Dundalk LeisureCraft Panoramic Barrel Sauna User manual

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Dundalk LeisureCraft Panoramic 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

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Dundalk LeisureCraft Panoramic Barrel Sauna
Assembly Instructions
Index
Sauna Base Preparation (Standard) – Page 3
Sauna Barrel Assembly (Standard) – Page 4 to 12
Standard Bench Installation (Standard) – Page 13 to 17
Signature Bench Installation (Option) – Page 18 to 25
Lounge Bench Installation (Option) – Page 26 to 29
Electric Heater Installation (Option) – Page 30 to 32
Harvia Wood Heater Installation (Option) – Page 33 to 39
Sauna Vent Kit (Option) – Page 40,41
Sauna Light (Option) – Page 42,43
Cove Assembly (Option) – Page 44,45
Completion/Maintenance/Warranty – Page 46 to 49

Sauna Base Preperation
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Dundalk LeisureCraft
Panoramic 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 76”x6' (193x182) 76'x7' (193x214) 76'x8' (193x244) 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”

Panoramic Barrel Sauna Assembly (Standard)
Mark the centre of the cradles horizontally. Fig. 2a
*Please note that the number of Barrel Cradles supplied depends on the overall length of the sauna.
*Saunas with overall lengths greater than 10’ (305cm) have 3 cradles while saunas less than 10’ (305cm) have 2.
Make sure the placement for your sauna is level with a
slight slope to the back for drainage.
Start by laying 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
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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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 won’t go all the way
through the material and come out the other side.
Measure 5” (13cm) from each end of the stave to the
cradles, as shown. Fig. 2b

Using 2 people, gently place the acrylic dome into the
groove at the back of the sauna.
Panoramic Barrel Sauna Assembly (Standard)
5
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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Attach the stave supports using 2 ½” (64mm) screws
making sure they are flush with the curve of the cradle.
*These supports are temporary to assist in the
installation of the acrylic dome and will be removed
later in the assembly process .
Start laying down the wall staves. Keep the dado grooves
in line with the correctly positioned bottom stave.
Make sure there are no gaps between the edges of the
staves, and that the groove line for the dome is lined up
perfect.
Place the door section into the dado groove in the staves.
Make sure the door is centered with the middle stave.

Use the top special stave to go from the front wall to the
dome to help stabilize the sauna.
*The top special stave has 2 concaved edges
(inset 2.)
Panoramic Barrel Sauna Assembly (Standard)
6
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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Inset. 2
Using your carpenters level and rubber mallet, level up
the front wall.
Install the front side wall panels.
Screw each side panel into place at the top and bottom
with 2 ½” (64mm) screws.
Start adding staves from the bottom up gently tapping
them with the rubber mallet to finesse them into place.

Panoramic Barrel Sauna Assembly (Standard)
7
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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Secure every 2nd stave on the bottom of the sauna with
the provided nails. (if required)
Continue installing the staves from the bottom up
installing a few staves at a time, alternating sides.
When installing 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.
When you reach the top, you will find that the last wall
stave doesn't look like it fits properly, this is normal.

Panoramic Barrel Sauna Assembly (Standard)
8
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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Assemble the steel bands by sliding the rod with a nut
on one end through the other end 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 ensuring
the band is 3” (8cm) from the end of the stave so it is in
the same location as the dome groove.
Slide the front wall band around the sauna using the
nails as a guide to where the front wall is.
Measure all around the sauna to ensure the
measurement of the band is consistent with the front
wall location.
*If a porch and/or changeroom option is chosen, a
band should be positioned over top of each of those
walls also.

Panoramic Barrel Sauna Assembly (Standard)
9
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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The final band should be centered between the sauna
walls.
Snug up all bands with a cordless drill or ¾” (19mm)
wrench.
Use the rubber mallet to tap the staves 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.
Once this is achieved and the “peak” at the top is gone,
you can start adjusting the band.
Tighten all bands as tight as possible.
* Don’t be worried about making them too tight,
you cannot overtighten!
Remove the plywood wall supports from the back of the
sauna.
Carefully remove the protective plastic from the acrylic
dome.

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.
10

Reinstall the now narrower Top Stave following the
sauna assembly instructions.
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
11
¾”
(2cm)

Panoramic Barrel Sauna Assembly (Standard)
12
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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Install towel hanger at desired height on outer wall using
1 1/2” (38mm) screws.
* The main structure of your Panoramic 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
Harvia M3 Wood Burning
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.

Standard Bench Installation (Standard)
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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.
13
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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

Standard Bench Installation (Standard)
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Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
Install the Dome bench bracket ½” (13mm)from the
dome groove in the staves making sure the top of the
bench bracket is level.
If the sauna floor is purchased, the Front of the dome
bench bracket should sit tight to the side of the flat
floor.
Using the pre drilled holes in the bracket, screw the
dome bench bracket to the sauna on the top and
bottom with 2” (51mm) screws.
Repeat on opposite side of sauna.
You can use a level to ensure both brackets are at same
height.
* For Electric Heater option skip to next step!
If you purchased a Harvia M3 wood heater or full
length benches on both sides with your Panoramic
Barrel Sauna install the bench brackets on the front
wall on either side in the same manner as the dome
bench brackets.

If you purchased an electric heater with your
Panoramic Barrel Sauna Install the bench bracket on
the front wall opposite the side of where the electric
heater will be mounted.
To install the short bench bracket, first measure the
short sauna bench and then measure the same
distance from the outside of the dome bench bracket
to position the front bracket.
Standard Bench Installation (Standard)
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Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
Place the curved dome bench on the dome
bench brackets.
Do not Fasten yet!
Place the side benches on the side bench brackets.
Do not Fasten yet!

Match up the dome bench with the 2 side benches and
screw from the bottom of the dome bench brackets
into the dome bench using 2 ½” (64mm) screws.
* The Bench should not be rubbing on the
Panoramic dome at all.
Screw the side benches down from the top into the
support braces.
Ensure to screw in between the bench seat slats so
that the screws are not visible.
Standard Bench Installation (Standard)
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Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
Do this at the front and back braces.
Repeat on other side bench
Install 2 of the remaining 4 smaller bench supports
under the side bench.
Place them under the horizontal bench support slats
and screw the front leg in to the floor with a 2 ½”
(64mm) screw.
Fasten the top bench down by screwing between the
bench seat slats using 1 ½” (38mm) screws to make the
screws less visible.
Repeat for opposite side bench.

Standard Bench Installation (Standard)
17
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Panoramic Barrel Sauna Assembly Instructions
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To install the standard porch seats, screw the legs
into the end of the seats with 2 ½ ” (64mm) screws.
Attach brace from the seat to the leg with a 2 ½ ”
(64mm) screw.
Use a level or carpenters square to make to make sure the porch seat is level.
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)
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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.
18
Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
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

Signature Bench Installation (Option)
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Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
(Electric Heater Models)
Position the short bench enclosure ½” (13mm) from the
dome groove on the edge of the floor at the dome end,
Do not Fasten!
* For the Harvia M3 Heater option, or full length
benches on both sides, skip this step!
With the short bench enclosure square to the floor,
use it as a guide to install the angled bench supports
to the barrel wall using 2 ½” (64mm) screws.
* Do not fasten the front enclosure yet.
Repeat at other end of bench. With the long bench enclosure square to the floor,
use it as a guide to install the angled bench supports
to the front barrel wall using a 2 ½” (64mm) screw.
The top of the flat end of the bench support and the
top of the front enclosure should be flush.

Signature Bench Installation (Option)
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Dundalk LeisureCraft
Panoramic Barrel Sauna Assembly Instructions
Screw bench brackets into end walls as well using 3- 2 ½”
(64mm) screws in each bracket.
* Do not fasten the front enclosure yet.
If you purchased a Harvia M3 wood heater or full length
benches on both sides with your Panoramic Barrel Sauna
perform this step for both side benches of your sauna.
Remove the front enclosures and gently place the
bench seats on the 2 x 4 (51mm x 104mm)
brackets. Ensure that seats are all the way back
against the side of the barrel.
Using 2 ½” (64mm) screws, Install the small support
brackets ensuring they are flush with the bottom of the
bench seats.
With a 2 ½” (64mm) screw, fasten the bottom of the
support into the floor.
Make sure seats stay back against the side of barrel.
Screw up through brackets into the bench seat
using 1 ½” (38mm) screws.
(3 screws per bracket)