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Instructions step 1 - 3
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Page 9 of 13
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Important notes.
1.) The four vertical corner frame uprights (a1, a1, b1 and b2) have holes drilled
through two sides (face and edge) of the wood. Careful consideration of the
measurements and placement of the holes will make the project a lot
easier.
2.) All the bolts are 10mm (3/8") thick, but you should drill all the holes 12mm (1/2"), thus allowing
a bit of play.
3.) If the stock you use is a different width and thickness to that shown in
the plans, then you may also need to use different length bolts.
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Step 1. Let's begin!
Familiarize yourself with the plans and read the important notes preceding these instructions.
Cut all the members to the lengths stated in the cutting list and in the plans.
Always cut the longest members first. This makes for less waste.
Carefully mark and drill 12mm (1/2") holes according to the plans.
Mark every member with a marking pencil or crayon, for example: mark a1, a2 etc. on the appropriate member, so you can easily find and identify each piece when assembling the frame.
Step 2a. Assemble the front frame (a)
First assemble front frame (a). This is best done by laying the two upright members a1 horizontally on top of blocks that are sitting on the ground. This is to allow your hand to fit underneath the frame to put washers and nuts on the bolts.
Using the plans and pictures for reference, lay the other frame members (cross members a2, roof members a3 and collar tie a4 in place so that the appropriate holes line up with one another. Insert the correct length bolts into the holes, and add the washers and nuts from underneath.
The two roof members a3 can be further secured to each other by placing a piece of galvanized strap over the apex and nailing it to the top of both roof members.
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Step 2a. Add the climbing wall (a)
Lay (centralize) the uncut plywood sheet on the frame cross members. The top of the sheet should be flush (even, line up) with the top of the collar tie a4. It is easier to cut the openings etc. after the plywood sheet has been fixed to the frame.
First screw the sheet to the frame with 50mm screws approx 200mm apart along members a2 and a3 (as shown in photo). Then drill and bolt the perimeter of the sheet to the frame, approx 50mm in from the edge of the sheet (as marked with the x in the photo)
Mark and cut the sheet. Cut off the top corners of the sheet flush with the roof members a3. Use the front elevation (a) plan for reference when cutting out the door and climbing holes. The placement of the climbing holes (approx 120 diameter) and the door shape, angle and size (approx 750 x 500) can be of your own choice. It is a good idea to make the door on an angle (about 7 degrees). Gravity will ensure the door will then always swing open, rather than swing shut and therefore avoid the possibility of jamming little fingers.
Save the piece cut out of the door hole, as this will become the door.
Ensure that the frame members are parallel and square.
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Step 3. Assemble the back frame (b)
Make up frame b in the same way as frame a.
Nail the wall cladding boards to the two upper cross members b3. Have the bottom of the boards flush (even) with the bottom of the lower cross member. The top of the boards will go above the top cross member a5.
Ensure that the frame members are parallel and square.
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