OLT Garden Chalet 4x2 User manual

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Thank you for purchasing a 4x2
Garden Chalet. Please take the time
to identify all the parts prior to
assembly.
Please use Safety Eyewear and Gloves
while Assembling. Be sure to read and
follow all operating instructions for any
tools used during assembly.
Remember- NO SAW CUTTING IS
REQUIRED!
Safety Points and Other Considerations
Our products are built for use based on
proper installation and normal residential
use, on level ground.
Please follow the instruction manual when
building your Grand Garden Chalet and
retain the manual for future maintenance
purposes.
Some of the safety and usage measures
you may wish to consider include:
-If the product is elevated, any structural
and building code requirements are solely
the customer's responsibility, and should
be abided by.
-In high or gusty wind conditions it is
advisable to keep the structure securely
grounded.
-Have a regular maintenance plan to ensure
screws, doors, roof and parts are tight.
Garden Chalet 4X2
Assembly Manual
Page 1
Revision #9
Oct 21th, 2012
In the event of a missing or broken piece, simply call the Outdoor Living Today
Customer Support Line @ 1-888-658-1658 within 30 days of the delivery of your
purchase. It is our commitment to you to courier replacement parts, free of charge,
within 10 business days of this notification. Replacement parts will not be
provided free of charge after the 30 day grace period.
4x2 Garden Chalet Dimensions:
A: Outside Height (Rear) =73 3/4"
B: Outside Height (Front) = 67 3/4"
C: Outside Width =48"
D: Outside Depth =23 1/4"
E: Door Width = 40"
F: Door Height = 61 1/4"
G: Inside Height (Rear) =67"
H: Inside Height (Front) =61"
I: Inside Width =44"
J: Inside Depth =20"

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AB
L
D
Z
Q
Y
N
M
T
H
G
BB
O
E
Exploded View and Parts List for 4’x2’ Garden Chalet
F
CIJK
U
V
W
R
DD
AA
P
S
Trim Section
H 2 - Front Corner Door Trims - 1/2” x 2 1/2” x 65 1/2”
L 2 - Upper Rear Horizontal Trim - 1/2” x 2 1/2” x 20 5/8”
M 2 - Side Skirting - 1/2” x 3 1/2” x 21”
N 1 - Rear Skirting - 1/2” x 3 1/2” x 45”
O 4 - Filler Trim - 1/2” x 1 1/2” x 33”
P 2 - Side / Front Corner Trim - 1/2” x 1 1/2” x 62”
Q 2 - Side / Rear Corner Trim - 1/2” x 2 1/4” x 66 3/4”
R 2 - Rear Corner Trim - 1/2” x 1 1/2” x 67”
S 1 - Center Rear Trim - 1/2” x 1 1/2” x 67”
T 1 - Front Door Header Trim - 1/2” x 1” x 41”
Shelf Section
Y 1 - Vertical Shelf Support - 1 1/2” x 1 1/2” x 35”
Z 4 - Shelf Support s - 3/4” x 1 1/2” x 17 3/4”
AA 2 - Shelves - 17 1/2” x 18 7/8”
BB 1 - Interior Door S top - 3/4” x 1 1/2” x 8”
CC 2 - Black Door Handles
DD 1 - Black Barrel Bolt
Miscellaneous (Not Shown on Illustration above)
1 Barrel Bolt Plywood S pacer - 1/2” x 2 1/2 x 2 1/2”
1 Interior Silver Barrel Bolt
X
Floor Section
A 1 - Floor Section - 20 1/2” x 45” x 2 1/2”
B 4 - Floor Legs - 1 1/2” x 3 1/2” x 4”
Wall Section
C 2 - Side W alls - 18 1/2” x 62 1/2”
D 2 - Rear W alls - 22” x 67”
E 1 - Door Header - 1 1/2” x 2 1/2” x 41” - Dado Cut
G 2 - Angle Cut Gable Siding Pieces (lef t / right) - 1/2” x 18 1/2”
I 4 - Black “T” Hinges
J 2 - Door Panels - 20 1/4 x 61 3/8”
K 1 - Door Flange - 1/2” x 2 1/2” x 61 3/8”
Roof Section
F 1 - Shingled Roof Panel - 24”d x 46”w
U, 5 - 16” long x 5” wide Shingles (includes 1 extra)
V 3 - 16” long x 6” wide Shingles (includes 1 extra)
W 2 - 8 1/2” long x 6” wide Last Row Shingles
X 1 - Roof Ridge Cap - 1/2” x 2 1/2” x 47”
Parts List
Note: We recommend you drill a 1/8” pilot hole for each screw , to avoid splitting wood. The hole depth should be
equal to 3/4 the length of screw.
Note: All Trim and Skirting pieces are graded best face rough.
This means the rough side will be exposed when completing these Sections.
CC

4x2 GARDEN CHALET HARDWARE PACKAGE
2 1/2”
Note: screws and nails shown actual size.
1 1/4”
3/4”
2”
3/4”
1 1/4”
7/8”
(I) Tee Hinge x4 (CC) Door Handle X 2
Black
Silver
Black
Finishing
Shingle
Square Drive Bit
Hardware Kit (Provided)
Safety Glasses Work Gloves
Safety Equipment Required (Not Provided)
Ladder
Screw Gun/Drill Tape Measure
Hammer Wood Clamp
Level Pliers
Tools Required (Not Provided)
Silver Barrel Bolt
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(DD) Barrel Bolt
1”
Utility Knife
Page 3
1/8” & 3/8” Drill Bits
1 1/2”
Bolt with Black Head, Silver Nut and W asher

1. Flip Floor (A) over on a level surface. Locate Legs (B) and position in each corner tight to floor and
framing and attach with 2- 2 1/2” screws. Complete all Leg att achments. Flip Floor over and complete Leg
attachments by screwing 1 - 2 1/2” screws through Floor Boards into each Leg. Level Floor before
proceeding to Step 2. You can find the Square Drive Bit for the screws in with the Hardware Kit Bag.
Front
2. Locate Side Walls (C) and Rear Walls (D). Make sure
walls are in correct orientation (Siding cut flush with Wall
Framing at bottom). Position Side Wall on Floor so it sit s
flush with front and side. Have helper hold Side W all while
Rear Wall is positioned on Floor. Screw Side Wall down
to floor with 2 - 2 1/2” screws when aligned correctly .
Optional - Caulking wall seams will help prevent moisture
from entering at seam. Caulking not Included in Kit.
Front
Rear
Side Wall (C)
Side Wall Flush with Floor
Frame at Front and Side
At Rear, a gap
will exist.
Caulking
Optional - Caulking
seams will help prevent
moisture from entering
at seam. Caulking not
included in kit.
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You can find the
Square Drive Bit for
the screws in with
the Hardware Kit
Bag.
2 1/2” Screws

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Page 5
4. With Side and Rear Wall correctly positioned, attach together at top, middle and bottom of
vertical wall frames with 3 - 2 1/2” screws. Screw Rear W all down to floor with 2 - 2 1/2” screws
when aligned correctly.
5. Position 2nd Rear Wall Panel on Floor as per Step 3 & 4. Attach wall frames together at top,
middle and bottom with 3 - 2 1/2” screws. Screw 2nd Rear W all down to floor with 2 - 2 1/2” screws
when aligned correctly.
Side Wall
Rear Wall
3. Align Rear Wall flush to
floor at the back and wall
framing of Side and Rear
Walls together.
Rear Wall
Siding Flush
with Floor at
back.
Wall Framing
aligned together.
approx. 1/2” gap
Rear Wall
Wall Frames
aligned
Rear Wall
approx. 1/2” gap
2 1/2” Screws

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6. Position right Side Wall Panel on Floor as per Step 2-4.
7. With Side Wall Panel correctly aligned, attach Rear and Side Wall together at top, middle and
bottom of vertical wall frames with 3 - 2 1/2” screws.
8. Screw right Side Wall Panel to floor with 2 - 2 1/2” screws when wall correctly aligned to floor .
Optional - Caulking
seams will help prevent
moisture from entering
at seam. Caulking not
included in kit.
Caulking

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9. Locate Door Header (E) and place between Side Wall framing with dado cut facing down and to
the front.
Door
Header (E)
Dado cut to
front, facing
down.
Aligned flush at
front and top
10. Prior to
attaching Door
Header, drill 2
pilot holes with
1/8” drill bit
through Side Walls
and into the end of
Header. Have
your helper hold
Header and Wall
steady. Secure
with 2 - 2 1/2”
screws per side.
You will want Front Corner Trim (P) to cover
screws in Step 24. Use Trim to confirm screw
location.
11. Lay Roof Panel (F) on flat level ground. Note, overhanging Out side Shingles have been removed to
avoid shipping damage and will need to be inst alled now. Locate U ,V & W Shingles. There are 4 -
5” wide x 16” long UShingles, 2 - 6” wide x 16” long VShingles and 2 - 6” wide x 8.5” long WShingles.
Align Roof Panel so thick end of
Shingle (butt end) is facing front.
Extra Shingles are included.
U
V
U
W
UV
U
W

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12. Position and attach U Shingle (5” wide) on Roof Panel with 3 - 7/8” Shingle Nails. See
above for details.
U
Align U Shingle tight
against Roof Shingle.
U
V
Secure with 3 - 7/8”
Shingle Nails
Flush with other
Roof Shingles.
21. Place and attach V Shingle (6” wide) directly on top of Shingle U. Shingle V will slide under 2nd row
Shingle. Secure with 3 - 7/8” Shingle nails at least 9” from Butt. Place and att ach a second U Shingle (5”
wide) in line with 2nd row of shingles. Secure with 3 - 7/8” Shingle nails at least 9” from Butt.
Thick End
5” wide
6” wide
V
Thick End
U
5” wide
Secure with 3 - 7/8”
Shingle Nails
2nd Row Shingle
W
6” wide
24. To finish side, place and att ach W Shingle (6” wide x 8.5” long) in line with 3rd and final row of
shingles. Shingle W will partially cover Shingle U. Secure with 2 - 7/8” Shingle nails 2”- 3” from top.
(Nails will be covered by Ridge Cap - X). Complete att achment of Shingles on opposite Roof Panel Side
following Steps ???.

11. Place Shingle Roof Panel (F) on Wall Framing and Door Header. At the front, recess the
Plywood sheathing of the Roof slightly back 1/8”.
Shingled Roof Panel (F)
11. Align plywood sheathing of the Roof evenly from side to side as illustrated above.
Recessed
1/8” back
from Header.
Header
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11. From inside, secure Roof to Wall Framing and Door Header with 7- 2 1/2” screws. Screw on
angle to make sure screws don’t penetrate completely through shingle roof p anel.
Angle 2 1/2” screws from
Header and Wall Framing into
Plywood Roof Sheathing.

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12. Locate both Angle Cut Gable Siding Pieces - Left/Right Pieces (G) . Starting with the left
side, place above Side Wall so lap sidings fit together.
Left Side Angle Cut Gable Siding (G)
Roof and Angle Cut Gable
Siding close together.
Gable and Wall Siding
evenly aligned at rear.
14. Complete right side Angle Cut Gable Siding Piece as per Step 12-13.
Gable and Wall Siding
evenly aligned at rear.
13. When correctly aligned, nail Angle
Cut Gable Siding with 4 - 1 1/2” finishing
nails. Try to nail into the framing of Side
Wall.

15. Locate Front Corner Door Trims (H). Position flush with
Side Wall framing and flush with bottom of Floor . Attach with
8 - 1 1/4” finishing nails. Complete both sides. See Step 24 for
complete front trim alignment.
Front
Corner
Door
Trims (H)
Trim Flush to
bottom of Floor Flush with
2x2 Side
Wall frame
Completed Front
Corner Door Trims
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Side Wall Frame.
16. Locate Black “T” Hinges (I). Attach Hinges to
Horizontal Door Trim using 1 - 1 1/2” Bolt with
Black Head.
Note - Door is Pre-drilled for Bolt. Tighten #10
Silver Bolt using wrench. Finish Hinge by securing
with
2 - 3/4” Black Screws. Drill small pilot holes first to
prevent wood from splitting. Complete both
Doors.(4 Hinges).
Starting with left side Door, lift until Hinges contact
3/4” Black
Screws
1 1/2” Bolt
with Black Top
#10 Nut with Washer
- Silver
Pre-Drilled
Left Door complete
with Hinges attached.
Hor. Door
Trim

1 - 2” screws per
Hinge initially.
17. Leave a gap on left side and bottom of
Door approximately 1/8”. Use a shingle to
shim the door at bottom to help position
door evenly.
When door is aligned correctly, screw Hinge
into Vertical Door Frame Trim with 2” Black
Screws.
Use only 1 screw initially per hinge until
both door alignments are confirmed. Drill
pilot holes to prevent wood from splitting.
Shim with
Shingle
1/8”
gap
1/8” gap
Gap between
Top of Door
and Door
Header
19. Position Right Side Door as per Steps 16-17. Once again, use only 1 screw per hinge initially to
secure Door to Vertical Door Frame Trim. Open and close both Doors to confirm proper Door closing.
Re-adjust Door Screws if necessary. When satisfied, complete Hinge attachments with 2 additional 2”
Black Screws per Hinge.
1 - 2” Black
Screw initially
Complete with 2 additional 2”
Black Screws per Hinge when
Doors are positioned correctly.
Gap
between
Doors will
be covered
by Door
Flange (K)
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Door Flange (K)
to be positioned
on Left Door.
20. Open Left Door and position Door Flange (K) flush against
Horizontal Door Trim making sure also to align evenly at top and
bottom of Door Trim. From the inside screw Flange to door with 6 - 1”
screws. Important - Drill Pilot Holes first to prevent splitting of wood.
Left Door
Left Door
Hor. Door Trim
22. Locate Side and Rear Skirting (M & N) pieces. Starting with the side, position tight to Corner Door
Trim and flush with bottom of Floor. Secure with 3 - 1 1/4” Nails per piece. Complete other side. Position
Rear Skirting Piece between Side Skirting and secure with 6 - 1 1/4” nails.
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23. Filler Trims (O) or nailing strips
are positioned in rear side corners.
There are 2 Fillers per rear corner.
Starting with Lower Trim, position
flush to bottom of Side Skirting and
nail with 3 - 1 1/2” nails. Place 2nd
Filler Trim directly above and secure
with 3 - 1 1/2” nails. Complete both
sides.
Filler Trims (O)

Flush with
Bottom Skirting
Center
Rear Trim
(S)
26. Place Center Rear Trim (S) over
Rear Wall Seam. Trim should sit flush
at bottom with Skirting. When correctly
aligned, secure with 8 - 1 1/2” nails.
24. Place Side / Front Corner Trim (P) tight to Corner Door Trim and flush to top of Skirting at bottom.
Nail secure with 6 - 1 1/2” nails. Complete both sides.
Side / Front
Corner Trim
(P)
25. Locate Side / Rear Corner Trims (Q) and Rear Corner Trims (R). Position 1 each in rear corner
as illustrated above. At bottom, Trims should sit flush with Side and Rear Skirting. When correctly
aligned, secure each piece with 8 - 1 1/2” nails.
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Side / Rear Corner
Trim (Q & R)
21. Position Upper Rear Horizontal Trims (L)
underneath rear shingle roof overhang. Nail Trim
into Wall Framing and with 3 - 1 1/2” finishing nails.
Complete both sides.
L - Upper Rear
Horizontal Trims.

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27. Locate Front Door Header Trim (T) and place between Corner Door Trim flush against Door
Header and Plywood Roof. Make sure Door Header Trim is positioned so it does not impede the
opening and closing of Doors. When correctly positioned, secure with 5 - 1 1/2” finishing nails.
Front Door
Header Trim (T)
Roof Ridge
Cap (X)
36. Center Roof Ridge Cap (X) from side
to side on the rear roof shingles. Overhang
the Ridge Cap slightly off the back of the
shingles. Secure with 4 - 2 1/2” screws. Be
sure to screw through the Ridge Cap and
into Rear Wall framing.
Drill pilot holes in Ridge Cap to prevent
wood from splitting.
37. Shelving may be mounted on Left or Right Side of Chalet. This Assembly Manual illustrates the
Shelving being mounted on the Left Side. First, locate the Vertical Shelf Support (Y). Measure 19” from
Left Side Wall Framing from the inside. Mark position on Door Header . Drill Pilot Hole near end of Shelf
Support to prevent splitting and attach to Door Header with 1 - 2 1/2” screw .
20 1/2”
19”
Drill Pilot Hole
to prevent
Splitting.
Door Header
Vertical Shelf
Support (Y)

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38. Locate 1 Shelf Support (Z) and position on Vertical Shelf
Support and Rear Wall framing. Drill pilot hole in Shelf Support to
prevent splitting and attach with 1 - 1 1/4” screw on each end.
Note - Make sure Shelf Support is level prior to att aching. Attach 2nd
Shelf Support to Side Wall framing as described above. Place
Shelf (AA) on top of Shelf Supports.
Shelf
Support
(Z)
Positioned 3/4”
on Side Wall
framing. Drill
pilot hole on
angle before
screwing.
39. Secure Shelf to Shelf Supports with 4 - 1 1/4” screws. Drill pilot
holes to prevent wood from splitting.
40. Complete positioning and attachment of 2nd Shelf as per Step 38-39.

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41. Attach Interior Door Stop (BB) to Floor with 2 - 1 1/4” screws. To align correctly, close Doors in
best close Door position. Mark and att ach. Drill pilot holes to prevent splitting.
42. Install the Barrel Bolt Plywood Spacer 3/4” from top of the Right Door with 2 - 1” screws. Position the
Interior Silver Barrel Bolt on the Plywood Spacer and use 3/4” Silver screws supplied in Hardware Package
to attach. Tap barrel of bolt with Hammer to mark location on Header . Open Door and Drill with a 3/8” bit.
Right Door
43. Attach Door Handles (CC). Handles are positioned on top section of each door and mounted with
3/4” Black Screws. Attach Black Barrel Bolt (DD) as illustrated above with 3/4” Black Screws.
Note how female part of Barrel Bolt is positioned higher than male. Do a dry run first to position Barrel
Bolt correctly. Important - Drill pilot holes with 1/8” drill bit prior to securing with screws to prevent
wood splitting.
Important: Drill shallow Pilot
Holes to prevent splitting
Install 3/4”
from top of
Door.

Congratulations on assembling
your 4x2 Garden Chalet!
Note; Our Sheds are shipped as
an unfinished product. If exposed
to the elements, the western red
cedar lumber will weather to a
silvery-gray color. If you prefer to
keep the cedar lumber looking
closer to the original color, we
suggest that you treat the wood
with a good oil base wood st ain.
You may also wish to p aint your
new shed rather than stain it. In
both cases we recommend that
you consult with a paint and stain
dealer in your area for their
recommendations.
We hope your experience constructing our 4x2 Garden Chalet has been both positive and
rewarding. We value your feedback and would like to hear back from you on how well we are doing
in the following areas:
1. Customer Service
2. On Time Shipping
3. Motor Freight Delivery
4. Quality of Materials
5. Assembly Manual
6. Overall Satisfaction.
Please call, write or email us at:
The materials contained in this Assembly
Manual may be downloaded or copied
provided that ALL copies retain the
copyright and any other proprietary
notices contained on the materials. No
material may be modified, edited or
taken out of context such that it s use
creates a false or misleading statement
or impression as to the positions,
statements or actions.
Canadian Address
9393 287th Street
Maple Ridge, British Columbia
Canada V2W 1L1
United States Address
P.O. Box 96
Sumas, Washington
USA 98295
Toll Line: 1.888.658.1658 | Fax: [phone] | [e-mail]
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