Dundalk LeisureCraft CTC22LU User manual

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Dundalk LeisureCraft Luna 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:
View the assembly process on
* 2 People (recommended)
* Step or Extension Ladder
* Cordless Drill (we supply the bit)
* Tape Measure
* Staple Gun
* Utility Knife
* Hacksaw
* 3/16” Drill bit
* 1 ½” or less staples or nails to fasten bevel siding
Ver. 2.7

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Index
Sauna Base Preparation (Standard) – Page 3
Luna Sauna Assembly (Standard) – Page 4 to 19
Standard Bench Installation (Standard) – Page 20 to 24
Lounge Bench Installation (Option) – Page 25 & 26
Electric Heater Installation (Option) – Page 27 to 29
Wood Heater Installation (Option) – Page 30 & 31
Harvia Wood Heater Installation (Option) – Page 32 to 36
Sauna Vent Kit (Option) – Page 37 to 39
Sauna Light (Option) – Page 40 & 41
Completion/Maintenance/Warranty – Page 42 to 44
Dundalk LeisureCraft Luna Sauna
Assembly Instructions

Sauna Base Preperation
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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
* All measurements in above chart are “width x lengths”
Sauna Size 8'x6' (244x182) 8'x7' (244x214) 8'x8' (244x244)
Minimum Base Size 96"x72" 96"x84" 96"x96"
(244x182cm) (244x214cm) (244x244cm)
Options
Porch Add 24" (60cm) to total length.
Changeroom Add 48" (120cm) to total length.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Make sure you have a solid base for your Luna sauna
and lay out the cradle pieces.
Gather up your pieces for the back wall.
This should consist of 15 straight pcs and 4 pcs with
rounded corners of 2x6x80”(5cm x 15cm x 203cm)
* 2 of each with rounded corners will have dado
grooves on the opposite side of the curves, 2 will be
for the right side and 2 for left side of back wall.
.
4
Lay out the pieces as shown, including the rounded
corner pieces.
To make the next steps easier, line up the back wall
staves as best you can.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Make sure staves are tight together.
5
Place a washer and nut on each end of the threaded rod
for each hole.
Tighten up all the nuts with a wrench, socket or impact
driver.
Slide one of the threaded rods through the top holes.
Repeat for the bottom holes.
* This will take some finessing
* If the Dundalk wood stove is chosen there will be an
extra threaded rod in the middle of the back wall.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Using the assembled back wall as a guide, start the
assembly of the front wall with one of the side rounded
staves.
.
6
Slide one of the threaded rods through the top hole and
add 5 short staves onto the threaded rod.
Repeat process for the bottom set of holes.
Carefully insert the first window in between the short
staves. The groove of the window should sit over the
edge of the blocks.
Cut off any excess threaded rod with a hacksaw.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Thread one small stave on each threaded rod.
.
7
Carefully insert the door between the 2 small staves.
Add 4 more small staves on each threaded rod to
support the door.
Next, Thread on a full size stave.
Again this stave should sit inside the groove of the
window.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Finish the front wall by adding the corner stave.
8
Tighten the nuts again in the same manner as the back
wall. Cut off excess with a hacksaw.
* Tapping the staves gently with a rubber mallet can
help get them to settle tight to each other.
Carefully remove both front and back walls and place
where they will not get damaged or fall over.
Thread on a full size stave, then 5 short staves then the
other window in the same manner as the opposite side.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Start laying out the bottom staves, there will be 7 staves
on either side of the center stave.
* The staves for the Luna without the porch option are
symmetrical and can be used on the left or right side of
the center stave.
•If the porch option is chosen,
•there will be right and left sides, make sure all dado
grooves line up with each other.
Luna Sauna Assembly (Standard)
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Measure out the center stave so it is centered on the
first cradle. The cradle should be approx. 7” back from
the end of the stave.
.
9
Using 2 ½” (64mm) screws , secure the center stave to
the cradle.
Repeat at other end.
Space out the remaining cradles evenly, measure them
to center and secure center stave to cradles using a 2 ½”
(64mm) screw per cradle.
Lay out the center stave as shown.
* This stave will have convex edges on
both sides as in inset.1.
Inset. 1
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Use a rubber mallet to tap all the staves tight together.
* Secure staves into each cradle using 2 ½ (64mm)
screws.
.
10
After laying out the bottom staves, line them up so the
ends are flush.
* All the grooves should be in line with each other.
Insert the back wall in to the groove on the sauna floor.
* You may need to use a rubber mallet to “finesse” the
wall into the groove.
.
Make sure both sides are sticking out past sauna floor
equally to ensure wall is centered.
.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Once both walls are centered in the grooves, use staves
to temporarily brace the walls to prevent them from
falling.
* Use a stave on either side of the sauna and a few on
top to ensure the sauna is stable.
.
11
Repeat process for the front wall.
Start adding the 2”x 4” staves to both sides.
Use the Rubber mallet to tap them tight to each other.
.
Secure staves to the top and bottom corners of the
sauna wall with 3 ½” (89mm) screws.
* The staves on the corners use 3 ½” (89mm) screws
while the staves on the flat wall use 2 ½” (64mm)
screws.
.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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You will use 6 of the smaller staves to make each of the
4 corners.
.
12
Continue to add the 2” x 4” staves on both sides in the
same process, tapping tight to each other then securing
with screws.
Once you have the 6 corner 2” x 4” pieces in place to
make the corner, start adding the larger 2” x 6” staves
to build up each wall.
.
Install 11 of the full size 2” x 6” staves on each side wall
and then build the top corners with 6 of 2” x 4” corner
staves in the same manner as the bottom corners.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
* Do not fasten the top staves with screws yet!
.
13
Once the top corners are assembled, start installing the
2” x 6” staves again from each side.
Continue the assembly by adding the roof staves using
only the rubber mallet at this time.
.
When you reach the center, you may find that the last
roof stave doesn't fit properly, use the rubber mallet to
finesse it into place.
Once all staves are installed, secure each stave with
2 ½” (64mm) screws into the walls.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Adding Spacer to Top Stave
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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 picture)
You will need to follow the following instructions to add this spacer to the top special stave.
14

Making Top Stave narrower
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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.
15
¾”
(2cm)

Luna Sauna Assembly (Standard)
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Put a screw in each stave to hold the staves tight to
each other.
.
16
The following 2 steps are only required if the porch
option was chosen, and only on the front of the sauna.
Using 2 ½” (64mm) screws to secure the front staves
together.
* Pre drill these holes with the 3/16” drill bit to
prevent the staves from splitting.
With 2 people, place the roofing membrane over the
sauna. Try to make sure the membrane is even on both
sides of the sauna.
.
Pull the rubber membrane over the front off the sauna
staves and secure with staples.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Cut the excess rubber off the back of the sauna and
then secure both the front and back of the membrane
with more staples.
.
17
After securing the front of the membrane to the sauna,
pull the rubber tight to the back and secure with
staples.
To install the sauna trim, start with the longest piece on
the front bottom. Center this piece so the same
distance is left on either side.
.
Center out the corner trim pieces and secure at either
end with 2” (51mm) screws.
•Pre drill these holes to prevent splitting the trim pieces.
Repeat on other corner
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
ph: 519-923-9813 | [e-mail]| web: www.dundalkleisurecraft.com
Continue to line up the trim pieces all the way around
the front of the sauna and secure with 2” (51mm)
screws.
Repeat for the back of sauna.
.
18
After both corner pieces are secured, make sure the
long front piece is level and then secure in the same
manner.
To install the siding, start at the bottom with the top of
the siding flush with the bottom wall stave.
* You can use staples or nails to secure the siding but
nothing longer than 1 ½” (38mm).
.
Continue to attach siding to the sauna maintaining a 4”
(102mm) space between the siding.
Use the included spacer block to help with this.
* Secure each shingle along the bottom edge so that it
catches the top of the shingle underneath it.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Luna Sauna Assembly (Standard)
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Secure the next piece over top the membrane like
shown.
.
19
When you get to the rubber membrane, secure the
bevel siding under the membrane.
Continue to add the bevel siding till you reach the top.
.
Using a utility knife, cut off any excess roofing
membrane.
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions

Standard Bench Installation (Standard)
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The Dundalk Leisurecraft Luna Sauna is available with the choice of 3 different bench layouts.
Two-tiered L shaped Bench
(L bench available on right or left side)
Side Wall Benches
* Lounge bench upgrade only available on Side wall layout.
Back Wall two-tiered Bench
20
Dundalk LeisureCraft
Luna Sauna
Assembly Instructions