| Deck Spiff-Up: Building a Redwood Frame for a Shade Canopy |
From "Weekend Handyman"
episode WKH-108 |
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Note: Click here for a materials list and complete instructions without images. Time: 16 hours over two days. Difficulty Rating: It's rated a 2 on a scale of 1 to 5.
Materials for Complete Project: redwood for frame and bench (varies according to frame dimensions)
3 pieces of 2" x 6" x 14"
2 pieces of 2" x 6" x 16"
10 pieces of 2" x 4" x 12"
5 pieces of 1" x 8" x 12"
3 pieces of 4" x 4" x 12"
shade canopy with tracks
inset deck lighting kit
handsaw
circular saw
jigsaw
forstner bit
cordless drill
hand tools
clamps
measuring devices First, you'll need to gather your tools and materials, determine the size of the area to be covered and order the canopy. The key to your design is to figure out how much of the deck you want to be covered by the canopy (figure A) and how far the canopy will project out from the house. The deck that was used for this particular project is small: 12' x 14-1/2'. In this case it makes sense that the canopy will cover most of the deck, from the side edge all the way to where the house begins, and the canopy will extend from the house to the end of the deck, or at least the first step. For this project, Weekend Handyman host Paul Ryan used redwood to match the deck. He needed two upright posts that will support the header beam (where the tracts will attach), and two return boards for the posts back to the house. These are to steady the structure, and they'll add a pleasant visual element (figure B--illustration of the posts, boards and beams). Note: For this stucco house, a frieze board (see image, right) was added for decoration, and fortunately this board will be much easier for attaching the canopy than stucco would be. Building the Front Posts for Canopy Frame - Build a box (figure C--made from treated lumber) to support the base post and mount into place flush with the top of the deck stringers and the kick-plate to secure the post. Visually lineup where the post should go, and make a mark and then a notch for the 4" x 4" post (figure D).
- Clamp the upright posts for the canopy together and notch where the header fits.
Tip: To make a square cut with a circular saw, simply hold the speed square to the side as a guide to make the cut. - Make a series of parallel cuts (figure E) to create a notch, break it off with a hammer and clean up any ridges with a chisel. Be sure to chisel along the wood grain.
- Create decorative edge on the header by tracing a desired decorative molding (figure F) onto header board, cut with a jigsaw.
- Attach the front posts--visually line up the posts where you want them, make mark and notch where you're going to put the post.
- Clamp a bock to the post that will sit on the deck and keep it at the right height.
- Raise the post and level it.
- Use carriage bolts to attach the post to the deck.
- Raise the other post (to level use sticker boards since the post doesn't touch the ground or have a box). Level post, clamp a 2" x 4" on one side angled to the ground for support and clamp another 2" x 4" in the other direction (figure G).
- Once the posts are level, bolt them into place with carriage bolts.
- Attach the double-sided header.
- Measure each side while on the ground, which is safer than when the headers are up in the air, and make a mark, then transfer to other header board.
- Raise the first header board and bolt it on.
- Bring the second header board up, clamp and bolt it on (figure H).
- Attach the return boards.
- Measure the distance between the header and the frieze board, which is a board on the house--stucco in this case--that the return boards will attach to. p>
- Add however many inches (14" for this particular project) you want to measurement for return to hang over the front to create the pergola style.
- Cut the boards and add a decorative edge, as before, if desired.
- Raise the boards, rest on headers and slide the return boards back to the frieze board.
- Attach the return board with galvanized metal brackets (figure I).
- Square where the first return board meets the header and screw it in.
- Repeat for the other return board.
RESOURCES :
Retractable Canopies (ShadeTree)
Model #: Forester
Color: Southwestern Stripe
Product Tips:
- The shades retract, and you can install a locking mechanism to stop the rollers.
- Each panel has a "wind release" mechanism that allows the canopy to move freely in tracks in heavy winds, reducing damage.
ShadeTree Systems
Website: www.shadetreecanopies.com
Inset Lighting (Rockler Woodworking and Hardware)
In-Deck Lighting Disks
Model #: 36805
Rockler Woodworking and Hardware
Website: www.rockler.com
Deck Fasteners (Rockler Woodworking and Hardware)
Ebty Invisible Deck-Fastening System
Model #: 30424
Deckmaster Hidden Deck-Fastening System
Model #: 30606
Rockler Woodworking and Hardware
Website: www.rockler.com
California Redwood Association
Website: www.calredwood.org
GUESTS :
Curt Yoder
Production Manager, ShadeTree Systems
Columbus, OH
Phone: 614-844-5990
Brad Becker
Technical adviser, Rockler Woodworking and Hardware
Website: www.rockler.com
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