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The arbor is constructed from 6x6 posts topped with header boards and joists made from untreated lumber. The wood was given two coats of heavy-duty primer and two coats of paint before construction began.
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In this segment of Build an Outdoor Kitchen, the arbor posts are anchored using temporary braces while the headers and overhead beams are installed.Materials: cordless drill
hammer-drill
circular saw
miter saw
wedge anchors
hammer
palm nailer (optional)
tape measure
level
carpenters square
air compressor
2x2 lumber
6x6 posts
3/4-inch plywood
post brackets
carriage bolts
joist nails
liquid-nails adhesive
caulking gun
paint, paint rollers, paintbrushes
clamps
grout
grout bag
safety glasses
- The posts are stabilized temporarily using scrap 2x4's to hold them secure and plumb while the overhead portion of the arbor is constructed. Before attaching the headers across the posts, cut some scrap 2x4's and screw one end into the post as shown (figure A).
- The 2x4 should extend downward diagonally to the ground. At the lower end, drive a stake into the ground. Make sure that the attached post is plumb and level, then secure the lower end of the brace to the stake using wood screws (figure B).
- With the uprights secure, work can begin attaching the header boards to the posts. These 2"x12" boards are attached to either side of the posts to help support the arbor. Measure and mark the correct length of each beam according to your plan, and cut them to length using a circular saw.
- Secure the beams to the posts using 3-1/2" decking screws (figure C).
Note: Although the patio has a slight slope away from the house for drainage, the arbor roof should be installed so that it's level. Therefore, check to be sure that the header boards are level as you install them (figure D). This will give the proper appearance to the arbor and a level reference for installation of cabinets and cabinet tops.
- Once the first two header boards are installed, snap a chalk line across the next set of posts. Our design calls for the bottom of each beam to be 14 feet above the ground (figure E).
- Line up the next beam along the chalk line, check for level and attach the beam with decking screws (figure F).
- Repeat the process on the other side of the posts.
- Once all of the header beams have been secured in place, it's time to permanently secure the structure with lag bolts.
- Using a 12" wood bit, drill a hole all the way through the drop beams and post (figure G).
- Once the hole is drilled, hammer in a 12" carriage bolt (figure H).
- Slip two washers and a nut onto the carriage bolt and tighten down securely.
- Place two carriage bolts at every post location (figure I).
- Once all of the beams have been installed, prime and paint the ends of each board using a small paintbrush.
- The arbor joists will cap the arbor and run perpendicular to the header beams. Our design calls for the joists to be cut with a diagonal as a visual corner detail. In order to make perfectly uniform cuts on all of the joists, we created a custom jig (figure J). Since there are 22 joists in the arbor, the jig will be used to mark 44 separate cuts. The jig will help simplify the process of making all those cuts so that they are identical.
- To make our jig, we simply cut a 45-degree angle on both sides of a 3/4-inch piece of plywood. Attach a 3-inch strip to the leading edge.
- Slide the jig into place on the end of each joist to mark the proper angle (figure K).
- Use a circular saw, and cut along the marked line (figure L).
- Repeat the process to make the cuts on both ends of all of the joists.
Important: Included in this segment are the steps in this outdoor home-improvement project as shown in the episode. These steps are general guidelines that are applicable for similar construction projects. For any construction projects, there may be procedures, specifications, equipment, etc. that are specific to the specific site and circumstances. There may also be variations according to the type and brand of materials you select. Always consult local building codes when undertaking significant home-improvement projects, and read and follow the manufacturer's directions and precautions that come with any materials, tools or equipment you decide to use.Next: Hooking Up the Gas Fire-Pit
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