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The Biggest Project Yet!
The Biggest Project Yet!
The idea for putting up a playset in the backyard started to firm up in early spring of 2025. My son would be turning 3 in May and my daughter was already crawling. There were a lot of options to consider in the world of playsets. The more I thought about it, I wanted something that would outlast my kids' childhoods and could withstand my own play (because I want to jam on this thing too!). Ultimately, I wanted the best: Rainbow Brand. Those playsets are not cheap to buy new though. Even a small set runs $8000 and that's before installation, shipping and any add-ons. But, the nice thing about Rainbow playsets, is they are constructed using the finest cedar boards and, if cared for, can last for many decades. I set my eyes on Facebook Marketplace which was flooded with used playsets, some of which were Rainbows. The trick was finding one a good price point, that was still in good shape. I struck out on a number of options before landing on our winner. From the Facebook photos, I could tell that the playset was located in a wide open space on gravel which both help to prevent rot. The big beams looked good and the the thing was huge. One of the biggest residential playsets on the market: a Rainbow King Kong Super Castle Deluxe II. The dream of having a restored version in our yard started budding.
First I had to rip the playset out of the previous owners yard in Sheboygan Falls, WI. On May 31st, I hitched a trailer and headed down. Myself and four other guys worked on disassembling and loading the playset up. It was clear during our deconstruction that there was more rot than I anticipated. All of the platform decking and most of the railing was rotted. One of the main horizontal beams also had significant damage. It was not ideal and I started to question if this project was really worth it. I kept in mind that the main bones were fine and that the canopy, tire swing and massive slide were all in good shape too. I negotiated a lower price for the unit and pushed on. We loaded up the trailer and I got everything back safely. Now the real work could begin.
Once home with my arsenal of tools, I set out to restore, repair and, in many cases, rebuild this playset. I wanted it to look brand new, and stand the test of time. I have done my best to detail that process in the pictures and commentary below.
Aside from restoring the playset itself, I wanted to give it a proper home in the yard. After settling on the perfect location in the yard, I hired a contractor (Tony) to dig up the turf and grade the area flat. After this was done, I pinned down landscape paper, spread pea gravel and installed railroad ties on the borders. Aside from aesthetics, these railroad ties were crucial for retaining the woodchips.
In July 2025, I put the finishing touches on the playset. In the end, it was much more work than I anticipated, but I am proud to say that's because I did not cut corners. From meticulous beam restoration to sledgehammering a hundred pieces of rebar though railroad ties, you get out what you put in... Now it's time to play!
Original Facebook photos taken by the previous owners.
The deconstruction process. Shout out to my Dad, Uncle John, Luke and Zach for helping with the tear down
The journey home. This was also the first job for my new trailer which was essential for this whole project.
Hardware restoration was a significant part of this restoration. All of the metal components had some level of rust. Lag screws and deck screws were corroded beyond saving and simply thrown away, but most of the large carriage bolts, washers and swing hardware pieces were salvageable. These were thrown into a vinegar bath, scrubbed with a wire brush, dried and then sprayed with a galvanizing product (zinc). This part of the project really sucked to be honest.
Before
In process hardware restoration
There are four yellow brackets on the playset. These only required a scrubbing and a couple coats of spray paint. The result is outstanding and gives it a nice pop of color.
These are all the salvaged beams from the playset. These photos were taken after removing the hardware and prior to pressure washing
One of the main platform beams had rot on the top 1/3 lengthwise. This beam was ripped and then grafted with a treated 2x4 to restore the width
All of the railing and decking were replaced due to rot. These are the replica sections I built from treated lumber. I was able to save a few of the railing spindles which are mismatched.
Some of the rotted braces were beyond repair. These were replicated with treated lumber.
A large beam had a small section that was rotted. I cut that area away and grafted on fresh cedar.
Each beam needed a lot of TLC and you can see most of that process in this photo. Although methodical and time consuming, this restoration process was crucial to ensuring the longevity of the playset. Here was the process for each beam:
Pressure wash, let dry
Excavate any major areas of rot and epoxy if necessary
Router edges with 1/2" round over bit if necessary
Sand with 100 grit
Blow off dust
Paint with solid stain (Behr Redwood)
Add a second coat if necessary. Some of this wood was so dry that the stain would soak in and dry completely within 15 minutes.
Sprayed grass killer on the area to make the root system friable and easier to excavate.
Post excavation and grading. Thank you to Tony Pultz at Bella Terra for this part!
Landscape paper pinned into place. Wes is helping to shovel pea gravel to the edges.
Loading up railroad ties in Denmark, WI (another Facebook Marketplace deal). Each tie weighs ~200 lb and I bought 18. That is pushing the absolute max on this trailer. By the way, the guy I bought from was an true pro with his excavator. He dropped each tie on the trailer with precision.
The ties make it home safely. Whew!
Installing the ties was the most physically demanding part of this project. Each tie needed to be set in place, leveled with gravel, drilled and adhered by sledgehammering 3 ft pieces of rebar. Goodluck to whoever rips these out in 60 years.
The playset starts to take shape once again. This was a very satisfying moment in the process. Up until this point, the components were disjointed and strewn about the yard and barn.
20 yards of playground quality wood chips are spread. This step really helped to level the area and will provide essential cushioning for the inevitable roughhousing .
Finally Finished!
Finally Finished!
Last pieces to go on were the fully reconstructed Jacob's Ladder (left) and repaired canvas canopy. The only thing left to do is to stain the new treated wood on the deck/railing which will happen in 2026.
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