PlayNation Play Systems Ella's Castle - Wood Roof Add-On User manual

NOTE: Wooden parts to assemble a roof, chimney and two dormers are
included with this kit. All other wood components or accessories shown in
the picture above are NOT included.
ASSEMBLY MANUAL
Copyright © 2011 PlayNation Play Systems, Inc.
All Rights Reserved
www.PlayNation.com. • 190 Etowah Industrial Court • Canton, GA 30114 • [phone]
Latest Revision: January 28, 2011
Ella’s Castle - Wood Roof Add-On

Warranty and Safety Guidelines……………………………....……….......……………… 3-7
General Information, Denitions and Site Plan…............................................…........ 8-11
Tool List, Hardware, Lumber and Accessory Checklist……….....…………………….12-15
Boards to REMOVE from your playset................................………….........................…16
Removal of Tarp, Tarp Boards and Center Posts…………………...................……. Step 1
Attaching Center Posts…………......…………………………..............................….. Step 2
Drill holes for Roof Supports……………………………...……...........................…… Step 3
Attaching Roof Supports.......................................................................................... Step 4
Attaching Roof Peak Supports................................................................................ Step 5
Attaching Roof Starters and Roof Peak................................................................... Step 6
Attaching Roof Boards / Chimney and Dormers...................................................... Step 7
Attaching Roof Finishers and End Caps….......…….................................………… Step 8
Sun / Sun Support Assembly………………...................................................…...… Step 9
Sun / Sun Support Assembly Installation.…………………………..….....…………. Step 10
Sun Ray Installation………………………………............................................…… Step 11
Re-attaching Steering Wheel.....................................………................................. Step 12
Warranty Card.................................................................................................... Last Page
PLEASE READ OWNER’S MANUAL CAREFULLY
BEFORE STARTING ASSEMBLY!
TABLE OF CONTENTS
Page 2

Page 3
IMPORTANT – PLEASE READ
As fresh lumber acclimates to its new environment, the natural tendencies of the tree
can show itself 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.
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. Defects that develop
because the product is exposed to extreme climate conditions are not covered by this
warranty. Defects that develop as a result of faulty or improper installation of the product
are also not covered by this warranty.
Most cracks are not warrantable, however if you believe that the integrity of your
play set is compromised by this natural occurrence, please follow the warranty claim
procedure found at www.playnation.com. Click on the “Customer Care” tab on the left
hand side of the page, then click on “Warranty Claim” and follow the instructions.
We appreciate your purchase and know that you will enjoy your play system for many
years to come.
IF YOU HAVE MISSING OR DAMAGED PARTS OR NEED ASSISTANCE
ASSEMBLING, PLEASE CALL PlayNation Play Systems, Inc. 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:
PlayNation Play Systems, Inc.
190 Etowah Industrial Court
Canton, GA 30114
Tel. [phone]
Fax. [phone]
[email protected]
Check for revised instructions at www.playnation.com/instructions.html

Page 4
Thank you for choosing PlayNation Play Systems, Inc.
We’ve included everything you need, except tools, to build your very own professional
looking play set. When complete, your new play set should far exceed the quality of
play set 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 play set
that doesn’t compromise quality for simplicity. Yet you’ll appreciate how quick and
easy construction really is! Our play set kits are designed for children ages 3 to 11.
PlayNation Play Systems, Inc. believes every child should have a play set and with our
kits they can! You can rest assured your new play set 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.
This set features our step-by-step 3D illustrated manual, plus all the required hardware
and pre-milled lumber to construct a wooden roof with dormers and chimney.
NOTE: Wooden parts to assemble a roof, chimney and two dormers are
included with this kit. All other wood components or accessories shown in
the picture below are NOT included.

Page 5
Limited Manufacturers Warranty
PlayNation Play Systems, Inc. (“PlayNation”) warrants its play sets to be free from
defects in workmanship and materials, under normal use and conditions at its original
installation, for 10 years for structural wood components and for one year for all other
components (e.g., hardware, plastics, tarps, rope ladder, etc.)
Cosmetic defects or natural defects of wood (e.g., warping, seasonal checking or
cracking, knots, or knot holes, etc.) that do not affect the structural integrity of the
product are not covered by this warranty. Defects that develop because the product is
exposed to extreme climate conditions, or that develop as a result of faulty or improper
installation of the product, are not covered by this warranty. Fading or discoloration of
any part or accessory, 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 properly maintain the play set. Instructions for proper
maintenance can be found on PlayNation’s website. Imperfections or defects that
develop because of a failure to properly maintain the play set are not covered by this
warranty.
PlayNation 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
verication of the defect, which, at PlayNation’s discretion, may be accomplished by
submitting photographs or by delivery of the defective part to PlayNation. Any warranty
claim must include proof of purchase, including the 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 used for commercial,institutional or multi-familling dwelling use. This warranty
does not cover (a) products that have been damaged by acts of God, negligence,
misuse, or accident, or that have been modied 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.
PLAYNATION 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. PLAYNATION WILL NOT BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES. This warranty is valid only in the United States
of America, is nontransferable and does not extend to the owners of the product
subsequent to the original purchaser, and only applies to the product as originally
installed (in other words, installing the product and then later disassembling and
reinstalling the product at the same or another location voids the warranty). 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
specic legal rights. You may also have other rights which vary from state to state.

Page 6
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 play set.
As with any home project, good judgment and respect for power tools will greatly reduce
the risk of injury. PlayNation recommends you follow all tool manufacturers’ safety
guidelines. Always wear eye protection and safety gloves to prevent injury. In several
phases of construction two people may be required for lifting and securing of lumber.
While play set is being constructed, please keep children off the equipment until the
project is complete. Bolts and screw heads should be checked regularly for tightness.
The ground ladder, rope ladder, slide, swings and other areas where children spend a
majority of their playtime should be checked more frequently.
PlayNation shall not be liable for incidental, indirect or consequential damages or
injuries that result from the building and/or playing on our play sets. Adult supervision is
recommended anytime a play set is being used.
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.
• On-site adult supervision is required.
• Teach children not to use the equipment in a manner other than intended.
• 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 to never crawl on top of a fort roof.
• 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.
WARNING: Children must NOT use this play set until unit has been
completely assembled and inspected by an adult to insure set has
been properly installed.

Page 7
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 PlayNation 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 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.
• Rake the playground surface periodically to prevent compaction and maintain
appropriate depths.
• 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 unit is discarded.

Page 8
General Info to Review Before Installation
• Depending on your experience, assembly of PlayNation Playsets 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 more
clearly 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 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.
• Check all bolt connections seasonally.
• Place the set on level ground, not less than 6ft from any structure or obstruction such
as a fence, garage, house, overhanging branches, laundry lines, or electrical wires.

Thru Hole
Counter Sunk Hole
Page 9
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 to 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 to how to offset these parts.
EXAMPLE OF OFFSET HOLES DOWN
EXAMPLE OF OFFSET HOLES UP
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 thru hole, but does not extend
through the wood itself. When using a counter-sunk hole the bolt will be inserted
through the thru hole. In some cases the bolt head with a washer will occupy the
counter-sunk hole. In other cases a nut with a 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 necessary to tap the head of the lag screw with a hammer. You
should also be sure to tighten the lag screws completely. Power tools such as an impact
wrench or power drill should have enough torque to drive the lag screws without using a
hammer, but make sure not to over tighten as this can cause the threads to “strip out” in
the post.

Page 10
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 insert
and installed ush to the wood.
This picture shows an end view of the T-nut
insert and installed ush to the wood.
WARNING: DO NOT EMBED THE TOP
OF THE T-NUT INTO THE
FACE OF THE WOOD
Cross Section end views, you are looking at an Xray 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

Please familiarize yourself with the manual, parts/components and general con-
struction process of your new playset before getting started.
SITE PLAN:
Playset height: 11’ - 6”
Approximate Wood Roof/Chimney/Dormers assembly time: 2-4 Hours
6 foot unobstructed safety perimeter around playset recommended
Page 11
48.00
109.01
36.50
127.70
60.78
117.85
16.0016.00
125.79
85.13
Wave Slide
Ladder
Rock Wall
Trapeze
Swing
(1)
Swing
Belts (2)
Rope
Ladder

Page 12Page 12
REQUIRED TOOL LIST
___ Standard or Cordless Drill w/ Phillips Bit (#2 square bit provided)
___ 1/8” Drill Bit
___ 3/16” Drill Bit
___ ½” Wrench, Socket, and Deep Well Socket
___ 9/16” Wrench, Socket, and Deep Well Socket
___ Level
___ Tape Measure
___ Extension Cord (if using standard drill)
___ Hammer
___ Pencil
___ Locking Pliers (Vise Grips)
___ Rubber Mallet
___ Small Flat Blade Screwdriver
KIT CONTENTS
___ (Qty) Description
___ (1) Ella’s Castle Wood Roof Add-On Assembly Manual
Fort Hardware:
see following pages
Wood Components:
see following pages

Use the ruler to the right to measure your bolts and screws. Picture views shown
below are 1:1 scale and can be used to match bolt and screw sizes.
#8 x 2”
Wood Screw
Qty: 42
#8 x 2-1/2”
Wood Screw
Qty: 12
5/16” Washer
Qty: 4
#2 Square
Drive Bit
Qty: 1
5/16” x 3-1/2”
Hex Lag
Screw
Qty: 4
#8 x 1-1/2”
Wood Screw
Qty: 152
#8 x 1-1/4”
Wood Screw
Qty: 8
5/16” Tee Nut
Qty: 2
Page 13

Picture Description Qty.
1 X 4 X 55”
Roof
Finisher
(Tongue Only)
2
1 X 4 X 55”
Roof
Starter
(Groove only)
2
1 X 5 X 55”
Roof
Board
(Tongue and
Groove)
34
2 X 4 X 48”
Front Center
Post
1
2 X 4 X 48”
Roof End
Cap
2
2 X 4 X 70”
Roof Support
(Left)
2
2 X 4 X 70”
Roof Support
(Right)
2
Page 14

Picture Description Qty.
2 X 4 X 73-3/4”
Rear Center
Post
1
2 X 6 X 16”
Sun
2
3-1/2” X 3-1/2” X
55”
Roof Peak As-
sembly
1
5/4 x 3 x 51”
Sun Support
2
5/4 X 4 X 11-3/8”
Ray
4
5/4 X 6 X 13”
Roof Peak
Support
2
Chimney
Dormers
1
2
Page 15

Picture Description Qty.
2 X 4 X 70”
Rear Center
Post
1
2 X 4 X 48”
Center Tarp
Board
1
2 X 4 X 54-1/2”
Tarp Board
2
2 X 4 X 44-1/4”
Front Center Post
1
THE BOARDS ON THIS SHEET WILL BE REMOVED FROM YOUR PREVIOUSLY
CONSTRUCTED ELLA’S CASTLE PLAYSET.
Page 16

Step 1: Removal of Tarp, Tarp Boards and Center Posts.
1: Remove the 1-1/4” screws which hold the Tarp to the Tarp Boards.
2: Remove the Tarp from the playset and set aside.
3: Remove the lag screws at the end of the 2 X 4 X 54-1/2” Tarp Boards and set the
Tarp Boards aside.
4: Remove the wood screws that secure the 2 X 4 X 48” Center Tarp Board and set the
Center Tarp Board aside.
5: Remove the wood screw and hex bolt that secure the 2 X 4 X 44-1/4” Front Center
Post and set the Front Center Post aside. (Save the hex bolt and washer for Step 2.)
6: Remove the Steering Wheel by using a at blade screwdriver to pop off the cap at the
center. (See Step 12 for an exploded view of the Steering wheel). Then remove the lag
screw that attaches the Steering Wheel to the Rear Center Post.
Place the Steering Wheel and the hardware that attaches it in a safe location since you
will have to re-attach it later in Step 12.
7: Remove the wood screws and hex bolt that secure the 2 X 4 X 70” Rear Center Post
and set the Rear Center Post aside. (Save the hex bolt and washer for Step 2.)
8: Place the Tarp, removed fasteners and all the removed boards away from the work
area.
2 X 4 X 54-1/2”
Tarp Board
2 X 4 X 48”
Center Tarp Board
2 X 4 X 44-1/4”
Front Center Post
2 X 4 X 70”
Rear Center
Post
Tarp
2 X 4 X 54-1/2”
Tarp Board
Steering Wheel is typically
mounted here. (Not Shown) Page 17

Step 2: Center Posts
1: Take the 2 x 4 x 73-3/4” Rear Center Post, and line up the hole in the post with the
through hole in the Swing Beam Side Rail. Take note that the hole in the Rear Center
Post is not on center, and the shorter end of the post will face down.
2: When the Rear Center Post is lined up properly, install a 5/16” t-nut into the hole in
the Rear Center Post.
3: Fasten the Rear Center Post to the fort with 5/16 x 4” hex bolts and 5/16” washers
through the Swing Beam Side Rail, and into the t-nuts of the rear center post.
4: Make sure that the Rear Center Post is square and level, and fasten with 2-1/2” wood
screws through the bottom of the post.
5: Take the 2 x 4 x 48” Front Center Post, and install a 5/16” t-nut into the hole in the
Front Center Post. Line up the hole in the post with the through hole in the Side Rail.
6: When the Front Center Post is lined up properly, fasten the Front Center Post to
the fort with a 5/16 X 4” hex bolt and a 5/16” washer
through the Side Rail, and into the t-nut of the Front
Center Post.
7: Use a 2-1/2” wood screw
to keep the Front Center Post
stabilized and to keep it from
spinning after it has been
installed.
5/16”
T-Nut
2 x 4 x 73-3/4”
Rear Center Post
2 x 4 x 48”
Front Center Post
5/16”
Washer
Use a 2-1/2”
Wood Screw
above T-Nut
5/16 x 4”
Hex Bolt
Use two 2-1/2” Wood Screws in this location Page 18

A
A
B
C
SECTION A-A
SCALE 1 : 64
Step 3: Drill holes for Roof Supports
1: On the end of the INSIDE surface of the 4 x 4 x 108” Swing Beam Side Rail and the 4
x 4 x 108” Side Rail you will need to drill two 3/16” diameter holes 2-1/2” deep. One hole
per end.
2: Measure as shown below and drill a hole in each end of both rails on the INSIDE
SURFACE.
1”
1-3/4”
3/16”
Diameter
Hole
1”
1-3/4”
3/16”
Diameter
Hole
4 X 4 X 108”
Swing Beam
Side Rail
4 x 4 x 108”
Side Rail
Drill
Holes
Drill
Holes
Page 19

Step 4: Roof Supports
1: Find two 2 x 4 x 70” Roof Support - Left and two 2 x 4 x 70” Roof Support - Right.
Lean the angled end of each roof support against the center posts. The other end of
each roof support should have the counter-sunk hole facing the inside.
2: Fasten the counter-sunk end of each roof support to the inside of the rails with one
5/16” x 3-1/2” lag screw and one 5/16” washer.
2 x 4 x 70” Roof
Support - Right
5/16” x 3-1/2”
Lag Screw
2 x 4 x 70” Roof
Support - Left
5/16” Washer
Counter-sunk
hole faces
inside.
Page 20