Gorilla Playsets Malibu Pioneer Peak 1500DWR User manual

™
™
playsets
playsets
Copyright © 2017 Gorilla Playsets
All Rights Reserved
190 Etowah Industrial Court
Canton, GA 30114
www.gorillaplaysets.com
Malibu Pioneer Peak
Model: 1500DWR
(BOXES: 1501, 1509N, 1509W,
1510, 1511, 1523, 1528, 1529,
Tire Swing & Slide Box)
Amber Post Option
BOXES: 1519, 1533-2bx,
1522, 1524
Timber Shield Post Option
BOXES: CB, X1, TSB, 120
*51-0076-W*
51-0076-W REV A: 6/15/2017
™
™
playsets
playsets

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 to use our “Quick
Response Center” located at:
www.gorillaplaysets.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 INSTRUC-
TIONS AT:
www.gorillaplaysets.com/manuals

GORILLA PLAYSETS WARRANTY –2017
Gorilla Playsets® (“Gorilla”) warrants its play sets to be free from defects in workmanship and materials, under
normal use and conditions, for 10 years for above ground structural wood components and for one year for all
other components (e.g., swings, hardware, plastics, tarps, rope ladder, etc.).
Gorilla warrants all remaining products, including but not limited to its, Malibu Playhouse, Free Standing Swing Set,
Free Standing Tire Swing, See-Saw, Children’s Picnic Table with Umbrella, Play-Zee-Bo™, Cedar Toy Chest,
Interlocking Sandbox and spring riders to be free from defects in workmanship and materials, under normal use
and conditions, for a period of 1 year.
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 Gorilla’s website. Imperfections or conditions that develop because of a failure to
properly maintain the swing set are not covered by this warranty.
Gorilla 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 Gorilla’s discretion, may
be accomplished by submitting photographs or by delivery of the defective part to Gorilla Playsets • 190 Etowah
Industrial Ct. • Canton, GA 30114 • 1-800-882-0272 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, Gorilla 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.
GORILLA 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. GORILLA 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.

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. Gorilla 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.
Gorilla shall not be liable for incidental, indirect or consequential damages or
injuries that result from building and/or playing on our play sets. Adult supervision is
recommended anytime a play set is being used.
WEIGHT LIMITS FOR GORILLA 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.
Gorilla 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.

Product registration
Gorilla Playsets™manufactures
the nest quality products that
are designed for outstanding
strength and durability. We back
our products with unparalleled
warranties. In the unlikely event
that you need to contact us about
covered repairs, we must have a
valid Product Registration on le.
3 Easy Ways To REgisTER
oPtion 1 Complete the online registration form at:
http://www.gorillaplaysets.com/register
oPtion 2 Fax this completed form to:
[phone]
oPtion 3
Mail this completed form to:
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA 30114
Name:_______________________________________________________ Email: ______________________________________
Address: __________________________________________________________________________________________________
Comments:________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
Would you recommend this product to friends & family?
Please select
your age How would
you rate the
quality of this
product?
18-30
2-3
41-50
6-7
Yes
 Excellent
 Above Average
 Average
 Below Average
Poor
No
31-40
4-5
51+
8+
How old are
your children?
Where did you buy this product?
Your registration information:
Date of Purchase Store Store City Store State
Street City State Zip
May we add you to our mailing list? Yes No
May we use your comments on websites or other marketing materials? Yes No
Number of
children
- malibu Pioneer Peak -

THIS PAGE INTENTIONALLY LEFT BLANK

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. Our
own Stain/sealant is available online here: http://www.gorillaplaysets.com/Playground-Sealant-p/10-0003.htm
Oil based stain or water based stain may be used. Should you choose to use other stain 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
to the store with you so they can color match the tint of the stain or sealant.
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.

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.gorillaplaysets.com/Swing-Set-Safety-s/85.htm
https://www.gorillaplaysets.com/Maintenance-s/129.htm
http://www.gorillaplaysets.com/manuals.html (Click on your specific model)
http://www.gorillaplaysets.com/Warranty-s/82.htm
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.
Gorilla Playsets
190 Etowah Industrial Court
Canton, GA. 30114

Model: 1500DWR
(BOXES: 1501, 1509N, 1509W,
1510, 1511, 1523, 1528, 1529,
Tire Swing & Slide Box)
REV A: 6.15.2017
Amber Post Option
BOXES: 1519, 1533-2bx,
1522, 1524
Timber Shield Post Option
BOXES: CB, X1, TSB, 120

Safety Guidelines………………………………………...............................……...Pages 3-6
Leveling Fort, General Information and Denitions……………………...............Pages 6-8
How to Install T-Nuts, Board Identication, Predrill Lag Screw Directions and
Swing Beam Loading........................................................................................Pages 9-13
Site Plan, Required Tool List and Kit Contents...............................................Pages 14-15
Hardware, Lumber and Accessory Checklist......……………………………....Pages 16-42
Adding T-Nuts to Corner Posts...…………………………………..………...…........... Step 1
Framing Fort……………………………………..…………………………..……..... Steps 2-9
Mounting Deck...............…………………………....……………….…………...….... Step 10
Rock Wall Assembly and Installation…..…………...…..……..……...….…….. Steps 11-15
Ramp Assembly and Installation.……………………..……............................. Steps 16-19
Center Post and Panel Slat Installation.......................................................... Steps 20-21
Swing Beam Assembly……….……………………..……..............................… Steps 22-29
Roof Assembly.……...……………………….………........................................ Steps 30-35
Front Gable Assembly/Installation.................................................................. Steps 36-37
Front Wall Assembly and Completion of Main Roof....................................... Steps 38-42
Hanging Swings, Safety Board…………………………………............…........ Steps 43-44
Picnic Table Assembly and Installation...……………………………......…....... Steps 45-47
Tire Swing Assembly and Installation…………………………….....……......... Steps 48-55
Rope Ladder Assembly and Installation…………………….…….……................... Step 56
Telescope and Safety Handles………………………..……............................. Steps 57-58
Climbing Ropes, Sandbox Seats/Name Plate, Steering Wheel..................... Steps 59-61
Solar Wall Light, Ground Stakes.................................................................... Steps 62-63
PART 2: Clatterbridge Assembly....................................................................... Steps 1-34
Appendix: Chimney and Dormer Instructions, Bridge Mesh Instructions............Page 152
PLEASE READ OWNER’S MANUAL CAREFULLY
BEFORE STARTING ASSEMBLY!
TABLE OF CONTENTS
2

Safety and Maintenance Tips for Your New Play Set:
NOTE: Your children’s safety is our #1 concern. Observing the
following statements and warnings reduces the likelihood of serious
or fatal injury. Please review these safety rules regularly with your
children.
• This play set is designed for the use of 4 occupants who have a combined weight not
exceeding 800 pounds on the elevated oor, 3 occupants who have a combined weight
of 425 pounds on the swing area, for a total Unit capacity of 7 occupants who have a
combined weight of 1225. (This weight does not include any picnic table area(s).)
• On-site adult supervision is required.
• Teach children not to walk close to, in front of, behind, or between moving swings or
other moving playground equipment.
• Teach children to sit in and never stand on swings
• Teach children not to twist the chains and ropes and not to loop them over the swing
beam, since this may reduce the strength of the chain or rope.
• Teach children not to jump from swings or other playground equipment in motion.
• Teach children not to push empty seats. The seat may hit them and cause serious
injury.
• Teach children to sit in the center of the swings with their full weight on the seats.
• Teach children not to use the equipment in a manner other than intended.
• Teach children to always go down slides feet rst. Never slide headrst.
• Teach children to look before they slide to make sure no one is at the bottom.
• Teach children to never run up a slide, as this increases their chances of falling.
• The parents should have the children dress appropriately with well-tting shoes. Loose
clothing such as scarves and ponchos should not be worn. Always take off, tie up or
tuck in cords and drawstrings on children’s clothing. These things can get caught on
playground equipment and strangle a child.
• Teach children not to climb when the equipment is wet.
• Teach children to never jump from a fort deck. They should always use the ladder,
ramp or slide.
• Teach children to never crawl or walk across the top of monkey bars or swing beam.
• Teach children to never crawl on top of a fort roof or on the outside of a tube slide.
• Verify that any suspended climbing ropes, chains, or cables are secured at both ends
and that they cannot be looped around an adult hand.
• Teach children not to attach items to the playground equipment that are not specically
designed for use with the equipment, such as, but not limited to, jump ropes, clothesline,
pet leashes, cables and chain as they may cause a strangulation hazard.
• Teach children to never wrap their legs around swing chain.
• Teach children to never slide down the swing chain.
• Teach children to remove their bike or other sports helmet before playing on the
playgound equipment.
• Teach children to NEVER look at the sun or other bright light through any accessory
such as but not limited to a telescope, periscope or binoculars.
WARNING: Children must NOT use this play set until it has been
completely assembled and inspected by an adult to insure it has been
properly installed and the swing beam legs are anchored.
3

Safety and Maintenance Tips for Your New Play Set:
(continued)
Playgrounds should be inspected on a regular basis. If any of the following conditions are noted,
they should be removed, corrected, or repaired immediately to prevent injuries.
• Hardware that is loose, worn or that has protrusions or projections.
• Exposed equipment footings.
• Scattered debris, litter, rocks, or tree roots.
• Splinters, large cracks, and decayed wood components.
• Deterioration and corrosion on structural components, which connect to the ground.
• Missing or damaged equipment components, such as handholds, guardrails, swing seats.
• Check all nuts and bolts twice monthly during the usage season and tighten as required.
(But not so tight that you crack the wood) We recommend you check the swing beam and
hardware often due to wood expansion and contraction. It is particularly important that this
procedure be followed at the beginning of each season.
• Remove plastic swing seats and take indoors or do not use when the temperature drops below
32°F. Reinstall swings and other swing equipment at the beginning of the usage season.
• Oil all metallic moving parts monthly during the usage period.
• Check all coverings for bolts and sharp edges twice monthly during usage season to be certain
they are in place. Replace when necessary. It is especially important to do this at the beginning
of each new season.
• Check swing seats, ropes, cables and chains monthly during usage season for evidence of
deterioration. Replacement should be made of any swing seat that has developed cracks in the
plastic seats. Ropes, cables and chains should be removed and replaced if excessive wear is
found. Contact us for warranted replacement parts.
• Swing chains, rings, ropes, etcetera should always be fastened to a rotating swing hanger.
NEVER attach a chain, ring, rope, etcetera to a stationary hanger such as but not limited to an
eye bolt. Severe wear could occur leading to an injury.
• For rusted areas on metallic members such as monkey bars, hand supports brackets, etc.;
sand and repaint, using a non lead-based paint meeting the requirements of Title 16 C.F.R. Part
1303. These requirements are available at: http://www.cpsc.gov/
• Inspect wood parts monthly. The grain of the wood sometimes will lift in the dry season
causing splinters to appear. Light sanding may be necessary to maintain a safe playing
environment. If you are treating your play set with stain regularly, it will help prevent severe
checking/splitting and other weather damage.
• Once or twice a year, depending on your climate conditions, you must apply some type of
protection (sealant) to the wood of your unit. Prior to the application of sealant, lightly sand any
“rough” spots on your set. Please note this is a requirement of your warranty.
• Creating and maintaining the play set on a level location is very important. As your children
play, your play set will slowly dig its way into the soil, and it is very important that it settles
evenly. Make sure the play set is level and true once each year or at the beginning of each play
season.
• Twice a month during the usage season rake the playground protective surfacing materials to
prevent compaction and maintain appropriate depths. Replace the protective surfacing materials
as required.
• Disposal Instructions: When the play set is no longer desired, it should be disassembled and
disposed of in such away that no unreasonable hazards will exist at the time the play set is
discarded.
4

Play Set Surfacing Recommendations:
Below are some of the recommendations that the U.S. Consumer Product Safety
Commission (CPSC) offers from its Handbook for Public Playground Safety. The guide
can be downloaded in full at www.cpsc.gov/cpscpub/pubs/325.pdf
1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the
ground, protective surfacing under and around all playground equipment is the most
critical safety factor on playgrounds.
Certain manufactured synthetic surfaces also are acceptable; however, test data on
shock absorbing performance should be requested from the manufacturer.
Asphalt and concrete are unacceptable. They do not have any shock absorbing
properties. Similarly, grass and turf should not be used. Their ability to absorb shock
during a fall can be reduced considerably through wear and environmental conditions.
Certain loose-ll surfacing materials are acceptable. Surfacing materials are acceptable,
such as the types and depths shown in the table.
Fall Heights and Materials
Type Of Material 6 in. depth 9 in. depth 12 in. depth
Double-Shredded bark mulch 6’ Fall Height 10’ Fall Height 11’ Fall Height
Wood Chips 6’ Fall Height 7’ Fall Height 12’ Fall Height
Fine Sand 5’ Fall Height 5’ Fall Height 9’ Fall Height
Shredded Tires* 10-12’ Fall Height N/A N/A
Fine Gravel 6’ Fall Height 7’ Fall Height 10’ Fall Height
*This data is from tests conducted by independent testing laboratories on a 6-inch depth of uncompressed shredded tire samples
produced by four manufacturers. The tests reported critical heights, which varied from 10 feet to greater than 12 feet. It is
recommended that persons seeking to install shredded tires as a protective surface request test data from the supplier showing the
critical height of the material when it was tested in accordance with ASTM F1292.
It should be recognized that all injuries due to falls cannot be prevented no matter what
surfacing material is used.
5

2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential
under and around equipment where a child might fall. This area should be free of other
equipment and obstacles onto which a child might fall. Stationary climbing equipment
and slides should have a fall zone extending a Minimum of 6’ in all directions from the
perimeter of the equipment.
Swings should have a fall zone extending a minimum of 6’ from the outer edge of the
support structure on each side. The fall zone in front and back of the swing should
extend out a minimum distance of twice the height of the swing as measured from the
ground to the top of the swing support structure.
LEVELING YOUR FORT DURING ASSEMBLY
• Complete the steps which will be the basic frame of the fort. {i.e. four corner posts with
base (sand box boards) and deck supports}
• Position in the most level area chosen for the play set, keeping in mind the location
and size of the swing beam, ladder, slides, etc. that extend off the fort.
• Once the frame is in the nal position, check for vertical and horizontal levelness to
determine which side(s) will need to be dug into the ground to level the play set.
• With a shovel, score the ground around the outside edges of the sandbox boards on
the ‘high’ side of the fort. This is the area that will be dug in. Make sure to score deep
enough; the scored lines will be your digging template.
• Push the frame off and away from the scored area, far enough to dig and remove dirt
to reach the appropriate depth.
• Dig a channel along the scored line(s) for the base of the fort (corner post and
sandbox boards) to rest into. Dig the channel(s) to the same level depth. The bottom
of the channel(s) should be level to each other so your frame doesn’t teeter or rock
because the channel(s) are uneven.
• Once you have removed enough grass and dirt, slide/push the frame into the
channel(s). Place a level on the vertical and horizontal boards of the frame to determine
if enough soil, or too much, was removed.
• Repeat this process until the basic frame is plumb and level and in its nal position
before completing the rest of the assembly.
• Measure to make sure fort is square.
Important: if you require a channel depth of more than 6”, then we
recommend you have your play set area professionally graded before
completing assembly.
Example Play area:
= Area to be scored and
channeled for levelness
The diagonal measure-
ments should be the
same from corner post to
corner post. If not, adjust
corner posts so that the
distance is equal.
Side View of
Playset Frame
(Grade is the
Slanted Line)
6

General Info to Review Before Installation
• Depending on your experience, assembly of the playset can take as little as 6 hours
up to 24 hours, depending on size, after inventory of parts; therefore, we recommend
you set aside a full two days for assembly.
• Identify all of the parts for your play set. Empty each box and lay out boards so you
can see each part. Your instruction book will have detailed drawings that will make it
easy for you to recognize individual parts. Keep all hardware and metal parts separate
from wooden pieces.
• After everything is laid out, check carefully to ensure all parts are present. Make sure
there are no broken boards.
• Find an area to sort your hardware. It is best to open the hardware on a solid surface
so that you do not lose any pieces in the grass. This will save time and familiarize you
with all the different pieces in the hardware bag.
• Important note: Wood has some natural defects such as knots, surface cracks, etc…
We reject parts that are structurally defective. We use a high quality lumber in our
structures; however, you should inspect each part for splinters or rough spots and sand
them smooth to prevent injury.
• After familiarizing yourself with all of the components, read all instructions thoroughly.
Reading instructions after you have studied the parts will help you understand the
installation process, and help to eliminate unnecessary mistakes.
• Pay close attention to the diameter and length of each bolt and screw.
• Never tighten hardware completely at rst. It helps to have some adjustment for bolt
alignment while you are attaching parts together. After everything is square, tighten
each joint.
• After the main unit is assembled it is critical that the oor is level and square. If the
main frame is not level, the walls and oor will be out of square.
• After you complete installation, make sure every bolt, screw, and nut is tight, and every
board is secure. Wood will expand and contract with the seasons.
• Place the set on level ground, not less than 6 feet from any structure or obstruction
such as a fence, garage, house, overhanging branches, laundry lines, or electrical
wires.
7

Counter-Sunk Hole
Through Hole
This page is a list of denitions and explanations used throughout our
instructions to aid you in the assembly of your play set.
Offset Holes- Throughout the installation procedures we will refer to parts with offset
holes. This refers to the orientation of the holes on the board. An offset hole is one that
is closer to one side than it is the other or in other words, it is not centered on the board.
In the procedures you will be instructed to attach the boards with the holes offset up or
with the holes offset down. This refers to which side of the board the hole/holes should
be closer to. Offset holes up= hole/holes will be closer to the top of the board. Offset
holes down= hole/holes will be closer to the bottom of the board. Note: some parts do
not have offset holes, but instead the holes are on center. Therefore there will not be
any reference on how to offset these parts.
EXAMPLE OF OFFSET HOLES UP
EXAMPLE OF OFFSET HOLES DOWN
Counter-sunk holes - Many of the parts that will be used have counter-sunk holes. A
counter-sunk hole is one that surrounds one side of a through hole, but does not extend
through the wood it’s self. When using a counter-sunk hole the bolt will be inserted
through the through hole and either the head of the bolt and washer or nut and washer
will occupy the counter sunk hole.
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.
8

Common Installation Practice Installing T-nuts
When installing T-nuts into the wood, use a smooth faced hammer to set the face of the
T-nut ush into the wood.
Insert the barrel of the T-nut into the
predrilled hole. Using a smooth faced
hammer, drive the T-nut until the face
of the T-nut is ush to the wood.
This picture shows the T-nut inserted
and installed ush to the wood.
This picture shows an end view of the T-nut
installed ush to the wood.
WARNING: DO NOT EMBED THE TOP
OF THE T-NUT INTO THE
FACE OF THE WOOD
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.
Corner Post
T-nut
Flush (Correct)
9

A
T-NUT
CORNER POST
BOARD YOU ARE
ATTACHING TO
CORNER POST.
WASHER
HEX HEAD BOLT
FRONT SIDE OF
CORNER POST
BACK SIDE OF
CORNER POST
T-NUT
FLANGE
IS HERE.
BOARD YOU
ARE ATTACHING
TO CORNER POST.
WASHER
HEX HEAD BOLT
CROSS SECTION VIEW
OF BOARD, CORNER
POST AND FASTENERS.
CORNER POST
DETAIL A
SCALE 2 : 1
FLANGE
SHAPED END
WITH TEETH
TEETH
BARREL
SHAPED
END GOES
INTO HOLE IN
CORNER POST.
T-NUT DETAILS
THREADS ON
INSIDE OF
BARREL .
HOW A T-NUT WORKS
THE FIRST STEP IN OUR ASSEMBLY INSTRUCTIONS IS TO INSERT T-NUTS INTO THE CORNER
POSTS. A T-NUT IS A FASTENER WHICH IS THREADED ON THE INSIDE AND IT FUNCTIONS
JUST LIKE A STANDARD HEX NUT. YOU INSERT THE T-NUTS INTO THE PREDRILLED HOLES IN
THE CORNER POSTS.
THE T-NUT HAS A BARREL SHAPED END WHICH GOES INTO THE HOLE IN THE CORNER POST.
THE T-NUT ALSO HAS AN FLANGE SHAPED END WITH TEETH. THE TEETH PENETRATE INTO THE
CORNER POST WOOD TO PREVENT THE T-NUT FROM SPINNING WHEN YOU TIGHTEN THE
HEX HEAD BOLT.
SHOWN BELOW YOU WILL SEE THE T-NUT IS HAMMERED INTO THE CORNER POST ON THE
BACK SIDE. THE BOARD IS BEING ATTACHED ON THE FRONT SIDE OF THE CORNER POST.
10

BOARD IDENTIFICATION
2-4-3600-BPB
TAG
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 3
8" WIDTH
13
8"
THICKNESS
11

2 x 4 board
Corner post
Corner Post
4 x 4 board
PRE-DRILL LAG SCREW DIRECTIONS
posts with an 11/64" drill bit. Remove the
holes in the 4 x 4 board into the corner
right. Install the 4 x 4 board.
to drill the holes to a total depth of 2-5/16" as shown at
4 x 4 board. Continue to drill the holes to
a total depth of 2-13/16" as shown at the
the right. Install the 2 x 4 board.
board into position. Spot drill through the
below. Place the board into position. Spot Drill through
the holes in the 2 x 4 board into the corner posts with
Example 5/16" diameter x 3-1/2" lag screw
the right. Install the 2 x 4 board.
This would be like the 2 x 4 board installation shown
drill the holes to a total depth of 2-5/16" as shown at
an 9/64" drill bit. Remove the 2 x 4 board. Continue to
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
Example 3/8" diameter x 5" lag screw
This would be like the 4 x 4 board
installation shown below. Place the
LAG SCREW DIAMETER DRILL BIT SIZE
5/16" DIAMETER 9/64"
3/8" DIAMETER 11/64"
Pre-drilling holes for lag screws will make it easier to drive the screws in by hand.
"Jobber" length drill bits are available in sizes that are longer than standard drill bits and
those are ideal for the job. When using the drill bit you will have to "spot" drill the post
and then remove the board you are attaching to finish drilling the hole.
Pay attention to the DIAMETER of the lag screw you are installing. Your playset may
come with two different diameter lag screws. Each diameter will require a different size
drill bit. When installing lag screws DO NOT OVERTIGHTEN.
Corner Post
2 x 4 board
4 x 4 board
Corner Post
7"3 16
"
16
2 5
16
15
4 "
2 13
16 "
12