DIY Network

Cedar Pergola Assembly From "Home Transformations" episode DHTR-106

	This plain California patio will be transformed ...
	... into an outdoor entertainment paradise.

In the first part of this project, homeowners Brett and Todd Jones tackled the replacement of a bedroom window with French doors that will lead to the new outdoor room. In part two of the transformation, the trio will build a pergola from a kit.

Cedar Pergola Assembly:

(All instructions are provided in kit. These are the how-to steps as performed by host Michael Ray Wisely and the homeowners for their particular project.)

Materials:

Crescent wrench
Phillips screwdriver
Hammer
Bubble level
Tape measure
Step ladder
Knee pads
1/2" hammer drill
Masonry drill bit
Impact wrench
Post anchor with spacer
5/8" bolt (included as part of the pergola anchor kit)
Chalk
Vacuum

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

1. To build the first side of the perfola, join two 4 x 4 posts and one 2 x 6 with carriage bolts and washers. A carriage bolt has a rounded head and when tapped into place, is secure against turning or movement. Repeat for opposite end.

2. Next attached the side rails. (Tip: While all hardware should be included in the kit, be sure to purchase hot dip galvanized hardware should you need additional components.)

3. Join end and side rails to the opposite end by carefully standing completed section upright, then over, so that the ends of the side rails are square and touching the ground. Again, join with carriage bolts, one large flat washer and one small flat washer, one lock washer and one nut (figure A).

   Tip: If holes do not line up evenly when trying to assemble, lightly loosen the nuts on the carriage bolts and step on until bolts can be inserted through the post. Then secure all four nuts.

4. Use a ladder to access and tighten the top bolts (figure B). Once the frame of the pergola is constructed, add the extensions. The long wedge extensions are attached with carriage bolts through the pre-drilled holes (figure C).

5. Use the spacers provided with the kit to determine placement of roof slats (figure D). Secure spacers with 2" brass screws and grommets.

6. Drill pilot holes to prevent wood from splitting, then add lag bolts that will secure the slats (figure E).

7. Add wedge extensions at the ends of the pergola. Secure decorative wood ball, join slats evenly and secure. Secure perpendicular slats at tends (figure F).

8. With the pergola constructed, it's time to determine placement and secure the structure to the existing concrete patio. First, mark position of posts with chalk.

9. Use a post anchor with a spacer that will lift the wood away from the ground. A bracket will secure the post to the patio. Use a 1/2" two-speed hammer drill to pre-drill the holes for the bolts using the bracket hole as your guide (figure G).

10. Vacuum dust away, then set the bracket in place and use an impact wrench to drive in the 5/8" masonry bolt (figure H).

11. Align the posts in the bracket and secure with nails (figure I).

Safety Tip: After the pergola assembly, the Joneses and host Wisely prepare for the gas outdoor kitchen installation by using a power trencher to dig for the future gas line and conduit installation. Before you dig in your own backyard, call 1-800-CALL-BEFORE-YOU-DIG to make sure you don't hit any power or existing gas lines.

RESOURCES :

Danove Cedar Outdoor Pergola in Natural
www.OutdoorDecor.com
Arthur Wilbur Company, Inc. P.O. Box 3089
Tuscaloosa, AL 35403-3089