DIY Network

Pergola on a Patio: Layout From "Weekend Remodeling" episode WKR-203

Host Fuad Reveiz shows you how to build a beautiful custom pergola in this episode of Weekend Remodeling.

This is an intermediate level project and rated 3 on a "difficulty" scale from 1 to 5, with 5 being the most difficult.

Materials:

Lumber --

• 8 x 8 pre-made columns
  
• 6 x 6s (milled to sturdy the columns)
  
• 2 x 10s (used for lentils)
  
• 2 x 8s (used for rafters)
  
• 2 x 4s (used for purlins on top of rafters)

Tools:

Tape measure
Table saw
Jig saw
Router
Heavy-duty drill and auger bits
Chalk line
Level
Exterior caulk

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

Getting started on this job should be easier than most because there's no demolition involved. You will need a good plan of attack, however, and host Fuad Reveiz recommends that you take a look at some computer software that can help assist in the planning and design -- and most important, you can get a sneak peek at the finished project.
The first thing you must do is figure out where the pergola will go. Measure and layout where the columns will stand, and once you know this information, you'll be able to take the rest of the measurements from those points.

1. Stretch the tape measure all the way across the patio and mark the center point.

2. Measure more than six feet in each direction from the center and make a mark (figure A). This will be the distance between the front columns.

3. At the ends of the marks, measure out eight feet from the curved patio wall (for this particular project only) and mark the exact location for the two front columns.

   Note: The brick in this particular patio was a perfect grid, so it was easy for Reveiz to use it as a guide to line up the rear columns. You may not be so fortunate, so take exact measurements. You can use scrap pieces of the column as a template for the brick (figure B). Reveiz had some room to play with, so he decided to place the column on the center of the brick. This makes drilling the holes for the anchor pins easier.

4. Once you trace around the column, use a square to mark the center. Repeat the same procedure on the rear columns. And be sure to set the columns slightly away from the wall.

5. To mark the center column simply measure between the two columns at the back. Mark with a square just like the rest.

6. The layout is looking good. Now it's time to get the columns set where you need them. To make sure the columns stay put once they're in place, be sure to use steel rods (figure C).

7. Before you do anything else, paint the lumber while it's still on the ground. A lot of wood is involved in this project, so it's easier to put the first coat on now.

   Expert Advice: Depending upon the climate, treated Southern pine can take up to completely dry. You should hold off painting, staining or applying any type of finish until you're sure the wood is completely dry.

8. Once you've finished the first go at painting, it's time to work with the columns. First, cut each column off at eight feet. Since the columns are hollow, you'll need to cut down a 6 x 6 piece of lumber to insert into the column -- simply hammer the post into the column. Stop just before the final portion is inserted, nail a piece of lumber lengthwise (figure D) in order to make sure you don't hammer the post too "far" into the column.

9. Add some 3" wood screws to make sure the post is secure and will stay in place. One screw per side should suffice.

10. Measure and mark 20" from the bottom and 12" from the top of the column, and use a router to smooth the corners. Lightly sand the edges as well.

11. Use a jigsaw (figure E) to drill out a hole in the center of the posts.

12. Now the columns are ready to paint.

13. To get the patio ready for the columns, drill a 1" hole in the brick using a hammer drill (figure F).

14. Mark each steel rod allowing 13" above the hole, and then insert the steel rods into the holes, making sure to keep them plumb. Hammer the rods into the ground.

15. Once the rods are hammered and secured, simply slide the columns down over the rods (figure G).

16. Use a level to make sure the columns are plumb.

You're now halfway through day one of this level 3 intermediate project. In the next segment, Reveiz will build and install the lentils on the pergola.

RESOURCES :

Southern Pine Council
Website: www.southernpine.com

GUESTS :

Richard Wallace
Representative
Southern Pine Council
Phone: 504-443-4464
Website: www.SouthernPine.com

Richard Lehner
Construction Innovators
10710 Coward Mill Rd.
Knoxville, TN 37931
Phone: 865-560-1970
Website: www.constructioninnovators.com