Backyard Discovery SAHARA 1804517 User manual

SAHARA
OUTDOOR PRODUCT
MODEL: # 1804517
Made in China
INS-1804517-A-12x12 SAHARA PERGOLA-ENG 03-19-2020
Save this assembly manual for future reference in the event that
you need to order replacement parts.
For the most up to date assembly manual,
to register your product or to order replacement parts please visit
www.backyarddiscovery.com
BOOKLET INCLUDES:
• Owner's Manual
• Frequently Asked Questions
• Assembly Instructions
• Warranty Information

Important Assembly Notes
1) While assembling unit, take time before and after each step to make sure unit is level. If unit is
not level, assembly will be difficult and improper assembly may result. Extra care must be taken to
ensure the unit is square.
2) Pay close attention to the ITEMS NEEDED FOR EACH STEP. They can be a valuable aid when
sorting your wood and hardware. Assembly will be made easier if items are sorted by step.
3) Pay close attention to make sure you are using the correct hardware in the correct step. Using
incorrect hardware may result in improper assembly.
4) Whenever a T-nut is used, follow these directions. Place T-nut in pre-drilled hole. Tap in with hammer.
Place bolt with washers in the opposite side. Hand tighten to make sure the bolt is in the T-nut.
DO NOT over tighten.
5) The written notes may include important information not shown in the illustrations.
Basic Setup Dimensions
Place the unit on level ground. Check carefully for overhead lines and ensure there
is at least 6 ft [2 m] clearance to any overhead electrical wires.
12'
[3658 mm]
12'
[3658 mm]
8'-10"
[2692 mm]
7'- 1/2"
[2146 mm]
7'-5 13/16"
[2282 mm]
8'-4 1/16"
[2541 mm]
10'
[3048 mm]
6'
[1829 mm]
6'
[1829 mm]
12'-5 15/16"
[3809 mm]
12'-5 15/16"
[3808 mm]

(Level 24")
(Square)
(Tape Measure)
(Cordless Drill or Electric Drill)
(Drill Attachments: Phillips
Head & Socket Driver)
(An Adult w/ an Adult Helper)
(Rubber Mallet - Optional)
(Ladder)
(Phillips Screw Driver)
(3/16" Concrete
Drill Bit)
Tools Required for Installation:
(These are the tools that are generally required for assembly of our outdoor products. These tools are not included with the
outdoor product purchase.)

Parts Identification
Wood Components
(NOT TO SCALE)
Important Note:
In the event the INK STAMP dent f er s not easy to read or s m ss ng from a wood component, match the un que geometr c
shape and d mens ons of the wood component found n a spec f c assembly step to the PARTS IDENTIFICATION sect on when
requ red. Th s w ll a d n dent fy ng the part for assembly and (or) customer serv ce ssues.
D2 - BEAM - W4L11716
1 3/8"x5 1/4"x144" (36x134x3658)
(4)
D1 - BEAM - W4L11715
1 3/8"x5 1/4"x144" (36x134x3658)
(2)
D3 - BEAM - W4L11717
1 3/8"x5 1/4"x144" (36x134x3658)
(8)
D4 - BEAM - W4L11721
1 3/8"x5 1/4"x144" (36x134x3658)
(2)
P1 - PURLIN - W4L11718
1 3/8"x1 3/8"x132" (36x36x3354)
(25)
(8) -AB1 - ANGLE BRACE - W4L14282
1 3/8"x6 7/16"x40 13/16" (34x163x1036)
(8) -AB2 - ANGLE BRACE - W4L14281
1 3/8"x6 7/16"x35 3/4" (34x163x908)
(2) - PT1 - POST - W2A02557
7"x7"x94 1/2" (178x178x2400)
(2) - PT2 - POST - W2A02560
7"x7"x94 1/2" (178x178x2400)
H1 - PERLIN SPACER BLOCK - W4L11735
15/16"x3 3/8"x4 3/16" (24x86x107)
(2)

Parts Identification
Hardware
- BOLT HEX 1/2x11 BLK - H100751
(18)
- BOLT HEX 1/2x4 BLK - H100752
(34)
- LAG SCREW WH 5/16x5-1/2 BLK - H100204
(18)
- CONCRETE ANCHOR 1/4"x2" - H100120
(18)
- SCREW PFH 8x1-1/2 BLK - H100200
(22)
- WASHER FLAT 1/2 BLK - H100755
(132)
- WASHER SPLIT 1/2 BLK - H100754
(52)
(18)- WASHER LOCK EXT 8x19 BLK - H100198
- SCREW PFH 8x2-1/2 BLK - H100201
(204)
( HALF SCALE )
- WASHER FLAT 8x19 BLK - H100630
(17)
- LAG SCREW HEX 1/2x2 BLK - H100758
(34)
- T-40 TORX WRENCH - A100041
(2)
- T-40 TORX BIT - A100042
(2)
- LAG SCREW WH 1/4x3 BLK - H100792
(18)
- NUT LOCK 1/2 BLK - H100753
(50)
- WASHER LOCK EXT 6x15 BLK - H100405
(18)

Parts Identification
Accessories
(NOT TO SCALE)
- "A" REVISION TAG - A100314
(1)
- 7x7 POST FOOT - A6P00296
(4)
- STEEL POST ANCHORING PLATE WITH FLANGE -
A4M00949
(8)
- STEEL POST PLATE - A4M00950
(8)
- GROUND STAKE 16 INCH - A4M00951
(8)
- LTP ID TAG (SMALL) WITHOUT AGES - A4M01010
(1)
(2) - T-30 TORX WRENCH - H100114
(2) - T-30 TORX BIT - H100147

STEP 1
SCREW PFH
8x1-1/2 BLK
(16)
SCREW PFH 8X1 1/2 BLK
(16 PLCS)
7x7 POST FOOT
(4 PLCS)
ALL POSTS
BOTTOM END
WITHOUT PLUG
(2) - PT1 - POST - W2A02557
7"x7"x94 1/2" (178x178x2402)
(2) - PT2 - POST - W2A02560
7"x7"x94 1/2" (178x178x2402) - 7x7 POST FOOT - A6P00296
(4)
NOTE:
CENTER FOOT ON POST

STEP 2
BOLT HEX 1/2x11 BLK
(4 PLCS)
WASHER SPLIT 1/2 BLK
(4 PLCS)
BOLT HEX
1/2x11 BLK
(4) WASHER
FLAT 1/2 BLK
(8)
WASHER
SPLIT 1/2
BLK
(4)
D2 - BEAM - W4L11716
1 3/8"x5 1/4"x144" (36x134x3658)
(2)
(1) - PT1 - POST - W2A02557
8 1/16"x8 1/16"x108 1/16" (204x204x2402)
(1) - PT2 - POST - W2A02560
8 1/16"x8 1/16"x108 1/16" (204x204x2402)
D2
D2
PT1
PT2
NOTE HOLE LOCATION
FOR PROPER
ORIENTATION
BOTH POSTS
***HAND TIGHTEN ONLY AT THIS TIME***
WASHER FLAT 1/2 BLK
(8 PLCS)
NUT LOCK
1/2 BLK
(4)

STEP 3
BOLT HEX
1/2x11 BLK
(4) WASHER
FLAT 1/2 BLK
(8)
WASHER
SPLIT 1/2
BLK
(4)
D2 - BEAM - W4L11716
1 3/8"x5 1/4"x144" (36x134x3658)
(2)
(1) - PT1 - POST - W2A02557
8 1/16"x8 1/16"x108 1/16" (204x204x2402)
(1) - PT2 - POST - W2A02560
8 1/16"x8 1/16"x108 1/16" (204x204x2402)
BOLT HEX 1/2x11 BLK
(4 PLCS) WASHER SPLIT 1/2 BLK
(4 PLCS)
D2
D2
PT1
PT2
NOTE HOLES LOCATION
FOR PROPER
ORIENTATION
BOTH POSTS
***HAND TIGHTEN ONLY AT THIS TIME***
WASHER FLAT 1/2 BLK
(8 PLCS)
NUT LOCK
1/2 BLK
(4)

STEP 4
BOLT HEX
1/2x11 BLK
(8) WASHER
FLAT 1/2 BLK
(16)
WASHER
SPLIT 1/2
BLK
(8)
BOLT HEX 1/2x11 BLK
(8 PLCS)
WASHER SPLIT 1/2 BLK
(8 PLCS)
WASHER FLAT 1/2 BLK
(16 PLCS)
D1
D4
D4
D1
NOTE HOLE LOCATIONS
FOR PROPER
ORIENTATION
ALL POSTS
D1 - BEAM - W4L11715
1 3/8"x5 1/4"x144" (36x134x3658)
(2)
D4 - BEAM - W4L11721
1 3/8"x5 1/4"x144" (36x134x3658)
(2)
1
23456789101112131415
13
12
11
10
9
8
7
6
5
4
3
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19
20 21 22 23
2221201918171615141312111098765432
1
!
***TIGHTEN ALL HARDWARE FROM PREVIOUS STEPS AT THIS TIME***
PT1
PT2
PT1
PT2
NUT LOCK
1/2 BLK
(8)

STEP 5
WASHER
FLAT 1/2 BLK
(32)
WASHER
SPLIT 1/2
BLK
(16)
BOLT HEX
1/2x4 BLK
(16)
(8) -AB2 - ANGLE BRACE - W4L14281
1 3/8"x6 7/16"x35 3/4" (34x163x908)
BOLT HEX 1/2x4 BLK
(16 PLCS)
123456789101112131415
13
12
11
10
9
8
7
6
5
4
3
2
1
1 2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
2221201918171615141312111098765432
1
!
WASHER SPLIT 1/2 BLK
(16 PLCS)
FLUSH
NUT LOCK
1/2 BLK
(16)
LAG SCREW
WH 1/4x3
BLK
(8)
WASHER
LOCK EXT
6x15 BLK
(8)
WASHER LOCK EXT 6x15 BLK
(8 PLCS)
LAG SCREW WH 1/4x3 BLK
(8 PLCS)

STEP 6
BOLT HEX
1/2x4 BLK
(16)
WASHER
FLAT 1/2 BLK
(32)
WASHER
SPLIT 1/2
BLK
(16)
(8) -AB1 - ANGLE BRACE - W4L14282
1 3/8"x6 7/16"x40 13/16" (34x163x1036)
BOLT HEX 1/2x4 BLK
(16 PLCS)
WASHER SPLIT 1/2 BLK
(16 PLCS)
123456789101112131415
13
12
11
10
9
8
7
6
5
4
3
2
1
1 2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
2221201918171615141312111098765432
1
!
NOTE:
SQUARE POSTS AND TIGHTEN
ALL ANGLE BRACE
HARDWARE AT THIS TIME.
FLUSH
NUT LOCK
1/2 BLK
(16)
LAG SCREW
WH 1/4x3
BLK
(8)
WASHER
LOCK EXT
6x15 BLK
(8)
LAG SCREW WH 1/4x3 BLK
(8 PLCS)
WASHER LOCK EXT 6x15 BLK
(8 PLCS)

STEP 7
LAG SCREW
WH 5/16x5-1/2
BLK
(16) WASHER
LOCK EXT
8x19 BLK
(16)
WASHER LOCK EXT 8x19 BLK
(16 PLCS)
LAG SCREW WH 5/16x5-1/2 BLK
(16 PLCS)
D3
(8 PLCS)
NOTE:
ALIGN HOLES IN D3 WITH PILOT HOLES
IN D1 FOR PROPER ORIENTATION.
D1
D1
D3 - BEAM - W4L11717
1 3/8"x5 1/4"x144" (36x134x3658)
(8)

STEP 8
SCREW PFH
8x2-1/2 BLK
(200)
SCREW PFH 8X2 1/2 BLK
(200 PLCS)
P1 - PURLIN - W4L11718
1 3/8"x1 3/8"x132" (36x36x3354)
(25)
P1
(25 PLCS)
TOP RIGHT VIEW
P1
NOTE:
START WITH THE MIDDLE PERLIN & THEN WORK OUTWARD,
USING SUPPLIED PERLIN SPACER BLOCKS (H1).
5'-11 5/16"
[1811 mm]
4 3/16"
[107 mm]
TYP 24 PLCS
4 5/8"
[117 mm]
H1 - PERLIN SPACER BLOCK - W4L11735
15/16"x3 3/8"x4 3/16" (24x86x107)
(2)
H1
FRONT
RIGHT SIDE
H1

STEP 9
LAG SCREW HEX 1/2x2 BLK
(32 PLCS)
WASHER FLAT 1/2 BLK
(32 PLCS)
STEEL POST PLATE
(8 PLCS)
STEEL POST ANCHORING PLATE WITH FLANGE
(8 PLCS)
- STEEL POST PLATE - A4M00950
(8)
- STEEL POST ANCHORING PLATE WITH FLANGE -
A4M00949
(8)
WASHER
FLAT 1/2 BLK
(32)
LAG SCREW
HEX 1/2x2
BLK
(32)

STEP 10
CONCRETE
ANCHOR
1/4"x2"
(16)
GROUND STAKE 16 INCH
(8 PLCS)
WASHER FLAT 8x19 BLK
(16 PLCS)
CONCRETE ANCHOR 1/4"x2"
(16 PLCS)
- GROUND STAKE 16 INCH - A4M00951
(8)
WASHER
FLAT 8x19
BLK
(16)
NOTE:
GROUND STAKES ARE USED IF
LOCATING PERGOLA ON GRASS.
NOTE:
IF MOUNTING ON CONCRETE.
USING BASE WITH FLANGE AS
A TEMPLATE DRILL HOLES
USING A 3/16" CONCRETE BIT
FOR HARDWARE.
NOTE:
IF INSTALLING ON A DECK, YOU MUST
ENSURE THERE IS AMPLE
STRUCTUAL SUPPORT UNDER DECK.
THEN USING POST BASE AS A
TEMPLATE, DRILL 3/16" HOLES FOR
HARDWARE IN LOCATIONS
SHOWN BELOW.

STEP 11
- "A" REVISION TAG - A100314
(1) - LTP ID TAG (SMALL) WITHOUT AGES - A4M01010
(1)
SCREW PFH
8x1-1/2 BLK
(4)
LTP ID TAG (SMALL) WITHOUT AGES
(1 PLCS)
SCREW PFH 8x1-1/2 BLK
(2 PLCS)
NOTE:
CONSUMER PREFERENCE ON INSTALL.
CONSULT CONSUMER FOR LOCATION.
"A" REVISION TAG
(1 PLCS)
SCREW PFH 8x1-1/2 BLK
(2 PLCS)
FRONT VIEW
BACK VIEW