Dundalk LeisureCraft Cedar User manual

ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft Cedar Barrel Sauna
Assembly Instructions
Please read and understand the complete instructions prior to assembly and use of your sauna. Customer agrees not to hold
Dundalk LeisureCraft Inc. and any of its authorized dealers liable for improper installation, maintenance and repair of this product
Requirements:
2 People (recommended)
* Carpenter’s Hammer
* Step Ladder
* Cordless Drill (we supply the bit)
* Tape Measure
Carpenter’s Level
* Rubber Mallet
View the assembly process on
Ver. 2.8

ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Index
Sauna Base Preparation (Standard) – Page 3
Sauna Barrel Assembly (Standard) – Page 4 to 14
Standard Bench Installation (Standard) – Page 15 to 18
Signature Bench Installation (Option) – Page 19 to 24
Lounge Bench Installation (Option) – Page 25 to 28
Electric Heater Installation (Option) – Page 29 to 31
Wood Heater Installation (Option) – Page 32 to 33
Harvia Wood Heater Installation (Option) – Page 34 to 37
Sauna Vent Kit (Option) – Page 38 to 39
Sauna Light (Option) – Page 40 to 41
Cove Assembly (Option) – Page 42 to 43
Completion/Maintenance/Warranty – Page 44 to 46

Sauna Base Preperation
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Concrete Pad
Sauna Base Preparation
A solid base for your sauna is recommended and can be made from any of the following.
Wooden Deck
Crushed Gravel Patio Stones/Paver Blocks
(Refer to the below chart for minimum base requirements)
It is recommended to build a base larger than required to provide
a sitting area for cooling off during your sauna session.
3
Sauna Size 6'x6' (182x182) 6'x7' (182x214) 6'x8' (182x244) 7'x6' (214x182) 7'x7' (214x214) 7'x8' (214x244)
Minimum Base
Size
48"x60"
(120x150cm)
48"x72"
(120x183cm)
48"x84"
(120x213cm)
60"x60"
(150x150cm)
60"x72"
(150x183cm)
60"x84"
(150x213cm)
Options
Porch Add 24" (60cm) to total length.
Changeroom Add 48" (120cm) to total length.
* All measurements in above chart are “width x lengths”

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
*Please note that the number of Barrel Cradles
supplied depends on the overall length of the sauna.
*Saunas with an overall length of 10’ (305cm) or
greater have 3 cradles while saunas that are less than
10’ (305cm) have 2.
*Please Refer to the diagram on the right for the
correct configuration of your sauna and options.
(if any)
Make sure the placement for your sauna is level with a
slight slope to the back for drainage.
Start by layin out the cradles.
Lay the first bottom stave in the center of the
cradles.
This stave will have convex edges on
both sides as in inset.1.
Inset. 1
Fig 2a
Fig 2b
4
Mark the centre of the cradles horizontally. Fig. 2a
Measure 5” (13cm) from each end of the stave to the
cradles, as shown. Fig. 2b

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Secure stave into cradle using 2 ½” (64mm) screws.
Repeat for remaining cradles.
*Always ensure that you have the correct screw length so
that there will be enough thread to hold, and especially, so
that the screw does not go all the way through the
material and come out the other side.
Place the back wall into the dado grooves closest to
back of sauna.
Make sure the back wall panel is centered with the
middle stave.
*The back Wall will not have the square cut out if ordered
with the electric heater option.
Start laying down the wall staves. Keep the
dado grooves in line with the correctly positioned
bottom stave.
Make sure the staves are flush.
5

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Use rubber mallet to tap wall into back groove.
Using your carpenters level and rubber mallet,
level up the front and back walls.
Repeat this process to install the door panel on the
front wall.
Make sure the door is centered with the middle stave.
Use the top stave to go from the front
wall to back wall to help stabilize the sauna.
* The top stave has 2 concaved edges as in inset 2.
Inset. 2
6

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Install the front half moon side wall panels.
Screw into place at the top and bottom with
2 ½” (64mm) screws.
Use the rubber mallet to finesse them into place.
Repeat for back wall.
* Note that the bench brackets face inside of sauna.
Once both ends are on, start installing the wall
staves.
7

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Install a few staves at a time, alternating sides.
Continue to add staves on both sides to the top.
Secure every 2nd stave on the bottom of the sauna with
the provided 2 ½” (64mm) nails to hold staves in place.
( If required)
When installing the staves, tap tightly together
while leaving as much of a gap as possible
between stave and wall using the pencil line as a guide
as in picture.
* This will make the tightening of the bands easier.
8

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
When you reach the top, you will find that the last wall
stave doesn't look like it fits properly, this is normal.
For the middle bands, toss one end over the sauna
while pushing the other underneath.
*If a porch and/or changeroom option is chosen, the bands
should be positioned over top of where the walls are.
Assemble the steel bands by sliding the rod with a nut
on one end through the other and secure with a second
nut.
Slide the band over the front of the sauna about
2” (5cm) from the edge of the stave.
Repeat the process for the back of the sauna.
9

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Measure all around the sauna to ensure the
measurement of the bands are consistent.
Secure band in same manner as previous step.
Snug up bands with the cordless drill.
Make sure ends of sauna are flush.
Use the rubber mallet to tap the staves out & in as
needed to get the last wall stave and top stave to sit
properly together.
Tap up (from the inside of the sauna so you don’t break
the ends) or down, by hammering on the band to attain
a uniform circle shape.
When the wall staves take on the proper
shape, tighten the steel bands a little more snug.
Continue to use the rubber mallet to finesse the staves
into place until they look just about perfect.
10

Adding Spacer to Top Stave
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Adding a Spacer
to the
Top Sauna Stave
Locate the Top Stave with the 2
concave sides and remove all the
screws out of the stave.
Insert square spacer in between
the two stave halves.
Screw all pieces back together with
3” (76mm) screws
Reinstall the now wider Top Stave following the
sauna assembly instructions.
In your sauna package you will find a spacer stave that is square on both sides that is only required If there
happens to be a “gap” after installing all of the staves, (as in Fig.1)
You will need to follow the following instructions to add this spacer to the top special stave.
11
Fig.1
Tips to follow when adding the spacer to the top stave
Do not assemble the sauna when the wood is wet, allow it time to dry out after being exposed to moisture.
Loosen the bands so you have enough room to maneuver the staves underneath them.
If you run out of threads on the bolts and the bands are not tight enough,, that’s usually an indication that you
need to add a spacer to the top stave.

Making Top Stave narrower
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
In rare instances, your sauna staves will be too tight not allowing the staves to settle into position correctly.
(as in picture)
This doesn’t happen often and the sauna staves and bands are always better being as tight as possible.
You will need to follow the following instructions to make the top special stave narrower.
Making the Top Sauna Stave
narrower
Locate the top special stave and remove all
the screws.
Measure from flat edge 3/4 “ (2cm) on each stave and
safely cut to make staves thinner.
¾”
(2cm)
A circular saw or table saw is best for cutting the staves.
Follow all of your saws safety precautions when cutting staves.
Screw the 2 pieces back together with
2” (64mm) screws
Reinstall the now narrower Top Stave following the
sauna assembly instructions.
12
¾”
(2cm)

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
The front and back bands should be 2” (5cm) from the
end of the staves.
* Space out middle bands according to sauna size and how
many bands are included.
Tighten all bands as tight as possible.
* Don’t be worried about making them too tight,
you cannot overtighten!
Center outer the door handle (small) on outside of the
door and secure with 2” (51mm) screws using the
pre-drilled holes.
*Magnets are very strong and may require some force to
pull the door open the first time.
Repeat this process for the inside handle installing it at
desired height centered horizontally on door.
* If the Changeroom option is ordered, install the inside
and outside handles in the same manner.
13

Sauna Barrel Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
Install towel hanger at desired height on outer wall
using 1 ½” (38mm) screws.
If ordered, Install the thermometer centered above the
door using a 1 ½“ (38mm) screw.
•The main structure of your Cedar Barrel Sauna is complete.
•Please refer to each of the remaining sections to install the various upgrades and options chosen.
Benches
*Standard
*Signature
*Lounge
Heater
Saaku Electric
Standard Wood Burning Stove
Harvia M3 Wood Burning Stove
14

Standard Bench Installation (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
The flat floor (If Purchased) Is shipped semi assembled.
You will need to add the bottom support onto the floor before assembling the benches.
Flip over flat floor, measure the center and place the
bottom support in the center.
15
Locate the flat floor (A) and bottom support (B).
Secure the bottom support to the bottom of the flat
floor using 2 ½” (6mm) screws in the pre drilled holes.
Flip the flat floor back over and it is ready to be
installed inside the sauna.
Start the assembly of your standard benches by
installing the flat floor.
(If Purchased)
Ensure the flat floor is centered in sauna and that it
is level, you can use the door frame to confirm it is
level.
A
B
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions

To begin, Bring in the long sauna benches.
Place the long benches down on the wall brackets and
then snug up against the back wall.
Standard Bench Installation (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
16
Secure benches to wall supports by attaching with
1 ½” (38mm) screws.
Ensure to screw in between the bench seat slats so that
the screws are not visible.
Space out the bench supports under the crossers on
the bottom of the benches.

Standard Bench Installation (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
17
Secure the support leg to the floor using a
2 ½” (64mm) screw in each support.
Repeat above steps for opposite bench.
Screw the bench supports from the bottom up using
3- 1 ½” (38mm) screws in each support.
To install the standard porch seats, screw the legs into
the end of the seats with 2 ½ ” (64mm) screws.
Attach the angled brace from the seat to the leg with
2 ½ ” (64mm) screws.
Use a level or carpenters square to make to make sure
the porch seat is level.

Standard Bench Installation (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
18
Secure the porch seat to the front wall from
underneath using (3) - 2 ½” (64mm) screws.
Screw the front of the porch seat into the wall from the
outside using a 2 ½” (64mm) screw.
Repeat for standard porch bench on other side.
Secure the leg to the floor using a 2 ½” (64mm) screw.
Repeat on other porch bench ensuring they are level
with each other.

Signature Bench Installation (Option)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
The flat floor (If Purchased) Is shipped semi assembled.
You will need to add the bottom support onto the floor before assembling the benches.
Flip over flat floor, measure the center and place the
bottom support in the center.
19
Locate the flat floor (A) and bottom support (B).
Secure the bottom support to the bottom of the flat
floor using 2 ½” (6mm) screws in the pre drilled holes.
Flip the flat floor back over and it is ready to be
installed inside the sauna.
Start the assembly of your standard benches by
installing the flat floor.
(If Purchased)
Ensure the flat floor is centered in sauna and that it
is level, you can use the door frame to confirm it is
level.
A
B
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions

Signature Bench Installation (Option)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Position the front wall
enclosure at the edge of
the flat floor to determine
the seat bracket height.
* Do not Fasten yet!
Using the front enclosure as a guide, Install the
wall brackets with 3 pcs 2 ½” (64mm) screws,
again making sure they are level with the sauna
walls or door and flush with the top of the front
enclosure.
Dundalk LeisureCraft
Cedar Barrel Sauna Assembly Instructions
20
Repeat for all 4 sides.
(2 on the front wall and 2 on the back wall)
* Remove the front wall enclosures from the sauna.
Bring both sauna bench seats in and place on sauna
wall brackets
* Do not fasten yet.