Backyard Discovery 2101548 Use and care manual

Made in Malaysia INS-2101548-A-MANDALAY 12x10-ENG 
For the most up to date assembly manual,
to register your set, or to order replacement parts please visit
www.backyarddiscovery.com
SAVE THIS ASSEMBLY MANUAL FOR FUTURE REFERENCE IN THE EVENT THAT
YOU NEED TO ORDER REPLACEMENT PARTS.
Model # 2101548
MANDALAY 12 x 10
GAZEBO
Owner's Manual & Assembly Instructions
MANUFACTURED BY:
Backyard Discovery
3305 Airport Drive
Pittsburg, KS 66762
800-856-4445
average 2 person assembly time
assembly time may vary based on skill level

• 18+ Years of Experience Servicing Big Box Retailers and Direct Consumers
• Highly Skilled, Specialized, Courteous, Professional Service Technicians
• Over 140,000 Installations Annually
• Satisfaction Guarantee
• Flexible Appointments, including weekends
• Coverage across the nation
• White Glove Service Visit www.gocongure.com for more info!
*Installation services are only available to U.S. customers.
With Go Congure, we bring you 18 years of experience right to your doorstep.
We service a wide array of indoor and outdoor recreation products that most consumers
don’t have the time or ability to deliver & install themselves.
We do the heavy lifting, so you don’t have to!
*Installation services are only available
to U.S. customers.
INSTALLATION
SERVICES
AVAILABLE!*
Need a helping hand?
Let our team of professionals handle the installation for you!
2

The store where you made your purchase
does not stock parts for this item.
If you have assembly questions or you are missing or
have damaged parts, please call
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you can also visit www.backyarddiscovery.com
or e-mail [e-mail]
Please have the following information ready when you make your call:
• Model Number of the product located on the front of the assembly manual
• The item description and number from the parts list from the manual that was included in your box

• Read entire assembly manual, paying special attention to the important tips and safety information.
• To ensure there are no missing pieces do a complete inventory by rst separating and identifying all parts.
• Make sure to check packing material for small parts that may have fallen out during shipment.
• Structures are not intended for public use. The Company does not warranty any of its residential structures
subjected to commercial use.
• This manual contains helpful information concerning assembly preparation, installation procedure and
required maintenance.
• Always keep safety in mind as your structure is being built.
• Keep these instructions for future reference.
Please Read This Before Starting Assembly
Owner’s Manual
3

Owner’s Manual Limited Warranty
4
Tracking Number Reference Label
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Please read entire booklet completely before beginning the assembly process
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•Wood is NOT flMMBNF retardant and will burn. Grills, fir JSe pits
and chimineas are a fir JSe hazard if placeEtoo close to
yourstructure.
•Wear gloves to avoid injury during installation.
•During installation, follow all safety warnings provided
with your tools and use safety glasses.
•Check all nuts and bolts twice monthly during the usage
season and tighten as required.(But not so tight that you
crack the wood) It is particularly important that this
procedure be followed at the beginning of each season.
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• Inspect wood parts monthly. The grain of the wood
sometimes will lift in the dry season causing splinters to
appear. Light sanding may be necessary to maintain asafe
environment. Treating your Product with protection
(sealant) after sanding will help prevent severe checking/
splitting and other weather damage.
• We have applied aOPJMCBTFEstain to yourunit. This is
done for color only. Once or twice a year,depending on
your climate conditions, you must applysome type of
protection (sealant) to the wood of your unit.Prior to the
application of sealant, lightly sand any “rough”spots on
your set. Please note this is a requirement ofyour
warranty.
OWNERS SHALL BE RESPONSIBLE FOR MAINTAINING THE LEGIBILITY OF THE WARNING LABELS
IT IS IMPORTANT TO CHECK AND TIGHTEN ALL HARDWARE AT THE BEGINNING AND DURING
THE SEASON AS THEY MAY LOOSEN DUE TO WOOD EXPANSION AND CONTRACTION.
Owner’s Manual Safety Warnings and Maintenance Instructions
5

About Our Wood
:PVSBackyard Discovery QSPEVDUJTNBEFPVUPG.FSBOUJ wood. Although we take
great care in selecting the best quality lumber available, wood is still a product of nature
and susceptible to weathering which can change the appearance of your set.
Your Backyard Discovery structure is designed and constructed of quality
materials. As with all outdoor products it will weather and wear. To maximize
the enjoyment, safety and life of your structure it is important that you properly
maintain it.
What causes weathering? Does it aect
the strength of my product?
One of the main reasons for weathering is the
eects of water (moisture); the moisture content
of the wood at the surface is dierent than the
interior of the wood. As the climate changes,
moisture moves in or out of the wood, causing
tension which can result in checking and or
warping. You can expect the following due to
weathering. These changes will not aect the
strength of the product:
1. Checking is surface cracks in the wood along
the grain. A post (4”x 4”) will experience more
checking than a board (1”x 4”) because the surface
and interior moisture content will vary more widely
than in thinner wood.
2. Warping results from any distortion (twisting,
cupping) from the original plane of the board and
often happens from rapid wetting and drying of
the wood.
3. Fading happens as a natural change in the
wood color as it is exposed to sun-light and will
turn grey over time.
How can I reduce the amount of
weathering to wood product?
1. Your wood product is coated with aOPJM
based stain.Sunlight will break down the
coating, so we recommend applying
aOPJMCBTFEstain on a yearly basis
(see your local stain and paint supplier for a
recommended product). You must apply some
type of protection (sealant) to the wood of your
product. Please note this is a requirement
of your warranty. Most weathering is just
the normal result of natureBOEXJMMOPUBGGFDU
TBGFUZ. However if you are concerned that a part
has experienced a severe weathering problem
please call our customer service department for
further assistance.
2. Inspect wood parts monthly. The grain ofthe
wood sometimes will lift in the dry season
causing splinters to appear. Light sanding may
be necessary to maintain a safe environment.
Treating your Product with protection (sealant)
after sanding will help prevent severe checking/
splitting and other weather damage.
Instructions for Proper Maintenance
Owner’s Manual
6

Protrusion Hazard
Proper Hardware Assembly
´
CorrectIncorrect
Bolt and Barrel Nut Assembly
Insert barrel nut through the lock washer and press the pair
through the provided hole. Insert your bolt through the
second lock washer and insert the pair into the provided hole
opposite from the barrel nut. Turn clockwise to thread into the
barrel nut. Do not completely tighten until instructed. /2&.:$6+(5
%2/7
%$55(/187
Bolt and T-Nut Assembly
Tap T-nut into the provided hole. Insert your bolt through
the lock washer and insert into the provided hole opposite
from the T-Nut. Turn clockwise to thread into T-nut. Do not
completely tighten until instructed.
7187
/2&.:$6+(5
%2/7
Lag Assembly
Normally there will be a pre-drilled pilot hole on assemblies
that require a Lag Screw. If there is no pilot hole, line up the
two boards as they are to be attached and use the factory
drilled hole as a guide to drill another pilot hole into the
adjoining board. This will keep the wood from splitting. Only a
lock washer is required for steps with Lag Screws. /2&.:$6+(5
/$*6&5(:
If you see exposed
threads and your bolt
protrudes beyond the
T-Nut you may have over
tightened the bolt or
used incorrect hardware.
If you’ve overtightened,
remove the bolt and add
washers to eliminate the
protrusion.
Assembly Tips
Owner’s Manual
/2&.:$6+(5
7

192(x2)
199(x2)
198(x2)
378(x2)
Hardware Identication
Hardware bags are printed with
a seven digit alpha-numeric part
number. During assembly you only
need to reference the last three
digits of the part number as noted
in each step. This will make nding
the correct hardware easier.
BOLT WH
5/16 x 1-3/4
ASSEMBLY TIP:
Keep and eye out for these boxes which will contain helpful pictures and information making
the assembly process as quick and painless as possible.
Sorting Wood
Sorting Hardware
When removing the wood from the boxes we recommend arranging them by part number before you begin
assembly. This will allow for faster assembly and easily identify any parts that may be missing or damaged.
To help with assembly we recommend sorting your hardware bags with the seven digit alpha-numeric number
printed on the bags or by hardware type (i.e. bolts, nuts, etc.). Organizing your hardware will make assembly easier.
NUT BARREL
H100545
SCREW
H100695
T-NUT
H100699
WASHER FLAT
H100706
BOLT HEX
H100716
BOLT
H100718
SCREW PWH
H100742
G2
G1
F2
F1
E1
E2
H100378
(x2)
Assembly Tips
Owner’s Manual
8

Owner's Manual ǻŸŸĶǣNJsLJȖÞNjs_¯ŸNjÝŘǣǼĶĶǼÞŸŘ
5/16
1/4
(2 NEEDED)
1/2
3/8
9

9.82 ft
[3 m] 7.2 ft
[2.2 m]
12.13 ft
[3.7 m]
9.92 ft
[3 m]
12.13 ft
[3.7 m]
9.76 ft
[3 m]
10.16 ft
[3.1 m]
11.21 ft
[3.4 m]
8.82 ft
[2.7 m]
10.76 ft
[3.3 m]
Remove plastic covering from metal roof panels before installing each piece. Place roofing materials on a nonabrasive,
flat surface before and after assembly as it could bend, dent or scratch
Metal Roof Assembly
The hardware to attach the post mounts to the structure is included.
The hardware to mount the structure permanently to a concrete surface is included.
The hardware to mount the structure permanently to a wood deck is NOT included and will need to be purchased
separately. You must ensure there is ample structural support under the deck before permanently attaching.
Post mounts are provided with your structure which allows you to permanently install your structure to a
pre-existing or new wood or concrete surface.
Pay close attention to the items needed for each step. Make sure you are using the correct hardware for each
step. Using incorrect hardware may result in improper assembly
Remember to double check for underground utilities and overhead electrical lines
It is critically important that you start with square and level footings, concrete pad or deck to
attach your structure
Owner's Manual
DǣÞOǢsǼȖƼ^ÞŎsŘǣÞŸŘǣ˓ǣǣsŎEĶɴŗŸǼsǣ
15.67 ft
[4.8 m]
10

Owner's Manual ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
BEAM - W4L13703
1"x4 5/8"x63 1/8" (24x116x1604)
MD1
(x2)
BEAM - W4L13709
1"x4 5/8"x64 5/8" (24x116x1640)
MD2
(x8)
BEAM - W4L13700
1"x4 5/8"x35 5/8" (24x116x906)
MD3
(x4)
BEAM - W4L13702
1"x4 5/8"x54 3/4" (24x116x1390)
MD4
(x4)
ANGLE BRACE - W4L13705
7/8"x4 5/8"x30 3/8" (21x116x770)
MD5
(x4)
ANGLE BRACE - W4L13710
7/8"x4 5/8"x33" (21x116x839)
MD6
(x4)
OUTSIDE RAFTER - W4L13707
7/8"x3 3/8"x77 3/8" (21x86x1966)
MH1
(x4)
RAFTER - W4L13706
7/8"x3 3/8"x77 3/8" (21x86x1966)
MH2
(x6)
ANGLE BRACE - W4L13713
1"x4 5/8"x35 5/8" (24x116x905)
MD7
(x8)
ANGLE BRACE - W4L13714
1"x4 5/8"x35 5/8" (24x116x905)
MD8
(x8)
11

Owner's Manual ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
ɟŸŸ_NŸŎƼŸŘsŘǼǣʹŗŸǼǼŸǢOĶsʺ
SHEATHING BOARD - W4L13701
7/8"x3 3/8"x84 1/4" (21x86x2141)
MH3
(x8)
END RAFTER - W2A03065
2 1/16"x5"x80 5/8" (52x116x2048)
MRP2
(x2)
POST - W2A03062
5 3/4"x5 3/4"x89 1/2" (146x146x2274)
MP2
(x2)
END RAFTER - W2A03063
2 1/16"x5"x80 5/8" (52x116x2048)
MRP1
(x2)
POST - W2A003061
5 3/4"x5 3/4"x89 1/2" (146x146x2274)
MP1
(x2)
FASCIA - W4L13708
7/8"x3 3/8"x59 1/4" (21x86x1504)
MH7
(x4)
RAFTER - W4L13715
7/8"x3 3/8"x79 13/16" (21x86x2027)
MH5
(x2)
RAFTER - W4L13716
7/8"x3 3/8"x27 3/8" (21x86x695)
MH6
(x2)
RIDGE CAP STIFFENER - W4L13717
1"x2 3/8"x47 5/8" (24x60x1210)
MJ1
(x2)
RIDGE CAP STIFFENER - W4L13718
1"x2 3/8"x69 1/4" (24x60x1760)
MJ2
(x2)
POST - W2A03064
5 11/16"x5 11/16"x33 1/4" (144x144x845)
MP3
(x2)
SHEATHING BOARD - W2A03066
13/16"x3 3/8"x34 13/16" (21x86x884)
MH4
(x8)
12

Owner's Manual ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
NUT BARREL WH BLK
5/16x1-1/2
(x42)
H100193
BOLT WH BLK
5/16x2-1/4
(x4)
H100205
NUT BARREL WH BLK
5/16x7/8
(x74)
H100192
T-NUT BLK
5/16
(x9)
H100379
BOLT WH BLK
5/16x1 1/2
(x66)
H100407
BOLT WH BLK
5/16x1 1/4
(x9)
H100459
BOLT WH BLK
5/16x1
(x9)
H100468
LAG SCREW WH BLK
5/16x1 1/2
(x34)
H100471
BOLT WH BLK
5/16x8-1/2
(x4)
H100850
BOLT WH BLK
5/16x6 3/4
(x26)
H101037
LAG SCREW WH BLK
1/4x1 1/2
(x22)
H100403
BOLT WH BLK
5/16x3/4
(x34)
H100663
BOLT WH BLK
5/16x5 3/4
(x18)
H100974
NUT BARREL WH BLK
5/16x5/8
(x18)
H100469
13

Owner's Manual ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
ËNj_ɠNjsNŸŎƼŸŘsŘǼǣ
6&5(:7)+%/.
8x2-1/2
(x4)
+
6&5(:7)+%/.
8x2
(x78)
+
6&5(:7)+%/.
8x1 1/2
(x30)
+
WASHER LOCK EXT BLK
12x19
(x108)
H100199
WASHER LOCK EXT BLK
8x19
(x96)
H100198
WASHER FLAT BLK
8x19
(x17)
H100630
CONCRETE ANCHOR 1/4"x2"
(x18)
H100120
SCREW 7WH BLK
8x3/4
(x17)
+
NUT LOCK BLK
5/16
(x9)
H100479
WASHER FLAT BLK
5/16
(x9)
H100770
SCREW WOODGRIP
10x3/4
(x148)
H100833
TORX BIT
T-40
(x2)
A100042
TORX WRENCH
T-40
(x2)
A100041
SCREW SETTER
(x1)
H100764
SCREW TAPPING
1/4x3/4
(x17)
H100759
6&5(:7)+%/.
10x3-1/2
(x22)
+
SCREW 7WH BLK
8x1
(x33)
+
TORX WRENCH
T-30
(x2)
H100114
TORX BIT
T-30
(x2)
H100147
SCREW PWH BLK
8x1/2
(x4)
H100408
14
TORX BIT
T-20
(x2)
H100879
TORX BIT
T-2
(x)
+

Owner's Manual
OOsǣǣŸNjɴNŸŎƼŸŘsŘǼǣʹŗŸǼǼŸǢOĶsʺ
ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
"A" REVISION TAG
(x1)
A100314
ROOF BRACKET
(x6)
A4M00961
BRACKET
(x4)
A4M01138 BRACKET
(x2)
A4M01139
BRACKET
(x4)
A4M01141
BRACKET
(x4)
A4M01140
L BRACKET
(x4)
A4M01137
KINGSLEY PARK TAG
(x1)
A4M01163
15

OOsǣǣŸNjɴNŸŎƼŸŘsŘǼǣʹŗŸǼǼŸǢOĶsʺ
Owner's Manual ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
6x6 POST FOOT
(x4)
A6P00418
POST ANCHORING PLATE
(x8)
A4M00977
POST PLATE
(x8)
A4M00978
ELECTRICAL ENCLOSURE
(x1)
9205413
16

Owner's Manual ƻNjǼǣÝ_sŘǼÞ¯ÞOǼÞŸŘ
OOsǣǣŸNjɴNŸŎƼŸŘsŘǼǣʹŗŸǼǼŸǢOĶsʺ
RIDGE CAP 29 GA
(x2)
A4M01116
ROOF EDGE TRIM
(x4)
A4M00982
ROOF EDGE TRIM SPLICE
(x2)
A4M00983
RIDGE CAP PROTECTOR
(x2)
A6P00398
RIDGE CAP SPLICE
(x1)
A4M01127
29 GA STEEL SHEETING
(x8)
A4M01124
17

COMPLETE THIS STEP TWICE
FOR EASE OF ASSEMBLY WE RECOMMEND USING
SAW HORSES FOR STEPS 1 THROUGH 3.
6x6 POST FOOT
(x4)
A6P00418
6&5(:7)+%/.
8x1 1/2
(x16)
+
ǻÝƻʲ
˧˦˧ ʹɮ˧ʺ
ǢNNJrɟ˚ˠˠˀˡ˃
POST - W2A03062
5 3/4"x5 3/4"x89 1/2" (146x146x2274)
MP2
(x2)
ōƻˠ ʹɮˠʺ
ƻŷǢǻ
ōƻˡ ʹɮˠʺ
ƻŷǢǻ
Ǣǻrƻˠ
POST - W2A003061
5 3/4"x5 3/4"x89 1/2" (146x146x2274)
MP1
(x2)
ˣˠ˧ ʹɮˡʺ
˥ɮ˥ƻŷǢǻ®ŷŷǻ
ŗŷǻrʲ
USE FEET AS A TEMPLATE &
PRE-DRILL POSTS WITH A 1/8"
(3mm) DRILL BIT BEFORE
INSTALLING SCREWS.
18

COMPLETE THIS STEP TWICE
PILOT HOLE
DOWN
2'-1 1/2" [653 mm]
ʹōƻˠʺ
ʹōƻˡ)
LAG SCREW WH BLK
1/4x1 1/2
(x8)
H100403
WASHER LOCK EXT BLK
8x19
(x8)
H100198
NUT BARREL WH BLK
5/16x1-1/2
(x24)
H100193
BEAM - W4L13709
1"x4 5/8"x64 5/8" (24x116x1640)
MD2
(x8)
POST - W2A03064
5 11/16"x5 11/16"x33 1/4" (144x144x845)
MP3
(x2)
BRACKET
(x4)
A4M01138
BRACKET
(x4)
A4M01140
BOLT WH BLK
5/16x6 3/4
(x24)
H101037
ō^ˡ ʹɮˠʺ
Drō
ō^ˡ ʹɮˠʺ
Drō
ō^ˡ ʹɮˠʺ
Drō
ō^ˡ ʹɮˠʺ
Drō
ōƻˢ ʹɮˠʺ
ƻŷǢǻ
Ǣǻrƻˡ
FACE HOLES INWARD
ON EACH POST
L BRACKET
(x4)
A4M01137
ˠˢ˦ ʹɮˡʺ
ĵDNJNħrǻ
ˠˣ˟ ʹɮˡʺ
DNJNħrǻ
ˠˢ˧ ʹɮˡʺ
DNJNħrǻ
NOTE:
PILOT HOLE FACE DOWN
ˣ˟ˢ ʹɮˣʺ
ĵµǢNNJrɟ˚ˠˠˀˡ˃ ˟ˢ˦
ʹɮ˧ʺ
Dŷĵǻ˚˥˚ˢˀˣ˃
ˠ˨˧ ʹɮˣʺ
ɟǢËrNJ˚˧ɮˠ˨
ˠ˨ˢ ʹɮ˧ʺ
ŗȕǻDNJNJrĵ˚ˠˠˀˡ˃
˟ˢ˦ ʹɮˣʺ
Dŷĵǻ˚˥˚ˢˀˣ˃
ˠ˨ˢ ʹɮˣʺ
ŗȕǻDNJNJrĵ˚ˠˠˀˡ˃
19

COMPLETE THIS STEP TWICE
6&5(:7)+%/.
10x3-1/2
(x8)
+
BOLT WH BLK
5/16x1 1/2
(x16)
H100407 NUT BARREL WH BLK
5/16x7/8
(x16)
H100192
WASHER LOCK EXT BLK
12x19
(x16)
H100199 WASHER LOCK EXT BLK
8x19
(x16)
H100198
Ǣǻrƻˢ
ANGLE BRACE - W4L13714
1"x4 5/8"x35 5/8" (24x116x905)
MD8
(x8)
ō^˧ ʹɮˡʺ
ŗµĵrDNJNr
ō^˧ ʹɮˡʺ
ŗµĵrDNJNr
˟˧ˠ ʹɮˣʺ
ǢNNJrɟ˚ˢˠˀˡ˃
ˣ˟˦ ʹɮ˧ʺ
Dŷĵǻ˚ˠ˚ˠˀˡ˃
ˠ˨˧ ʹɮ˧ʺ
ɟǢËrNJ˚˧ɮˠ˨
ˠ˨˨ ʹɮ˧ʺ
ɟǢËrNJ˚ˠˡɮˠ˨
ˠ˨ˡ ʹɮ˧ʺ
ŗȕǻDNJNJrĵ˚˦ˀ˧˃
20