Backyard Discovery Montpelier 30211, Owner'S Manual

Page 1: ... od d d de e e el l l l 3 3 3 30 0 0 02 2 2 21 1 1 11 1 1 1 Manufacturer Backyard Discovery 3001 North Rouse Pittsburg KS 66762 1 800 856 4445 Made in China INS 30211 01 BRS 06 24 10 Features the fastening system Register your new swing set on line www swingsetonline com you will also find any updates on assembly instructions and information to order replacement parts Save this assembly manual for...

Page 2: ...EMBLY MANUAL COMPLETELY PAYING SPECIAL ATTENTION TO THE IMPORTANT TIPS AND SAFETY INFORMATION AFTER YOU HAVE READ THE ASSEMBLY MANUAL YOU WILL BE ABLE TO DECIDE IF YOU NEED PROFESSIONAL HELP TO COMPLETE THE ASSEMBLY OF THE PLAYSET SEPARATE AND IDENTIFY ALL PARTS TO MAKE SURE THAT YOU HAVE ALL OF THE PARTS LISTED IF YOU CAN T FIND ALL OF THE PARTS CHECK THE PACKING MATERIAL SMALL PARTS MAY HAVE FAL...

Page 3: ...y being void and or safety violations that could result in serious injury This manual contains helpful information concerning Assembly Preparation Installation Procedure and Required Maintenance Always keep the safety of your children in mind as your play structure is being built and as your children play on the set Before your children play on the set please review the Operation Instructions with...

Page 4: ...forms and slides out of direct sunlight to reduce the likelihood of serious burns A slide that faces north will receive the least direct sunlight 9 Separate active and quiet activities from each other For example locate sandboxes away from swings or use a guardrail or barrier to separate the sandbox from the movement of the swings Suggested Playground Surfacing Playground equipment should never be...

Page 5: ...ombined weight should not exceed a designated weight on the elevated floor or the swing area the total Unit capacity is outlined in the assembly section of instruction manual The maximum fall height and recommended play area is also available on the assembly manual for the specific unit 2 On site adult supervision is required 3 Instruct children not to walk close to in front of behind or between m...

Page 6: ...n 5 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 ch...

Page 7: ...ded Third Party Assembly Customer may in their sole discretion elect to use a third party person or service to assemble this product Backyard Discovery assumes no responsibility or liability for any charge incurred by the Customer for any assembly services Please see our warranty for more information about damaged and missing part replacement coverage Backyard Discovery will not reimburse Customer...

Page 8: ... stationary equipment such as climbers and slides However because children may deliberately jump from a moving swing the shock absorbing material should extend in the front and rear of a swing a minimum distance of 2 times the height of the pivot point measured from a point directly beneath the pivot on the supporting structure X3 4 This information is intended to assist in comparing the relative ...

Page 9: ...at the customer s discretion 6 Why does it seem that my swing set is developing cracks Wood is a natural material no two pieces are exactly alike Each piece has its own characteristics and personality and reacts differently to climate changes When any wood product is exposed to the elements it develops wood checks A check is the radial separation of the wood fibers running with the grain of the wo...

Page 10: ...ing the rough cut sizes from the sawmill and not the finished dimensions Retailers home stores etc all use this accepted practice for describing lumber dimensions However Backyard Discovery playsets are designed and constructed using the actual dimensions so everything fits properly and remains so during the life of the playset 11 The end beam is not straight up and down Why not This is normal Bac...

Page 11: ...el 24 Open End Wrenches 1 2 7 16 Nut Drivers 1 2 9 16 Tape Measure 3 8 Drive Ratchet 1 2 9 16 STD Sockets 1 2 9 16 Deep Sockets Claw Hammer 3 8 Cordless Drill or Electric Drill 3 16 5 16 3 8 Drill Bits Drill Attachments Phillips Head Screw 3 8 Socket Driver Torque Head Screw An Adult w an Adult Helper Phillips Straight Blade Screw Drivers Rubber Mallet Optional Ladder ...

Page 12: ... phases Using incorrect hardware may result in improper assembly 4 Whenever a T nut is used follow these directions Place T nut in pre drilled hole Tap in with hammer Place bolt with washers in the opposite side Hand tighten to make sure the bolt is in the T nut DO NOT over tighten 5 Read the steps of each phase thoroughly The written steps may include important information not shown in the illust...

Page 13: ... 3 8 36x86x1812 2 E5 CLUB HOUSE LEG W101490 1 3 8 x3 3 8 x42 1 2 36x86x1078 2 E71 MONKEY BAR RAIL W100974 1 3 8 x3 3 8 x60 5 8 36x86x1539 2 E77 ANGLE BRACE W100991 1 3 8 x3 3 8 x74 3 8 36x86x1890 2 F1 DECK BRACE W101504 1 3 8 x2 3 8 x15 3 4 36x60x400 4 G1 SWING BEAM MOUNT W101495 1 x5 1 4 x40 3 8 24x134x1024 1 H1 FLOOR RAIL W101449 1 x3 3 8 x64 3 4 24x86x1644 1 H2 FLOOR RAIL W101457 1 x3 3 8 x64 3...

Page 14: ...460 4 H79 END SUPPORT W100992 1 x3 1 2 x42 24x86x1072 1 H80 GROUND BOARD W100990 1 x3 3 8 x87 3 8 24x86x2218 1 H81 MONKEY BAR BRACE W100993 1 x3 3 8 x53 1 4 24x86x1352 2 H82 MONKEY BAR GROUND BOARD W100994 1 x3 3 8 x70 3 8 24x86x1786 1 J1 FLOOR SUPPORT W101037 1 x2 3 8 x3 24x60x76 4 K1 BASE BOARD W101451 5 8 x5 1 4 x64 3 4 16x134x1644 2 K2 BASE BOARD W101452 5 8 x5 1 4 x40 3 8 16x134x1024 2 K3 ARC...

Page 15: ... 16x112x1024 2 L4 CLUB HOUSE WALL RAIL W101491 5 8 x4 3 8 x40 3 8 16x112x1024 1 L5 OUTER FLOOR BOARD W101486 5 8 x4 3 8 x37 1 2 16x112x952 2 L6 BAY WINDOW W100571 5 8 x4 3 8 x30 1 2 16x112x774 2 L7 GABLE MOON W100572 5 8 x4 3 8 x13 16x112x330 2 L9 DOOR BOARD W101233 5 8 x4 3 8 x35 16x112x890 1 L10 DOOR BOARD W101229 5 8 x4 3 8 x35 16x112x890 1 M1 WALL BOARD W101501 5 8 x3 3 8 x34 3 8 16x86x874 2 M...

Page 16: ...3 3 8 x40 3 8 16x86x1024 1 M7 WALL BOARD W100579 5 8 x3 3 8 x40 16x86x1016 2 M8 WALL RAIL W101454 5 8 x3 3 8 x40 3 8 16x86x1024 6 M9 WALL RAIL W101496 5 8 x3 3 8 x37 1 2 16x86x951 2 M10 WALL RAIL W101494 5 8 x3 3 8 x37 1 2 16x86x951 1 M11 WALL BOARD W100583 5 8 x3 3 8 x20 16x86x508 9 M12 WALL RAIL W101731 5 8 x3 3 8 x6 3 4 16x86x173 2 M13 WALL RAIL W101500 5 8 x3 3 8 x8 1 2 16x86x216 2 M14 BENCH S...

Page 17: ...101230 5 8 x3 3 8 x35 3 4 16x86x908 2 M21 DOOR BOARD W101232 5 8 x3 3 8 x21 1 4 16x86x540 2 M22 DOOR BOARD W101231 5 8 x3 3 8 x6 1 4 16x86x160 2 M73 REAR SUPPORT W100610 5 8 x3 3 8 x19 1 4 16x86x488 1 M77 SLIDE BRACE W100544 5 8 x3 3 8 x17 1 4 16x86x438 1 M78 CENTER SLIDE BRACE W100545 5 8 x3 3 8 x17 1 4 16x86x438 2 N1 GABLE BOARD W100590 5 8 x2 3 8 x31 1 2 16x60x800 2 N3 BENCH GROUND BOARD W10084...

Page 18: ...100596 5 8 x2 3 8 x6 1 4 16x60x158 6 N10 BENCH LEG W100846 5 8 x2 3 8 x15 3 4 16x60x400 4 N11 DOOR STOP W101236 5 8 x2 3 8 x2 16x60x51 1 O1 DOOR SUPPORT W101234 5 8 x1 3 8 x21 16x34x534 3 R1 ROOF BOARD W101503 3 4 x5 1 2 x42 1 2 18x140x1081 14 T7 BENCH SEAT SUPPORT W100848 1 x1 3 8 x5 7 8 24x34x150 2 W70 SWING BEAM SUPPORT W100956 2 x3 3 8 x47 3 8 50x86x1204 1 Y1 WALL BOARD W101499 5 8 x4 x34 3 8 ...

Page 19: ...70 26 CY SCREW PWH 8x5 8 H100128 4 AC WASHER LOCK EXT 8x19 H100030 113 BG T NUT 5 16 H100074 33 D NUT BARREL WH 5 16x7 8 H100005 51 B NUT BARREL WH 5 16x5 8 H100004 11 AD WASHER LOCK EXT 12x19 H100031 60 AA LAG SCREW WH 5 16x2 1 2 H100028 2 CM BOLT WH 5 16x1 2 H100115 15 T BOLT WH 5 16x4 H100020 4 KA BOLT WH 5 16x4 1 2 H100021 1 LC LAG SCREW WH 1 4x1 1 2 H100145 9 KT BOLT WH 1 4x1 H100137 7 V BOLT...

Page 20: ...BX WASHER SPLIT 5 16 H100095 4 CJ NUT LOCK 5 16 H100110 11 CE WASHER FLAT 9x18 H100106 9 CD WASHER FLAT 8x27 H100105 17 CX SCREW 4x5 8 H100127 11 CB WASHER FLAT 17x30 H100103 4 BZ SWING HANGER QUICK LINK H100099 4 CG WASHER LOCK INT 8x15 H100108 2 BP SCREW PFH 8x1 1 2 H100086 83 CH SCREW TAPPING 14x1 1 2 H100109 13 KS NUT BARREL WH 1 4x5 8 H100136 7 2 T 30 Wrench H100114 2 T 30 Torx Driver A100147...

Page 21: ... TAG 2011 A100164 1 DD TRIANGLE PLATE 105 5 HOLE A100005 2 HZ KNOB A100071 1 EA HAND GRIP YELLOW PLASTIC A100043 4 KC METAL GROUND STAKE BROWN A100178 6 GD L BRACKET 66x66x127 GREEN A100140 2 EJ L BRACKET GREEN 54x67 A100053 6 GK WINDOW FRAME GREEN 216x267 A100146 6 FA QUICK LINK A100069 4 EZ CHAIN GREEN 51 25 A100068 4 DP SWING SEAT GREEN A100027 2 1 LM WAVE RIDER BOARD A100231 DH TRIANGLE PLATE ...

Page 22: ...GHT H74 4 LADDER RUNG H76 8 SCREW PFH 8x2 QTY DESCRIPTION LABEL 1 RIGHT UPRIGHT H75 8 SCREW PFH 8x2 4 Ft Ladder Phase 1 2 Phase Notes Assemble with hardware as shown Center rungs in rail grooves H74 H76 SCREW PFH 8x2 H75 SCREW PFH 8x2 ...

Page 23: ...QTY DESCRIPTION LABEL 1 REAR SUPPORT M73 4 SCREW PFH 8x2 4 Ft Ladder Phase 3 Phase Notes Assemble with hardware as shown SCREW PFH 8x2 M73 ...

Page 24: ... hardware as shown TRIANGLE PLATE 100 4 HOLE BE SURE TO PLACE FLAT SIDE OF PLATE AGAINST SIDE OF BOARD BOLT WH 5 16x1 1 2 T NUT 5 16 BOLT WH 5 16x2 L BRACKET GREEN 54x67 NUT LOCK 5 16 WASHER FLAT 8x27 E71 RIGHT SIDE VIEW OF TRIANGLE PLATE QTY DESCRIPTION LABEL 2 MONKEY BAR RAIL E71 2 TRIANGLE PLATE 100 4 HOLE DH 4 L BRACKET GREEN 54x67 EJ 4 T NUT 5 16 BG 4 BOLT WH 5 16x1 1 2 H 2 WASHER FLAT 8x27 C...

Page 25: ...t Monkey Bar Phase 2 Phase Notes Assemble with hardware as shown Repeat with other side BOLT WH 5 16x1 1 2 T NUT 5 16 E4 QTY DESCRIPTION LABEL 2 MONKEY BAR UPRIGHT E4 4 T NUT 5 16 BG 4 BOLT WH 5 16x1 1 2 H ...

Page 26: ...4 Ft Monkey Bar Phase 3 Phase Notes Assemble with hardware as shown SCREW TAPPING 14x1 1 2 MONKEY BAR RUNG 559 QTY DESCRIPTION 12 SCREW TAPPING 14x1 1 2 6 MONKEY BAR RUNG 559 ...

Page 27: ...x19 WASHER LOCK EXT 8x19 BOLT WH 5 16x1 1 2 LAG SCREW WH 5 16x2 WASHER FLAT 9x18 QTY DESCRIPTION LABEL 2 BOLT HEX 5 16x2 3 4 AN 2 T NUT 5 16 BG 2 WASHER FLAT 9x18 CE 2 WASHER LOCK INT 8x15 CG 4 BOLT WH 5 16x1 1 2 H 4 LAG SCREW WH 5 16x2 Z 8 WASHER LOCK EXT 8x19 AC 4 NUT BARREL WH 5 16x7 8 D 4 WASHER LOCK EXT 12x19 AD 2 MONKEY BAR BRACE H81 1 MONKEY BAR GROUND BOARD H82 ...

Page 28: ...otes Assemble with hardware as shown SCREW TAPPING 14x1 1 2 WASHER LOCK INT 8x15 WASHER FLAT 9x18 HAND GRIP YELLOW PLASTIC QTY DESCRIPTION 4 SCREW TAPPING 14x1 1 2 4 WASHER FLAT 9x18 4 WASHER LOCK INT 8x15 2 HAND GRIP YELLOW PLASTIC ...

Page 29: ...M PHASE 1 QTY DESCRIPTION LABEL 1 SWINGBEAM SUPPORT SB73 1 END SUPPORT W70 2 BOLT WH 5 16x2 1 2 M 6 WASHER FLAT 8x27 CD 2 BOLT WH 5 16x1 3 4 J 4 NUT LOCK 5 16 CJ 2 BOLT HEX 5 16x2 3 4 AN 2 TRIANGLE PLATE 105 5 HOLE DD 2 L BRACKET 66x66x127 GREEN GD 2 NUT BARREL WH 5 16x7 8 D 2 WASHER LOCK EXT 12x19 AD Phase Notes Assemble with hardware as shown W70 SB73 WASHER LOCK EXT 12x19 NUT LOCK 5 16 WASHER F...

Page 30: ...2 K 5 WASHER LOCK EXT 12x19 AD 1 BOLT WH 5 16x4 1 2 KA 2 LAG SCREW WH 5 16x2 Z E77 E77 H79 H80 NUT BARREL WH 5 16x7 8 WASHER LOCK EXT 12x19 BOLT WH 5 16x2 WASHER LOCK EXT 8x19 BOLT WH 5 16x2 WASHER LOCK EXT 8x19 WASHER LOCK EXT 12x19 NUT BARREL WH 5 16x7 8 WASHER LOCK EXT 12x19 NUT BARREL WH 5 16x7 8 WASHER LOCK EXT 8x19 LAG SCREW WH 5 16x2 WASHER LOCK EXT 8x19 BOLT WH 5 16x4 1 2 ...

Page 31: ... QTY DESCRIPTION LABEL 4 SWING HANGER QUICK LINK BZ 4 WASHER FLAT 17x30 CB 4 WASHER FLAT 8x27 CD 4 NUT LOCK 5 16 BF Phase Notes Assemble with hardware as shown SB73 NUT LOCK 5 16 WASHER FLAT 8x27 SWING HANGER QUICK LINK WASHER FLAT 17x30 ...

Page 32: ...ND OF THE PLASTIC SLIDE BED USING A 5 16 DRILL BIT AND USING THE DIMENSIONS SHOWN BELOW THIS END WILL BE THE TOP OF THE SLIDE TAKE NOTE OF SLIDE BED SURFACE FINISH THE DULL SIDE WILL BE TOWARDS THE GROUND PLACE SLIDE BRACE CENTERED ON THE BOTTOM DULL SIDE AND 1 4 FROM THE EDGE TRANSFER HOLES ON THE BOARD THROUGH THE SLIDE BED AS SHOWN BELOW USE A 5 16 DRILL BIT ATTACH SLIDE BRACE TO SLIDE USING HA...

Page 33: ... BEND THE SLIDE BED TOWARDS THE TOP OF THE SLIDE AND INSERT THE BED INTO THE SLIDE CAVITY MAKE SURE SLIDE BED IS COMPLETELY DOWN IN THE SLIDE CAVITY PLACE THE OTHER SLIDE RAIL ON A FLAT SURFACE WITH THE SLIDE CAVITY UP HAVE A HELPER HOLD THE TOP END OF SLIDE BED AND BEGIN INSERTING THE SLIDE BED AND SLIDE BRACES INTO THE CAVITY AND SUPPORT POCKETS STARTING AT THE BOTTOM OF SLIDE AND WORKING UP TO ...

Page 34: ...e LX PIVOT PIN 16x92 H100152 4 MQ BOLT M10x19MM H100154 8 MA SHOULDER BOLT M5x22MM H100155 4 MB BARREL NUT M5x13MM H100156 4 MD SCREW PFH 10x3 4 BLACK H100158 8 CF WASHER LOCK INT 10x18 H100107 8 MC WASHER LOCK INT 7x12 H100157 8 ...

Page 35: ... MP Bushing as shown ATTACHMENT SLEEVE Upper Tube ATTACHMENT SLEEVE Step 2 Slide the ML Hand Grip onto the end of Upper Tube Next slide MG Boot onto Lower Tube Now insert Lower Tube into the open end of Upper Tube Slide the ML hand grip down until the holes in the uprights align with the holes in the grip Secure the uprights and hand grip into place using 2 MA Shoulder Bolt M5x22MM MC Washer Lock ...

Page 36: ...wn until the holes in the uprights align with the holes in the grip Secure the uprights and hand grip into place using 2 MA Shoulder Bolt M5x22MM MC Washer Lock Int and MB Barrel Nut M5x13MM as shown Step 3 Insert 1 MP Bushing into one end of Attachment Sleeve Next insert 1 LX Pivot Pin and another MP Bushing as shown MP LX MP MA MC MC MB LZ LY LX MP MG MP MJ LZ MK ML Parts needed 1 LY LOWER TUBE ...

Page 37: ... 1 Slide MG boot up the swing arm assembly to allow veiw of attachment sleeve Align swing arm attachment sleeves with the wave rider bracket and secure using LZ Bolt M10x19MM and CF Washer Lock Int 10x18 as shown ATTACHMENT SLEEVE ATTACHMENT SLEEVE Step 2 Slide MG boot down the swing arm assembly to the LW Wave Rider Board and secure using MQ Screw PFH 10x3 4 Black as shown WAVE RIDER BRACKET WAVE...

Page 38: ...chment sleeves with the LX or MH beam bracket and secure using MQ Bolt M10x19MM and CF Washer Lock Int 10x18 as shown UPPER TUBE UPPER TUBE Parts needed 1 LX BEAM BRACKET 86x134 GREEN A100232 MH BEAM BRACKET 50x134 GREEN A100237 1 LEFT SWING ARM ASSEMBLY 1 RIGHT SWING ARM ASSEMBLY Hardware needed 4 MQ BOLT M10x19MM H100154 4 CF WASHER LOCK INT 10x18 H100107 CF MQ LX CF MQ CF MQ MH RIGHT SWING ARM ...

Page 39: ...DECK BRACE W101504 2 J1 FLOOR SUPPORT W101037 Step 2 Attach L1 Wall Rail K1 Base Board to E1 E3 Tower Legs using hardware D AD AC and H as shown H AC AC D AD AD L1 E3 E1 BG BG K L AC AC Z AC D AD J1 BG CK D AD AD AC AC H H1 F1 J1 F1 K1 Note It is vital that the fort be level before and after each phase of assembly Step 4 Attach J1 Floor Support to E1 E3 Tower Legs using Screws CK as shown Step 1 U...

Page 40: ...he respective boards as shown Phase Notes Assemble with hardware as shown For ease during assembly assemble uprights flat on the ground Parts needed 1 E2 TOWER LEG W101445 1 E3 TOWER LEG W100450 1 L2 WALL RAIL W101487 1 H2 FLOOR RAIL W101457 1 K1 BASE BOARD W101451 2 J1 FLOOR SUPPORT W101037 Hardware needed 8 D NUT BARREL WH 5 16x7 8 H100005 8 AD WASHER LOCK EXT 12x19 H100031 10 AC WASHER LOCK EXT...

Page 41: ... phase of assembly BG AC To prevent board splitting you must pre drill each board with a 1 8 drill bit before attaching Step 2 Pre Drill attach L3 Wall Rail to E1 E2 Tower Legs using Lag Screws Z and Washers AC as shown Step 3 Pre Drill attach M6 Floor Rail to E1 E2 Tower Legs using Lag Screws Z and Washers AC as shown Step 4 Pre Drill attach K2 Floor Board to E1 E2 Tower Legs using Lag Screws Z a...

Page 42: ...HER LOCK EXT 12x19 H100031 2 D NUT BARREL WH 5 16x7 8 H100005 2 Z LAG SCREW WH 5 16x2 H100027 Step 1 Attach F1 Deck Braces to M6 Floor Rail using Bolt H Washers AC AD and Nut Barrel D as shown M6 H AC D AD Z AC F1 F1 E2 E1 Note It is vital that the fort be level before and after each phase of assembly Step 2 Attach F1 Deck Braces to E1 E2 Tower Legs using Lag Screws Z and Washers AC as shown ...

Page 43: ...hat the fort be level before and after each phase of assembly To prevent board splitting you must pre drill each board with a 1 8 drill bit before attaching Step 2 Pre drill attach M3 Floor Board to H1 H2 Floor Rails using Screws CK as shown H2 H1 Step 3 Attach M2 Floor Runner to the center of L5 Outer Floor Boards M3 Floor Boards using Screws BR as shown Note Do not overtighten screws overtighten...

Page 44: ...OCK EXT 8x19 H100030 4 AD WASHER LOCK EXT 12x19 H100031 4 H BOLT WH 5 16x1 1 2 H100010 4 D NUT BARREL WH 5 16x7 8 H100005 Step 1 Attach Club House Leg E5 to the inside of Wall Rail L1 and L2 with hardware D AD AC H as shown L1 E5 AC AC H AD AD D L2 E5 Note It is vital that the fort be level before and after each phase of assembly E1 E2 ...

Page 45: ...p 5 Attach M8 Wall Rail to E3 Tower Legs using Lag Screw Z and Washer AC as shown H AC AC AD D M9 Z AC AC L4 E5 D AD AC H M8 D AD M10 AC H AC Z E2 D AD E5 M13 Z AC H AC M10 Z AC M8 E3 E3 M9 M12 M13 Note It is vital that the fort be level before and after each phase of assembly To prevent board splitting you must pre drill each board with a 1 8 drill bit before attaching E1 Step 3 Pre drill and att...

Page 46: ...litting you must pre drill each board with a 1 8 drill bit before attaching Note Due to the changing size of the wood as a result of moisture content you may need to adjust the spacing of your wall slats 1 16 to 1 8 when assembling walls It would be best to line up the boards on the wall before attaching to estimate if a larger or smaller gap is needed Note Do not overtighten screws overtightening...

Page 47: ...before and after each phase of assembly Note Do not overtighten screws overtightening may cause the screw to stick through the boards and may cause sharp points The head of the screw should NOT sink into the wood for this phase it should be flush Note Due to the changing size of the wood as a result of moisture content you may need to adjust the spacing of your wall slats 1 16 to 1 8 when assembli...

Page 48: ...tting you must pre drill each board with a 1 8 drill bit before attaching Note Do not overtighten screws overtightening may cause the screw to stick through the boards and may cause sharp points The head of the screw should NOT sink into the wood for this phase it should be flush Note Due to the changing size of the wood as a result of moisture content you may need to adjust the spacing of your wa...

Page 49: ...oard splitting you must pre drill each board with a 1 8 drill bit before attaching Note Due to the changing size of the wood as a result of moisture content you may need to adjust the spacing of your wall slats 1 16 to 1 8 when assembling walls It would be best to line up the boards on the wall before attaching to estimate if a larger or smaller gap is needed Note Do not overtighten screws overtig...

Page 50: ...ard splitting you must pre drill each board with a 1 8 drill bit before attaching Note Due to the changing size of the wood as a result of moisture content you may need to adjust the spacing of your wall slats 1 16 to 1 8 when assembling walls It would be best to line up the boards on the wall before attaching to estimate if a larger or smaller gap is needed Note Do not overtighten screws overtigh...

Page 51: ...d M8 Wall Rail and K2 Base Board using screws BR as shown Step 2 Pre drill and attach M11 Wall Boards to M8 Wall Rail and K2 Base Board using screws BR as shown Note Due to the changing size of the wood as a result of moisture content you may need to adjust the spacing of your wall slats 1 16 to 1 8 when assembling walls It would be best to line up the boards on the wall before attaching to estima...

Page 52: ...w Frame using the proper screws as shown Step 1 Center pre drill and attach N9 Bay Window Rails to the edge of L6 Bay Window Rails using Screws BQ Pre drill attach N5 Bay Window Rails to the edge of L6 Bay Window Rails using Screws BQ as shown Step 4 Center and attach GK Window Frame Green to the outside of the Bay Window Assembly with Screws BC as shown L6 L6 N5 N5 N9 N9 BQ BQ BQ L6 L6 N9 N5 N5 N...

Page 53: ... CK as shown Phase Notes Assemble with hardware as shown Hardware needed 6 CK SCREW PFH 8x2 H100111 Parts needed 1 BAY WINDOW ASSEMBLY Fort Assembly Phase 15 Bay Window Assembly M9 L2 CK Note It is vital that the fort be level before and after each phase of assembly To prevent board splitting you must pre drill each board with a 1 8 drill bit before attaching ...

Page 54: ...g Screws BC as shown Hardware needed 37 BR SCREW PFH 8x1 1 8 H100088 4 BC SCREW PWH 8x3 4 H100070 10 CX SCREW 4x5 8 H100127 Parts needed 1 L9 DOOR BOARD W101233 2 M19 DOOR BOARD W101230 2 M21 DOOR BOARD W101232 2 M22 DOOR BOARD W101231 1 L10 DOOR BOARD W101229 3 O1 DOOR SUPPORT W101234 1 GK WINDOW FRAME GREEN 216x267 A100146 1 HZ KNOB A100071 2 FR LEAF HINGE A100093 L9 L10 M19 M21 M19 HZ BR O1 O1 ...

Page 55: ...l and attach FR Hinge to M1 Wall Board using Screws CX as shown CX M1 FR BR M1 N11 Step 2 Pre drill and attach N11 Door Stop to M1 Wall Board using Screws BR Make sure the top of N11 Door Stop is flush with L4 Club House Wall Rail as shown Note It is vital that the fort be level before and after each phase of assembly To prevent board splitting you must pre drill each board with a 1 8 drill bit be...

Page 56: ... 2 GK WINDOW FRAME GREEN 216x267 A100146 Hardware needed 8 BC SCREW PWH 8x3 4 H100070 Phase Notes Assemble with hardware as shown Step 1 Attach GK Window Frame Green 216x267 to M16 Wall Board using Screws BC as shown GK BC BC GK M16 M16 M16 ...

Page 57: ...101455 Hardware needed 7 BQ SCREW PFH 8x1 1 4 H100087 Phase Notes Assemble with hardware as shown Step 1 Attach H4 Table Supports to M8 Wall Rail using Screws BQ as shown BQ BQ H4 H4 K4 M8 BQ Step 2 Attach K4 Counter Top to M8 Wall Rail and H4 Table Supports using Screws BQ as shown ...

Page 58: ... 4 KV WASHER LOCK EXT 6x15 H100138 Phase Notes Assemble with hardware as shown Step 1 Pre drill and attach EA Hand Grip Yellow Plastic to E5 Club House Leg using Screws LC Washer KV as shown E5 LC KV KV EA KV LC KV E3 EA Step 2 Pre drill and attach EA Hand Grip Yellow Plastic to E3 Tower Leg using Screws LC Washer KV as shown ...

Page 59: ...Board to H3 Roof Rafters using Screws BR Attach N6 Gable Board to H3 Roof Rafters using Screws BR Attach N7 Gable Boards to H3 Roof Rafters using Screws BR as shown L7 BR N1 H3 H3 N7 N6 N7 BR BR BR BR BR N1 H3 H3 L7 N6 N7 N7 Step 2 Pre drill and attach L7 Gable Moon to N1 N6 N7 Roof Rafters using Screws BR as shown Note It is vital that the fort be level before and after each phase of assembly To ...

Page 60: ...e Notes Assemble with hardware as shown Step 1 Attach R1 Roof Board to the edge of Gable End Assembly using Screws BP as shown BP BP BP BP R1 R1 GABLE END ASSEMBLY GABLE END ASSEMBLY GABLE END ASSEMBLY BP R1 R1 R1 R1 R1 R1 R1 R1 BP BP Step 2 Attach the remaining R1 Roof Boards to the edge of Gable End Assembly using Screws BP as shown ...

Page 61: ... Attach the Roof Assembly to M8 Wall Rail using Bolts V and Washer AC into T Nut BG on the back side of M8 Wall Board as shown M8 V AC M8 V AC ROOF ASSEMBLY ROOF ASSEMBLY Note It is vital that the fort be level before and after each phase of assembly Step 2 Attach the Roof Assembly to M8 Wall Rail using Bolts V and Washer AC into T Nut BG on the back side of M8 Wall Board as shown Step 3 Attach th...

Page 62: ...x19 H100031 Phase Notes Assemble with hardware as shown Step 1 Attach N10 Bench Legs to N3 Bench Ground Board using Screws BR Attach T7 Bench Seat Support to N10 Bench Legs using Screws BP Attach EJ L Bracket to N3 Bench Ground Board using Bolt CM Washer AD and Nut Barrel B as shown T7 N10 N10 N3 B CM BR BP EJ B AD EJ BR N3 N10 T7 N10 BP M18 BP BP BP BP BP BP N10 N10 N10 N10 M18 Step 2 Attach M18 ...

Page 63: ...D WASHER LOCK EXT 12x19 H100031 2 CM BOLT WH 5 16x1 2 H100115 Phase Notes Assemble with hardware as shown Step 1 Attach the Bench Assembly to K2 Base Board using Bolts CM Washer AD and B Barrel Nut as shown Repeat the same process to complete the assembly on the opposite side CM K2 BENCH ASSEMBLY EJ AD B ...

Page 64: ...EMBLY Hardware needed 2 Z LAG SCREW WH 5 16x2 H100027 2 AC WASHER LOCK EXT 8x19 H100030 Phase Notes Assemble with hardware as shown Step 1 Attach the Ladder Assembly to H1 Floor Rail using Lag Screws Z and Washer AC as shown LADDER ASSEMBLY H1 Z Z AC AC ...

Page 65: ...1 MONKEY BAR ASSEMBLY Hardware needed 4 CM BOLT WH 5 16x1 2 H100115 Phase Notes Assemble with hardware as shown Step 1 Attach the Monkey Bar Assembly to L1 Wall Rail using Bolts CM through the angle brackets into T Nut BG as shown CM CM EJ EJ L1 ...

Page 66: ...4 H100007 2 F BOLT WH 5 16x1 H100008 Step 1 Attach the Swing Beam Assembly to G1 swing beam mount using Bolts AJ Washer BX Washer CD through the angle brackets into T Nut BG as shown Step 2 Attach Backyard Discovery ID Tag HC on Swing Beam SB73 using Screws CY as shown AJ BX CD GD G1 HC CY SB73 E SB73 WAVE RIDER MOUNTING BRACKET Step 3 Attach the Wave Rider Assembly to SB73 Swing Beam using the Wa...

Page 67: ...H100115 Parts needed 1 SLIDE ASSEMBLY Step 3 Finish attaching the Slide Assembly to the fort floor using the Safe T Fuse hardware as shown Step 2 Insert Bolts CM through wave slide and deck boards as shown Step 1 After centering wave slide in the opening use a drill with a 5 16 bit to drill a hole through the holes on the slide and through the fort floor SLIDE ASSEMBLY CM B AD ...

Page 68: ...ground surface Using eye in Stake as guide drill thru Ground Boards K1 with 3 8 drill bit and attach KC Stakes with KT Bolts KW Lock Washers CE Flat Washers and KS Barrel Nuts as shown Now measure in 6 from outside Swing Beam Ground Board H80 and mark ground Twist Stakes until eye is approximately 3 from ground surface Using eye in stake as guide drill thru Swing Beam Ground Board with 3 8 drill b...

Page 69: ...pacities stated in the applicable Assembly Manual x Acts of nature including but not limited to wind storms hail floods excessive water exposure x Improper installation including but not limited to installation on uneven unlevel or soft ground x Minor twisting warping checking or any other natural occurring properties of wood that do not affect performance or integrity Backyard Discovery products ...