Tried using PVC pipes and got frustrated trying to cut them straight. Switched to using the white sturdy plastic connectors (like the Zome Ball stuff) and it's SO much better. Kids can actually build it themselves without me intervening constantly. If you're thinking about this, skip the PVC approach and just spend the extra money. It's worth not wanting to pull your hair out.
Do you have a link to the specific connectors you're using? Trying to set something up for my 5 and 7yo and the independence factor would be huge.
PVC pipes are such a pain for this. The connectors are the move - Zome Balls are pricey though. Have you looked at the knockoff plastic connector sets? Work just as well and way cheaper.
This is helpful because I was about to start a PVC fort project and now I'm rethinking it. So basically: skip PVC, get connector balls, kids can build independently. That's the key insight.
The 'kids can actually build it themselves' part is the real win here. PVC requires adult intervention which defeats the purpose of backyard fun. Your setup sounds way better.
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We did something similar with those ball connectors and honestly it's been the best backyard investment. Kids spend hours building and redesigning without needing me to cut anything or fix their mistakes.