Almost Heaven Saunas Hillsboro Sauna Operating instructions

Almost Heaven Saunas
THE AUTHENTIC SAUNA EXPERIENCE
®
Hillsboro Sauna
Installation &
Owner’s Manual
In addition to reading this manual through to the end before proceeding with assembly
you may nd our instruction video helpful.
You can nd it at: youtube.com/user/almostheavensauna

ELECTRICAL REQUIREMENTS
All electrical wiring must be performed by A QUALIFIED LICENSED ELECTRICIAN. Because of the heat involved in the sauna, it is required that
you use copper wire with 90ºC insulation. Do not use aluminum wire to make the connection. Consult with an electrician so you can determine
the requirements for your particular situation. All wiring must conform to all national, state and local codes and regulations and according to the
instructions provided with the heater.
Be sure the surface where you are placing the sauna is at and level. A concrete, tile, vinyl, laminate or similar surface is suitable; placing the
sauna on carpet is not recommended. It is suggested that you lay out all of the components so that it is easy to identify the pieces once you get
started with assembly.
You will need the following tools to assemble your Hillsboro Sauna:
Rubber mallet
Hand saw
Hammer
Cordless drill
Stepladder
Level
Square
Tape measure
You will nd the following wood components as well as labeled bags of screws and hardware. (dimensions are approximate)
4 – Bottom rails
1 –19” wall section with square vent hole
4 – 19” wall sections without plastic clips
2 – 19” wall sections with plastic clips on one edge
1 – 23” wall section with plastic clips on both edges
2 – 90° corner posts without plastic clips on the edges
1 – 90° corner post with black clips on both edges
1 – Vertical window post with clips on one side and window groove on the other
1 – Vertical hinge post
2 – Door headers (one for left door installation, the other for right door installation)
1 – Glass window section
1 – Window oor support
2 – Front and back (long) roof support rails
2 – Left and right (short) roof support rails
2 – Horizontal bench supports
2 – Vertical bench section supports
1 – Vertical bench section
1 – Sauna bench
1 – Back support
1 – Heater fence (consists of (3) upright posts and (4) horizontal rails)
1 – Step (consists of (1) top, (2) legs, and (2) 45° supports
2 – Roof sections
4 – Roof trim pieces
1 – Glass door
1 – Hinge kit
NOTE: It is recommended that two people do the assembly of the sauna.
These instructions explain assembly with the door on the front left corner of the sauna. You can assemble the entire sauna in a reverse layout to
what is shown, which would place the door on the front right corner of the sauna. If you choose to reverse the assembly then be sure to do all
assembly opposite of the directions shown.
Read this entire manual through to the end before proceeding with the assembly.
Almost Heaven Saunas
THE AUTHENTIC SAUNA EXPERIENCE
®
Assembly video along with the instructions are available at:
youtube.com/user/almostheavensauna

Step 1
Locate the (4) bottom rails and position as shown. Overlap the corner
joints and be sure the rails are square to each other.
Step 2
Screw a single 5x70 screw into each of the 3 corners. NOTE: You will
hear the wood “crack” as you insert the screw, but this is due to the
soft nature and grain of the wood and will not aect the integrity of
the wood or structure.
Step 3
Find the 19”wall section with the square cut out hole and position on the
left rear of the bottom rail. NOTE: These instructions place the door on
the left of the sauna when viewing from the front. If
you want the door on the right side then place the
square cut hole on the right rear of the sauna. With
one person holding this wall section have another
person position one of the 2 90° corner posts (with-
out the black clips) onto the wall section and then
another 19” wall section on the rail perpendicular to
the rst element section.
NOTE: It is helpful to tap the wall sections to each
other, to the corner post and to the bottom rail us-
ing a rubber mallet.
Step 4
Verify that the wall sections are square to the rails, perpendicular to each other, and
that the at top of the wall sections and corner posts align. Using a cordless drill
with the appropriately sized bit (included) use 6x20
screws and secure the 90° post to the two wall sec-
tions. Cover each screw hole with one of the wood
plugs by tapping into place with the rubber mallet.
NOTE: Because the wall sections utilize both vertical
and horizontal boards, you will hear a“cracking” sound
as you draw the wood tight with the screw. This is
normal and will not result in splitting of the wood.

Step 5
Place two additional 19”wall sections on the back wall of the sauna.
There will be no screws used in these sections, but be sure the wall
sections are placed rmly to the bottom rail so that the at top sec-
tions are ush with each other. NOTE: In step 14 you will begin to
secure the wall sections together using the roof support rails.
Step 6
Place the second 90° corner post without the plastic clip on the rear right corner of the sauna and position
another 19” wall section perpendicular to it. As with step 4, screw the corner post to the wall sections using
6x20 screws.
Step 7
Place the 19”wall section with the plastic clips on the right side of the sauna with the clips facing the front.
Step 8
Place the 23”wall section on the front of the sauna. Us-
ing 2 people, take the 90° corner post with black plastic
clips on both sides and attached to the two wall sections.
Raise the post several inches above the wall sections and
position so the groove and the tongue pieces align. Then,
gently tap the post down with a rubber mallet so that the
clips nest into each other.
NOTE: The clips allow the wall sections to connect securely
and rmly without the use of screws, but everything must
line up for them to t correctly. You must position the 90°
post several inches above the wall section before nesting
the post to the walls. The clips will slide into each other to hold the post. If the clips will not easily slip
together, then take a Phillips head (+) screwdriver and loosen the screws holding the clips by up to 1 full
turn. Loosening the clip will not aect the holding power of the clip but will allow the clips to connect
more easily.

Step 9
Place the 19”wall section with black plastic clips on one side onto
the left hand side of the sauna with the clips facing the front of the
sauna.
Plastic Clips
Step 10
Find the vertical piece with the window
groove on one side. Hang the black clips on
the front wall section and line up the post with
the window groove to the wall. Make marks
on the window post with a pencil where you
will attach the black clips. Screw the clips in,
making sure to keep them loose, and attach to
the front wall section as described in step 8.
Step 11
Find the vertical hinge post and line up next to the left wall section. The
clips must be installed to this post. They are not installed at the factory,
as the positioning of the clips will depend on whether you place the
door on the right or left of the sauna.
Lining up the post to the left wall section, use a square to mark owhere
the clip must be positioned to properly align with the clip on the left wall
section. Once the location has been established, screw in the clip using
the screws provided. Repeat for all 3 clips and insert the post according
to the instructions in Step 8. Remember, keeping the clips slightly loose
will allow them to nest easier and will not aecting the holding power of
the clip.
Step 12
Find the door headers and select the left door header (right door header if the
door is on the right.) You can determine the correct header by noting the groove
for the glass window. The header will position above the door with the groove for
the window to the right and facing down.
Note: you can tighten or loosen the screws to help clip the wall elements together.

Step 13
Find the glass window section and position into
the groove of the vertical wall section post. Then,
position the header for the door so that the groove
goes over the top portion of the glass window.
Insure that the top of the header is ush with the
tops of the wall sections and screw into place us-
ing 4x70 screws inserted on an angle.
Step 14
Place the window oor support below the glass by sliding under the glass from
the side and tapping into place with the rubber mallet.
Step 15
You will now install the roof support rails, which will both support the
roof and secure the wall sections to each other. Locate (2) front and
rear (long) and (2) left and right (short) roof support rails. Position the
long roof support rails on the front and rear of the sauna, measuring
1-1/2” down from the top of the wall sections. Screw into place using
(1) 4x70 screw into each wall section. Next, place the short roof sup-
port rails on the right and left of the sauna, measuring 1-1/2” down and
lining up with the front and rear supports. Screw into place using (1)
4x70 screw into each wall section.
Step 16
Find the two horizontal bench supports. On both the left and right sides of the sauna
room, from the oor measure 32” up and make a mark. Place the bottom of the hori-
zontal bench support at your mark and screw into place using (4) 5x70 screws each. Be
sure that the bench support is level and that it butts up to the rear wall of the sauna.

Step 17
Find the two vertical bench supports. Position the right and left vertical
bench supports so that they butt up against the bottom and front edge
of the horizontal bench supports as shown.
Screw into place using (2) 5x70 screws each.
Step 18
Find the vertical bench section and position in front
of the vertical bench supports. Using (4) 4x60s
screws, from the backside attach the vertical bench
section to the vertical bench supports as shown.
Step 19
Place the sauna bench in place
over the horizontal bench sup-
ports. You will need to crawl below
the bench and secure to the wall
sections using (5) 4x60 screws, one
into each wall section.
Bench is not screwed down but
instead placed on top.
Step 20
Find the back support and position the bottom 10” (+/- depending on
your preference) above the bench. Using (6) 3.5x40 screws, attach to
the rear wall through the vertical boards and between the horizontal
slats on the rear of the back support as shown.

Step 21
Locate the vent cover and position over the wall opening. Attach
with (4) 3.5x40 screws.
Note: if the vent cover is sti, you can force it owith a mallet
or sand it.
Step 22
Find the (2) roof sections and place over the roof support rails. Be
sure the tongue and groove sections are facing in as shown so that
the smooth edges are around the perimeter. It is not necessary to
screw the roof sections down.
Step 23
Find the (3) upright posts and (4) hori-
zontal rails for the heater fence. Tap the
pieces together using a rubber mallet to
form an “L”and install to the front and
side walls using 3x40 screws. The top of
the horizontal heater fence rails should
be 26” above the oor.
Step 24
The step consists of the top, two legs, and two 45° supports. Assemble
as shown with the wide trim on one side of the step facing the front
and the two 45° supports at the back. Screw the legs to the to the step
top using (4) 4x60s screws. Fit the pins of the 40° supports into the
holes and secure the other ends to the step top using (4) 3.5x40 screws.

Step 25
Find 4 pieces of roof trim. Place the long piece with the two 45° angles on the front, and the
two short pieces on the sides. Attach to the sauna using 3.5x40 screws, (4) in each long piece
and (2) in each short piece. Screw from the top and into the roof sections. NOTE: The rear
piece of trim is generally not used as the sauna is placed against a wall. However, if you use
the rear trim then it will need to be cut to t around the two side pieces of trim.
Step 26
Locate the door magnet and door gasket. Insert
the magnet into the pre-drilled hole above the
door and push the gasket into the groove around
two sides of the door (the groove that is in the
door header and vertical hinge post).
Optional rear trim
Magnet
Gasket
Step 27
Attach the hinges to the door using
the gaskets and screws provided with
the hinges. Position the hinges exactly
as shown for building the sauna with
the door on the left. Use the small
hex wrench to remove and reinstall
the hinge cover, and use the large hex
wrench to attach the hinges to the
door.

Step 28
Before attaching the door, place it in the opening and insure that there is a
1/8” gap between the glass and the door header, and about a ½” gap at the
oor. With one person holding the door up (or set on ½” spacers at the oor)
screw the hinges into the vertical hinge post using the screws included with
the hinges. Secure one screw in each hinge and then close the door to be
sure of the t. Once the t is veried secure the remaining screws.
NOTE: There will be a ½” gap below the glass and also a ¼” +/- gap between
the door and the window. This is necessary in order to allow proper airow
into the sauna. Adjusting the opening of the wall vent will determine the
amount of air that ows through the sauna, but it is important that there is a
gap around the glass door.
Step 29
Install the handle on the door using the screws provided.
Refer to the separate installation guide for the LED light bar and heater installation.
Almost Heaven Saunas
THE AUTHENTIC SAUNA EXPERIENCE
®

OPERATION
After the sauna has been installed, sweep down the inside to remove any sawdust and wood shavings, and then vacuum com-
pletely. Using a damp cloth and warm water, wipe down the entire sauna including the benches to remove any remaining dirt,
dust and debris. Rinse othe sauna stones and install them in or on the heater in accordance with the heater manufacturer’s
instructions. Improper placement of heater stones can result in lower than desired heat temperatures. The rst time you turn
the heater on, set it to the maximum setting and operate it for about 30 minutes with the door propped open. Then close the
door and allow your sauna to come up to the desired temperature.
Since you most likely will use your sauna as both a “wet sauna”and a “dry sauna”, you should install the sauna stones that have
been included with the heater, following the manufacturer’s instructions. These stones are necessary if water will be sprinkled
on the heater to create the “wet sauna”, and they will produce more consistent heating in the dry mode (without the use of
water). It is common for a stone to occasionally crack during initial heating. If excess amounts of water are used during sauna,
prop door open to let the humidity escape. Not much water is necessary to achieve a “wet sauna”.
The amount of ventilation in the sauna can be adjusted by means of the vent located toward the top of the sau-na. It is impor-
tant to have adequate fresh air owing through the sauna, and this ow can be adjusted with the movable vent cover.
TRADITIONAL STEPS IN TAKING A SAUNA BATH
STEP #1 Set your heater so that the sauna room achieves the desired temperature, usually between 150º F and 170º F.
As a novice, you should begin at the lower end of this range and work your way up to the higher temperatures
over several sauna baths.
STEP #2 Remove all clothing (except maybe your swimsuit), eyeglasses, contact lenses, jewelry, etc. Take a quick shower
with warm water and soap, or a quick dip in your hot tub.
STEP #3 Enter the sauna initially for about 5 to 15 minutes. Bring a towel into the sauna onto which you can sit or lay.
Leave the sauna room once you have begun to perspire freely.
STEP #4 Now you may take a cold plunge in your swimming pool, shower or snow bank. After that, relax and cool down
for another 10 to 20 minutes.
STEP #5 Re-enter the sauna. On this return visit you may wish to sprinkle small amounts of water onto the stones creating
bursts of steam. If the water spills through the heater and onto the oor, you are using too much, although this
will not hurt the heater or the sauna.
STEP #6 After your nal visit to the sauna, relax for at least 20 minutes. Shower with soap and warm water. Finish your
shower with cooler water to close the pores of your skin. Dress only after you have cooled down completely.
NOTE: Whatever your sauna regimen, it is important that you keep yourself hydrated by drinking plenty of water!
Almost Heaven Saunas
THE AUTHENTIC SAUNA EXPERIENCE
®
1017