Gorilla Pioneer Peak User manual

POST. USE A DAB OF SILICONE ON
SIDE OF FORT
THE TOP HOLES IN ALL THE CORNER
PLACE A PLASTIC PLUG INTO EACH OF
SHOULD BE FACING THIS DIRECTION.
EACH PLUG TO SEAT THE HOLES.
HOLES AT THE TOP OF CORNER POSTS
NO T-NUT
IN THESE
HOLES
4 X 4 X 96"
CORNER POST
LEFT (SWING BEAM) FRONT OF FORT
STEP 1: ATTACHING T-NUTS TO THE CORNER POSTS
1: THIS STEP IS CRITICAL TO BUILDING THE FORT PROPERLY. IF ANY MISTAKES ARE MADE HERE, YOU WILL NEED TO
DIS-ASSEMBLE AND THEN RE-ASSEMBLE TO MAKE YOUR CORRECTIONS.
2: MAKE SURE HOLES ARE FREE OF ANY OBSTRUCTIONS. USE A BOLT TO CLEAN OUT ANY DEBRIS.
3: LAY OUT EACH OF THE 4 X 4 X 96" CORNER POSTS IN THE AREA YOU INTEND ON BUILDING THE FORT.
4: USE THE DIAGRAM BELOW TO CORRECTLY IDENTIFY AND ORIENT THE NECESSARY DIRECTION THE POSTS
SHOULD FACE.
5: USE A HAMMER TO SEAT THE T-NUTS AFTER INSERTING THEM INTO THE HOLES SHOWN IN THE DIAGRAM BELOW.
6: THE BARREL OF THE T-NUT SHOULD GO IN THE HOLE FIRST. HAMMER THE T-NUT UNTIL IT IS FLUSH/ALMOST FLUSH
TO THE CORNER POSTS.
39

2 X 6 X 47-1/2"
TOP PANEL BOARD
2 X 6 X 47-1/2"
5/16" WASHER
BOTTOM PANEL BOARDHEX BOLT
5/16" X 4-1/2"
2 X 6 X 47-1/2"
SANDBOX BOARD
STEP 2: ASSEMBLING THE RIGHT SIDE FRAME
FRONT
OF
FORT
1: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS AT THE BOTTOM OF THE
CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN.
2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE
T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
3: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS IN THE MIDDLE
OF THE CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN.
4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM HOLES OF THE BOTTOM PANEL
BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE TOP HOLES WILL BE USED LATER.
5: LAY THE 2 X 6 X 47-1/2" TOP PANEL BOARD ON TOP OF THE RIGHT SIDE CORNER POSTS. THE HOLES IN
THE TOP PANEL BOARD MUST BE OFFSET DOWN.
6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE TOP PANEL BOARD TO
THE T-NUTS INSTALLED ON THE CORNER POSTS.
7: DO NOT INSTALL LAG SCREWS AT THIS TIME.
40

SANDBOX BOARD
(OFFSET HOLES DOWN)
(OFFSET HOLES DOWN)
2 X 6 X 47-1/2"
BOTTOM PANEL BOARD
DETAIL A
SWING BEAM SUPPORT
5/16" WASHER
4 X 4 X 47-1/2"
2 X 6 X 47-1/2"
5/16 X 4-1/2"
HEX BOLT
A
STEP 3: ASSEMBLING THE LEFT SIDE FRAME
1: LAY THE LEFT SIDE CORNER POSTS ON THE GROUND IN THEIR PROPER ORIENTATION.
2: LAY THE 2 X 6 X 47-1/2" SANDBOX BOARD ON TOP OF THE LEFT SIDE CORNER POSTS AT THE BOTTOM OF THE
CORNER POSTS. THE HOLES IN THE SANDBOX BOARD MUST BE OFFSET DOWN.
3: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE
T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
4: LAY THE 2 X 6 X 47-1/2" BOTTOM PANEL BOARD ON TOP OF THE LEFT SIDE CORNER POSTS IN THE MIDDLE OF THE
CORNER POSTS. THE HOLES IN THE BOTTOM PANEL BOARD MUST BE OFFSET DOWN.
5: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE BOTTOM HOLES OF THE BOTTOM PANEL
BOARD TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE TOP HOLES WILL BE USED LATER.
6: LAY THE 4 X 4 X 47-1/2" SWING BEAM SUPPORT ON TOP OF THE LEFT SIDE CORNER POSTS. THE THREE COUNTER-
SUNK HOLES IN THE MIDDLE OF THE SWING BEAM SUPPORT MUST FACE DOWNWARD.
7: FIND TWO TORQUE WASHERS. PLACE A 6-1/2" CARRIAGE BOLT THROUGH THE TORQUE WASHER, MAKING SURE
THAT THE TEETH ARE FACING IN THE SAME DIRECTION AS THE THREADS OF THE CARRIAGE BOLT. PLACE THE TORQUE
WASHER/CARRIAGE BOLT ASSEMBLY INTO THE CORNER POST HOLES SO THAT THE HEAD OF THE CARRIAGE
BOLT FACES WHAT WILL BE THE INSIDE OF THE FORT. USE A HAMMER TO SET THE TORQUE WASHER INTO THE CORNER
POST.
8: ATTACH THE SWING BEAM SUPPORT AS SHOWN
IN DETAIL A.
FRONT
OF
FORT
THE THREE COUNTER-
SUNK HOLES ON THE
SWING BEAM SUPPORT
WILL FACE DOWN WHEN
PROPERLY INSTALLED.
3/8" NUT
TORQUE WASHER
3/8" WASHER
BOLT CAP
6-1/2" CARRIAGE
BOLT
41

95
8
"
27 1
8
"
111
16
"
111
16
"
1"
1"
2 X 4 X 70"
DECK SUPPORT
95
8
"
27 1
8
"
13
4
" 13
4
"
1"
1"
2 X 6 X 70"
FRONT FACE BOARD
STEP 3A: DRILL HOLES FOR BRIDGE CHAINS
1: LOCATE ONE 2 X 4 X 70" DECK SUPPORT AND ONE 2 X 6 X 70" FRONT FACE BOARD.
2: MEASURE AS SHOWN BELOW AND MAKE MARKS ON EACH BOARD.
3: PLACE A SCRAP PIECE OF WOOD UNDER THE BOARD BEFORE YOU DRILL THE 1" HOLES
WITH A SPADE BIT.
42

5/16" WASHER
HEX BOLT
5/16 X 4-1/2"
2 X 4 X 70"
DECK SUPPORT
COUNTER-SUNK
HOLES ON CENTER
FRONT OF PLAY SET
HOLES FOR CLATTER BRIDGE
CHAIN.
LEFT SIDE
OF PLAY
SET
STEP 4: DECK SUPPORTS
YOU WILL NEED AN EXTRA PERSON FOR THIS STEP.
1: WITH HELP, STAND UP THE LEFT AND RIGHT SIDE ASSEMBLIES.
2: FASTEN THE 2 X 4 X 70" DECK SUPPORTS TO THE HOLES AT 54-3/4" WITH 5/16 X 4-1/2" HEX BOLTS AND 5/16"
WASHERS FROM THE INSIDE OF THE FORT
43

ROPE LADDER
2 X 6 X 70"
5/16" WASHER
RUNNER
BOARD
FRONT FACE
2 X 6 X 102"
5/16 X 4-1/2"
HEX BOLT
2 X 6 X 102"
ROPE LADDER
SUPPORT
FRONT OF PLAY SET
HOLES
FOR
CLATTER
BRIDGE
LEFT SIDE
OF PLAY SET
STEP 5: FRONT FRAME ASSEMBLY
1: PLACE THE 2 X 6 X 102" ROPE LADDER RUNNER ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE
ROPE LADDER RUNNER SHOULD BE OFFSET UP.
2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE
T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
3: PLACE THE 2 X 6 X 70" FRONT FACE BOARD WITH NOTCHES ON THE FRONT OF THE CORNER POSTS. THE HOLES IN
THE FRONT FACE BOARD SHOULD BE OFFSET UP.
4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE FRONT FACE BOARD TO
THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
5: PLACE THE 2 X 6 X 102" ROPE LADDER SUPPORT ON THE FRONT OF THE CORNER POSTS. THE HOLES IN THE ROPE
LADDER SUPPORT SHOULD BE OFFSET UP.
6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE ROPE LADDER SUPPORT TO
THE T-NUTS INSTALLED ON THE CORNER POSTS.
44

STEP 6: REAR FRAME ASSEMBLY
1: PLACE THE 2 X 6 X 70" SANDBOX BOARD ON THE BOTTOM REAR OF THE CORNER POSTS. THE HOLES IN THE
SANDBOX BOARD MUST BE OFFSET UP.
2: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE SANDBOX BOARD TO THE
T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
3: PLACE THE 2 X 6 X 70" BOTTOM PANEL BOARD AT THE MIDDLE OF THE REAR CORNER POSTS. THE HOLES IN
THE FRONT FACE BOARD MUST BE OFFSET UP.
4: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE TOP HOLES OF THE BOTTOM PANEL BOARD
TO THE T-NUTS INSTALLED ON THE CORNER POSTS. THE BOTTOM HOLES WILL BE USED LATER.
5: PLACE THE 2 X 4 X 70" REAR TOP PANEL BOARD NEAR THE TOP OF THE REAR CORNER POSTS. THE HOLES IN THE TOP
PANEL BOARD MUST BE OFFSET UP.
6: USE 5/16 X 4-1/2" HEX BOLTS AND 5/16" WASHERS TO ATTACH THE HOLES OF THE TOP PANEL BOARD TO
THE T-NUTS INSTALLED ON THE CORNER POSTS.
BOTTOM PANEL BOARD
REAR TOP PANEL BOARD
2 X 6 X 70"
OFFSET HOLES UP
SANDBOX BOARD
OFFSET HOLES UP
2 X 4 X 70"
HEX BOLT
5/16" WASHER
OFFSET HOLES UP
2 X 6 X 70"
5/16 X 4-1/2"
REAR OF FORT
45

5/16" WASHER
5/16" X 3-1/2"
LAG SCREW
***IMPORTANT***
INSTALL LAG SCREWS AND WASHERS
ONLY IN THESE FOUR 2 X 6 BOARDS FIRST.
THEN LEVEL/SQUARE THE FRAME. FINALLY,
INSTALL LAG SCREWS IN THE REMAINING
2 X 6 BOARDS.
STEP 6A: LEVELING THE PLAY SET AND LAGS
1: INSTALL LAG SCREWS ONLY IN THE FOUR 2 X 6 BOARDS AT DECK HEIGHT AT THIS TIME.
THIS IS TO MAKE THE STRUCTURE RIDGID FOR THE LEVELING AND SQUARING PROCESS.
2: PLACE THE FRAME IN ITS FINAL POSITION AND FOLLOW THE PROCEDURES AT THE FRONT
OF THE MANUAL TO LEVEL AND SQUARE THE STRUCTURE. HAVE AN ASSISTANT HELP YOU
LIFT THE FRAME AS REQUIRED. DO NOT INSTALL REMAINING LAG SCREWS UNTIL AFTER THE
FRAME HAS BEEN LEVELED AND SQUARED.
3: ONCE THE FRAME IS LEVEL, SQUARE AND SET INTO POSITION; GO BACK AND INSERT
THE 5/16" X 3-1/2" LAG SCREWS AND 5/16" WASHERS IN ALL OF THE REMAINING HOLES OF
THE 2 X 6 PARTS ON THE FRONT, SIDES AND REAR OF THE PLAY SET. NOTE: THERE WILL NOT
BE ANY PREDRILLED HOLES IN THE CORNER POSTS FOR THE LAG SCREWS.
46

DETAIL B
SCALE 1 : 8 2-1/2" WOOD SCREW
3" WOOD SCREW
3" WOOD
SCREW
2" WOOD
SCREW
2" WOOD
SCREW
2 X 6
BOTTOM
PANEL
BOARD
2 X 4 X 13"
ANGLE
SUPPORT
2 X 4 X 18"
ANGLE
SUPPORT
DETAIL A
SCALE 1 : 8
MOVE THIS ANGLE
SUPPORT DOWN TO
AVOID OVERLAPPING
THE HOLE.
2 X 6
BOTTOM
PANEL
BOARD
2 X 4 X 13"
ANGLE
SUPPORT
2 X 4 X 18"
ANGLE
SUPPORT
2 X 4
DECK
SUPPORT
A
STEP 6B: ANGLE SUPPORTS
TOP OF ANGLE SUPPORTS
SHOULD BE FLUSH OR LOWER
THAN THE DECK SUPPORT
1: FOUR 2 X 4 X 13" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE LEFT AND
RIGHT SIDES OF THE PLAY SET TO THE 2 X 6 BOTTOM PANEL BOARDS. THE TOP OF THE
ANGLE SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
2: AT THE TOP USE 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE ANGLE
SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE ANGLE
SUPPORT TO THE CORNER POST.
3: FOUR 2 X 4 X 18" ANGLE SUPPORTS ARE MOUNTED UNDER THE DECK ON THE FRONT
AND REAR OF THE PLAY SET TO THE 2 X 4 DECK SUPPORTS. THE TOP OF THE ANGLE
SUPPORT SHOULD BE FLUSH OR LOWER THAN THE TOP OF THE DECK SUPPORT.
4: AT THE TOP USE TWO 2-1/2" WOOD SCREWS THROUGH THE DECK SUPPORT INTO THE
ANGLE SUPPORT. AT THE BOTTOM USE ONE 2" AND ONE 3" WOOD SCREW TO FASTEN THE
ANGLE SUPPORT TO THE CORNER POST.
47

STEP 7: BOTTOM PANEL BOARDS
FASTEN TO THE CORNER POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
1: PLACE THE 2 X 4 X 47-1/2" END PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD WITH OFFSET HOLES UP AND
2: PLACE THE 2 X 4 X 14" BOTTOM PANEL BOARD ON TOP OF THE 2 X 6 PANEL BOARD AND FASTEN TO THE CORNER
POSTS WITH 5/16 X 3-1/2" LAG SCREWS WITH 5/16" WASHERS.
OFFSET HOLES UP LAG SCREW
5/16" X 3-1/2"
5/16" WASHER
END PANEL BOARD
2 X 4 X 47-1/2"
FRONT OF
FORT
FORT
OF
LAG SCREW
FRONT
2 X 4 X 14"
BOTTOM PANEL BOARD
COUNTER-SUNK HOLES
ON CENTER
5/16" X 3-1/2"
5/16" WASHER
48

FRONT FACE BOARD
BOTTOM PANEL BOARD
RIGHT SIDE BOARDS
LEFT SIDE BOARDS
! ATTENTION !
IN THE FOLLOWING THREE STEPS YOU WILL BEGIN THE INSTALLATION OF THE DECK SPACERS
AND DECK BOARDS. IF YOU HAVE DIFFICULTY GETTING THE DECK BOARDS/DECK SPACERS TO
FIT BETWEEN THE FRONT FACE BOARD AND BOTTOM PANEL BOARD DO THE FOLLOWING:
1: LOOSEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET. REMOVE THE
SCREWS ON ONE SIDE OF EACH DECK SPACER.
2: ALLOW THE DECK BOARDS TO DROP DOWN IN BETWEEN THE FRONT FACE BOARD AND
BOTTOM PANEL BOARD.
3: TIGHTEN UP THE BOARDS ON THE LEFT AND RIGHT SIDES OF THE PLAY SET.
4: RE-INSTALL THE SCREWS IN THE DECK SPACERS. THEN INSTALL THE DECK BOARDS AS
INDICATED IN THE INSTRUCTIONS.
49

BOTH ENDS WITH A1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW. THE HOLE AT 20-3/16" IS THE CENTER OF THE
STEP 8: DECK SPACERS
BOARD AND ONLY NEEDS TO BE DRILLED ONCE. THIS HOLE IS TO ATTACH THE CENTER DECK SUPPORT TO THE
DECK SPACER.
THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD
1: PRE-DRILL THE ENDS OF THE 5/4 X 4 X 40-3/8" DECK SPACERS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL
2: PLACE THE 5/4 X 4 X 40-3/8" DECK SPACER AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE
CORNER POSTS AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE PREDRILLED HOLES AND INTO THE DECK
SUPPORT BELOW. NOTE THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK SPACER.
THIS IS THE CENTER OF THE
BOARD. THIS HOLE ONLY
NEEDS TO BE DRILLED ONCE.
5/4 X 4 X 40-3/8"
DECK SPACER
8
3
1
1" 8"
20 "
3
"
16
16
11
"
2
111
16 "
REMOVED FOR CLARITY.
2" WOOD SCREW
NOTE: BOTTOM PANEL BOARDS AND END PANEL BOARD
5/4 X 4 X 40-3/8"
DECK SPACER
FRONT OF FORT
50

USE 2-1/2" WOOD SCREWS IN THESE LOCATIONS
ON EACH SIDE.
STEP 9: CENTER DECK SUPPORT
1: FIND THE 2 X 4 X 70" CENTER DECK SUPPORT WITHOUT HOLES.
2: FROM THE UNDERSIDE OF THE DECK SPACERS THAT WERE PREVIOUSLY INSTALLED, PLACE THE CENTER DECK
SUPPORT AT THE CENTER OF THE DECK SPACERS (USE THE HOLE ON CENTER AS A GUIDE) AND MAKE A MARK ON
THE OUTSIDE OF THE FORT TO REPRESENT A CENTER LINE.
3: USE 2" WOOD SCREWS TO ATTACH THE DECK SPACERS TO THE CENTER DECK SUPPORT.
4: CENTER THE 2 X 4 X 70" CENTER DECK SUPPORT ON THESE MARKS AND PUSH THE CENTER DECK SUPPORT FLUSH
TO THE BOTTOM SIDE OF THE DECK BOARDS.
5: USING TWO 2-1/2" WOOD SCREWS, INSTALL THE 2 X 4 X 70" CENTER DECK SUPPORT THROUGH THE OUTSIDE OF
THE 2 X 6, AND INTO THE END OF THE CENTER DECK SUPPORT. REPEAT THIS STEP ON THE OPPOSITE END OF THE
FORT.
CENTER DECK SUPPORT
2 X 4 X 70"
2" WOOD SCREW
51

"1 8
4 8
3
1"
1
8"
"4 8
1
8
1
4 "
"
3
8
16
23 11 "
4
2 3"
1
4
1
8"
STEP 10: DECK BOARDS
THE FOLLOWING STEP IS RECOMMENDED TO PREVENT POSSIBLE SPLITS IN THE WOOD
1: PRE-DRILL THE ENDS OF THE DECK BOARDS TO PREVENT INSTALLATION DAMAGE. PRE-DRILL BOTH ENDS WITH A
1/8" DRILL BIT AT THE DIMENSIONS SHOWN BELOW.
PREDRILED HOLES AND INTO THE DECK SUPPORT BELOW. LEAVE A UNIFORM (APPROX. 1/4") SPACE BETWEEN THE
DECK BOARDS. NOTE: THE TOP OF THE SCREW HEAD SHOULD BE FLUSH TO THE TOP OF THE DECK BOARDS.
FRONT FACE BOARD AND THE REAR BOTTOM PANEL BOARD AND ATTACH IT WITH 2" WOOD SCREWS THROUGH THE
DECK BOARD
2: START WITH A 5/4 X 6 X 47-3/8" DECK BOARD AT ONE END OF THE FORT. CENTER THE BOARD BETWEEN THE
5/4 X 6 X 47-3/8"
2" WOOD SCREW
LAY ALL DECK BOARDS ACROSS THE DECK SUPPORTS BEFORE SECURING THEM TO THE
FORT. THIS WILL ENSURE THAT YOU HAVE EQUAL SPACING ACROSS THE DECK.
52

2 X 4 X 66"
ROCK WALL
SIDES
A
STEP 11: ROCK WALL
1: FIND TWO 2 X 4 X 66" ROCK WALL SIDES.
2: POSITION THE ROCK WALL SIDES SO THAT THE HOLES IN THE BOARDS ARE BOTH FACING THE SAME WAY.
3: INSERT T-NUTS INTO THE INSIDE OF THE ROCK WALL SIDES AND SET WITH A HAMMER.
T-NUT
53

STEP 12: ROCK WALL
1: FIND ELEVEN 5/4 X 6 X 23-7/8" ROCK WALL BOARDS, AND ONE 5/4 X 6 X 23-7/8" BOTTOM ROCK WALL BOARD(1
HOLE).
2: STARTING FROM THE TOP, PLACE ONE ROCK WALL BOARD ON TOP OF THE ROCK WALL SIDES, FLUSH TO THE TOP
OF THE ROCK WALL SIDES, AND ATTACH WITH TWO 2" WOOD SCREWS IN EACH SIDE.
3: CONTINUE DOWN THE ROCK WALL WITH THE REMAINING ROCK WALL BOARDS, FASTENING EACH BOARD WITH
TWO 2" WOOD SCREWS ON EACH END.
4: THE FINAL BOARD WILL BE THE BOTTOM ROCK WALL BOARD WITH ONE HOLE. ATTACH WITH TWO 2" WOOD
SCREWS PER SIDE.
5: IN SOME CASES, THERE WILL BE EXCESS LENGTH ON THE ROCK WALL SIDES. THIS IS DUE TO MILLING VARIATIONS,
AND IS ALSO USED TO HELP LEVEL THE ROCK WALL SIDES ON UNEVEN GROUND.
6: ROCK WALL SIDES MAY NOT BE EVEN WITH THE BOTTOM ROCK WALL BOARD DUE TO MILLING VARIATIONS AND
WOOD SHRINKAGE.
2" WOOD SCREW
5/4 X 6 X 23-7/8"
BOTTOM ROCK
ROCK WALL BOARD
5/4 X 6 X 23-7/8"
WALL BOARD
TOP IS FLUSH TO
ENDS OF SIDES.
54

A
STEP 13: ROCK WALL
1: FASTEN THE 90 GREEN BRACKET TO THE ROCK WALL SIDES WITH 5/16 X 1-1/2" HEX BOLTS AND 5/16" WASHERS.
2: DO NOT FULLY TIGHTEN THE HEX BOLTS INTO THE T-NUTS AT THIS TIME.
5/16" WASHER
GREEN BRACKET90
5/16" X 1-1/2"
HEX BOLT
55

1-1/4" PAN HEAD SCREW
CLIMBING ROCKS
WASHER
LONG AS THEY WILL ALLOW PROPER ACCESS TO THE FORT. BE CREATIVE!
CONFIGURATION MAY BE DIFFERENT THAT WHAT YOU SEE BELOW. ROCKS CAN BE ARRANGED IN ANY PATTERN AS
STEP 14: ROCK WALL
1: FIND TEN ROCKS AND THIRTY 1-1/4" PAN HEAD SCREWS WITH WASHERS.
2: MOUNT THE ROCKS IN A STAGGERED MANNER ON THE ROCK WALL BOARDS. THREE PAN HEAD SCREWS AND
WASHERS WILL SECURE EACH ROCK TO THE WALL.
NOTE: THE IMAGE SHOWN BELOW IS A GENERIC ARRANGEMENT OF ROCKS ON THE ROCK WALL. YOUR ACTUAL
3: PLACE THE 5/4 X 3 X 23-7/8" ROCK WALL TOP CAP ON TOP OF THE ROCK WALL SIDES. FASTEN THE ROCK WALL
TOP CAP TO THE ROCK WALL SIDES WITH 2" WOOD SCREWS.
ROCK WALL TOP CAP
5/4 X 3 X 23-7/8"
2" WOOD SCREW
56

3/4"
7-3/4"
5/16" WASHER
5/16" X 1-1/2" HEX BOLT
B
STEP 15: ATTACHING THE ROCK WALL
1: PLACE THE ROCK WALL INTO POSITION ON THE FRONT - RIGHT OF THE FORT AS SHOWN BELOW. THE GREEN
BRACKETS SHOULD BE 3/4" ABOVE THE BOTTOM OF THE FRONT FACE BOARD. USING THE 90 GREEN BRACKETS AS
A TEMPLATE; DRILL A 3/8” HOLE THROUGH THE BOTTOM PANEL BOARD.
2: GO UNDERNEATH THE DECK TO INSERT A T-NUT INTO THE BACKSIDE OF THE 3/8” HOLES IN THE FRONT FACE
BOARD.
3: ATTACH THE ROCK WALL WITH 5/16 X 1-1/2” BOLTS AND 5/16” WASHERS.
4: WHEN THE BRACKETS ARE SECURE, AND THE ROCK WALL IS IN ITS FINAL POSITION; TIGHTEN THE 5/16 X 1-1/2”
BOLTS ON THE ROCK WALL SIDES.
57

RAMP SIDE
BOARD FIRST
LARGE HOLES SHOULD BE CLOSEST TO THE FLOOR
2 X 4 X 18-3/4"
RAMP SUPPORT
2-1/2"
WOOD SCREW
2 X 4 X 96"
INSTALL THIS BOARD SECOND
INSTALL THIS
1"
4"
44 3
4"
CHECK TO SEE IF THESE TWO HOLES
ARE DRILLED THROUGH COMPLETELY
IN THE RAMP SIDES. IF THEY ARE NOT
DRILLED ALL THE WAY THROUGH THEN
CAREFULLY REAM THEM OUT WITH A
3/8" DRILL BIT.
ROUND END
STEP 16: CLIMBING RAMP
1: LAY OUT THE 2 X 4 X 96" RAMP SIDE BOARDS MAKING SURE THE LARGE HOLES ON TEH ENDS ARE CLOSEST TO THE
FLOOR.
2: FIRST PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE SQUARE END OF THE 2 X 4 X 96" RAMP SIDE
BOARDS. OFFSET THE BOARD 1" FROM THE END. FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE BOARDS
WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
3: SECOND PLACE ONE 2 X 4 X 18-3/4" RAMP SUPPORT BOARD AT THE ROUND END OF THE 2 X 4 X 96" RAMP SIDE
BOARDS. OFFSET THE BOARD 4" FROM THE ROUND END. FASTEN THE RAMP SUPPORT BOARD TO THE RAMP SIDE
BOARDS WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
4: PLACE THE REMAINING 2 X 4 X 18-3/4" RAMP SUPPORT BOARD ACROSS THE RAMP SIDE BOARDS IN THE MIDDLE,
44-3/4" FROMT HE SQUARE END AND FASTEN WITH TWO 2-1/2" WOOD SCREWS PER SIDE.
NOTE: CLIMBING RAMP TO BE INSTALLED INSTEAD OF LADDER ON THIS MODEL. THE LADDER PARTS ARE INCLUDED
IN THE PACKAGE BUT ARE NOT USED.
58