Assembly Manual By Creative Playthings (Slide Not Included) If you have problems or questions about your Creative Playthings play set, DO NOT CALL THE RETAILER. Contact Creative Playthings Customer Service at 1-800-598-4997 or customerservice@creativeplaythings.com All hardware on this set is specially coated for corrosion resistance. If non-creative Playthings hardware is used, it must be galvanized or stainless steel. This product is intended for single family home/residential use only and not intended for use in any public setting. Placement in any public setting constitutes a misuse of this product. Please read the owner s manual before the assembly of your Play set. it provides additional information on the care and use of your Play Set. You must carefully read the entire instruction manual before proceeding with the assembly or use of your new Play Set. Creative Playthings takes great care to design its products with your child s safety in mind. However, only with careful supervision and proper safety instructions, can you be assured of safe play time on any product designed for children. Save these instructions for reference in case you need to contact customer service.
Playset Safety For safety sake, please take time to read all instructions completely and caution your children appropriately. Observing the following statements & warnings reduces the likelihood of serious or fatal injury: Children should use equipment only in its intended manner. Children should not wear loose or stringed clothing while using playground equipment. Children should not play on equipment in wet weather conditions due to potentially slippery surfaces. Children should NOT walk too closely in front of, behind, or between moving swings and trapezes. Children should NOT swing empty swing seats. Children should NOT jump off swings and/or trapeze while they are in motion. Children should NOT twist swing chains because this will weaken the chain. Children should sit in the center of the swings with their full weight on the seats. Children should NOT be on the top surface of the swing beam. Children should NOT use the equipment in a manner other than intended. Children should NOT get off the equipment while it is in motion. On-site adult supervision is required at all times for children of all ages. Until assembly is complete, DO NOT let your children use the Play Set. Never fasten anything not approved by Creative Playthings to your Play Set. Accessories or items not approved by Creative Playthings include; Dog runs, clothes lines, electrical devices, or bird feeders etc. Suspended ropes, chains, and cables must be secured at both ends. Suspended ropes, chains, and cables must not be capable of looping back on themselves. Do not allow more than 120 lbs. on Single occupancy swing accessories such as the Sling Swing and Trapeze. Do NOT allow more than 175 lbs. on multiple use swing accessories such as the Back-to-Back Glider. Do NOT allow more children on the Play Set than can simultaneously use all the swing stations at one time. Children MUST NEVER wear bicycle helmets while playing on the play-set. Assembly Safety: Adult assembly required Face slide away from the sun. Keep the work area clean and clear of obstructions. Children should stay out of the work area until the safe play area is cleared of obstacles, the Play Set has been completely assembled, all hardware has been tightened and checked, and all tools have been picked up. Keep children off the Play Set until it has been completely assembled. Parts of the assembly process may require help from another competent adult. Do not stand on the platform until the Play Set has been completely assembled, use a step ladder if you can not reach high enough. Follow the manufacturers' safety recommendations for the tools and equipment you use. Avoid assembling your Play Set in poor weather conditions. Wear proper clothing and safety equipment (safety glasses, boots, and gloves) while assembling your Play Set. Page 2
Safe Play Area Selecting the correct location for your play product is important for your children s safety and the product s longevity. Play Set Dimensions: The Play Set has ground dimensions of 14'-9" x 12'-6", without slide. The Play Set requires a level ground surface of 26'-9" x 30'-5" for a Safe Play Area. Additional accessories may increase the size of the Safe Play Area. The maximum fall height for your is 87" as measured from the top of the upper platform. Safe Play Area: The Safe Play Area refers to a zone extending 6' (2 meters) beyond the Play Set on all sides, including the slide and the space above the Play Set. Because children may deliberately jump from a moving swing, the Safe Play Area must be extended to 14' (4.27 meters) in front of and behind a swinging Accessory. The ground surface must be level. Installing your Play Set on sloping ground can cause it to lean or rack. This leaning puts additional stress on all connections and joints and in time will cause those connections to loosen and fail. The Safe Play Area must be free of all structures, landscaping, trees and branches, rocks, wires, and other obstacles to safe play. Children can be seriously injured running, or swinging into these obstacles. Remove all tripping hazards from the Safe Play Area. Tripping hazards include; roots, stumps, rocks, landscaping, sprinkler heads, railroad ties, plumbing and electrical connections. Do not install your Play Set over concrete, gravel, asphalt, packed earth, or any other hard surface. The following is a list of recommended ground covers from the Consumer Product Safety Commission. Recommended Ground Cover Suggested Material uncompressed Depth Double Shredded Bark Mulch 9" Uniform Wood Chips 12" Fine Gravel 12" Fine Sand 12" Any edging used to contain the ground cover must be beyond the Safe Play Area. (i.e. Landscape Timbers) Safe play area using recommended ground cover. 14' (4.27 M) 6' (2 M) Landscape Timbers 6' from play structure. 6' (2 M) 14' (4.27 M) 6' (2 M) 6' (2 M) Whichever is greater A fall onto a hard surface could result in serious injury. Page 3
Hardware Bag Contents Illustrations are representative of hardware. Slight variation of appearance may occur. Assembly Hardware: 3/8" Flat Washer 5/16" Flat Washer 1/4" Flat Washer 8mm Flat Washer 5/16 Lock Washer 1/4" Lock Washer 3/8" Nylon Lock Nut 1/4" Weld Nut, Short 1/4" Weld Nut Swing Hanger for Glider (Not to Scale) Swing Hanger, Screw Type (Not to Scale) Access. Bracket (Not to Scale) 5/16" Weld Nut 50527-701 Harrison Extra Hardware 57 17001-104 Weld Nut 1/4" 9 17001-101 Weld Nut, Short 1/4" 97 12002-205 Flat Washer 1/4" 61 12017-205 Lock Washer 1/4" 79 17020-103 Screw #6 x 1-1/8" 44 17020-106 Screw #8 x 1-5/8" 19 17020-109 Screw #8 x 2-1/2" 6 17120-502 Self-Drill Screw #10 x 1-1/2" 8 17019-305 Pan Hd Screw #12 x 3/4" 22 17003-409 1/4 x 1" 4 17003-609 1/4 x 1-1/2" 7 17003-809 1/4 x 2" 17 17003-1009 1/4 x 2-1/2" 6 17003-1209 1/4 x 3" 2 17003-1409 1/4 x 3-1/2" 23 17003-1609 1/4 x 4" 1 17003-1809 1/4 x 4-1/2" 2 17003-2009 1/4 x 5" 8 17036-601 Lag Screw 1/4 x 1-1/2" 26 17036-801 Lag Screw 1/4 x 2" 2 17036-1001 Lag Screw 1/4 x 2-1/2" 5 17036-1201 Lag Screw 1/4 x 3" 3 17036-1601 Lag Screw 1/4 x 4" 2 17001-105 Weld Nut 5/16" 2 12002-206 Flat Washer 5/16" 2 12017-206 Lock Washer 5/16" 2 17003-1611 5/16 x 4" 50539-800 Tower Two Hardware 86 17001-104 Weld Nut 1/4" 151 12002-205 Flat Washer 1/4" 108 12017-205 Lock Washer 1/4" 29 17001-101 Weld Nut, Short 1/4" 12 12002-203 Flat Washer 8mm 130 17020-103 Screw #6 x 1-1/8" 177 17020-106 Screw #8 x 1-5/8" 8 17020-105 Screw #10 x 1-1/2" 17 17020-112 Screw #8 x 2" 6 17020-109 Screw #8 x 2-1/2" 12 17120-502 Self-Drill Screw #10 x 1-1/2" 6 17019-202 Pan Hd Screw #6 x 1/2" 2 17019-305 Pan Hd Screw #12 x 3/4" 8 17003-409 1/4 x 1" 4 17003-609 1/4 x 1-1/2" 21 17003-809 1/4 x 2" 18 17003-1009 1/4 x 2-1/2" 4 17003-1209 1/4 x 3" 23 17003-1409 1/4 x 3-1/2" 12 17003-1609 1/4 x 4" 4 17003-1809 1/4 x 4-1/2" 3 17119-409 Truss Head Bolt 1/4 x 1" 5 17036-601 Lag Screw 1/4 x 1-1/2" 39 17036-801 Lag Screw 1/4 x 2" 11 17036-1201 Lag Screw 1/4 x 3" Page 4 50531-700 CF Beam Fasteners 2 17001-104 Weld Nut 1/4" 3 12002-205 Flat Washer 1/4" 2 12017-205 Lock Washer 1/4" 5 17020-109 Screw #8 x 2-1/2" 2 17003-1009 1/4 x 2-1/2" 1 17036-1201 Lag Screw 1/4 x 3" 10 17001-105 Weld Nut 5/16" 19 12002-206 Flat Washer 5/16" 10 12017-206 Lock Washer 5/16" 1 17003-611 5/16 x 1-1/2" 4 17003-1211 5/16 x 3" 3 17003-1811 5/16 x 4-1/2" 2 17003-2211 5/16 x 5-1/2" 50530-700 Glider Bracket Hardware 4 12002-206 Flat Washer 5/16" 4 17036-1802 Lag Screw 5/16 x 4-1/2" 4 12052-107 Nylock Nut 3/8" 8 12002-207 Flat Washer 3/8" 4 14228-100 Swing Hanger for Glider 50104-700 Swing Hanger 4 Pack 4 12002-206 Flat Washer 5/16" 4 17004-100 Swing Hanger, Screw Type More hardware is included than is required for assembly. Other hardware with telescope steering wheel and Nameplate
Hardware Bag Contents 1/4 x 1" 1/4 x 1-1/2" 5/16 x 4-1/2" Lag Screw 1/4 x 1" Truss Head Bolt 1/4 x 2" 5/16 x 2" Lag Screw 1/4 x 4" Lag Screw 1/4 x 2-1/2" 1/4 x 3" Lag Screw 1/4 x 3" 1/4 x 2-1/2" Lag Screw 1/4 x 3-1/2" 1/4 x 2" Lag Screw 1/4 x 4" 1/4 x 1-1/2" Lag Screw 1/4 x 4-1/2" #6 x 1-1/8" Screw 1/4 x 5" #10 x 1-1/2" Screw 5/16 x 1-1/2" #8 x 1-5/8" Screw #8 x 2" Screw 5/16 x 3" #8 x 2-1/2" Screw 5/16 x 4" #10 x 1-1/2" Self-Drill Screw 5/16 x 4-1/2" #6 x 1/2" Pan Head Screw 5/16 x 5-1/2" #12 x 3/4" Pan Head Screw Page 5
Pre assembly Information CREATIVE PLAYTHINGS Play SetS USE A FEW STANDARD CONNECTIONS. BECOMING FAMILIAR WITH THESE CONNECTIONS WILL SIMPLIFY ASSEMBLY AND INSURE A SAFER PLAY PRODUCT FOR YOUR CHILDREN. & Weld Nut Assembly Procedure: Assembly Layout: Align the holes in the parts to be fastened. Start preliminary tightening of bolt into weld nut by hand. Tighten each bolt with a wrench until the lock washer is fully compressed between the head of the bolt and the flat washer. Lock Washer Flat Washer Weld Nut Correct Assembly: Bolt has been screwed securely into weld nut and the connection is tight. Check connections periodically for tightness during the life of the Play Set. Do not over tighten. Incorrect Assembly: If during assembly or maintenance the bolt protrudes 1/8" past the weld nut, use additional flat washers, call customer service or replace the bolt at a local hardware store. You may be overtightening or using the wrong size bolt. Failure to replace this bolt with a shorter one could result in serious injury. Typical Installation - Lag Screws: Pilot drill with the appropriate diameter drill bit and then use a socket to tighten. DO NOT over tighten Lag Screw Flat Washer Typical Installation - Wood Screws: Use an electric drill or screw gun to drive screws. Drill 1/8" pilot holes where required. We recommend that you lubricate the threads of the screws with beeswax or soap to ease installation and minimize breaking screws. It is very important to make certain that the tops of all screws are flush with the surface of the wood and there are no protruding sharp edges. Page 6
Maintenance Instructions YOUR CREATIVE PLAYTHINGS Play Set IS STAINED AT OUR FACTORY. STAINING IS NOT NEEDED AT THE TIME OF INITIAL ASSEMBLY. Re-staining Information: Pigmented, exterior, water repellent stains are recommended and will provide an excellent barrier against moisture without hiding the natural wood grain or leaving a film that may later crack or peel. We recommend that you apply stain according to the instructions and precautions recommended by the stain manufacturer. It should take three or more quarts to cover your set. Contact your local dealer or call Creative Playthings for our staining products. All rungs are pre-finished at the factory and do not require any finishing at the time of initial assembly. Do not paint, or varnish rungs or steps. Avoid using finishes that create slippery surfaces. Maintenance: Wooden playground equipment will last for years with proper maintenance. Maintenance of the Play Set finish will vary depending on weather climate. As a safety precaution, check all hardware, such as nuts and bolts, for tightness twice a month during use and at the beginning of each play season. Tighten as required and specified in these instructions. Do not over-tighten. Check structure twice monthly during usage for any evidence of deterioration. If upon inspection, hardware has sharp edges, rusted or structural pieces have signs of premature failure; replace them through Creative Playthings Customer Service. Oil all metallic moving parts monthly during the usage season. The swings, trapeze, tent, rope ladders, and any other removable plastic accessories should be removed and taken indoors when outside temperatures drop below 32 F (0 C). Wood will expand and contract as it adjusts to temperature changes and varying moisture conditions. Checks or cracks are a natural characteristic of all wood and will not affect the strength or durability of the wooden components. To maintain the finish of your set, a light sanding and an application of an exterior stain will repair scratches and prevent wood from aging prematurely. Finishes applied to ladder rungs must not create a slippery surface. Never varnish. The wood parts of your Play Set should never be disposed of by burning. Dispose of all parts so as not to create a hazard. "Check all coverings for bolts and sharp edges and replace when required." "Check swing seats, chains, ropes, and other means of of attachments for evidence of deterioration". Replace through Creative Playthings Customer Service. Twice a month during play season rake and check depth of loose fill protective surfacing materials to prevent compaction and to maintain appropriate depth. Replace as necessary. Tools & Materials Suggested for Finishing & Assembly: Claw Hammer Screwdriver or driver drill (Medium Phillips) Carpenter s Level Locking Pliers Box Wrench or Sockets (7/16" & 1/2") 10 ft. Tape Measure Electric Drill Framing Square 1/8", 3/16", 5/16" and 3/8" Drill Bits 6 ft. Step Ladder Page 7
Playset View G U BS AD CB BR AE R H W I N CV BZ AC D B AZ CP BD BA CO K CT L BU V CZ AO CI BT CD AK CJ BM AG AI Q BW AA CR AF CF AN T CK DA (Slide Not Included) AH CE BH BO CU CX AB CY CC E BJ CS AS AJ CL O BI J BL C BC BB AP CA S BF Y M BG BK A AY Z BV CN CM AR AL AQ BN CG Page 8
All wooden parts are marked on the end for identification. The mark consists of the three digits before the hyphen in the part number. Thus 33687-102 is marked 687. COMPONENT VIEW Take inventory of all parts, making sure nothing is missing or defective. If you find that parts are missing or defective call the Creative Playthings Customer Service Department at 1-800-833-4001. * Not marked on Play Set View page. A 6 32561-402 Angle Brace 2x3x17-1/4" Z 1 33688-402 Horiz Support 2x4x35-7/16" B 2 33687-402 Beam Leg 2-3/4x3-3/8x80-11/16" AA 5 33717-402 Spacer Board 1x4x20-1/2" C 2 33726-402 Front Post 2x4x88-1/2" AB 2 33740-402 Entrance Slat 1x6x24-1/2" D 2 33731-402 Mid Post 2x4x32-1/2" AC 27 33741-402 Short Wall Slat 1x4x19-1/2" E 1 33739-402 Short Wall Support 5/4x4x23-1/4" AD 6 33744-402 Rafter 2x3x31" F 1 33742-402 Ceiling Joist 1x4x14-5/8" AE 6 33747-402 11-1/2" Window Slat 1x6x11-1/2" G 2 33743-402 End Joist 1x6x22" AF 6 33751-402 Rock Board 1x6x20-1/2" H 2 33746-402 Window Horizontal 1x2x26" AG 4 33807-402 Gusset 2x3x7-3/8" I 4 33749-402 Window Vertical 1x2x11-1/2" AH 1 33808-402 Inner Deck Support 2x4x33-1/4" J 1 33754-402 Bottom Rope Support 5/4x6x27-1/2" AI 2 33811-402 Long Inside Post 2x4x77-3/4" MQHAR-601 Box 1 K 1 33755-402 Ladder Rail Left 2x3x63-1/2" L 1 33756-402 Ladder Rail Right 2x3x63-1/2" M 2 33757-402 Swing Mount 2x3x23-1/2" N 2 33759-402 Roof Upright 2x4x20-3/4" O 2 33791-402 Chalkboard Batten 1x4x15" MQHAR-602 Box 2 AJ 2 33812-402 AK 3 33816-402 AL 2 33825-402 AM* 1 33826-402 AN 2 33827-402 Long Outside Post 2x4x89" Backing Slat 1x4x25" Table Brace 2x3x11-1/2" Table Cleat 1x6x9" Table Support 2x3x14" P* 1 33813-402 Upper Stringer 2x3x36-1/4" AO 2 33828-402 Long Tent Support 1x4x71" Q 1 33817-402 Backing Slat Spacer 1x4x16" AP 2 33829-402 Tent Upright 1x4x29" R 1 33818-402 Inner Wall Bottom 1x4x21-3/8" AQ 1 33932-402 Bottom Block 2x4x5-1/4" S 2 33821-402 Side Wall Support 1x6x37" AR 1 33933-402 Left Post 2x4x88-1/2" T 1 33823-402 Lunch Seat 5/4x6x31-1/2" AS 1 33934-402 Right Post 2x4x88-1/2" U 2 33831-402 Tent End 2x3x37" AT* 1 33935-402 Box Back 1x6x5-1/8" V 1 33832-402 Tent Beam 2x3x35-3/4" AU* 1 33936-402 Box Front 1x6x3-1/4" W 2 33848-402 Window Sill 2x3x32-3/4" AV* 1 33937-402 Box Bottom 1x4x4" X* 2 33914-402 End Deck Board 1x4x35-7/8" AW* 2 33938-402 Box Side 1x4x5-1/8" Y 1 33940-402 Swing Beam 2-3/4x5-1/4x89" Page 9 AX* 1 33939-402 Box Top 1x6x5-1/8"
COMPONENT Playset View VIEW BX 9 33733-402 Deck Board 1x6x41-1/2" AY 1 33689-402 Back Upright 2x4x46" BY 3 33734-402 Narrow Deck Board 1x4x38-5/8" AZ 1 33690-402 Front Upright 2x4x40-11/16" BZ 1 33735-402 End Support 1x6x41-1/2" BA 4 33725-402 Post Inside 2x4x56" CA 12 33745-402 Roof Board 1x6x39-1/2" BB 2 33727-402 BC 2 33728-402 BD 1 33729-402 BE 1 33732-402 BF 1 33736-402 Sandbox End 1x6x41-1/4" Sandbox Side 1x6x59-1/2" Platform Front 1x6x41-1/2" Stringer 2x3x59-1/2" Left Wall Support 5/4x6x59-1/2" MQHAR-604 Box 4 CB 2 33748-402 CC 1 33753-402 CD 1 33820-402 CE 2 33822-402 CF 2 33824-402 Panel Band 1x4x39-1/2" Top Rope Support 5/4x6x39-1/2" Lower Wall Support 1x4x38-3/4" Side Wall Bottom 1x4x37" Table Board 1x6x39-1/2" BG 1 33737-402 Lower Wall Support 5/4x4x59-1/2" CG 2 33833-402 Lookout Base Side 1x6x40-3/4" BH 1 33738-402 Right Wall Support 5/4x6x59-1/2" CH* 5 33913-402 Lookout Deck Board 1x6x38-3/4" MQHAR-603 Box 3 BI 2 33750-402 BJ 1 33760-402 BK 1 33761-402 BL 1 33805-402 BM 1 33806-402 BN 1 33809-402 BO 2 33810-402 BP* 1 33814-402 BQ* 1 33815-402 BR 1 33830-402 BS 1 33917-402 Cargo Rail 2x3x63-1/2" Platform Right 2x4x59-3/8" Platform Left 2x4x59-3/8" Chalkboard Vertical 2x3x55-1/2" Lookout Post Right 2x4x47" Lunch Base End 1x6x41-1/2" Lookout Platform Side 2x4x41" Center Ladder Rail 2x3x51" Roof Ladder Rail 2x4x44" Lookout Post Left 2x4x47" Gym Roof Support 2x4x44" MQHAR-605 Box 5 CI 2 33915-402 CJ 1 33916-402 CK 2 14109-400 CL 1 15173-500 CM 2 40580-400 CN 1 15086-200 CO 1 40577-400 CP 1 40578-104 End Wall Support 1x6x38-3/4" Platform End 1x6x38-3/4" Seat Supports Chalkboard Glider Handle Assembly Glider Seat, Yellow Sling Swing Ring Trapeze CQ* 7 36515-102 Ground Stake CR 1 50428-400 Climbing Rocks, 6 CS 1 40508-100 Cargo Net CT 5 14202-400 Ø1"x15" Rung, Green CU 2 14203-400 Ø1"x18" Rung, Green CV 1 14099-400 6" Triangle Plate, Green CW* 1 14100-400 6" L-Brace, Green CX 7 15034-100 Hand Grips, Yellow DA 1 33973-402 Ladder Slat 5/4x4x15-3/4" 1 50104-700 NyGlide Swing Hanger 4 Pack 1 50527-701 Harrison Extra Hardware 1 50539-800 SYP Tower Two Hardware Bag 1 50531-700 CF Beam Fasteners BT 2 33918-402 BU 1 33919-402 BV 1 33924-402 BW 1 33931-402 Back Post Top 2x4x40-1/8" Rock Stringer 2x3x57-1/4" Safety Rail 2x3x59-3/8" Platform Back 1x6x41-1/2" MQHAR-606 Box 6 CY 1 40510-100 Tic Tac Toe CZ 1 40571-400 Tent, Green 35x89" 1 50475-100 Playtime Play Pack 1 1 50530-400 Glider Bracket Box 1 50530-700 Glider Bracket Hardware 1 50536-100 Funtime Nameplate Pack Page 10
Note: It will take two to three days for one person to assemble this project. Assembly Instructions Assembly: Throughout this guide a Assembly consists of one, one Lock Washer, one Flat Washer and one Weld Nut. Long Weld Nuts are used unless otherwise noted. Read all of the instructions before starting assembly. To avoid backtracking, review the first 15 steps to make sure that the components face the proper direction before assembling the posts. BT All 1/4 x 2-1/2" Hex Bolt Assemblies All 1/4 x 2-1/2" Hex Bolt Assemblies C AR All 1/4 x 2-1/2" Hex Bolt Assemblies AS BA BA AI View from the front of the set. STEP 1 Front Posts: Locate two Front Posts (C) and two Inside Posts (BA). Fasten one Inside Post to each Front Post using 1/4 x 2-1/2" Assemblies as shown above. Be sure to note the orientation of the holes on the narrow faces of the boards. The front left post assembly uses two Assemblies and the right front post uses three. Try to align all of the holes along each board for future attachments. View from the front of the set. STEP 2 Middle Posts: Locate Left Post (AR), Right Post (AS), and two Inside Posts (BA). Fasten one Inside Post to each Post using 1/4 x 2-1/2" Assemblies as shown above. Be sure to note the orientation of the holes on the narrow faces of the boards. The left post assembly uses two Hex Bolt Assemblies and the right post uses three. Try to align all of the holes along each board for future attachments. STEP 3 Back Posts: Locate the Long Inside Posts (AI), the Long Outside Posts (AJ) and the Back Post Tops (BA). Assemble each post as shown above using four 1/4 x 2-1/2" Assemblies. Be sure to note the orientation of the holes on the narrow faces of the boards. Also note the position of the holes offset from the center on the wide face of the Long Inside and Long Outside Posts. Try to align all of the holes along each board for future attachments. AJ View from the back of the set. Page 11
STEP 4 Base Sides: Insert a 1/4" Short Weld Nut into the top hole at one corner of a Lookout Base Side (CG). Pass one 1/4 x 4" Hex Bolt though a Lock Washer, a Flat Washer, the top hole of a Sandbox Side (BC), and the middle left post assembly to secure the Lookout Base Side. Secure the Sandbox Side to the left post using one 1/4 x 2" Lag Screw and Flat Washer from the outside. Secure the Lookout Base Side to the left post using one 1/4 x 2" Lag Screw and Flat Washer from the inside. Fasten The Sandbox Side to the front left post assembly using a 1/4 x 3" Assembly through the top hole and a 1/4 x 2" Lag Screw and Flat Washer through the bottom. Repeat the process with the other Sandbox Side, Lookout Base Side and the right post assemblies. BC Short Weld Nut 4" Assembly w/ Short Weld Nut CG BB 4" Assembly in top holes 2" Lag Screw in Bottom Holes 3" Assembly 2" Lag Screw in bottom holes STEP 6 Platform Ends: Fasten the Platform Front (BD) to the front left and right post assemblies as shown at right. Use 1/4 x 4" Assemblies in the top holes and 1/4" x 2" Lag Screws with 1/4" Flat Washers in the bottom holes. Fasten the Platform Back (BW) to the middle post assemblies in the same way. STEP 5 Base Ends: Fasten one Sandbox End (BB) to the outside of the front left and right post assemblies as shown at left. Use 1/4 x 4" Hex Bolt Assemblies in the top holes and 1/4" x 2" Lag Screws with 1/4" Flat Washers in the bottom holes. Fasten the other Sandbox End (BB) to the inside of the middle left and right post assemblies in the same way. 4" Assembly in top holes BD BW 2" Lag Screw in Bottom Holes Page 12
STEP 7 Platform Sides: Fasten the Platform Left (BK) to the left post assemblies in the orientation shown using two 1/4 x 2-1/2" Assemblies. Fasten the Platform Right (BJ) to the right front post assembly in the orientation shown using one 1/4 x 2-1/2" Hex Bolt Assemblies. Rest the other end of the Platform Right in place to be fastened in the following step. Three 1/4 x 2-1/2" Hex Bolt Assemblies BK BJ No Bolt STEP 8 Midposts & Top Rope Support: Align one Midpost (D) as shown at right. Fasten it to the Platform Left using one 1/4 x 2-1/2" Assembly. Fasten the Top Rope Support (CC) to the middle right post assembly and the Platform Right using one 1/4 x 3-1/2" Hex Bolt Assembly in the lower right hole. Fasten the other end of the Top Rope Support to the right Mid Post (D) and the Platform Right using one 1/4 x 3-1/2" Assembly in the lower left hole. Fasten one 1/4 x 2" Lag Screw and Flat Washer through the top right hole of the Top Rope Support and into the right post assembly. Use a level to assure that the right Midpost is plumb. Drill a 3/16" diameter pilot hole 1-1/4" into the right Mid Post through the top right hole in the Top Rope support. Secure using one 1/4 x 2" Lag Screw and Flat Washer. D 2" Lag Screw CC 2-1/2" Assembly 3/16" pilot drill 3-1/2" Assembly STEP 9 Stringer: Fasten the Stringer (BE) to the Platform Front and Platform Back using two 1/4 x 3" Lag Screws and Flat Washers as shown. 3" Lag Screw BE Page 13
STEP 10 Deck Boards: Locate the nine Deck Boards (BX) and three Narrow Deck Boards (BY) and lay them across the platform supports and Stringer in the arrangement shown at right. Align the ends of the Deck boards; the Narrow Deck Boards fit between the uprights. Starting at the front of the gym fasten each board using #8 x 1-5/8" Screws. For the first four boards, leave a gap of 1/8" or less to limit the possibility of clothing being snagged when children use the slide. Space the rest of the boards evenly. Note that the Narrow deck board between the Midposts need not align perfectly with the Midposts. BY Evenly space the back eight boards #8 x 1-5/8" Screws BX < 1/8" gap between 1st four boards BX STEP 11 Ladders: Fit five 15" Rungs (CT) into the holes in the Left Ladder Rail (K) and the Right Ladder Rail (L). Set the assembly flat on a solid surface. Make sure that the rungs are completely inserted with the ends of the rungs snug against the bottom of the holes. Use #10 x 1-1/2" Self-Drilling Screws, through the holes provided, to fasten the rungs in place. (The Self-Drilling Screws have a drill-bit tip. Point the screw toward the center of rung diameter and press firmly. Do not sink the head of the screw beyond flush with the surface of the wood). Fasten the Ladder Slat (DA) 2-1/4" from the top of the Ladder Rails using four #8 x 1-5/8" Screws. Assemble the Center Ladder Rail (BP), the Roof Ladder Rail (BQ) and two 18" Rungs as shown at right. Fasten the rungs using #10 x 1-1/2" Self-Drilling Screws in the same manner as used for the Access Ladder. L K BQ BP CT DA CU 2-1/4" STEP 12 Left Wall & Roof Supports: Before this step, check the top two holes in the Midposts (D). If a 1/4" bolt will not fit through the holes, make them bigger using a 5/16" drill. Orient the Left Wall Support (BF) with the four small holes closest to the top edge of the boards as shown at right. Fasten the Left Wall Support to the left front post using a 1/4 x 2" Assembly though the top hole and a 1/4 x 2" Lag Screw with Flat Washer in the bottom hole. Fasten the Left Wall Support to the left Midpost and one Roof Upright (N) using two 1/4 x 3-1/2" Assemblies as shown. Fasten the Left Wall Support to the back left post and Gym Roof Support (BS) using one 1/4" x 3-1/2" Assembly through the top hole only. 3-1/2" s 2" Hex Bolt 2" Lag Screw N D Top Hole Only BF BS Page 14
STEP 13 Right Wall & Roof Supports: As with the previous step. Check the top holes in the Midpost (D). Secure the Right Wall Support (BH) to the front right post, then the Midpost and Roof Upright (N) as in the previous step. Fasten the Roof Ladder Rail (BQ), now part of the upper ladder assembly, to the back right post and Right Wall Support using one 1/4 x 3-1/2" Assembly through the top hole in the Wall Support. Fasten the Center Ladder Rail to the Platform Back using a 1/4 x 3" Assembly. N 2" Hex Bolt 2" Lag Screw BH BQ 3-1/2" Hex Bolts 3" Hex Bolt Top Hole Only D STEP 14 End Support: Fasten the End Support (BZ) to the front left and right post assemblies as shown at right. Use 1/4 x 4" Assemblies in the top holes and 1/4" x 2" Lag Screws with 1/4" Flat Washers in the bottom holes. 4" Assembly in top holes 2" Lag Screw in bottom holes STEP 15 Lookout Posts and Platform Sides: 1) Fasten the back posts, assembled in step 3, to the Lookout Base Sides (CG), using 1/4 x 3" Assemblies through the top holes. Use 1/4 x 2" Lag Screws with Flat Washers in the lower holes. 2) Orient the Lookout Platform Sides (BO) with counterbored holes facing outward as shown at right. Fasten the Lookout Platform Sides to the back posts using 5/16 x 4" Assembly through the larger holes in the posts. 3) Fasten the other end of the Lookout Platform Sides to the back of the gym assembly using 1/4 x 5" Assemblies. The bolt goes through the bottom hole in the wall support, the gym post, the roof support and then through the bottom hole in the Lookout Platform Side. Use a 1/4" x 2-1/2" Lag Screw and Flat Washer through the top hole in each Lookout Platform Side to finish securing the part to the gym. 1/4 x 2-1/2" Lag Screw top holes CG 3 1/4 x 5" bottom holes BO 2 5/16 x 4" (Only 5/16" fastener on tower portion of swing set.) 1/4 x 3", top 3 1 1/4 x 2" Lag Screw bottom Page 15
STEP 16 Lunch Base and Platform End: Fasten the Lunch Base (BN) near the bottom of the lookout posts using two 1/4 x 4" Assemblies in the top Holes and two 1/4 x 2" Lag Screws and Flat Washers in the bottom holes. Fasten the Platform End (CJ) in the same way. Be sure the part is aligned properly and fastened in the correct position. CJ 1/4 x 4" BN 1/4 x 4" 1/4 x 2" Lag Screw 1/4 x 2" Lag Screw STEP 17 Inner Deck Support: Hold the Inner Deck Support (AH) in place as shown at right. The holes in the ends of the support should align with the counter-bored holes in the Lookout Platform Sides and the off-center hole near the middle should align with a hole in the Center Ladder Rail. Fasten the Inner Deck Support to the Lookout Platform Sides using 1/4 x 4" Lag Screws and Flat Washers. Fasten the Inner Deck Support to the Center Ladder Rail using one 1/4 x 3-1/2" Assembly. 1/4 x 4" Lag Screw 1/4 x 3-1/2" AH STEP 18 Upper Stringer: Fasten the Upper Stringer (P) to the Inner Deck Support using one 1/4 x 4" Lag Screw and Flat Washer. Align the Supper Stringer with the widest face horizontal and the top of the Stringer even with the top of the Inner Deck Support. Fasten the other end of the Upper Stringer to the Platform End using one 1/4 x 3" Lag Screw and Flat Washer. The top face of the Upper Stringer will be well below the top of the Platform End. 1/4 x 4" Lag Screw P 1/4 x 3" Lag Screw Page 16
Ensure the structure is in the place it will be used. Make any needed ground adjustments before proceeding. Assembly Instructions STEP 19 Angle Braces: Use a level to determine that all horizontals are level and posts are plumb. 1) Fasten two Angle Braces (A) to the Platform End of the high platform using two 1/4 x 2" Assemblies as shown. Fasten the bottom of the braces to the lookout posts using 1/4 x 4" Assemblies. 2) Fasten two Angle Braces (A) to the Platform Left using two 1/4 x 2-1/2" Assemblies as shown. Fasten the bottom of the braces to the lookout posts using 1/4 x 3" Lag Screws with Flat Washers. Be sure to drill 3/16" diameter pilot holes in the posts before using the Lag Screws. 3) Fasten two Angle Braces (A) to the front and back of the lower platform using two 1/4 x 2" Assemblies as shown. Fasten the bottom of the braces to the lookout posts using 1/4 x 3" Lag Screws with Flat Washers. Be sure to drill 3/16" diameter pilot holes before using the Lag Screws. 1/4 x 2" 1 1/4 x 4" 1/4 x 2-1/2" 2 1/4 x 3" Lag Screw 1/4 x 2" 3 Parts have been omitted for clarity 1/4 x 3" Lag Screw STEP 20 Gussets & Panel Bands: 1) Fasten the two lower Gussets (AG) in the positions shown using one 1/4 x 4" Assembly each. 2) Fasten a Panel Band (CB) to the gym and to a Gusset using a 1/4 x 3" Assembly. Pass the bolt through the top hole in the Panel Band, the upright and then the Gusset. Fasten the other end of the Panel Band to the Roof Upright using a 1/4 x 2" Assembly as shown. Use 1/4 x 2" Lag Screws and Flat Washers in the lower holes of the Panel Band. Repeat with the other Panel Band on the other side of the tower. Note: You may need to loosen the connection to the Roof Uprights when installing the Roof in a later step. IMPORTANT: Find two 1/4" Weld Nuts that will thread well onto 1/4 x 4-1/2" s. Insert the Weld Nuts into the back top of the uprights as indicated. STEP 21 Lookout Posts, Inner Wall Bottom: Fasten the Inner Wall Bottom (R) to the Lookout Post Left (BR) using a 1/4 x 4" Assembly with a Short Weld Nut (through the top hole only) as shown in the circle below. Fasten the Lookout Post Left to the left Gussets and Lookout Platform Side using three 1/4 x 2-1/2" Assemblies. 1/4 x 2" BM 2 1/4 x 2" Lag Screw CB 1/4 x 3" AG 1/4 x 3" BR 1 Insert 1/4" Weld Nuts here! 1/4 x 2-1/2" 1/4 x 4" Fasten the Lookout Post Right (BM) to the right Gussets and Lookout Platform Side using three 1/4 x 2-1/2" Assemblies. Fasten the Center Ladder Rail to the Inner Wall Bottom using on 1/4 x 3" Assembly. Short Weld Nut No fastener in this hole R BR 1/4 x 4" Do this first! 1/4 x 2-1/2" R Page 17
STEP 22 Lookout Deck Boards: Place one End Deck Board (X) on the Lookout Platform Supports between the back Lookout Posts. Fasten using three #8 x 1-5/8" Screws. Place the other End Deck Board (X) on the Lookout Platform Supports between front Lookout Posts with the front edge flush with the front edge of the Inner Deck Support. Fasten using three #8 x 1-5/8" Screws. Evenly space five Lookout Deck Boards (CH) between the End Deck Boards, with ends aligned. Fasten the Lookout Deck boards using five #8 x 1-5/8" Screws each. X CH CH CH CH CH X STEP 23 Right & Back Wall Supports: Fasten one Side Wall Support (S) and one Side Wall Bottom (CE) to the right side of the Lookout Posts as shown. Use 1/4 x 2" Assemblies in the top holes of each board. Use 1/4" x 2" Lag Screws with Flat Washers in the bottom holes of each board. Fasten one End Wall Support (CI) and the Lower Wall Support (CD) to the back of the Lookout Posts as shown. Use 1/4 x 4" Assemblies in the top holes of each board. Use 1/4" x 2" Lag Screws with Flat Washers in the bottom holes of each board. Make sure that the hole near the center of the End Wall Support is offset closer to the top of the board. S CI CD CE STEP 24 Left & Front Wall Supports: Fasten one Side Wall Support (S) and one Side Wall Bottom (CE) to the left side of the Lookout Posts as shown. Use 1/4 x 2" Assemblies in the top holes of each board. Use 1/4" x 2" Lag Screws with Flat Washers in the bottom holes of each board. Fasten one End Wall Support (CI) to the front of the Lookout Posts as shown. Use 1/4 x 4" Assemblies in the top holes of each board. Use 1/4" x 2" Lag Screws with Flat Washers in the bottom holes of each board. Make sure that the hole near the center of the End Wall Support is offset closer to the top of the board. Drill a 5/16" diameter hole through the End Wall Support where the hole at the top of the Center Ladder Rail lands. Fasten the Center Ladder Rail to the End Support using a 1/4 x 3" Assembly with a Short Weld Nut. Drill 5/16" dia. hole Short Weld Nut CI S CE Page 18
STEP 25 Assemble Roof Panels: Assembly of the Roof Panels will be easier on a work table or other flat surface. Lay Out Roof Rafters: Butt the square-cut end of two Rafters (AD) against a straight flat surface. Align the Rafters so they are parallel and the ends aligned and square. The distance between the Rafters should be 30". Measure from corner to corner both ways. When the two diagonal measurements are the same, the rafters are square. 30" AD AD 30" Fasten Roof Boards: Start at the angled end of the Roof Rafters. Rest one Roof Board (CA) on top of the Rafters flush to the angled end. Use a 1/8" diameter drill to make pilot holes before fastening the Roof Board to the Rafter using four #8 x 1-5/8" Screws. Drill and screw the first hole at an angle, as shown, to avoid the angled cut of the rafter. Continue with the next three Roof Boards, setting each against the previous Roof Board and fastening them. Once the position of the Rafters is stable, lay the rest of the Roof Boards in place. The sixth Roof Board should overhang the end of the Rafters by approximately 1/2". If the overhang is less than 1/2", evenly space the Roof Boards to achieve an overhang. If the overhang is greater, alternative holes should be made in the final Roof Board. Fasten the Roof Boards using #8 x 2" Screws. CA Center Roof Rafter: Find the center of the Roof Panel Assembly, halfway between the Rafters. Align the a Roof Rafter (AD) to the center of the Roof Panel and fasten it in place using 1/8" pilot holes and #8 x 1-5/8" Screws as with the other Rafters. Assemble Second Roof Panel: Flip the first Roof Panel to use it as a template to assemble the remaining Roof Panel. Place the remaining Rafters tight against the Rafters on the assembled panel. Align the ends. Fasten Roof Boards to the Roof Rafters using 1/8" diameter pilot holes and #8 x 1-5/8" Screws as with the first Roof Panel. Page 19
STEP 26 Roof Panels to Roof Uprights: Fasten one Roof Panel assembly to the left Roof Upright and Gym Roof Support using 1/4 x 4-1/2" Assemblies. The Weld Nut on the back of the Roof Support Post should already be in place from step 20. Repeat with the other Roof Panel on the right uprights. Rest the angled ends Roof Panels against each other. Hint: If you are having trouble making this connection, loosen or remove the connection between the Roof Upright and Panel Band. The Roof Upright can now be moved to allow better access. Be sure to re-secure the connection after the Roof Panels are in place. 1/4 x 4-1/2" STEP 27 Ceiling Joists: Adjust the Roof Panels so that the angled ends are even with each other. Fasten an End Joist (G) to the front of the Rafters on each end. Use two 1/4 x 2" Assemblies through the upper holes of each End Joist. Fasten the Ceiling Joist (F) to the center Rafters using two 1/4 x 2" Assemblies. Adjust the Roof so it looks even. Adjust the End Rafters to look straight and centered in place. Use a 3/16" diameter drill to make pilot holes in the Rafters through the lower holes in the End Rafters. Secure the End Joists to the Rafters using 1/4 x 2" Lag Screws and Flat Washers through the bottom holes. G Drill 3/16" diameter pilot holes. F STEP 28 Upper Wall Slats: Fasten five Short Wall Slats (AC) to the right Side Wall Support and right Side Wall Bottom using four #6 x 1-1/8" Screws each as shown at right. Slats should be evenly spaced between the uprights. The gap will be approximately 2-3/8" between Slats. Repeat with five Slats on the left side. Fasten five Slats across the back wall using #6 x 1-1/8" Screws. Evenly spaced, the gap between Slats will be approximately 3-1/4". Fasten three Slats to the front End Wall Support and Inner Wall Bottom using #6 x 1-1/8" Screws. Evenly spaced, the gap between Slats will be approximately 2-1/4". IMPORTANT: Never leave a gap larger than 3-1/2" unless it is larger than 9". A gap of this size can introduce a situation where a child's body can pass through but the child's head cannot. AC 3-1/4" 2-3/8" Roof omitted for clarity 2-1/4" Page 20
STEP 29 Lower and Short Wall Supports: Fasten the top back hole of the Lower Wall Support (BG) to the post shown using one 1/4 x 3-1/2" Assembly. Fasten the Lower Wall Support to the left Midpost and front left post using 1/4 x 2" Assemblies through the upper holes. Secure the three lower holes in the Lower Wall Support using 1/4 x 2" Lag Screws and Flat Washers. Fasten the Short Wall Support (E) to the right Midpost and front right Post using 1/4 x 2" Assemblies through the upper holes. Secure the lower holes using 1/4 x 2" Lag Screws and Flat Washers. BG BE STEP 30 Swing Mounts: Fasten the two Swing Mounts (M) to the Left Wall Support and Lower Wall Support using two 1/4 x 3-1/2" s each. Be sure to orient the Swing Mounts so the holes on the sides are closer to the top. M 3-1/2" s STEP 31 Lower Wall Slats & Entrance Slats: Fasten three Short Wall Slats (AC) to the Left Wall Support and Lower Wall Support using four #6 x 1-1/8" Screws each. Evenly space the Slats between the front left post and the left Midpost. The gap between the Slats will be approximately 1-5/8" Fasten six Short Wall Slats (AC) to the Left Wall Support and Lower Wall Support using four #6 x 1-1/8" Screws each. Evenly space the Slats between the back left post and the left Midpost. The gap between the Slats will be approximately 1-7/8". Fasten the Entrance Slats (AB) to the Right Wall Support and Rock Wall Mount using #6 x 1-1/8" Screws. Leave a gap of 19" between the Entrance Slats. 19" AB Page 21
STEP 32 Window Sills: Fit one Window Sill (W) between back left post of the lower tower and the Midpost. Align the top edge flush with the top edge of the Left Wall Support. Fasten in place using four #8 x 1-5/8" Screws from the outside of the gym, through the Left Wall Support and into the Window Sill. Repeat with the other Window Sill on the right side of the tower. Hint: If the space is too tight for the Window Sill to fit, you can either cut the Window Sill to fit using a saw, or loosen the fasteners holding the Left Wall Support and tap outward on the Midpost and left post to make room. Be sure to re-secure the fasteners. 1-5/8" Screws W Step 33 Windows: Fasten three 11-1/2" Window Slats (AE) to the left Panel Band and left Window Sill using four #6 x 1-1/8" Screws each. Position one Window Slat snug against the Left Post and another snug against the left Midpost. Position the third slat midway between the first two. Repeat on the right side of the gym. Hint: The windows will turn out best if measurement and calculations are made carefully. Use a small level to make sure the Slats are plumb. Roof omitted for clarity AE Fasten one Window Vertical (I) midway between the left and center Window Slat using two #6 x 1-1/8" Screws. Fasten another Window Vertical midway between the right and center Window Slat using two #6 x 1-1/8" Screws. Repeat on the opposite side of the tower. The Window Horizontal (H) should bisect the openings created by the Window Slats and Window Uprights halfway between the Panel Band and Left Wall Support. Fasten each Window Horizontal using four #6 x 1-1/8" Screws H I Page 22
STEP 34 Backing Slats: The Backing Slats are positioned behind the upper ladder to prevent an opening that will allow a child's body to pass while the child's head remains trapped. Fasten the Backing Slat Spacer (Q) in the position shown with the upper edge flush with the top of the Platform Back using three #6 x 1-1/8" Screws. Fasten the three Backing Slats (AK) to the Backing Slat Spacer and the Inner Deck Support using four #8 x 1-5/8" Screws each. Make sure the Backing Slats are vertical and evenly spaced. Make sure there are no gaps wider than 3-1/2". Q AK STEP 35a Tent Uprights: Fasten one Tent Upright (AP) to each Long Tent Support (AO) using 1/4 x 1" Assemblies as shown. The offset holes at the ends of the Long Tent Supports should be closer to the top of the boards. AP AO STEP 35b Tent Beam and End Supports: Align the top of the Tent Beam (V) flush with top center of one Tent Upright as shown. Fasten in place using one #8 x 2-1/2" Screw through the small hole in the Ten Upright. Drill a 3/16" diameter pilot hole through the Larger hole before fastening with one 1/4 x 2" Lag Screw with Flat Washer. Repeat with the other end of the Tent Beam and the other Tent Upright. Align the top outside corner of each Tent End (U) flush with the top end of a Long Tent Support and fasten in place in the same manner as the Tent Beam. STEP 36 Tent: Make sure the tent frame is fairly square and the Tent Uprights are positioned perpendicular to the Long Tent Supports. Fasten one end of the Tent (CZ) to one Tent End using four #12 x 3/4" Pan Head Screws with 1/4" Flat Washers through the Grommets as shown. Spread the Tent over the Tent Beam and stretch it neatly to the other Tent End. If the hem of the tent lands in the same place in relative to the Tent End, fasten it in place using four #12 x 3/4" Pan Head Screws with 1/4" Flat Washers through the Grommets. If uneven, go back to the other Tent End and fasten the tent in a better position before securing the final end. Flush to the top and end U Drill 3/16" dia. pilot holes for the Lag Screws #12 x 3/4" Pan Head Screw V Flush to the top center CZ Page 23
Step 37 Install Tent Frame: With the help of another adult and the use of a step ladder, set the tent frame assembly in place. Align the holes in the Long Tent Supports with the holes in the corner uprights. Align the holes in the Tent Uprights with the holes in the End Wall Supports. Fasten the Tent Uprights to the End Supports using 1/4 x 1" Assemblies. Fasten the Long Tent Supports to the corner uprights using 1/4 x 4" Assemblies. 1/4 x 1" s 1/4 x 4" Hex Bolts STEP 38 Rock Stringer: Fasten the top of the Rock Stringer (BU) to the Platform Back using one 1/4 x 2" Assembly. Use two #8 x 2-1/2" Screws to fasten the Bottom Block to the Rock Stringer flush with back and bottom edges of the Rock Stringer. Rest the Bottom Block against the adjacent Sandbox End. Use a level to make sure the Rock Stringer is plumb. Mark the center of the thickness of the Bottom Block on the Sandbox End. Drill two 3/16" diameter holes through the Sandbox End even with the mark, one 1" from the top and one 1" from the bottom of the Sandbox End. Fasten using one #8 x 1-5/8" Screw through each hole. 1/4 x 2" Hex Bolt BU AQ 1-5/8" Screws 2-1/2" Screws STEP 39 Rock & Spacer Boards: Fasten one Rock Board (AF) to the Rock Upright and adjacent post just below the Platform Back using four #8 x 1-1/2" Screws, in the position shown. Leave a gap of approximately 1/4" between the top of the Rock Board and the bottom of the Platform Back. Fasten the bottom Rock Board 1/4" above the Lookout Base Side in the orientation shown using four #8 x 1-1/2" Screws. Make sure the board is level. Evenly space Rock Boards and Spacer Boards (AA) in the opening between the existing Rock Boards. Alternate the orientation of the Rock Boards as shown. The gap between boards will be approximately 1/4". AF AA 1/4" Gap #8 x 1-5/8" Screws 1/4" Gap Page 24
STEP 40 Climbing Rocks: Fasten one Climbing Rock (CR) to each Rock Board using two 1/4 x 1" s, 1/4 Lock Washers, 8mm Flat Washers and Short Weld Nuts. 1/4" Lock Washer 8mm Flat Washer 1/4 x 1" 1/4" Short Weld Nut STEP 41 Safety Rail: Fasten the Safety Rail (BV) to the left posts using two 1/4 x 4" Assemblies. BV 1/4 x 4" s STEP 42 Lunch Seat: Fasten each Seat Support (CK) to the Lunch Base End using two 1/4 x 1" Assemblies with Short Weld Nuts. Fasten the Lunch Seat (T) to the Seat Supports using four 1/4 x 1-1/2" Assemblies w/ Long Weld Nuts. Insert the Weld Nuts from the top of the Lunch Seat. 1/4 x 1-1/2" s T CK 1/4 x 1" s w/short Weld Nuts Page 25
STEP 43 Table Supports: Fasten one Table Support (AN) to the inside of each back Lookout post using 1/4 x 4" Assemblies. Fasten a Table Brace (AL) to the outside of each Table Support using one 1/4 x 2-1/2" Assembly. Make sure the Table Supports are level. Place the lower angle of a Table Brace against the adjacent post. Mark the position of the hole. Drill a 3/16" diameter pilot hole 2" deep at the mark. Fasten the Table Brace to the post using one 1/4 x 3" Lag Screw and Flat Washer. Repeat with the other Table Brace. AL AN Step 44 Table Boards: Fasten two Table Boards (CF) to the Table Supports using four #8 x 2" Screws each. Fasten the Table Cleat (AM) to the bottom center of the Table Boards using four #6 x 1-1/8" Screws. Be careful not to sink the screws too deep; do not let the screw tips protrude from the top of the Table Boards. CF AM STEP 45 Cargo Rails: Fasten one Access Bracket to the top of each Cargo Rail (BI) using one 1/4 x 1-1/2" Assembly. Fasten each Bracket-Rail assembly to the Top Rope Support using one 1/4 x 1" Assembly. BI 1/4 x 1" 1/4 x 1-1/2" Page 26
STEP 46 Bottom Rope Support: Align the bottom corners of the Bottom Rope Support (J) with the bottom outside corners of the Cargo Rails. Drill 1/8" pilot holes through the small holes in the Bottom Rope Support into the Cargo Rails. Fasten the Bottom Rope Support to the Cargo Rails using two #8 x 2-1/2" Screws into the pilot holes. Make sure the Access Brackets are horizontal. Make sure the Cargo Rails are square to the Bottom Rope Support by measuring diagonals. Drill 3/16" pilot holes through the holes in the Bottom Rope Support and 2" into the Cargo Rails. Fasten using two 1/4 x 2" Lag Screws and Flat Washers. 3/16" dia. pilot holes 1/4 x 2" Lag Screws J 1/8" dia. pilot holes #8 x 2-1/2" Screws STEP 47 Cargo Net: Fasten the Cargo net (CS) to the Top Rope Support by passing the end of each rope through a hole and tying a figureeight knot. At least 3" of rope should extend beyond the knot. Fasten the bottom of the Cargo net to the Bottom Rope Support by passing the end of each rope through a hole and tying a figure- eight knot. At least 2" of rope should extend beyond the knot. It is important that the space between the top wooden support and a horizontal rope is not less than 9". This will ensure that children cannot slide their bodies through an opening that their head will not fit. The Cargo net should be examined weekly for wear and to make sure the knots are secure. Figure Eight Knot CS STEP 48a Access Ladder Brackets: Fasten one Access Bracket to inside of each Ladder Rail using 1/4 x 1-1/2" Assemblies as shown at right. 1/4 x 1-1/2" Page 27
STEP 48b Access Ladder to Gym: Note: Temporarily place the Slide into position to help judge the best placement of the Access Ladder. Make sure that all hardware has room to fit before drilling. See the standard placement below right. Lean the Access Ladder against the gym with the Access Brackets flat against the Platform Front and the lower edge of the Brackets flush with the lower edge of the Platform Front. Drill 5/16" diameter holes through the holes in the Brackets and through the Platform Front. Secure the Brackets using 1/4 x 1" Assemblies with Short Weld Nuts. 1/4 x 1" s w/ Short Weld Nuts Drill 5/16" dia. holes 1-3/8" Step 49 Chalkboard Vertical: Hold the Chalkboard Vertical (BL) against the Platform Right, 12" from the front right post as shown. Mark the position of the hole in the Chalkboard Vertical on the Platform Right. Drill a 5/16" diameter hole through the Platform Right at the mark. Fasten using one 1/4 x 2-1/2" Assembly. 12" 1/4 x 2-1/2" Use a level to ensure the Chalkboard Vertical is plumb. Mark the position of the hole near the bottom onto the Sandbox Side. Drill a 5/16" diameter hole through the Sandbox Side at the mark. Fasten using one 1/4 x 2" Hex Bolt Assembly. BL 1/4 x 2" BL STEP 50 Chalkboard: Determine the best height for the Chalkboard (CL) based on the height of the children who will use it. Also consider the best placement of the Chalk Box shown in the next step. Align the top corners of one Chalk Batten (O) with the top corners of the Chalkboard. Hold them in place against the front right post and Chalkboard Vertical. Fasten in place using two #8 x 2" Screws through the small holes in the Chalkboard Batten. Make sure the Chalkboard is flat against the verticals. Secure the other Chalkboard Batten at the bottom of the chalkboard using two #8 x 2" Screws through the small holes. Drill 3/16" diameter holes 2" deep through the larger holes in the Chalkboard Battens. Secure using four 1/4 x 2" Lag Screws with Flat Washers. From behind, secure the Chalkboard to the top and bottom Chalk Battens using #12 x 3/4" Pan Head Screws. 1/4 x 2" Lag Screw Back View O CL #8 x 2" Screw 1/4 x 2" Lag Screw Page 28