

PICTURE DESCRIPTION QTY.

PLASTIC COATED 4 X 6 X 120" SWING BEAM

SB-3-0

4 X 4 X 40" END WALL SLIDE MOUNT

4-4-4000-EWSM

2 X 4 X 29-1/4" SLIDE HEADER BOARD

2-4-2925-SHB

COUNT AND ORGANIZE YOUR LUMBER INTO LIKE STACKS (2 X 4, 2 X 6, 4 X 4, 4 X 6, ETC.). THIS WILL HELP IN IDENTIFYING COMPONENTS AND REDUCE YOUR BUILDING TIME

Page 39

PICTURE DESCRIPTION QTY.

WAVE

SLIDE

03-0013

13'

ROPE

LADDER

ROPES

SWINGS

W/CHAINS

04-0002

TRAPEZE

BAR

W/CHAINS

04-0006

Page 40

PICTURE DESCRIPTION QTY.

SWING

PLATE

11-5002

CLIMBING

ROCKS

(07-0008

IS A PACK

OF 5)

A-FRAME

SWING

LEG

BRACKET

11-5010

ROCKS

HARDWARE BOXES: 1501,1512,1528

HARDWARE

BOXES

EA.

Page 41

PICTURE DESCRIPTION QTY.

IRON

DUCTILE

SWING

HANGERS

11-4012

TELESCOPE

07-0001

10'

ROCK

WALL ROPE

Page 42

PICTURE DESCRIPTION QTY.

90 GREEN

BRACKET

11-5013

SPRING

CLIP

11-4003

SAFETY

HANDLES

(PAIR)

07-0005

Page 43

PICTURE DESCRIPTION QTY.

FRONT

PLASTIC ARCH

07-0027-G

PLASTIC

SUNBURST

07-0028-G

DORMER WINDOW

07-0029-G

SOLAR WALL

LIGHT

09-2003

Page 44

PICTURE DESCRIPTION QTY.

(NOT SHOWN)

MANUFACTURER

LOGO PLATE 1

GROUND

STAKE (PAIR)

07-0016-P

TIC TAC TOE

(UNASSEMBLED)

07-0010

STEERING

WHEEL

07-0004

UNASSEMBLED

DORMER

(1529 BOX)

UNASSEMBLED

CHIMNEY

(1529 BOX

OR SLIDE BOX)

Page 45

PICTURE DESCRIPTION QTY.

EXTREME

TUBE SLIDE

03-0014

Page 46

STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS

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

2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS. 3: LAY OUT EACH OF THE 4 X 4 X 108" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF

THE PLAYSET. 4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE DIRECTION THE POSTS SHOULD FACE. 5: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW. 6: 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.

HOLES AT THE TOP OF CORNER POSTS SHOULD BE FACING THIS DIRECTION

T-NUT

NO T-NUT

IN THESE

HOLES

(NOT USED)

NO T-NUT IN THESE HOLES (FOR SWING

BEAM MOUNT

USING

CARRIAGE

BOLTS)

4 X 4 X 108" CORNER POST

NO T-NUT IN THIS HOLE

LEFT (SWING BEAM) SIDE OF FORT

FRONT OF FORT

Page 47

STEP 2: ASSEMBLING THE RIGHT SIDE FRAME

1: LAY THE 2 X 6 X 79-1/2" ROPE LADDER RUNNER ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE HOLES IN THE ROPE LADDER RUNNER 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 ROPE LADDER RUNNER TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.

3: LAY THE 2 X 6 X 79-1/2" ROPE LADDER SUPPORT ON TOP OF THE RIGHT SIDE CORNER POSTS, AND MEASURE 14" FROM THE TOP OF BOTH CORNER POSTS.

4: BEFORE INSTALLING LAG SCREWS, MEASURE THE DISTANCE ACROSS THE OUTSIDE OF THE BOTTOM OF THE CORNER POSTS AND THEN MAKE THE OUTSIDE TOP OF THE CORNER POSTS EQUAL TO THAT MEASUREMENT. USE 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER SUPPORT TO THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.

EQUAL TO BOTTOM DIMENSION

14"

5/16" WASHER

5/16" X 3-1/2"

LAG SCREW

2 X 6 X 79-1/2" ROPE LADDER SUPPORT

5/16" WASHER

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

FRONT

FORT

2 X 6 X 79-1/2" ROPE LADDER RUNNER

BOTTOM DIMENSION

Page 48

STEP 3: ASSEMBLING THE LEFT SIDE FRAME

1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE CORNER POSTS. THE 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 THE T-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 LEFT SIDE CORNER POSTS IN THE MIDDLE OF THE CORNER POSTS. THE OFFSET 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 4 X 4 X 47-1/2" SWING BEAM SUPPORT ON TOP OF THE LEFT SIDE CORNER POSTS. THE THREE COUNTERSUNK HOLES IN THE MIDDLE OF THE SWING BEAM SUPPORT MUST FACE DOWNWARD.

6: FIND TWO TORQUE WASHERS. PLACE A 3/8" X 6-1/2" CARRIAGE BOLT INSIDE 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 HOLES OF THE CORNER POST 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.

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

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

DETAIL A

3/8" WASHER

3/8" NUT

BOLT CAP

3/8" X 6-1/2" CARRIAGE BOLT

TORQUE WASHER

THREE COUNTERSUNK HOLES ON BOTTOM FACE THE GROUND.

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

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

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

FRONT

FORT

Page 49

STEP 4: DECK SUPPORTS

YOU WILL NEED AN EXTRA PERSON FOR THIS STEP.

1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES.

2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS FROM THE INSIDE OF THE FORT.

3: HAVE AN ASSISTANT HOLD UP THE LEFT OR RIGHT SIDE FRAME WHILE YOU ATTACH THE BOARDS IN STEPS 5 AND 6 SO THAT THE STRUCTURE REMAINS STABLE DURING ASSEMBLY.

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

5/16" WASHER

2 X 4 X 70"

DECK SUPPORT

RIGHT SIDE FRAME

LEFT SIDE FRAME

FRONT OF FORT

Page 50

STEP 5: FRONT FRAME ASSEMBLY

1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE FRONT OF THE CORNER POSTS AT THE BOTTOM. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP.

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

3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS AT THE MIDDLE. THE HOLES IN THE FRONT 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 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 DOWN FROM THE TOP AS SHOWN. THE HOLES IN THE TOP PANEL BOARD MUST 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 (OFFSET UP)

LEFT SIDE FRAME

5/16" WASHER

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

2 X 6 X 70" FRONT FACE BOARD (OFFSET UP)

RIGHT SIDE FRAME

2 X 6 X 70" SANDBOX BOARD (OFFSET UP)

FRONT OF FORT

Page 51

STEP 6: REAR FRAME ASSEMBLY

1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET UP.

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

3: PLACE THE 2 X 6 X 70" REAR FACE BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE REAR 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 REAR FACE BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.

5: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD ON THE REAR OF THE CORNER POSTS. THE HOLES IN THE REAR TOP PANEL BOARD MUST BE OFFSET UP.

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

2 X 4 X 70" REAR TOP PANEL BOARD (OFFSET UP)

5/16" WASHER

5/16 X 4-1/2"

HEX BOLT

2 X 6 X 70" SANDBOX BOARD (OFFSET UP)

2 X 6 X 70" REAR FACE BOARD (OFFSET UP)

Page 52

STEP 6A: LEVELING THE PLAY SET AND LAGS

1: INSTALL LAG SCREWS ONLY IN THE THREE 2 X 6 BOARDS AT DECK HEIGHT AND THE ROPE LADDER SUPPORT AT THIS TIME. SQUARE EACH OF THESE THREE BOARDS TO THE POSTS AND THEN INSTALL THE LAG SCREWS. THIS IS TO MAKE THE STRUCTURE RIGID 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 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 THREE 2 X 6 BOARDS FIRST. THEN LEVEL/SQUARE THE FRAME. FINALLY, INSTALL LAG SCREWS IN THE REMAINING 2 X 6 BOARDS.

LEFT SIDE FRAME

FRONT OF FORT

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

5/16" WASHER

RIGHT SIDE FRAME

Page 53

STEP 6B: ANGLE SUPPORTS

1: TWO 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT SIDE

OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARD. THE TOP OF THE ANGLE SUPPORT

SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.

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

3: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT AND REAR OF THE PLAY SET TO THE 2 X 4 DECK SUPPORTS.

SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.

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

THE TOP OF THE ANGLE

TOP OF ANGLE SUPPORTS SHOULD BE FLUSH OR LOWER THAN THE DECK SUPPORT.

2 X 4 X 13" ANGLE SUPPORT

3" WOOD SCREW

2" WOOD SCREW

2-1/2" WOOD SCREW

3" WOOD SCREW

2 X 6 BOTTOM PANEL BOARD

2 X 4 X 18" ANGLE SUPPORT

DECK SUPPORT

2 X 4 X 13" ANGLE SUPPORT

2 X 6 BOTTOM PANEL BOARD

2 X 4 X 18" ANGLE SUPPORT

DETAIL B

SCALE 1 : 8

Page 54

STEP 7: BOTTOM PANEL BOARD

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

5/16" WASHER

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

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

Page 55

! ATTENTION !

IN THE FOLLOWING THREE STEPS YOU WILL BEGIN THE INSTALLATION OF THE DECK SPACERS AND DECK BOARDS. IF YOU HAVE DIFFICULTY GETTING THE DECK BOARDS/DECK SPACERS TO FIT BETWEEN THE FRONT FACE BOARD AND REAR FACE BOARD DO THE FOLLOWING:

1: LOOSEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET. REMOVE THE SCREWS ON ONE SIDE OF EACH DECK SPACER.

2: ALLOW THE DECK BOARDS TO DROP DOWN IN BETWEEN THE FRONT FACE BOARD AND REAR FACE BOARD.

3: TIGHTEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET.

4: RE-INSTALL THE SCREWS IN THE DECK SPACERS. THEN INSTALL THE DECK BOARDS AS INDICATED IN THE INSTRUCTIONS.

RIGHT SIDE BOARDS

REAR FACE BOARD

FRONT FACE BOARD

LEFT SIDE BOARDS

Page 56

STEP 8: DECK SPACER AND DECK BOARD

1: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER BETWEEN THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. FASTEN THE DECK SPACER TO THE DECK SUPPORTS WITH FOUR 2" WOOD SCREWS.

2: PLACE THE 5/4 X 6 X 47-3/8" DECK BOARD NEAR THE CORNER POSTS ON THE RIGHT SIDE OF THE FORT LEAVING A 1/4" GAP BETWEEN THE CORNER POSTS AND THE SIDE OF THE DECK BOARD. FASTEN THE DECK BOARD TO THE DECK SUPPORTS WITH 2" WOOD SCREWS.

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

2" WOOD SCREWS

DECK SPACER IS FLUSH TO INSIDE OF 2 X 4 BOTTOM PANEL BOARD.

2" WOOD

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

LEAVE A 1/4" GAP ON EACH END BETWEEN THE CORNER POST AND THE SIDE OF THE DECK BOARD.

SCREWS

Page 57

STEP 9: END WALL SLIDE MOUNT POST

1: FIND THE 4 X 4 X 40" END WALL SLIDE MOUNT POST.

2: MEASURE 26" INCHES FROM THE FRONT OF THE FRONT RIGHT CORNER POST AND MARK THE MEASUREMENT ON THE INSIDE OF THE 2 X 6 X 79-1/2" ROPE LADDER SUPPORT. MEASURE DOWN 2" FROM THE TOP OF THE ROPE LADDER SUPPORT AND MARK THE MEASUREMENT ON THE INSIDE. ALIGN THE TOP AND SIDE OF THE END WALL SLIDE MOUNT POST WITH THE MARKS.

3: USE THREE 2-1/2" WOOD SCREWS TO ATTACH THE END WALL SLIDE MOUNT POST TO THE ROPE LADDER SUPPORT FROM THE OUTSIDE OF THE ROPE LADDER SUPPORT.

4: THE END WALL SLIDE MOUNT POST CAN HANG FREELY AT THIS TIME.

26"

ROPE LADDER SUPPORT

4 X 4 X 40" END WALL SLIDE MOUNT POST

FRONT OF FORT

ROPE LADDER SUPPORT

#8 X 2-1/2" WOOD SCREWS (THREE)

4 X 4 X 40" END WALL SLIDE MOUNT POST

Page 58

STEP 10: DECK SUPPORTS

1: PLACE TWO 2 X 4 X 70" DECK SUPPORTS UNDER THE DECK BOARD/DECK SPACER AND BESIDE THE POST. HAVE AN ASSISTANT HOLD UP THE END OF THE DECK SUPPORT ON THE LEFT END. THE LEFT END SHOULD BE FLUSH AGAINST THE 2 X 6 BOTTOM PANEL BOARD. THE END CLOSEST TO THE POST INSTALLED IN STEP 9 SHOULD BE FLUSH WITH THE OUTSIDE OF THE POST OR TOWARD THE INSIDE. ATTACH EACH DECK SUPPORT TO THE POST WITH THREE 2-1/2" WOOD SCREWS.

2: DRILL 1/8" PILOTHOLES THROUGH THE DECK BOARD AND DECK SPACER AS SHOWN IN THE TOP VIEW BELOW.

3: SECURE 2" WOOD SCREWS THROUGH THE DECK BOARD INTO THE DECK SUPPORTS.

4: NOW SECURE THE FAR END OF THE DECK SUPPORTS TO THE DECK SPACER WITH 2" WOOD SCREWS.

DECK SPACER

2" WOOD SCREWS

HAVE AN ASSISTANT

HOLD THE END OF THE

DECK SUPPORTS WHILE

YOU PUT IN SCREWS

THROUGH DECK

BOARD AND DECK

SPACER.

2 X 4 X 70" DECK SUPPORTS

DECK BOARD

2-1/2" WOOD SCREWS

2 X 4 X 70" DECK SUPPORTS

2" WOOD SCREWS

POST INSTALLED IN STEP 9

DRILL 1/8" HOLES

DECK SPACER

TOP VIEW

DRILL 1/8" HOLES

DECK BOARD

Page 59

STEP 10A: DECK BOARDS

THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD

1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A 1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLES AT 22-1/8" & 17-3/8" ONLY NEED TO BE DRILLED ONCE.

5/4 X 3-3/8 X 22-1/2" DECK SPACER

5/4 X 3-3/8 X 14-1/2"

DECK SPACER

2" WOOD SCREW

5/4 X 3-3/8 X 14-1/2" DECK SPACER

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

5/4 X 3-3/8 X 22-1/2" DECK SPACER

2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW. LEAVE A UNIFORM (APPROX. 1/4") SPACE BETWEEN THE DECK BOARDS. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK BOARDS.

USE 2-1/2" WOOD SCREWS

IN THESE LOCATIONS

2 X 6 BOTTOM PANEL BOARD

3: USING TWO 2-1/2" WOOD SCREWS, ATTACH THE 2 X 4 X 70" CENTER DECK SUPPORTS TO THE 2 X 6 BOTTOM PANEL BOARD.

4: FASTEN DECK SPACERS AND DECK BOARDS TO THE CENTER DECK SUPPORTS WITH 2" WOOD SCREWS.

CENTER DECK SUPPORTS

Page 60

STEP 11: ROCK WALL

1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES.

2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY.

3: INSERT T-NUTS INTO THE INSIDE

OF THE ROCK WALL SIDES AND SET WITH A HAMMER.

T-NUT

2 X 4 X 66"

ROCK WALL

SIDES

Page 61

STEP 12: ROCK WALL

1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1 HOLE).

2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2" 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

2" WOOD SCREW

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

BOTTOM ROCK

WALL BOARD

Page 62

STEP 13: ROCK WALL

1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS.

2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.

GREEN BRACKET

5/16" WASHER

5/16" X 1-1/2"

HEX BOLT

Page 63

STEP 14: ROCK WALL

1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS AND WASHERS.

2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS WITH WASHERS WILL SECURE EACH ROCK TO THE WALL.

NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. 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 2-5/8 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.

5/4 X 2-5/8 X 23-7/8"

ROCK WALL TOP CAP

2" WOOD SCREW

Page 64

STEP 15: ATTACHING THE ROCK WALL

1: PLACE THE ROCK WALL INTO POSITION ON THE FORT AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE 3/4" FROM THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD.

2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES 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.

BRACKETS AS A TEMPLATE; DRILL

5/16 X 1-1/2”

HEX BOLT

5/16" X WASHER

3/4"

INSERT T-NUTS IN HOLES ON BACK SIDE OF FRONT FACE BOARD.

Page 65

STEP 16: 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 LADDER SIDES AND SET WITH A HAMMER.

2" WOOD SCREW

2 X 4 X 17" LADDER STEP

OF THE OUTSIDE

2 X 4 X 66"

LADDER SIDE

T-NUT

SLOTS ON BOTTOM

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.

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

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.

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

5/16" WASHER

ANGLE

90 BRACKET

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" WOOD SCREW

ANGLE BRACKETS TO THE

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

Page 66

STEP 17: LADDER TO FORT

1: CENTER THE LADDER IN THE OPENING OF THE REAR FACE BOARD ON THE REAR OF THE FORT AS SHOWN BELOW. THE BOTTOM OF THE 90 BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE REAR ENTRY BOARD. USING THE LADDER BRACKETS AS A TEMPLATE, DRILL A 3/8” HOLE THROUGH THE REAR ENTRY BOARD.

2: FROM THE UNDERSIDE OF THE DECK INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES ON THE REAR ENTRY BOARD.

3: ATTACH THE LADDER WITH 5/16 X 1-1/2” 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.

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

5/16" WASHER

REAR ENTRY BOARD

3/4"

INSERT T-NUTS IN HOLES ON BACK SIDE OF REAR ENTRY BOARD.

Page 67

STEP 18: CENTER POST FRONT/REAR

1: HAMMER A T-NUT INTO THE HOLE OF EACH 2 X 4 X 28-9/16" CENTER POST FRONT/REAR.

2: PLACE THE CENTER POST INSIDE THE RAILINGS AT THE FRONT AND REAR OF THE PLAYSET. LINE UP THE HOLES IN THE CENTER POSTS WITH THE HOLES IN THE RAILINGS.

3: FASTEN THE CENTER POSTS TO THE RAILINGS WITH 5/16" X 2-1/2" HEX BOLTS AND 5/16" WASHERS AT THE TOP.

4: SQUARE EACH CENTER POST TO THE DECK AND SECURE THE BOTTOM OF THE CENTER POST TO THE BOTTOM PANEL BOARDS WITH #8 X 2-1/2" WOOD SCREWS.

2 X 4 X 28-9/16" CENTER POSTS

RAILINGS

BOTTOM PANEL BOARDS

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

5/16" WASHER

RAILING

5/16" T-NUT

2 X 4 X 28-9/16" CENTER POST FRONT/REAR

BOTTOM PANEL BOARD

#8 X 2-1/2" WOOD SCREWS

DETAIL A

SCALE 1 : 8

Page 68

STEP 19: PANEL SLATS

1: FIND THIRTEEN 5/4 X 2-5/8 X 28-1/4" PANEL SLATS.

2: PRE-DRILL THE SLATS 1" FROM EACH END ON CENTER WITH A 1/8" DRILL BIT.

3: INSTALL THE PANEL SLATS AT EQUAL LENGTHS. SEE DETAIL BELOW FOR MEASUREMENTS.

4: ATTACH THE PANEL SLATS TO THE FORT WITH 2" WOOD SCREWS IN THE PRE-DRILLED HOLES.

REAR PANEL SLAT SPACING

2-3/4"

REAR PANEL

DETAIL C

SCALE 1 : 8

2" WOOD SCREW

SWING BEAM PANEL

5/4 X 2-5/8 X 28-1/4"

PANEL SLAT

FRONT PANEL SLATS ARE INSTALLED FLUSH TO THE NOTCH ON THE FRONT FACE BOARD.

SWING BEAM PANEL

SLAT DIMENSIONS (VIEW FROM OUTSIDE THE PLAY SET.)

1 8

" 11

Page 69

STEP 20: SWING BEAM PLATE

1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SUPPORT, LINING UP THE PILOT HOLES.

2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SUPPORT USING 3-1/2" CARRIAGE BOLTS ON TOP, AND 3/8" LOCK NUTS WITH 3/8" WASHERS FROM UNDERNEATH, IN THE COUNTER-SUNK HOLES OF THE SWING BEAM SUPPORT. 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.

3-1/2" CARRIAGE BOLT

SWING BEAM PLATE

3/8" WASHER

3/8" NUT BOLT CAP

Page 70

STEP 21: IRON DUCTILE SWING HANGERS

1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWINGBEAM. IF YOUR BEAM IS BOWED SLIGHTLY PLACE THE BOW SIDE UP; THE SWING HANGERS WILL BE ON THE BOTTOM.

2: FASTEN THE 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.

7" CARRIAGE BOLT

TORQUE WASHER

IRON DUCTILE SWING HANGER

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

DETAIL M

SCALE 1 : 8

Page 71

STEP 22: 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

3/8 X 3-1/2"

LAG SCREW

3/8" WASHER

SWING LEG BRACKET

4 X 4 X 108" SWING LEG

Page 72

STEP 23: REST SWING BEAM ON FORT

*TWO PEOPLE ARE REQUIRED FOR THIS STEP

1: LAY THE SWING BEAM ACROSS THE 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 73

STEP 24: 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

3/8" WASHER

3/8" LOCK NUT

BOLT CAP

TORQUE WASHER

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

Page 74

STEP 25: MOUNT SWING BEAM ON FORT

*AN EXTRA PERSON IS REQUIRED 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 ON 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 3-1/2" LAG SCREW AND A 3/8" WASHER.

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

TORQUE WASHER

9" CARRIAGE BOLT

3/8" WASHER

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

3/8" WASHER

3/8" NUT

BOLT CAP

Page 75

STEP 26: LEVEL SWING BEAM

1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE BEAM LEGS IN OR OUT AS NEEDED TO MAKE THE SWING BEAM LEVEL.

IMPORTANT NOTE: THE LEGS ARE DESIGNED TO ACCOMODATE SWING BEAMS ON UNEVEN GROUND (DOWN SLOPE). 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

B) BEND THE LEGS OUT SLIGHTLY TO MATCH YOUR GRADE.

OUT

Page 76

STEP 27: SWING LEG CROSS-MEMBER

1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS.

2: LEVEL CROSS-MEMBER AND MARK THE LOCATION OF THE SECURING HOLES INSIDE THE CROSS-MEMBER HOLES.

3: USE 3/8 X 3-1/2" LAG SCREWS WITH 3/8" WASHERS TO SECURE THE CROSS-MEMBER TO THE SWING BEAM LEGS.

3/8 X 3-1/2"

LAG SCREW

3/8" WASHER

2 X 4 X 58" CROSS-MEMBER

Page 77

STEP 28: ROOF SUPPORTS

1: WITH OFFSET HOLES DOWN, ATTACH THE 2 X 4 X 35.15" ROOF SUPPORTS TO THE FORT WITH 5/16 X 4-1/2" HEX BOLTS. THE ROOF SUPPORTS SHOULD MEET IN THE MIDDLE TO FORM A RIGHT ANGLE.

2: CONNECT THE ENDS WITH A 2-1/2" WOOD SCREW.

2 X 4 X 35.15" ROOF SUPPORT

2-1/2" WOOD SCREW

RIGHT SIDE

2 X 4 X 35.15" ROOF SUPPORT LEFT SIDE

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

5/16" WASHER

Page 78

STEP 29: ROOF PEAK SUPPORT

1: PLACE THE 5/4 X 6 X 10" ROOF PEAK SUPPORT AGAINST THE ANGLED ROOF SUPPORTS AND FLUSH TO THE SIDES OF THE ANGLED ROOF SUPPORTS. FASTEN THE ROOF PEAK SUPPORT TO THE ANGLED ROOF SUPPORTS WITH 2" WOOD SCREWS. REPEAT ON OTHER SIDE.

ROOF PEAK SUPPORT

2" WOOD SCREW

Page 79

STEP 30: ROOF STARTER REAR

1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER REAR 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 FLUSHED TO THE PEAK OF THE ROOF SUPPORT.

2: FASTEN THE ROOF STARTER 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

DIM B

76-7/8"

ROOF

ROOF STARTER

OVERHANG OVERHANG

1-1/2" WOOD SCREW

EXAMPLE: 76-7/8" MINUS 72.75" EQUALS 4.125".

4.125" DIVIDED BY 2 EQUALS 2.063" OVERHANG PER SIDE.

72.75" EXAMPLE DIMENSION

DIM A

1 X 4 X 76-7/8" ROOF STARTER REAR 1-4-7688-RSR (3-1/4" WIDE)

ROOF SUPPORT

BOTTOM OF ROOF SUPPORT ATTACHED TO CORNER POST

Page 80

STEP 31: ROOF REAR SECTION AND CHIMNEY

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

1-1/2" WOOD SCREW

ROOF BOARD

(SEVENTH ONE)

1 X 4 X 76-7/8"

ROOF FINISHER

ROOF BOARD (FIRST ONE)

ROOF STARTER REAR

5/16" X 3-1/2"

LAG SCREW

5/16"

WASHER

2 X 4 X 69-3/4"

ROOF FINISHER

SUPPORT

Page 81

STEP 32: ROOF FRONT SECTION

1: PLACE THE 1 X 4 X 76-7/8" ROOF STARTER FRONT BOARD AT THE PEAK OF THE ROOF OVERLAPPING THE ROOF STARTER REAR. THE HOLES IN THE ROOF STARTER FRONT SHOULD BE CENTERED ON THE ROOF SUPPORTS, AND THE FLAT TOP END OF THE ROOF STARTER FRONT SHOULD BE PLACED FLUSH TO THE TOP EDGE OF THE ROOF STARTER REAR.

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

3: 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.

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

1 X 3 X 76-7/8"

ROOF STARTER REAR

(3-1/4" WIDE)

1 X 4 X 76-7/8"

ROOF STARTER FRONT

FLAT TOP END FLUSH TO TOP EDGE

OVERLAP

1 X 4 X 76-7/8" ROOF STARTER FRONT (4" WIDE)

ROOF BOARDS

(FIRST ONE)

1-1/2" WOOD

SCREW

ROOF BOARDS

(SEVENTH ONE)

Page 82

STEP 33: DORMERS

1: USE THE INSTRUCTIONS PROVIDED IN THE APPENDIX TO BUILD THE DORMERS. AFTER INSTALLING THE SEVENTH ROOF BOARD NSTALL THE DORMER MOUNTING BLOCK 9-3/4" FROM THE SIDE EDGE OF THE ROOF TO THE SIDE EDGE OF THE DORMER MOUNTING BLOCK, AND 15" FROM THE BOTTOM OF THE SEVENTH ROOF BOARD TO THE TOP EDGE OF THE DORMER MOUNTING BLOCK. INSERT TWO #8 X 2" WOOD SCREWS THROUGH THE MOUNTING BLOCK INTO THE ROOF BOARD.

2: MOUNT THE DORMER ON TOP OF THE ROOF, 4-1/2" FROM THE BOTTOM EDGE OF THE SEVENTH ROOF BOARD TO THE BOTTOM EDGE OF THE DORMER, THE DORMER MOUNTING BLOCK SHOULD BE IN BETWEEN THE WALLS OF THE DORMER. MAKE SURE THE DORMER IS HORIZONTALLY PARALLEL TO THE ROOF BOARDS AND FULLY RESTING ON TOP OF THE ROOF. THE PRE-DRILLED HOLES ON EACH SIDE OF THE DORMER SHOULD BE CENTERED WITH THE DORMER MOUNTING BLOCK. INSERT ONE #8 X 2-1/2" WOOD SCREW THROUGH EACH HOLE ON BOTH SIDES INTO THE DORMER MOUNTING BLOCK.

3: REPEAT SUB-STEPS 1 TO 2 FOR THE OTHER DORMER.

4: INSTALL TWO 2" SCREWS FROM UNDERNEATH THE ROOF INTO THE DORMER MOUNTING BLOCKS.

DORMER

2-1/2" WOOD SCREW

2" WOOD SCREW

DORMER MOUNTING BLOCK

SEVENTH ROOF BOARD

15"

Page 83

STEP 34: FRONT GABLE ASSEMBLY

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 AND 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

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 84

STEP 35: ATTACHING THE FRONT GABLE

1: MOUNT THE GABLE ASSEMBLY RESTING ABOVE THE TOP PANEL 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

EQUAL

OVERHANG

ROOF

OVERHANG

1 X 4 X 29.29" ROOF FINISHER LEFT

(TEST FIT ONLY)

-7

EMPTY

1 X 4 X 29.29" ROOF FINISHER RIGHT

(TEST FIT ONLY)

EMPTY

TOP PANEL BOARD

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 11/2" WOOD SCREWFROM 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.

1-1/2" WOOD SCREW

NOTE: CORNER POST REMOVED FOR CLARITY

PULL TOWARDS YOU

Page 85

STEP 36: WALL PANEL SUPPORTS

1: PLACE THE 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE AND THE OPPOSITE END WITH THE COUNTERSUNK HOLE FLUSH AGAINST THE LEFT FRONT CORNER POST. MAKE SURE THE ANGLED END OF THE WALL PANEL SUPPORT IS FLUSH TO THE INSIDE OF THE GABLE ASSEMBLY. THE WALL PANEL SUPPORT TOP EDGE MUST BE PARALLEL AT 21-7/8" TO THE TOP EDGE OF THE TOP PANEL BOARD. ATTACH THE WALL PANEL SUPPORT LEFT TO THE GABLE ASSEMBLY WITH ONE #8 X 2-1/2" WOOD SCREW.

2: THE COUNTERSUNK HOLE WILL REMAIN EMPTY FOR NOW.

3: REPEAT SUB-STEPS 1 & 2 FOR THE OPPOSITE SIDE.

2 X 4 X 22.75"

WALL PANEL 2 X 4 X 22.75" WALL PANEL SUPPORT LEFT

SUPPORT RIGHT

DETAIL C

SCALE 2 : 15

TOP PANEL SUPPORT

2 X 4 X 22.75"

WALL PANEL SUPPORT LEFT

2-1/2" WOOD SCREW

EMPTY

Page 86

STEP 37: ROOF FINISHERS FRONT

1: PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT LEFT ANGLED END ON TOP OF THE GABLE ASSEMBLY LEFT SIDE. PLACE THE 1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT ANGLED END ON TOP OF THE GABLE ASSEMBLY RIGHT SIDE. FIT THE TONGUE END INTO THE GROOVE OF THE ROOF BOARD ABOVE THEM.

2: MAKE SURE THAT BOTH ROOF FINISHERS ENDS ARE FLUSH ON BOTH SIDES OF THE ROOF AND TIGHT TO THE GABLE ASSEMBLY.

TIP: DO THIS ONLY IF "THE ROOF FINISHERS ARE UNEVEN WITH THE OVERHANG". REMOVE THE ROOF FINISHERS SO YOU CAN ACCESS TO THE WOOD SCREWS ATTACHING THE WALL PANEL SUPPORTS. ONCE YOU REMOVED THE WALL PANEL SUPPORTS ON BOTH SIDES, PROCEED TO LOOSEN UP THE WOOD SCREWS ATTACHING THE GABLE ASSEMBLY FROM UNDERNEATH THE ROOF. SLIDE THE GABLE ASSEMBLY LEFT OR RIGHT. TEST FIT THE ROOF FINISHERS ON BOTH SIDES. ONCE THE CORRECT POSITION IS ACCOMPLISHED PROCEED TO RE-ATTACH THE REMOVED PIECES.

3: INSERT 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS INTO THE WALL PANEL SUPPORTS AND GABLE ASSEMBLY COUNTERSUNK HOLES.

4: FASTEN THE ROOF FINISHER FRONT LEFT AND ROOF FINISHER FRONT RIGHT TO THE ROOF SUPPORTS AND TO THE WALL PANEL SUPPORTS WITH #8 X 1-1/2" WOOD SCREWS ON BOTH SIDES OF THE ROOF.

1 X 4 X 29.29" ROOF FINISHER FRONT LEFT

1 X 4 X 29.29" ROOF FINISHER FRONT RIGHT

FLUSH

1-1/2" WOOD SCREW

ROOF BOARD

FLUSH

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

5/16" WASHER

DETAIL D

1 X 4 X 29.29" ROOF FINISHER FRONT LEFT

1-1/2" WOOD SCREW

5/16" WASHER

WALL PANEL SUPPORT LEFT

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

Page 87

STEP 38: ROOF BATTEN

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 1-1/2" WOOD SCREWS THROUGH THE PRE-DRILLED HOLES ALONG THE BATTEN.

2: REPEAT THE PREVIOUS SUB-STEP FOR THE OTHER SIDE.

ROOF SUPPORT

FLUSH

SEVENTH ROOF BOARD

1-1/2" WOOD SCREW

ROOF BATTEN

Page 88

STEP 39: WALL PANEL BOARDS

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.

NOTE: ROOF BOARDS REMOVED FROM VIEW FOR CLARITY

CORNER POST

1/4"

WALL PANEL SUPPORT

GABLE ROOF SUPPORT

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

1 X 4 X 15.75 WALL PANEL BOARD

1 X 4 X 19.31" WALL PANEL BOARD

CORNER POST

Page 89

STEP 40: PLASTIC SUNBURST

1: MOUNT THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS ON THE LEFT AND RIGHT SIDE OF THE ROOF, THE PLASTIC SUNBEAM MUST BE UP AGAINST THE OVERHANGING ROOF BOARDS. FASTEN THE PLASTIC SUNBEAM TO THE ROOF SUPPORTS USING TWO #8 X 2-1/2" WOOD SCREWS ON THE TOP AND SIX #8 X 2" WOOD SCREWS ON THE REMAINING HOLES.

2" WOOD SCREW (X6)

PLASTIC SUNBEAM

2-1/2" WOOD SCREW (X2)

ROOF SUPPORT

Page 90

STEP 41: HANGING THE SWINGS

1: START BY ATTACHING ONE SPRING CLIP TO EACH IRON DUCTILE ON THE SWING BEAM.

2: ATTACH ONE CHAIN PER ACCESSORY TO EACH SPRING CLIP.

3: ADJUST HEIGHT AS NEEDED

SPRING CLIP

SWING CHAIN

Page 91

STEP 42: SAFETY BOARD

1: MEASURE 24" FROM THE BOTTOM OF THE CORNER POSTS ON THE LEFT SIDE OF THE FORT. MARK THESE POSITIONS ON THE OUTSIDE OF THE CORNER POSTS. ATTACH THE 2 X 4 X 47-1/2" SAFETY BOARD WITH OFFSET HOLES ON THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16 WASHERS.

NOTE: THE OFFSET HOLES CAN BE PLACED UP OR DOWN IN THIS STEP.

24"

2 X 4 X 47-1/2" SAFETY BOARD

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

5/16" WASHER

Page 92

STEP 43: PICNIC TABLE

1: LOCATE TWO 2 X 4 X 14-3/4" PT TOP SUPPORTS, TWO 2 X 4 X 27-1/2" PT SEAT SUPPORTS, TWO 2 X 4 X 32-1/2" PT LEGS AND TWO 5/4 X 3 X 13-1/4" PICNIC TABLE SLATS.

2: FOR THE LEFT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4" PT TOP SUPPORT AND A 2 X 4 X 27-1/2" PT SEAT SUPPORT PARALLEL TO ONE ANOTHER. PLACE A 2 X 4 X 32-1/2" PT LEG ON TOP AT THE 7-1/2" DIMENSION. THE TOP OF THE PT LEG SHOULD BE FLUSH TO THE TOP OF THE PT TOP SUPPORT. ATTACH THE PT LEG TO THE SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS.

3: FOR THE RIGHT SIDE ASSEMBLY, PLACE A 2 X 4 X 14-3/4" PT TOP SUPPORT AND A 2 X 4 X 27-1/2" PT SEAT SUPPORT PARALLEL TO ONE ANOTHER. PLACE A 2 X 4 X 32-1/2" PT LEG ON TOP AT THE 7-1/2" DIMENSION. THE TOP OF THE PT LEG SHOULD BE FLUSH TO THE TOP OF THE PT TOP SUPPORT. ATTACH THE PT LEG TO THE SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS.

4: PLACE THE PICNIC TABLE SLAT NEXT TO THE PICNIC TABLE LEG FOR EACH ASSEMBLY BELOW. LEAVE A 3/16" GAP BETWEEN THE TOP OF THE SLAT AND THE LEG. USE THE 6-15/16" DIMENSION TO LOCATE THE BOTTOM END OF THE SLAT. FASTEN THE PICNIC TABLE SLAT TO THE SUPPORTS WITH TWO #8 X 2" WOOD SCREWS.

TOP OF PIECES SHOULD BE FLUSH HERE

2 X 4 X 27-1/2" PT SEAT SUPPORT

#8 X 2-1/2" WOOD SCREW

2 X 4 X 32-1/2" PT LEG

2 X 4 X 14-3/4" PT TOP SUPPORT

#8 X 2" WOOD SCREW

5/4 X 3 X 13-1/4" PICNIC TABLE SLAT

10"

LEFT SIDE ASSEMBLY

TOP OF PIECES SHOULD BE FLUSH HERE

2 X 4 X 14-3/4" PT TOP SUPPORT

RIGHT SIDE ASSEMBLY

#8 X 2" WOOD SCREW

10"

15 16

5/4 X 3 X 13-1/4" PICNIC TABLE SLAT

2 X 4 X 27-1/2" PT SEAT SUPPORT

#8 X 2-1/2" WOOD SCREW

2 X 4 X 32-1/2" PT LEG

Page 93

STEP 44: PICNIC TABLE

1: MEASURE 26-3/8” FROM THE BOTTOM OF THE CORNER POSTS ON THE RIGHT SIDE OF THE PLAYSET. MAKE MARKS ON THE INSIDE OF THE CORNER POSTS WITH A PEN OR PENCIL AT 26-3/8"

2: PLACE THE TOP OF THE RIGHT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT FRONT CORNER POST. ATTACH THE RIGHT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS.

3: PLACE THE TOP OF THE LEFT SIDE ASSEMBLY FLUSH TO THE MARK ON THE RIGHT REAR CORNER POST. ATTACH THE LEFT SIDE ASSEMBLY TO THE INSIDE OF THE CORNER POST WITH #8 X 3" WOOD SCREWS.

RIGHT SIDE ASSEMBLY (LEG ON INSIDE)

NOTE: ROCK WALL AND LADDER REMOVED FOR CLARITY.

#8 X 3" WOOD SCREW

LEFT SIDE ASSEMBLY (LEG ON INSIDE)

26-3/8"

Page 94

STEP 45: PICNIC TABLE

1: LOCATE FOUR 5/4 X 6 X 43" PT TOP AND SEAT BOARDS.

2: CENTER THE HOLES IN THE BOARDS OVER THE TOP OR SEAT SUPPORTS.

3: FASTEN THE PT TOP AND SEAT BOARDS TO THE TOP OR SEAT SUPPORTS WITH #8 X 2-1/2" WOOD SCREWS.

5/4 X 6 X 43" PT TOP/SEAT BOARDS

#8 X 2-1/2" WOOD SCREWS

Page 95

STEP 46: ROPE LADDER

1: FIND THREE ROPE LADDER ROPES. MAKE A KNOT IN THE END OF EACH ROPE AND THREAD THE FREE END THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT. PULL EACH ROPE TAUGHT.

2: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER SUPPORT 14" AND TIE A KNOT. THE BOTTOM OF THE KNOT SHOULD BE 14 INCHES BELOW THE ROPE LADDER SUPPORT. SLIDE EACH ROPE THROUGH THE HOLES IN ONE ROPE LADDER RUNG. SLIDE THE RUNG UP AGAINST THE BOTTOM OF THE KNOTS.

3: TIE THREE KNOTS BELOW THE ROPE LADDER RUNG.

4: MEASURE DOWN FROM THE BOTTOM OF THE ROPE LADDER RUNG 10-5/8" AND MAKE A MARK ON THE ROPE WITH A PIECE OF TAPE OR A MARKER. THREAD ANOTHER ROPE LADDER RUNG ONTO THE HOLES.

5: WITH THE TOP OF THE RUNG EVEN WITH THE 10-5/8" MARK TIE THREE KNOTS BELOW THE SECOND ROPE LADDER RUNG.

6: REPEAT SUBSTEPS 4-5 FOR THE REMAINING ROPE LADDER RUNGS.

7: THREAD THE BOTTOM END OF EACH ROPE THROUGH THE HOLES IN THE ROPE LADDER RUNNER AND TIE THEM OFF. GRAB EACH ROPE AND ATTEMPT TO WRAP IT AROUND YOUR HAND. IF THE ROPE WRAPS AROUND YOUR HAND IT IS TOO LOOSE. IF THE ROPE IS TOO LOOSE UNTIE THE KNOT BEHIND THE ROPE LADDER RUNNER AND RETIE IT UNTIL YOU CAN NO LONGER WRAP THE ROPE AROUND YOUR HAND.

ROPE LADDER SUPPORT

1) TIE A KNOT IN EACH ROPE AND THREAD THEM THROUGH THE BACK SIDE OF THE ROPE LADDER SUPPORT.

2) MEASURE DOWN 14" BELOW THE BOTTOM OF THE ROPE LADDER SUPPORT AND TIE 3 KNOTS. THE BOTTOM OF EACH KNOT SHOULD BE 14" BELOW THE ROPE LADDER SUPPORT.

14"

2.1) SLIDE A ROPE LADDER RUNG AGAINST THE THREE KNOTS.

3) TIE THESE THREE KNOTS BELOW THE ROPE LADDER RUNG.

4) MEASURE DOWN 10-5/8" BELOW THE ROPE LADDER RUNG AND PLACE TAPE ON THE ROPE OR MARK WITH A PEN.

THIS IS THE VIEW AS IF YOU WERE STANDING AT THE RIGHT SIDE OF THE PLAY SET.

5) SLIDE THE NEXT ROPE LADDER RUNG UP TO THE MARKS OR TAPE. TIE THREE KNOTS UNDER THE ROPE LADDER RUNG.

6) REPEAT 4 & 5 FOR REMAINING ROPE LADDER RUNGS

7) TIE KNOTS ON BACK SIDE OF ROPE LADDER RUNNER.

ROPE LADDER RUNNER

Page 96

STEP 47: EXTREME TUBE SLIDE

1: ASSEMBLE THE EXTREME TUBE SLIDE (SEE INSTRUCTIONS ENCLOSED IN EXTREME TUBE SLIDE BOX.)

2: USE STEP 47A TO ATTACH THE SLIDE TO THE PLAY SET.

PLACE A PLASTIC "T-SHAPED" PLUG IN THE HOLE IN THE CORNER POST HERE BEFORE MOUNTING THE SLIDE TO THE PLAY SET IN THE NEXT STEP.

Page 97

STEP 47A: ATTACHING THE SLIDE TO THE FORT

1: ATTACH SLIDE ENTRY ASSEMBLY TO THE CORNER POST AND CENTER POST OF THE FORT WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" FENDER WASHERS.

2: DO NOT ATTACH THE BOTTOM RIGHT HOLE OF THE SLIDE ENTRY PLATE AT THIS TIME.

5/16" FENDER WASHER

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

LEAVE THIS HOLE EMPTY

Page 98

STEP 47B: SLIDE PANEL

1: FIND THE 2 X 4 X 21-1/2" END PANEL BOARD, AND THE 2 X 6 X 21-1/2" END PANEL BOARD. 2: PLACE THE 2 X 6 X 21-1/2" BOTTOM PANEL BOARD AGAINST THE CORNER POST WITH OFFSET HOLES DOWN, AND MOUNT THE BOTTOM RIGHT HOLE WITH A 5/16 X 4-1/2" HEX BOLT AND 5/16" WASHER INTO THE HOLE OF THE CORNER POST, AND INTO THE T-NUT. 3: FASTEN THE REMAINING HOLES OF THE 2 X 6 X 21-1/2" END PANEL BOARD TO THE CORNER POST AND CENTER POST WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 4: PLACE THE 2 X 4 X 21-1/2" END PANEL BOARD ABOVE THE 2 X 6 X 21-1/2" END PANEL BOARD, AND FASTEN TO THE CENTER POST AND CORNER POST WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS. 5: FROM THE INSIDE OF THE FORT, FASTEN THE 5/4 X 3 X 33 PANEL SLATS WITH 2" WOOD SCREWS. 6: TIGHTEN ALL HARDWARE ON THE SLIDE.

5/4 X 3 X 33" PANEL SLAT

2 X 4 X 21-1/2" END PANEL BOARD

5/16" WASHERS (3 THIS SIDE)

5/16 X 3-1/2" LAG SCREW (3 THIS SIDE) 5/16 X 3-1/2"

2 X 6 X 21-1/2" END PANEL BOARD

LAG SCREWS

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

5/16" WASHERS

5/16" WASHER

Page 99

STEP 47C: ATTACHING SLIDE HEADER BOARD

1: PLACE THE 2 X 4 X 29-1/4" SLIDE HEADER BOARD BETWEEN THE SLIDE AND THE ROPE LADDER SUPPORT. ATTACH SLIDE HEADER BOARD TO POSTS WITH 5/16 X 3-1/2" LAG SCREWS AND 5/16" WASHERS.

2 X 4 X 29-1/4" SLIDE HEADER BOARD

5/16" WASHER

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

2 X 6 X 79-1/2" ROPE LADDER SUPPORT

Page 100

STEP 48: ANGLE SUPPORTS ON TUBE SLIDE SIDE

1: TWO 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE RIGHT SIDE (TUBE SLIDE SIDE).

2: FOR THE ANGLE SUPPORT AT THE RIGHT REAR USE TWO 2-1/2" WOOD SCREWS THROUGH THE TOP OF THE BRACE INTO THE 2 X 6 X 21-1/2" END PANEL BOARD. USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE SUPPORT TO THE RIGHT REAR CORNER POST.

USE TWO 2-1/2"

WOOD SCREWS

TO FASTEN THIS

ANGLE SUPPORT

TO THE DECK

BOARD

3: FOR THE 2 X 4 X 18" ANGLE SUPPORTS AT THE RIGHT FRONT USE TWO2-1/2" WOOD SCREWS THROUGH THE DECK AND INTO THE ANGLE SUPPORT. USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE RIGHT FRONT ANGLE SUPPORTS TO THE RIGHT FRONT CORNER POST.

3" WOOD

SCREW

2" WOOD

SCREW

USE TWO 2-1/2" WOOD SCREWS TO FASTEN THE ANGLE SUPPORT TO THE 2 X 6 X 21-1/2" END PANEL BOARD.

2 X 4 X 18"

ANGLE SUPPORT

AT RIGHT REAR.

2 X 4 X 18" ANGLE SUPPORT AT RIGHT FRONT.