Page 1
Passage
Model: 1800
(BOXES: 1800-1, 1800-2
& Slide Box)
Copyright © 2016 PlayNation Play Systems, Inc.
All Rights Reserved
*52-2001-T*
52-2001-T
190 Etowah Industrial Court
Canton, GA 30114
www.playnation.com
Page 2
Please inspect and inventory all parts immediately upon accepting delivery. Use the
inventory pages in the manual to make sure you have received all necessary parts.
The quickest method to get any parts that are missing or damaged is use our “Quick
Response Center” located at:
www.playnation.com/support
DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE RETAILER DIRECTLY.
THE RETAILER DOES NOT STOCK COMPONENTS.
PLEASE RETAIN ALL INSTRUCTIONS FOR FUTURE REFERENCE. KEEP THEM IN A SAFE
PLACE WHERE YOU CAN REFER TO THEM AS NEEDED. CHECK FOR REVISED INSTRUCTIONS AT:
http://www.playnation.com/manuals.html
Page 3
PLAYNATION WARRANTY 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™ 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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Page 7
WARRANTY REGISTRATION
- PASSAGE (1800) -
PlayNaon 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 Registraon on le.
Where did you buy this product?:
Store Store City Store StateDate of
Purchase
OPTION 1
OPTION 2
OPTION 3
3 EASY WAYS TO REGISTER
Fax this completed form to:
(800) 880-3300
Complete the online registraon form at:
hp://www.playnaon.com/register
Scan this QR Code
with your smart
phone to complete
the form using your
OR
phone
Mail this completed form to:
PlayNaon Playsets
190 Etowah Industrial Court
Canton, GA 30114
Your registraon informaon:
Name: Email:
Address:
Street City State Zip
Please select
your age?
18-30
31-40
41-50
51+
How would
you rate the
quality of
this product?
How old are
your children?
2-3
4-5
6-7
8+
Would you recommend this product to friends & family?
Comments:
Excellent
Above Average
Average
Below Average
Poor
Yes No
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Page 9
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: 1800
(BOXES: 1800-1, 1800-2,
& Slide Box)
REV B: 2.22.2016
Page 12
TABLE OF CONTENTS
2
Safety Guidelines……………………………………….......……...........................Pages 3-6
Leveling Fort, General Information and Denitions…………………...................Pages 6-8
How to Install T-nuts, Board Identication, 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 16-26
Adding T-Nuts to Corner Posts...…………………………………..………...…...... Steps 1-2
Framing Fort……………………………………..…………………………..……..... Steps 3-7
Mounting Deck Supports…………………………....……………….…………...…...... Step 8
Attaching Fort Side Supports.....………………………...…..……..……...….……..... Step 9
Attaching Deck Spacers and Ladder Assembly..……………………..……...... Steps 10-12
Building and Mounting Rockwall…………….……………………..……........… Steps 13-15
Adding Deck Boards, Panel Supports and Wall Slats..……...……………..… Steps 16-18
Swing Beam Assembly………………………………………………………........Steps 19-27
Center Posts, Framing Tarp………………...…………………………….…....... Steps 28-29
Mounting Slide.………………………………………………………….....………....... Step 30
Hanging Swings……………………………………………………….…….……......... Step 31
Securing Tarp………………………………………………………………..……......... Step 32
Attaching Front Arch Board, Stringers, and Climbing Rope…….................... Steps 33-35
Flag Kits………………………………………………………………………………......Step 36
Attaching Accessories and Ground Stakes……………....…………………….. Steps 37-40
Attaching Safety Board.......................................................................................... Step 41
Attaching Logo Plate............................................................................................. Step 42
PLEASE READ OWNER’S MANUAL CAREFULLY
BEFORE STARTING ASSEMBLY!
Page 13
Safety and Maintenance Tips for Your New Play Set:
3
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 headrst.
• 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 specically
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:
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 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:
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.
Page 16
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)
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
7
• 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 denitions 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.
Page 19
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.
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
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
Page 21
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
Page 22
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
SWING BEAM LOADING
Weight Limits for Accessories:
13
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
1800 - Series (2016 only)
Set name: Passage
This set uses revised 1800 wood 2 x 6 arched front board and the new 8' Wiki slide. Ground stakes are new also.
The Outing this same year uses the injection molded slide instead of the Wiki slide.
Height: 10'-3"
Please familiarize yourself with the manual, parts/components and general
14
construction process of your new playset before getting started.
SITE PLAN:
13'-7"
TRAPEZE
3'-1"
BAR (1)
7
12'-7
3
16
3
8'-9
"
"
16
TOP VIEW
NOTE: TARP REMOVED
FOR CLARITY.
SWING BELT (2)
7'-3
"
8
3'-8"
3
16
"
5'-10
3'-9
1
"
2
1
1'-6
2
LADDER
ROCK
WALL
9
2'-8
"
16
"
Playset height:10 feet -3 inches
Swing Beam height: 7 feet - 2-1/2 inches
Deck Height: 4 feet
Approximate assembly time: 5-7 hours
(6) foot unobstructed safety perimeter around playset recommended
8’ WIKI
WAVE SLIDE
Page 25
REQUIRED TOOL LIST:
15
___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided)
___ Drill Bits 1/8”, 3/16”, 3/8”, 11/64”
___ ½” Wrench and Socket
___ ½” Deep Well Socket
___ 9/16” Deep Well Socket
___ 9/16” Wrench and Socket
___ Level
___ Tape Measure
___ Extension Cord (if using standard drill)
___ Hammer
___ Pencil
___ Locking Pliers (Vise Grips)
___ Shovel
KIT CONTENTS
Swings, Slides, Accessories:
___ (Qty ) Description
___ (2) Swingbelt w/ Chains
___ (1) Trapeze Swing
___ (1) 8’ Wiki Wave Slide
___ (1) Assembly Manual
___ (10) Rock Wall Grips (assorted colors)
___ (1) Telescope
___ (1) Steering Wheel
___ (2) Safety Handle
___ (1) Tarp (05-0013)
___ (4) Ground Stake
___ (2) Flag
Fort Hardware:
see following pages
Swing Beam Hardware:
see following pages
Wood Components:
see following pages
Page 26
11-0053
16
1800 HARDWARE
PAGE 1 OF 2
REV D: 8/24/2015 JH
9
#14 X 1-1/4"
PAN HEAD SCREW
QTY: 9
#8 X 1-1/4"
WOOD SCREW
QTY: 4
#8 X 2"
WOOD SCREW
QTY: 183
#8 X 2-1/2"
WOOD SCREW
QTY: 28
#8 X 3"
WOOD SCREW
QTY: 4
5/16" TEE NUT
QTY: 42
8
7
6
5
3/8" LOCK NUT
QTY: 21
5/16 X 4"
HEX BOLT
QTY: 32
5/16 X 2-1/2"
HEX BOLT
QTY: 6
TORQUE WASHER
5/16 X 1-1/2"
HEX BOLT
QTY: 4
QTY: 19
3/8" WASHER
QTY: 37
5/16" WASHER
QTY: 42
1/4"" WASHER
QTY: 6
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
11-0053
17
1800 HARDWARE
PAGE 2 OF 2
REV D: 8/24/2015 JH
3/8 X 2-1/2"
HEX LAG
SCREW
QTY: 8
3/8 X 3-1/2"
HEX LAG
SCREW
QTY: 8
9
8
7
6
#2 SQUARE
DRIVE BIT
QTY: 1
PLASTIC
BOLT CAP
QTY: 21
5
4
3
2
1
3/8" X 9"
CARRIAGE BOLT
QTY: 1
3/8" X 7"
CARRIAGE BOLT
QTY: 10
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.
3/8 x 6-1/2"
CARRIAGE BOLT
QTY: 4
3/8 x 4-1/2"
CARRIAGE BOLT
QTY: 4
3/8 x 3-1/2"
CARRIAGE BOLT
QTY: 2
Page 28
DESCRIPTIONPICTURE QTY.
18
8' WIKI
WAVE SLIDE
03-0015
SWING
W/CHAINS
04-0002
TRAPEZE BAR
W/CHAINS
04-0006
1
2
1
SWING PLATE
11-5002
CLIMBING ROCK
(5 IN A BAG)
07-0008
A-FRAME SWING
LEG BRACKET
11-5010
1
10
1
HARDWARE BOX: 1800
HARDWARE
BOX
1EA
INSTRUCTIONS
Page 29
DESCRIPTIONPICTURE QTY.
19
IRON DUCTILE
SWING HANGER
6
11-4024
GREEN
90
BRACKET
2
11-5013
10' ROPE
TARP
44" X 113"
05-0013
FLAG
09-1014
1
1
2
GROUND STAKE
(2 IN A BAG)
07-0016-P
TELESCOPE
07-0001
4
1
Page 30
PICTURE DESCRIPTION QTY.
20
STEERING WHEEL
(NOT SHOWN)
07-0004
SAFETY HANDLE
(2 IN A BAG)
07-0005
LOGO PLATE
1
2
1
Page 31
PICTURE DESCRIPTION QTY.
21
2 X 4 X 17"
LADDER STEP
2-4-1700-LS
2 X 4 X 29"
REAR CENTER
POST
2-4-2900-RCP
2 X 4 X 44"
CENTER TARP
BOARD
2-4-4400-CTB
4
1
1
2 X 4 X 44"
DECK AND
PANEL
SUPPORT
2-4-4400-DPS
2 X 4 X 44"
ROCK WALL SIDE
TOP PANEL
BOARD
2-4-4400-RWSTPB
2 X 4 X 44"
STRINGER
2-4-4400-S
5
1
1
2 X 4 X 45-1/2"
FRONT FACE
BOARD
2-4-4550-FFB
1
Page 32
PICTURE DESCRIPTION QTY.
22
2 X 4 X 45-1/2"
PANEL
SUPPORT
2-4-4550-PS
2 X 4 X 46-3/4"
END TARP
BOARD
2-4-4675-ETB
2 X 4 X 47-1/2"
FORT SIDE
SUPPORT
2
2
2
2-4-4750-FSS
2 X 4 X 51"
ROCK WALL
STRINGER
2-4-5100-RWS
2 X 4 X 56"
ROCK WALL SIDE
SUPPORT
2-4-5600-RWSS
2 X 4 X57"
LADDER
LEFT SIDE
1
2
1
2-4-5700-LLS
2 X 4 X 57"
LADDER
RIGHT SIDE
2-4-5700-LRS
1
Page 33
PICTURE DESCRIPTION QTY.
23
2 X 4 X 58"
SWING LEG
CROSS
MEMBER
2-4-5800-CM
2 X 4 X 73-9/16"
FRONT CENTER
POST
2-4-7356-FCP
2 X 4 X 81"
TARP SUPPORT
BOARD
1
1
2
2-4-8100-TSB
2 X 6 X 44"
END
SANDBOX
BOARD
2-6-4400-ESB
2 X 6 X 45-1/2"
FRONT ARCH
BOARD
2-6-4550-FAB
2 X 6 X 73"
LEFT SIDE
SANDBOX BOARD
1
1
1
2-6-7300-LSSB
2 X 6 X 73"
RIGHT SIDE
SANDBOX BOARD
2-6-7300-RSSB
1
Page 34
PICTURE DESCRIPTION QTY.
24
2 X 6 X 95-1/2"
END SANDBOX
BOARD
2-6-9550-ESB
3 X 3 X 96"
CORNER POST 1
1
1
3-3-9600-CP1
3 X 3 X 96"
CORNER POST 2
1
3-3-9600-CP2
3 X 3 X 96"
CORNER POST 3
3-3-9600-CP3
3 X 3 X 96"
CORNER POST 4
3-3-9600-CP4
3 X 3 X 96"
SWING LEG
3-3-9600-SL
1
1
2
4 X 4 X 44"
SWING BEAM
MOUNT
4-4-4400-SBM
1
Page 35
PICTURE DESCRIPTION QTY.
25
4 X 4 X 81"
TRAPEZE ARM
1
4-4-8100-TA
4 X 6 X 87-1/4"
SWING BEAM
1
4-6-8725-SB
5/4 X 3 X 28-1/2"
PANEL SLAT
14
125-3-2850-PS
5/4 X 4 X 18-1/2 "
LADDER BACK
125-4-1850-LB
5/4 X 4 X 39-1/2"
DECK SPACER
125-4-3950-DS
5/4 X 4 X 44"
BOTTOM ROCK
WALL BOARD
125-4-4400-BRWB
1
2
1
5/4 X 4 X 44"
ROCK WALL
BOARD
125-4-4400-RWB
15
Page 36
PICTURE DESCRIPTION QTY.
26
5/4 X 4 X 45-1/2"
DECK BOARD
125-4-4550-DB
10
Page 37
STEP 1: CORNER POST LAYOUT
27
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: LAY OUT EACH OF THE 3 X 3 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT SIDE OF THE
PLAYSET.
3: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE POSTS IN THE CORRECT DIRECTION.
NOTE: THE LADDER SIDE IS CONSIDERED THE FRONT OF THE PLAYSET WITH THE SWING BEAM EXTENDING OFF TO
THE LEFT SIDE.
LEFT SIDE WILL
HAVE EXTRA HOLES
AT THIS LOCATION
3 X 3 X 96"
CORNER POST
REAR CORNER
POSTS WILL HAVE
EXTRA HOLES AT
THIS LOCATION
CORNER POST #2
FRONT OF PLAY SET
CORNER POST #3
CORNER POST #4
CORNER POST #1
Page 38
STEP 2: INSERTING T-NUTS INTO CORNER POSTS
28
1: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW.
2: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH
TO THE CORNER POSTS.
T-NUT
CORNER POST #2
FRONT OF PLAY SET
CORNER POST #3
CORNER POST #4
CORNER POST #1
Page 39
STEP 3: ATTACHING SANDBOX AND TOP PANEL BOARD
29
1: THE 2 X 6 X 44" SANDBOX BOARD (WITH FOUR PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE RIGHT
SIDE CORNER POSTS, OFFSET HOLES UP, WITH 4" HEX BOLTS AND
2: THE 2 X 4 X 44" ROCK WALL SIDE TOP PANEL BOARD (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE TOP
SET OF HOLES ON THE RIGHT SIDE OF THE CORNER POSTS, OFFSET HOLES UP, WITH 4" HEX BOLTS AND
2 X 4 X 44"
ROCK WALL SIDE
TOP PANEL BOARD
(OFFSET UP)
5
" WASHERS.
16
5
" WASHERS.
16
CORNER POST #2
FRONT OF PLAY SET
CORNER POST #3
CORNER POST #1
CORNER POST #4
5
" WASHER
16
4" HEX BOLT
2 X 6 X 44"
SANDBOX BOARD
(OFFSET UP)
Page 40
STEP 4: ATTACHING END SANDBOX BOARD
30
1: THE 2 X 6 X 95
1
" END SANDBOX BOARD (WITH SIX PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE LEFT
2
SIDE CORNER POSTS WITH 4" HEX BOLTS AND
CORNER POST #2
5
" WASHERS.
16
CORNER POST #3
CORNER POST #1
CORNER POST #4
5
" WASHER
16
4" HEX BOLT
FRONT OF PLAY SET
1
"2 X 6 X 95
2
END SANDBOX
BOARD
Page 41
STEP 5: ATTACHING REMAINING SANDBOX BOARDS
31
1: THE 2 X 6 X 73" SANDBOX BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACHES TO THE BOTTOM OF THE FRONT
AND REAR CORNER POSTS WITH 4" HEX BOLTS AND
2: THE STRUCTURE SHOULD BE ABLE TO STAND ON ITS OWN, WITHOUT ANY SUPPORT, AT THIS STAGE.
5
" WASHERS.
16
CORNER POST #3
CORNER POST #4
CORNER POST #2
REAR
POSTS
CORNER POST #1
FRONT
POSTS
COUNTERBORED
HOLES FACE OUT
4" HEX BOLT
5
" WASHER
16
2 X 6 X 73"
SANDBOX BOARD
COUNTERBORED
HOLES FACE OUT
FRONT OF PLAY SET
Page 42
STEP 6: ATTACHING TARP SUPPORT BOARDS
32
1: THE 2 X 4 X 81" TARP SUPPORT BOARDS (WITH THREE PRE-DRILLED HOLES) ATTACH TO THE TOP OF THE FRONT
AND REAR CORNER POSTS WITH 4" HEX BOLTS AND
5
" WASHERS.
16
2: HOLES SHOULD BE CENTERED VERTICALLY ON BOTH BOARDS.
2 X 4 X 81"
TARP SUPPORT
BOARD
5
" WASHER
16
1
" HEX BOLT
4
2
SHORT END
OVERHANGS
ON THIS SIDE.
FRONT OF PLAY SET
Page 43
STEP 7: ATTACHING PANEL SUPPORT
33
1: THE 2 X 4 X 45
1
" PANEL SUPPORT (WITH TWO PRE-DRILLED HOLES) ATTACHES TO THE SET OF HOLES BELOW THE
2
TARP SUPPORT BOARD ON THE REAR OF THE FORT WITH 4" HEX BOLTS AND
2: HOLES SHOULD BE OFFSET DOWN.
4" HEX BOLT
5
" WASHER
16
5
" WASHERS.
16
2 X 4 X 45
1
"
2
PANEL SUPPORT
(OFFSET DOWN)
REAR OF PLAY SET
Page 44
STEP 8: ATTACHING DECK SUPPORTS
34
1: THE 2 X 4 X 44" DECK SUPPORT BOARDS (WITH TWO PRE-DRILLED HOLES) ATTACH TO THE SET OF HOLES ABOVE
THE END SANDBOX BOARDS ON THE INSIDE OF THE LEFT AND RIGHT SIDE CORNER POSTS WITH 4" HEX BOLTS AND
5
" WASHERS.
16
2: HOLES SHOULD BE OFFSET DOWN ON BOTH BOARDS.
5
" WASHER
16
4" HEX BOLT
2 X 4 X 44"
DECK SUPPORT
END SANDBOX
BOARDS
FRONT OF PLAY SET
Page 45
STEP 9: ATTACHING FORT SIDE SUPPORTS
35
1: LAY THE 2 X 4 X 47
THEY WILL BE INSTALLED ONTO THE FORT. PACE A T-NUT IN THE PRE-DRILLED HOLE ON EACH END AND SECURE
WITH A HAMMER.
2: THE 2 X 4 X 47
SANDBOX BOARD ON THE INSIDE WITH 2
AGAINST THE CORNER POSTS. SEE DETAIL A AND DETAIL B FOR CLARIFICATION IF NECESSARY.
3: ENSURE THAT THE TWO FORT SIDE SUPPORTS ARE ATTACHED PROPERLY TO THE END SANDBOX BOARD BEFORE
SECURING THEM TO THE CORNER POSTS.
1
" FORT SIDE SUPPORTS ON A FLAT SURFACE WITH THE ANGLED ENDS ORIENTATED THE WAY
2
1
" FORT SIDE SUPPORTS (WITH ANGLED ENDS) ATTACH TO THE HOLES ON THE ENDS OF THE END
2
1
" HEX BOLTS AND
2
5
" WASHERS. THE ANGLED ENDS SHOULD REST FLUSH
16
4: PREDRILLING A 1/8" PILOT HOLE THROUGH THE FORT SIDE SUPPORT ONLY MAY HELP PREVENT SPLITTING THE END
OF THE BOARD. USE A 2
WOOD SCREW 1" BELOW THE 2
1
" WOOD SCREW AT THE TOP OF THE BRACE 2
2
1
" WOOD SCREW. SEE DETAIL B FOR CLARIFICATION IF NECESSARY.
2
1
" BELOW THE ANGLED TIP, THEN USE A 3"
2
ANGLED TIP
DETAIL A
5
16
1
2
" HEX BOLT
2
END SANDBOX
BOARD
T-NUT
(INSTALL
FIRST)
" WASHER
1
2
" WOOD SCREW
2
1
" FROM TIP
2
2
3" WOOD SCREW
1" BELOW THE 2
WOOD SCREW
1
"
2
DETAIL B
CORNER
POST
CORNER
POSTS
B
2 X 4 X 47
FORT SIDE
SUPPORT
A
1
"
2
END SANDBOX
BOARD
Page 46
STEP 10: ATTACHING DECK SPACERS, PANEL SUPPORT
36
AND FRONT FACE BOARD
1: THE ORDER IN WHICH THESE BOARDS ARE INSTALLED IS VERY IMPORTANT, FOLLOW THE STEPS CAREFULLY.
1
2: FIRST, WITH OFFSET HOLES DOWN, SECURE THE 2 X 4 X 45
5
4" HEX BOLTS AND
" WASHERS.
16
" PANEL SUPPORT TO THE REAR CORNER POSTS WITH
2
3: SECOND, THE
5
X 4 X 39
4
1
" DECK SPACER MOUNTS BETWEEN THE REAR CORNER POSTS, FLUSH TO THE EDGES,
2
WITH TWO 2" WOOD SCREWS.
4: THIRD, THE
5
X 4 X 39
4
1
" DECK SPACER MOUNTS BETWEEN THE FRONT CORNER POSTS, FLUSH TO THE EDGES, WITH
2
TWO 2" WOOD SCREWS.
1
5: FOURTH, THE TOP SURFACE OF THE 2 X 4 X 45
" FRONT FACE BOARD WILL BE FLUSH TO THE TOP OF THE DECK
2
SPACER. SECURE THE FRONT FACE BOARD TO THE FRONT CORNER POSTS WITH THREE 2
SIDE.
2 X 4 X 45
1
"
2
PANEL SUPPORT
MOUNT FIRST
5
" WASHER
16
1
" WOOD SCREWS PER
2
4" HEX BOLT
1
2
" WOOD
2
SCREW
2" WOOD
SCREW
2 X 4 X 45
1
"
2
FRONT FACE
BOARD
MOUNT FOURTH
REAR OF PLAY SET
5
X 4 X 39
4
1
"
2
DECK SPACER
MOUNT SECOND
AND THIRD
FRONT OF PLAY SET
Page 47
STEP 11: LADDER ASSEMBLY
37
1: LAY ONE 2 X 4 X 57" LADDER SIDE ON A FLAT SURFACE WITH CHANNELS FACING DOWN. PLACE THE BARREL OF
A T-NUT IN THE HOLE AT THE TOP OF THE LADDER SIDE, AND SECURE WITH A HAMMER. REPEAT THIS STEP FOR THE
OTHER LADDER SIDE.
2: FLIP THE LADDER SIDE OVER SO THAT THE CHANNELS ARE FACING UP.
3: PLACE THE LADDER STEPS INTO THE CHANNELS, AND THEN PLACE THE SECOND LADDER SIDE ON TOP, WITH THE
CHANNELS FACING DOWN.
4: NOW PLACE TWO 2" WOOD SCREWS IN EACH STEP.
5: CAREFULLY TURN THE LADDER OVER AND FINISH THE OTHER SIDE WITH TWO 2" WOOD SCREWS PER STEP.
6: INSTALL TWO 90
5
7: INSTALL THE
X 4 X 18
4
SCREWS PER SIDE.
5
" WASHER
16
1
1
" HEX BOLT
2
2 X 4 X 17"
LADDER STEP
GREEN BRACKETS USING 1
1
" LADDER BACK ABOVE THE OPENING OF THE TOP CHANNELS WITH TWO 2" WOOD
2
1
" BOLTS AND
2
5
" WASHERS
16
BRACKET
90
T-NUT
2" WOOD SCREW
5
X 4 X 18
4
1
"
2
LADDER BACK
2 X 4 X 57"
LADDER SIDE - RIGHT
2" WOOD SCREW
2 X 4 X 57"
LADDER SIDE - LEFT
PRIOR TO ASSEMBLY
YOU MAY WISH TO
DRILL TWO 1/8"
HOLES CENTERED IN
THE CHANNELS OF
EACH LADDER SIDE.
Page 48
STEP 12: ATTACHING THE LADDER
38
1: THE LADDER ATTACHES TO THE FRONT SIDE AT THE RIGHT, FLUSH TO THE INSIDE EDGE OF THE CORNER POST.
2: THE BOTTOM EDGE OF EACH 90 GREEN BRACKET SHOULD BE 3/4" FROM THE BOTTOM OF THE 2 X 4.
3: MAKE SURE THE LADDER IS LEVEL AND MARK THE POSITION OF THE BRACKET HOLES ON THE 2 X 4.
3
4: DRILL
5: INSERT T-NUTS IN THE BACK OF THE HOLES.
" HOLES WHERE MARKED.
8
6: ATTACH THE BRACKETS TO THE 2 X 4 WITH 1
5
" WASHER
16
11" HEX BOLT
2
2 X 4
1
" HEX BOLTS WITH
2
3/4"
5
" WASHERS.
16
T-NUTS, INSTALL IN BACK SIDE
OF 2 X 4 AFTER DRILLING HOLES
FOR 90
GREEN BRACKETS.
FRONT OF PLAY SET
OUTSIDE EDGE OF LADDER
IS FLUSH TO THE INSIDE EDGE
OF THE CORNER POST
Page 49
STEP 13: ROCK WALL SIDE SUPPORTS
39
1: LAY THE 2 X 4 X 56" ROCK WALL SIDE SUPPORTS ON A FLAT SURFACE. PLACE THE BOTTOM ANGLED END WITH
HOLE ORIENTATED THE WAY THEY WILL BE INSTALLED ONTO THE FORT. PLACE A T-NUT IN THE PRE-DRILLED HOLE
ON THE END AND SECURE WITH A HAMMER.
2: LINE UP THE HOLE IN THE BOTTOM OF EACH 2 X 4 X 56" ROCK WALL SIDE SUPPORT (WITH ANGLED ENDS) TO THE
HOLES ON THE ENDS OF EACH EXTENDED SANDBOX BOARD. ATTACH EACH ROCK WALL SIDE SUPPORT TO THE
INSIDE OF EACH EXTENDED SANDBOX BOARD WITH 2
SHOULD REST FLUSH AGAINST THE CORNER POSTS.
3: ENSURE THAT THE TWO ROCK WALL SUPPORTS ARE ATTACHED PROPERLY TO THE SANDBOX BOARDS BEFORE
SECURING THEM TO THE CORNER POSTS.
1
" HEX BOLTS AND
2
5
" WASHERS. THE TOP ANGLED END
16
4: PREDRILLING A 1/8" PILOT HOLE THROUGH THE ROCK WALL SIDE SUPPORT ONLY MAY HELP PREVENT SPLITING
THE END OF THE BOARD. USE A 2
WOOD SCREW 1" BELOW THE 2
1
" WOOD SCREW AT THE TOP OF THE SUPPORT 2
2
1
" WOOD SCREW.
2
1
" BELOW THE TIP, THEN USE A 3"
2
TIP
21" WOOD SCREW
2
3" WOOD SCREW
2 X 4 X 56"
ROCK WALL
SIDE SUPPORT
1
" HEX BOLT
2
2
5
" WASHER
16
T-NUTS
Page 50
STEP 14: ATTACHING THE ROCK WALL BOARDS
40
1: BEGIN WITH THE UPPER MOST
TO THE ROCK WALL SUPPORT WITH TWO 2" WOOD SCREWS PER SIDE. THE
ROUNDED EDGE OF THE ROCK WALL BOARD SHOULD BE ABOUT 1/8" AWAY
FROM THE CORNER POSTS BEFORE ATTACHING. (SEE DETAIL H BELOW)
2: CONTINUE MOUNTING THE REMAINING ROCK WALL BOARDS TO THE
ROCK WALL SUPPORTS WITH 2" WOOD SCREWS. THERE SHOULD BE NO GAPS
BETWEEN THE BOARDS.
3: THE
5
X 4 X 44" BOTTOM ROCK WALL BOARD WITH ONE HOLE WILL MOUNT
4
AT THE BOTTOM. THIS BOARD WILL FASTEN WITH 2" WOOD SCREWS AS WELL.
5
X 4 X 44" ROCK WALL BOARD AND SECURE
4
H
1
"
8
DETAIL H
SCALE 1 : 6
5
X 4 X 44"
4
ROCK WALL BOARD
2" WOOD SCREW
5
X 4 X 44"
4
BOTTOM ROCK
WALL BOARD
(ONE HOLE)
Page 51
STEP 15: ATTACHING THE ROCKS
41
1: THE ROCKS SHOULD FOLLOW THE GENERAL STAGGERED LAYOUT SHOWN BELOW. HOWEVER, A DIFFERENT
CONFIGURATION CAN BE USED.
1
2: THE ROCKS INCLUDED WITH YOUR PLAYSET MAY VARY, IN ANY CASE, THE 1
WASHERS INCLUDED WITH THE ROCKS WILL BE USED TO ATTACH THE ROCKS.
" PANHEAD SCREWS AND 1/4"
4
ROCKS
1
" WASHER
4
1
" PANHEAD SCREW
1
4
Page 52
STEP 16: ATTACHING THE DECK BOARDS
42
1: TEN
5
X 4 X 45
4
2: SPACE THE DECK BOARDS EVENLY ACROSS THE SUPPORTS. THERE WILL BE APPROXIMATELY 3/16" GAPS
BETWEEN THE DECK BOARDS AND/OR DECK SPACERS.
3: SECURE EACH DECK BOARD TO THE DECK SUPPORTS WITH FOUR 2" WOOD SCREWS, TWO PER SIDE.
1
" DECK BOARDS WILL LAY ACROSS THE DECK SUPPORTS.
2
5
X 4 X 45
4
1
"
2
DECK BOARD
2" WOOD SCREW
DECK SPACER
DECK SPACER
Page 53
STEP 17: PANEL SUPPORTS
43
1: THE 2 X 4 X 44" PANEL SUPPORT BOARDS SHOULD HAVE THE HOLES OFFSET UP. USE 4" HEX BOLTS AND
WASHERS TO SECURE THE BOARDS TO THE CORNER POSTS.
1
"
2
5
" WASHER
16
4" HEX BOLT
2 X 4 X 47
PANEL SUPPORT
(OFFSET UP)
5
"
16
SWING BEAM SIDE OF FORT
(LEFT SIDE AS VIEWED FROM FRONT OF PLAY SET.)
Page 54
STEP 18: PANEL/WALL SLATS
44
1. BEGIN ON THE REAR WALL OF THE FORT WITH SEVEN SLAT BOARDS (
OF THE PANEL SUPPORT BOARDS. SPACE THE BOARDS AS SHOWN IN THE "REAR SLAT SPACING" DIAGRAM BELOW.
FASTEN EACH BOARD TO THE PANEL SUPPORTS WITH TWO 2" WOOD SCREWS.
5
X 3 X 28
4
1
"). PLACE THE SLATS ON THE INSIDE
2
5
2. GO TO THE LEFT SIDE WALL OF THE FORT WITH SEVEN SLAT BOARDS (
INSIDE OF THE PANEL SUPPORT BOARDS. SPACE THE BOARDS AS SHOWN IN THE "LEFT SIDE SLAT SPACING"
DIAGRAM BELOW. FASTEN EACH BOARD TO THE PANEL SUPPORTS WITH TWO 2" WOOD SCREWS.
REAR SLAT SPACING
5/4 X 3 X 28-1/2"
PANEL SLAT
X 3 X 28
4
(VIEW FROM REAR OF PLAY SET)
5
2
"
8
1
"). PLACE THE SLATS ON THE
2
2" WOOD
SCREWS
DETAIL G
SCALE 1 : 16
5
2
" SPACING
8
LEFT SIDE SLAT SPACING
(VIEW FROM LEFT SIDE OF PLAY SET)
2
7
16
REAR
SLATS
LEFT SIDE
SLATS
G
"
7
2
" SPACING
16
Page 55
STEP 19: SWING BEAM MOUNT AND TRAPEZE ARM
45
1: THE 4 X 4 X 44" SWING BEAM MOUNT HAS COUNTERBORED HOLES IN THE CENTER, AND ON THE ENDS. INSTALL
THE SWING BEAM MOUNT SO THAT THE COUNTERBORED HOLES ON EACH END OF THE BEAM FACE OUT, AND THE
COUNTERBORED HOLES AT THE CENTER FACE DOWN.
1
2: FASTEN THE SWING BEAM MOUNT TO THE CORNER POSTS USING 6
PLACE THE CARRIAGE BOLT INTO THE TORQUE WASHER, THEN INTO THE HOLE OF THE CORNER POST AND SET WITH
A HAMMER. USE
3
" LOCK NUTS AND WASHERS TO SECURE THE SWING BEAM MOUNT FROM THE OUTSIDE. PLACE
8
BOLT CAPS OVER THE EXPOSED THREADS AFTER SECURING.
3: THE 4 X 4 X 81" TRAPEZE ARM WILL ATTACH TO THE UNIT IN THE SAME MANNER AS THE SWING BEAM MOUNT. THE
TRAPEZE ARM WILL MOUNT ON THE OPPOSITE SIDE OF THE UNIT ABOVE THE ROCK WALL.
THE HOLE ABOVE THE SWING BEAM
MOUNT IS TO BE USED ON UNEVEN
(UPHILL) GROUND. IF INSTALLING
ON A RELATIVELY LEVEL SURFACE,
A
TRAPEZE
ARM
THIS HOLE WILL NOT BE USED.
B
3
" WASHER
8
3
" LOCK NUT
8
BOLT CAP
" CARRIAGE BOLTS WITH TORQUE WASHERS.
2
SWING BEAM MOUNT
COUNTERBORED
HOLES FACING
OUT
VIEW OF LEFT SIDE OF PLAY SET
6-1/2" CARRIAGE BOLT
AND TORQUE WASHER
COUNTERBORED
HOLES FACING
DOWN
4 X 4 X 44"
SWING BEAM
MOUNT
VIEW OF RIGHT SIDE OF PLAY SET
4 X 4 X 81" TRAPEZE ARM
Page 56
STEP 20: SWING BEAM PLATE
46
1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM MOUNT, LINING UP PILOT HOLES.
2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM MOUNT ON THE OUTER HOLES USING 3
ON TOP, AND
3
" WASHERS AND
8
3
" LOCK NUTS ON THE BOTTOM. PLACE GREEN BOLT COVERS OVER EXPOSED
8
THREADS AFTER SECURING.
3: LEAVE THE MIDDLE HOLE EMPTY, IT WILL BE USED LATER.
1
2
" CARRIAGE BOLTS
3
" WASHER
8
3
" LOCK NUT
8
BOLT CAP
1
3
" CARRIAGE BOLT
2
SWING BEAM
PLATE
Page 57
STEP 21: ATTACH SWING LEGS TO BRACKET
47
1: PLACE THE 3 X 3 X 96" SWING LEGS FLUSH TO THE TOP OF THE SWING LEG BRACKET. MARK THROUGH THE HOLE
LOCATIONS IN THE BRACKET ONTO THE SWING LEGS. DRILL 11/64" HOLES 2-1/2" DEEP AT EACH MARK.
2: FASTEN THE SWING LEGS TO THE SWING LEG BRACKET WITH 2
SWING LEGS FLUSH
TO TOP OF SWING
LEG BRACKET
1
" LAG SCREWS AND
2
3
" WASHERS.
8
1
" LAG SCREW
2
2
3
" WASHER
8
SWING LEG BRACKET
3 X 3 X 96" SWING LEG
Page 58
STEP 22: IRON DUCTILE SWING HANGERS
48
1: LINE UP THE HOLES OF THE IRON DUCTILE SWING HANGERS WITH THE HOLES IN THE SWING BEAM.
2: FASTEN THE IRON DUCTILE SWING HANGERS TO THE 4 X 6 X 87
TORQUE WASHERS ON TOP OF THE SWING BEAM, AND
3
" LOCK NUTS AND
8
1
" SWING BEAM USING 7" CARRIAGE BOLTS WITH
4
3
" WASHERS ON THE BOTTOM. PLACE
8
BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
3: FASTEN THE IRON DUCTILE SWING HANGERS TO THE TRAPEZE ARM IN THE SAME MANNER THAT YOUR FASTENED
THEM TO THE SWING BEAM. USE 4-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE TRAPEZE ARM.,
3
" LOCK NUTS AND
AND
8
3
" WASHERS ON THE BOTTOM. PLACE BOLT CAPS OVER ANY EXPOSED THREADS AFTER
8
SECURING.
1
"
4
7" CARRIAGE BOLTS
4 X 6 X 87
SWING BEAM
TORQUE
WASHER
TRAPEZE ARM
3
WASHER
"
8
3
LOCK NUT
"
8
BOLT CAP
IRON DUCTILE
SWING HANGER
BOLT CAP
1
"
4
CARRIAGE BOLTS
2
TORQUE
WASHER
IRON DUCTILE
SWING HANGER
3
WASHER
"
8
3
LOCK NUT
"
8
Page 59
STEP 23: REST SWING BEAM ON FORT
49
*TWO PEOPLE ARE REQUIRED FOR THIS STEP
1: SIT THE SWING BEAM LEGS UPRIGHT.
2: LINE UP THE PRE-DRILLED HOLES AND REST THE SWING BEAM ON TOP OF THE SWING BEAM SUPPORT PLATE AND
SWING LEGS. MAKE SURE THE IRON DUCTILE SWING HANGERS ARE FACING DOWN.
TIP: IF YOU ARE ALONE BUILDING THE PLAY SET THEN LAY THE SWING BEAM ACROSS THE TOP OF THE SWING BEAM
MOUNT AND THE TRAPEZE ARM ABOVE THE DECK OF THE PLAY SET. THEN PROCEED TO STEP 24 TO CONNECT THE
LEGS TO THE END OF THE BEAM. GET AN ASSISTANT TO HELP CARRY THE SWING BEAM OUT AWAY FROM THE FORT
BY THE LEGS AND REST THE END OF THE BEAM ON TOP OF THE SWING BEAM PLATE. NOW PROCEED TO STEP 25
AND ATTACH THE OTHER END OF THE SWING BEAM TO THE PLAY SET.
TWO HOLES AT THIS
END OF THE BEAM.
Page 60
STEP 24: SWING BEAM TO SWING BEAM LEGS
50
1: FASTEN THE SWING BEAM TO THE SWING LEG BRACKET USING 7" CARRIAGE BOLTS WITH TORQUE WASHERS ON
TOP OF THE SWING BEAM, AND
1
2: USE A 3
" LAG SCREW AND
2
3
" LOCK NUTS WITH
8
3
" WASHER IN THE MIDDLE HOLE OF THE SWING LEG BRACKET.
8
3
" WASHERS UNDERNEATH.
8
3: PLACE GREEN BOLT CAPS OVER EXPOSED THREADS AFTER SECURING.
7" CARRIAGE BOLT
TORQUE WASHER
3
" WASHER
8
3
" LOCK
8
NUT
BOLT CAP
1
3
" LAG SCREW
2
Page 61
STEP 25: SWING BEAM TO FORT
51
*AN EXTRA PERSON IS REQUIRED FOR THIS STEP
1: LINE UP THE PILOT HOLE ON THE END OF THE SWING BEAM WITH THE MIDDLE HOLE ON THE SWING BEAM PLATE.
2: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE AND SWING BEAM SUPPORT USING A 9" CARRIAGE BOLT
WITH TORQUE WASHER ON TOP AND A
3
" LOCK NUT AND
8
3
" WASHER ON THE BOTTOM. PLACE GREEN BOLT CAPS
8
OVER EXPOSED THREADS AFTER SECURING.
3: FASTEN THE SWING BEAM TO THE SWING BEAM PLATE FROM UNDERNEATH WITH A 3
1
" LAG SCREW AND
2
3
"
8
WASHER.
9" CARRIAGE BOLT
TORQUE WASHER
3
" WASHER
8
3
" LOCK NUT
8
BOLT CAP
3
" WASHER
8
1
LAG SCREW
3
"
2
Page 62
STEP 26: LEVEL THE SWING BEAM
52
1: PLACE A LEVEL ON TOP OF THE SWING BEAM AND ADJUST THE LEGS IN OR OUT AS NEEDED TO MAKE THE
SWING BEAM LEVEL.
Page 63
STEP 27: SWING LEG CROSS-MEMBER
53
1: POSITION THE 2 X 4 X 58" SWING LEG CROSS-MEMBER AGAINST THE SWING BEAM LEGS.
2: LEVEL CROSS-MEMBER, AND MARK THROUGH THE HOLES ONTO THE SWING LEGS.
3: AT THE MARKS DRILL 11/64" HOLES 2-1/2" DEEP.
4: SECURE THE CROSS-MEMBER TO THE SWING LEGS WITH 3/8" X 3
1
" LAG SCREWS AND
2
3
" WASHERS.
8
3/8" WASHER
3/8" X 3-1/2"
LAG SCREW
2 X 4 X 58"
SWING LEG
CROSS-MEMBER
Page 64
STEP 28: ATTACHING CENTER POSTS
54
1: THE 2 X 4 X 73
BOLTS,
5
" WASHERS, AND T-NUTS.
16
2: THE FRONT CENTER POST WILL BOLT TO THE FRONT TARP SUPPORT ON THE INSIDE WITH A 2
WASHER, AND A T-NUT.
9
" AND 2 X 4 X 29" CENTER POSTS WILL ATTACH TO THE TARP SUPPORT BOARDS WITH 2
16
1
" HEX
2
1
" HEX BOLT, A
2
5
"
16
3: MAKE SURE THE OPENINGS ARE EQUAL ON EACH SIDE OF THE FRONT CENTER POST AS SHOWN BELOW. THEN
ATTACH THE BOTTOM OF THE FRONT CENTER POST TO THE DECK SPACER FROM UNDERNEATH WITH TWO 2
1
"
2
WOOD SCREWS,
4: THE REAR CENTER POST WILL BOLT TO THE REAR TARP SUPPORT ON THE INSIDE WITH A 2
1
" HEX BOLT, A
2
5
"
16
WASHER, AND A T-NUT. SQUARE THE REAR CENTER POST OT THE REAR TARP SUPPORT. INSTALL TWO #8 X 2-1/2"
WOOD SCREWS THROUGH THE REAR CENTER POST INTO THE REAR TARP SUPPORT.
SQUARE POST TO THE REAR TARP SUPPORT.
THEN INSTALL TWO 2-1/2" WOOD SCREWS
ABOVE THE T-NUT
9
2 X 4 X 73
"
16
2 X 4 X 29"
REAR CENTER POST
FRONT CENTER POST
1
2
" HEX BOLT AND 5/16" WASHER
2
5
" WASHER
16
1
2
" HEX BOLT
2
REAR TARP SUPPORT
T-NUT
EQUAL
1
2
" WOOD SCREWS
2
EQUAL
Page 65
STEP 29: TARP BOARDS
55
1: THE 2 X 4 X 44" CENTER TARP BOARD WILL SECURE ON TOP OF THE CENTER POSTS WITH TWO 2
SCREWS PER SIDE.
3
2: THE TWO 2 X 4 X 46
" TARP BOARDS WILL SECURE ON THE ENDS OF THE TARP SUPPORTS WITH TWO 2
4
SCREWS PER SIDE.
1
" WOOD SCREW
2
2
1
2
" WOOD SCREW
2
2 X 4 X 44"
CENTER TARP
BOARD
2 X 4 X 46-3/4"
END TARP BOARD
1
" WOOD
2
1
" WOOD
2
2 X 4 X 46-3/4"
END TARP BOARD
Page 66
STEP 30: SLIDE
56
1: LAY SLIDE ON DECK EXTENDING ONTO/OVER DECK SPACER.
2: SECURE THE SLIDE TO THE DECK SPACER WITH THREE #14 x 1
*DO NOT OVER TIGHTEN*
1
" PAN HEAD SCREWS.
4
DECK SPACER
#14 X 1
*DO NOT OVER TIGHTEN*
1
" PAN HEAD SCREWS
4
8' WIKI
SLIDE
Page 67
STEP 31: HANGING THE SWINGS
57
1: PLACE EACH OF SWING CHAINS ONTO THE HOOK ON THE IRON DUCTILE SWING HANGERS. PLACE CHAINS
ONTO HIGHER OR LOWER LINKS TO ADJUST THE HEIGHT OF THE SWING.
2: REPEAT THIS PROCESS FOR THE TRAPEZE SWING.
*WARNING - DO NOT PLACE SWING BELTS ON THE TRAPEZE ARM.*
A
B
IRON DUCTILE
SWING HANGER
HOOK
SWING CHAIN
Page 68
STEP 32: TARP
58
1: LAY TARP ACROSS TARP BOARDS, MAKE SURE THE HEM SIDE IS DOWN. HAVE AN ASSISTANT HELP YOU. WRAP
THE TARP ENDS AROUND THE END TARP BOARDS TO THE INSIDE. LEAVE AN EQUAL AMOUNT OF THE END TARP
BOARD EXPOSED OVER THE TARP ENDS.
IF YOU WISH YOU MAY PREDRILL 1/8" HOLES AT THE EACH GROMMET LOCATION BEFORE INSTALLING THE SCREW
AND WASHER AT THAT LOCATION. CAUTION! IF YOU DRILL THROUGH THE END TARP BOARD YOU WILL DRILL
THROUGH THE TARP ON THE OUTSIDE.
2: BEGIN AT THE FRONT RIGHT SIDE CORNER. PREDRILL A HOLE IF YOU WISH, THENPLACE ONE 1
1
" PANHEAD SCREW
4
WITH 1/4" WASHER THROUGH THE GROMMET AND SECURE IT TO THE END TARP BOARD.
3: GO TO THE FRONT LEFT SIDE CORNER. PULL THE TARP TIGHT. PREDRILL A HOLE IF YOU WISH, THEN PLACE ONE 1
PANHEAD SCREW WITH 1/4" WASHER THROUGH THE GROMMET AND SECURE IT TO THE END TARP BOARD.
4: NOW THE MIDDLE RIGHT SIDE GROMMET WILL RECEIVE A SCREW, THEN THE SAME GROMMET ON THE OPPOSITE
SIDE (LEFT SIDE).
5: ESSENTIALLY, WHAT YOU ARE DOING IS ALTERNATING FROM SIDE TO SIDE, FROM THE FRONT OF THE FORT
MOVING BACK, TO KEEP THE TARP TIGHT AND WRINKLE-FREE.
EXPOSED END TARP BOARD
AREA ABOVE END OF TARP
1
"
4
TARP 44" X 113"
#14 X 1
PAN HEAD SCREW
1/4" WASHER
TARP GROMMET
DETAIL B
SCALE 1 : 6
1
"
4
B
Page 69
STEP 33: FRONT ARCH BOARD
59
1: PLACE THE 2 X 6 X 45
2: SECURE THE FRONT ARCH BOARD TO THE CORNER POSTS WITH 4" HEX BOLTS AND
1
" FRONT ARCH BOARD ACROSS THE FRONT CORNER AND CENTER POSTS.
2
5
" WASHERS IN THE TOP
16
HOLES. PREDRILL 11/64" HOLES ABOUT 2-1/2" DEEP THROUGH THE BOTTOM HOLES FOR THE 3/8" X 3-1/2" LAG
SCREWS. FASTEN A 3/8" X 3-1/2" LAG SCREW WITH A 3/8" WASHER IN EACH BOTTOM HOLE.
1
3: USE TWO 2
" WOOD SCREWS TO FASTEN THE FRONT ARCH BOARD TO THE FRONT CENTER POST.
2
1
2
WOOD SCREWS
2
2 X 6 X 45
FRONT ARCH BOARD
1
"
2
5
" WASHER
16
4" HEX
BOLT
3/8" X 3-1/2"
LAG SCREW
3/8"
WASHER
Page 70
STEP 34: STRINGERS
60
1: PLACE THE 2 X 4 X 44" STRINGER AND THE 2 X 4 X 51" ROCK WALL STRINGER UNDERNEATH THE DECK AND ROCK
WALL BOARDS.
2: FASTEN THE STRINGERS TO THE DECK AND ROCK WALL BOARDS FROM THE OUTSIDE WITH 2" WOOD SCREWS.
ONE SCREW PER BOARD.
NOTE: THE STRINGERS WILL MOUNT PERPENDICULAR TO THE DIRECTION OF THE DECK AND ROCK WALL BOARDS.
BOTH STRINGERS ARE CENTERED. THE ROCK WALL STRINGER WILL START AT THE TOP OF THE ROCK WALL BOARDS,
2 X 4 X 44"
STRINGER
2 X 4 X 51"
ROCK WALL
STRINGER
UNDERNEATH FORT
VIEW SHOWN IS FOR LOCATION REFERENCE. THE 2" WOOD
SCREWS WILL BE DRIVEN FROM THE OPPOSITE SIDE; THROUGH
THE DECK AND ROCK WALL BOARDS.
Page 71
STEP 35: CLIMBING ROPE
61
1: THREAD ONE END OF THE ROPE THROUGH THE HOLE ABOVE THE ROCK WALL. TIE A SECURE KNOT ON THE
INSIDE OF THE TOP PANEL BOARD.
2: YOU MAY TIE UP TO THREE KNOTS IN THE ROPE TO AID YOUR CHILD WHEN CLIMBING
3: THREAD THE OTHER END OF THE ROPE THROUGH THE HOLE IN THE BOTTOM ROCK WALL BOARD. PULL THE ROPE
TIGHT AND TIE A SECURE KNOT BEHIND THE BOTTOM ROCK WALL BOARD.
4: GRAB THE ROPE AND ATTEMPT TO WRAP IT AROUND YOUR HAND. IF THE ROPE WRAPS AROUND YOUR HAND IT
IS TOO LOOSE. UNTIE THE ROPE AND THE RETIE THE ROPE UNTIL IT NO LONGER WRAPS AROUND YOUR HAND.
TIE KNOT BEHIND THIS HOLE
YOU MAY ADD
KNOTS TO AID
YOUR CHILD
WHEN
CLIMBING.
TIE KNOT BEHIND THIS HOLE
Page 72
STEP 36: FLAG KITS
62
1: PLACE THE FLAGS ON THE FRONT OF THE CORNER POSTS AT THE FRONT SIDE OF THE
PLAY SET.
2: ATTACH EACH FLAG WITH THE 1/2" LONG PHILLIPS PAN HEAD SCREWS INCLUDED WITH
THE FLAG.
FLAG
FLAG
A
FLAG
1/2" PHILLIPS
PAN HEAD SCREWS
INCLUDED WITH
FLAG.
FRONT
CORNER POST
Page 73
STEP 37: STEERING WHEEL
63
1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. PLACE THE STEERING WHEEL AT
THE CENTER OF THE END OF THE SWING BEAM. NOW MOVE IT ABOUT 1/4" OFF CENTER TO THE
LEFT OR THE RIGHT. MARK THROUGH THE CENTER OF THE STEERING WHEEL INSERT AND THEN DRILL
A 11/64" PILOT HOLE AT THE MARK 2" DEEP.
2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO
THE END OF THE SWING BEAM. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING
WHEEL INSERT OR IT WILL NOT TURN.
3: SNAP THE STEERING WHEEL CAP ONTO THE CENTER OF THE STEERING WHEEL INSERT.
A
STEERING
WHEEL
CAP
STEERING WHEEL INSERT
INCLUDED
HARDWARE
STEERING WHEEL
END OF SWING BEAM
TIP: PREDRILL AN
11/64" PILOT HOLE
TO MAKE IT EASIER
TO DRIVE IN THE LAG
SCREW BY HAND.
Page 74
STEP 38: TELESCOPE
64
1: PLACE ONE OF THE ROUND TELESCOPE BRACKETS ON THE TRAPEZE ARM, CENTERED
ABOVE THE ROCK WALL OPENING, AND FASTEN WITH THE HARDWARE PROVIDED.
2: PLACE THE TELESCOPE ASSEMBLY INSIDE THE OPENING OF THE BRACKET.
3: PLACE THE OTHER ROUND TELESCOPE BRACKET ON THE OPPOSITE SIDE OF THE ROUND
TELESCOPE BRACKET INSTALLED IN SUBSTEP 1. ATTACH WITH THE PROVIDED SCREWS.
A
TELESCOPE
TRAPEZE
ARM
PROVIDED SCREWS
TELESCOPE
ROUND
TELESCOPE
BRACKET
Page 75
STEP 39: SAFETY HANDLES
65
1: PLACE THE SAFETY HANDLES AT THE DESIRED HEIGHT ABOVE THE LADDER OPENING ON
THE FRONT RIGHT CORNER POST AND THE FRONT CENTER POST.
2: ATTACH EACH SAFETY HANDLE WITH 1-1/4" PAN HEAD SCREWS AND 1/4" WASHERS
THAT COME WITH THE SAFETY HANDLES.
A
1-1/4" PAN HEAD
SCREW
1/4" WASHER
SAFETY
HANDLE
Page 76
STEP 40: GROUND STAKES
66
1: HAMMER A GROUND STAKE INTO THE EARTH NEXT TO EACH SWING LEG AT AN ANGLE. DO
NOT HOLD THE UPPER PORTION OF THE STAKE AFTER THE FIRST COUPLE OF HITS OR IT MAY
VIBRATE HARSHLY AGAINST YOUR HAND. IF THE TOP PART OF THE STAKE TWISTS WHEN IT
ENCOUNTERS A ROCK OR ROOT YOU MAY HAVE TO BEND THE TOP PORTION OF THE STAKE
AGAINST THE SWING LEG. FINALLY INSTALL THE SCREW AND WASHER.
2: ATTACH EACH GROUND STAKE TO THE SWING LEG WITH A #14 X 2" PAN HEAD SCREW AND
A 1/4" FENDER WASHER PROVIDED WITH THE GROUND STAKE.
3: ON THE CORNER POSTS ON THE ROCK WALL SIDE OF THE FORT, DRIVE THE GROUND STAKES
INTO THE GROUND TO A DISTANCE THAT WILL NOT INTERFERE WITH THE T-NUTS OR HEX BOLTS
THAT ARE INSTALLED IN THE SANDBOX BOARDS. THE GROUND STAKES WILL BE ON THE INSIDE OF
THE SANDBOX ON THE CORNER POSTS.
4: ATTACH EACH GROUND STAKE TO THE CORNER POST WITH A #14 X 2" PAN HEAD SCREW
AND A 1/4" FENDER WASHER PROVIDED WITH THE GROUND STAKE.
#14 x 2" PAN HEAD SCREW
AND 1/4" FENDER WASHER
GROUND STAKE
ON THE INSIDE OF THIS
CORNER POST (PARTIALLY
OBSTRUCTED FROM VIEW)
GROUND STAKE
#14 X 2" PAN HEAD SCREW
AND 1/4" FENDER WASHER
GROUND STAKE
Page 77
STEP 41: PANEL SUPPORT (SAFETY BOARD)
67
1: PLACE A 2 X 4 X 44" PANEL SUPPORT (SAFETY BOARD) AGAINST THE LEFT CORNER POSTS.
2: THE TOP OF THE BOARD SHOULD BE 24" ABOVE THE BOTTOM OF THE END SANDBOX BOARD. MARK
LOCATIONS AT 24" ON EACH POST.
3: PLACE THE TOP OF THE BOARD EVEN WITH THE MARKS. NOW MARK THROUGH THE HOLES IN THE BOARD
ONTO THE CORNER POSTS. DRILL 11/64" HOLES 2-1/2" DEEP AT THE HOLE MARKS.
4: NOW BOLT THE BOARD TO THE CORNER POSTS WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS.
2 X 4 X 44"
PANEL SUPPORT
(SAFETY BOARD)
A
1
" LAG SCREW3
2
3/8" WASHER
DETAIL A
SCALE 1 : 14
24"
Page 78
STEP 42: NAME PLATE
68
1: PLACE THE MANUFACTURER LOGO PLATE AT THE CENTER OF THE SWING BEAM.
2: FASTEN THE LOGO PLATE TO THE SWING BEAM WITH TWO #8 X 1-1/4" WOOD SCREWS.
PLACE LOGO PLATE HERE
AND ATTACH WITH TWO
#8 X 1-1/4" WOOD SCREWS.
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