Gorilla Playsets Blue Ridge Frontier 2009 User manual

Blue Ridge
Frontier 2009
ASSEMBLY MANUAL
Copyright © 2008 Gorilla Playsets
All Rights Reserved
Gorilla Playsets  190 Etowah Industrial Court  Canton, GA 30114  [phone]
12/MAR/2009 – Version 1.2.0

STOP…PLEASE READ!!
IF YOU HAVE MISSING OR DAMAGED PARTS OR
NEED ASSISTANCE ASSEMBLING, PLEASE
CALL gorilla playsetsMANUFACTURING
DIRECT.
[phone]
FACTORY HOURS – MON.–FRI., 8AM-5PM EST
DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT THE
RETAILER DIRECT. THE RETAILER DOES NOT STOCK COMPONENTS.
PLEASE RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE. KEEP THEM IN A
SAFE PLACE WHERE YOU CAN REFER TO THEM AS NEEDED.
CONTACT INFO:
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA 30114
Tel. [phone]
Fax. [phone]
[email protected]
Check for revised instructions at www.gorillaplaysets.com/support

Blue Ridge Frontier
TABLE OF CONTENTS
Warranty and Safety Guidelines………………………….……………………….…..4-10
Kit Contents and Tool List…………..……………………….……………………….11-30
Framing the play set...………………………………………...……………..…...steps 1-7
Constructing deck and upper panel boards………………..……………..…..steps 8-10
Constructing rock - wall and securing to fort…………………………..…....steps 11-15
Constructing and attaching climbing ramp..….……..………….…………...steps 16-19
Installing panel slats...……………………………..………..…………...…………step 20
Assembling Swing……………………………..………..…..………..….........steps 21-38
Assembling roof…………………………………..………..….....………..…...steps 29-33
Assembling sun ray……………………………..………..…..……..…….......steps 34-36
Hanging swings and installing safety board…………………………………steps 37-38
Securing supports then adding picnic table and benches…………..……..steps 39-41
Tire Swing Assembly………………………………………...………………...steps 42-49
Rope Ladder Installation………………………………………………………steps 50-51
Mounting slide..………..……………………………………….……………….......step 52
Mounting telescope………………………………………………………………….step 53
Attaching Tic-Tac-Toe panel………………………………………………….steps 54-56
Installing dormers and chimney………………………………………………steps 57-62
Installing angle supports………………………………………………………steps 63-64
Installing safety handles……………………………………………………………step 65
Installing Climbing Ropes………………………………………………………….step 66
Customer Registration Card………………………......…….…………..………………97
PLEASE READ OWNER’S MANUAL CAREFULLY BEFORE
STARTING ASSEMBLY!

Thank you for choosing gorilla playsets®for your new backyard playground!
We’ve included everything you need, except tools, to build your very own professional
looking playset. When complete, your new playset should far exceed the quality of playset kits
from other build-your-own companies. Our engineers and design team have over 30 years of
playground experience. What we’ve developed is a playset that doesn’t compromise quality for
simplicity. Yet you’ll appreciate how quick and easy construction really is! Our playset kits are
designed for children ages 3 to 11. gorilla playsets®believes every child should have a playset
and with our kits they can! You can rest assured your new playset is safe, durable and designed
to hold up to the elements. As parents ourselves, we know how important the security and well-
being of our children is, and this shows in all of our products.
Each playset features our step-by-step 3D illustrated manual, patented powder coated
swing beam bracket, heavy-duty swing belts with chains, slide(s), accessories, plus all the
required hardware and pre-milled lumber.
Quality Lumber
At Gorilla Playsets, we use only the finest, hand selected lumber available. Whether you
choose a playset made from our Premium Preserved Pine, Beautiful California Redwood,
Western Red Cedar, or Asian Cedar you can be assured that our lumber is strong, durable, and
conforms to the national standards for use in children’s play equipment. It’s this quality that
allows us to offer a 10 year warranty on the lumber used in our play sets.
Premium Preserved Pine
Our Premium Preserved Pine is double kiln dried. We utilize this process to minimize
shrinkage, warping, and cupping. Because our pine has been “pre-shrunk”, the hardware used to
assemble your playset will hold tight. Our preserved pine is clean, odorless, non-staining, and
non-irritating to humans, animals, or plants. Gorilla’s Preserved Pine uses one of the only exterior
wood preservation systems that is EPA approved. Our pine lumber is preserved with a
preservative system containing copper and azole compounds to protect against termite attack and
fungal decay. Our Premium Preserved Pine can withstand harsh weather conditions and is
effective for decades; making Gorilla Playsets the best choice in pine lumber built swing sets.
California Redwood and Western Red Cedar*
Our Beautiful California Redwood and Western Red Cedar playsets are a natural alternative
to preserved lumber. California Redwood naturally resists decay caused by the environment or by
insect infestation while Western Red Cedar is a preferred wood for purposes where an attractive
appearance and resistance to weather is important. All California Redwood and Western Red
Cedar Gorilla Playsets receive a factory stain and sealant process. To maintain this aesthetic
appeal, it is recommended that you seal your redwood and cedar play set once per year.
Asian Cedar (Cunninghamia Lanceolata)
Our durable Asian Cedar playsets are low-maintenance, and maintain their beauty for many
years. Asian Cedar has been harvested in Southeast Asia for more than 800 years, and is prized
because it naturally repels pests, fungus, and rot. Asian Cedar is used indoors and out where
durability is critical. Asian Cedar can be found throughout the U.S. in outdoor lawn furniture, and
on children’s play structures.
*Gorilla Playsets reserves the right to substitute Western Red Cedar with other species of
similar characteristics due to market availability.

Limited Manufacturers Warranty
gorilla playsets®warrants this product to be free from defects in workmanship and
materials, under normal use and conditions, for a period of 10 years for structural wood
components and one year for all other components (i.e., hardware, plastics, tarps, rope ladder,
etc.). Cosmetic defects that do not affect the structural integrity of the product, or natural defects
of wood such as warping, checking or any other physical properties of wood that do not present a
safety hazard, are not covered by this warranty.
gorilla playsets®will repair, or, at its discretion, replace any part within the stated warranty
period that is defective in workmanship or materials. This decision is subject to verification of the
defect upon delivery of the defective part to gorilla playsets®at 190 Etowah Industrial Court,
Canton, Georgia 30114. Any part(s) returned to gorilla playsets®must include proof and date of
purchase.
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 put to
commercial or institutional use. This warranty does not cover (a) products which have been
damaged by negligence, natural disasters, or accident by improper use, or which have been
modified or repaired by unauthorized persons, (b) the cost of labor, or (c) the cost of shipping the
product, any part, or any replacement product or part.
This warranty is valid only in the United States of America, is non-transferable and does not
extend to the owners of the product subsequent to the original purchaser. gorilla playsets®
disclaims all other representations and warranties of any kind, express, implied, statutory or
otherwise, including the implied warranties of merchantability and fitness for a particular purpose.
gorilla playsets®will not be liable for any incidental or consequential damages. 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 that vary from state to state.
IMPORTANT SAFETY GUIDELINES
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 playset.
As with any home project, good judgment and respect for power tools will greatly reduce the
risk of injury. gorilla playsets®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 playset 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.
gorilla playsets®shall not be liable for incidental, indirect or consequential damages or
injuries that result from the building and/or playing on our playsets. Adult supervision is
recommended anytime a playset is being used.

WEIGHT LIMITS FOR GORILLA PLAYSETS
•FORT PLATFORMS: 800 LBS. TOTAL WEIGHT
•SWING BELTS: 175 LBS.
•GLIDER SWINGS: 70 LBS. PER CHILD
•TRAPEZE: 125 LBS.
•FULL BUCKET SWING: 50 LBS.
•TODDLER BUCKET SWING: 50 LBS.
•INFANT SWING: 35 LBS.
•TIRE SWING: 125 LBS. TOTAL WEIGHT
•ROPE LADDER: 75 LBS.
•ROCK WALL: 150 LBS.
•ALL SLIDES: 125 LBS.
Gorilla Playsets 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 playset and injury to the users.

Safety and Maintenance Tips for Your New Play Set:
NOTE: Your children’s safety is our #1 concern. Observing the following statements and warnings
reduces the likelihood of serious or fatal injury. Please review these safety rules regularly with
your children.
•This playset is designed for the use of 4 occupants who have a combined weight not
exceeding 800 pounds on the elevated floor, 3 occupants who have a combined weight of
525 pounds on the swing area, for a total Unit capacity of 5 occupants who have a combined
weight of 1325. (this weight is not including the picnic table area)
•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 to not 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 first. Never slide headfirst.
•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-fitting 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.
•Teach children to never crawl on top of a fort roof.
•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 specifically
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 use Monkey Bar when swings or glider are installed.
•Teach children to never wrap their legs around swing chain.
•Teach children to never slide down the swing chain.
WARNING: Children must NOT use this playset until unit has been completely
assembled and inspected by an adult to insure set has been properly installed
and anchored.

Safety and Maintenance Tips for Your New Play Set: (continued)
Playgrounds should be inspected on a regular basis. If any of the following conditions are
noted, they should be removed, corrected, or repaired immediately to prevent injuries.
•Hardware that is loose, worn or that has protrusions or projections
•Exposed equipment footings
•Scattered debris, litter, rocks, or tree roots
•Splinters, large cracks, and decayed wood components.
•Deterioration and corrosion on structural components, which connect to the ground
•Missing or damaged equipment components, such as handholds, guardrails, swing
seats.
•Check all nuts and bolts frequently 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.
•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 or has exposed metal in the edges of the swing seat. If there
are already exposed metal inserts on the edge of the seat, immediately remove the
seats and chains to prevent serious injury. Ropes, cables and chains should be removed
and replaced if excessive wear is found. Contact Gorilla Playsets for warranted
replacement parts.
•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 CRF Part 1303.
•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 playset 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 playset on a level location is very important. As your
children play, your playset 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.
•Rake the surface periodically to prevent compaction and maintain appropriate depths.
Disposal Instructions: When the playset use is no longer desired, it should be
disassembled and disposed of in such away that no unreasonable hazards will exist at the time
the unit is discarded.

Play Set Surfacing Recommendations:
Below are some of the recommendations that the U.S. Consumer Product Safety Commission (CPSC)
offers from its
Handbook for Public Playground Safety . The guide can be downloaded in full at
www.cpsc.gov/cpscpub/pubs/325.pdf
1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground, protective
surfacing under and around all playground equipment is the most critical safety factor on playgrounds.
Certain manufactured synthetic surfaces also are acceptable; however, test data on shock absorbing
performance should be requested from the manufacturer.
Asphalt and concrete are unacceptable. They do not have any shock absorbing properties. Similarly, grass
and turf should not be used. Their ability to absorb shock during a fall can be reduced considerably
through wear and environmental conditions.
Certain loose-fill surfacing materials are acceptable. Surfacing materials are acceptable, such as the types
and depths shown in the table.
Fall Heights and Materials
Material Uncompressed Depth Compressed Depth
6" (152mm) 9" (228mm) 12"
(304mm) to 9" (228mm)
Wood Chips 7' (2.13m) 10' (3.05m) 11' (3.35m) 10' (3.05m)
Double-Shredded bark
mulch 6' (1.83m) 10' (3.05m) 11' (3.35m) 7' (2.13m)
Engineered Wood Fibers 6' (1.83m) 7' (2.13m) >12' (3.66m) 6' (1.83m)
Fine Sand 5' (1.52m) 5' (1.52m) 9' (2.74m) 5' (1.52m)
Coarse Sand 5' (1.52m) 5' (1.52m) 6' (1.83m) 4' (1.22m)
Fine Gravel 5' (1.52m) 7' (2.13m) 10' (3.05m) 6' (1.83m)
Medium Gravel 5' (1.52m) 5' (1.52m) 6' (1.83m) 5' (1.52m)
Shredded Tires* 10-12' (3.0- 3.6m) N/A N/A N/A
*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
re
q
uest test data from the su
pp
lier showin
g
the critical hei
g
ht 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.
2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under and around
equipment where a child might fall. This area should be free of other equipment and obstacles onto which
a child might fall. Stationary climbing equipment and slides should have a fall zone extending a Minimum
of 6' in all directions from the perimeter of the equipment.
Swings should have a fall zone extending a minimum of 6' from the outer edge of the support structure on
each side. The fall zone in front and back of the swing should extend out a minimum distance of twice the
height of the swing as measured from the ground to the top of the swing support structure.

LEVELING YOUR FORT DURING ASSEMBLY
•Complete the steps which will be the basic frame of the fort {i.e. four corner posts with
base (sand box boards) and deck supports}
•Position in the most level area chosen for the playset, 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 final 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 final 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:
THE DIAGONAL
MEASUREMENTS
SHOULD BE THE
SAME FROM
CORNER POST TO
CORNER POST. IF
NOT, ADJUST
FORT SO THAT
THE DISTANCE IS
EQUAL.
= AREA TO BE SCORED AND
CHANNELED FOR LEVELNESS