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 #8
June 11th, 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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A
B
L
D
CC
Q
Y
N
M
T
H
G
BB
O
E
Exploded View and Parts List for 4’x2’ Garden Chalet
AA
Z
F
C
I
J
K
VW
X
R
DD
EE
Not Shown:
Interior Door Stop
Interior Silver Barrel Bolt
Shingle Spacing Template
P
S
Trim Section
H 2 - Front Corner Door Trims - 1/2” x 2 1/2” x 65 1/2”
L 1 - Upper Rear Horizontal Trim - 1/4” x 1 1/4” x 43 3/4”
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
AA 1 - Vertical Shelf Support - 1 1/2” x 1 1/2” x 35”
BB 4 - Shelf Supports - 3/4” x 1 1/2” x 17 3/4”
CC 2 - Shelves - 17 1/2” x 18 7/8”
Miscellaneous (Not Shown on Illustration above)
1 Interior Door Stop - 3/4” x 1 1/2” x 8”
1 Barrel Bolt Plywood Spacer - 1/2” x 2 1/2 x 2 1/2”
1 Interior Silver Barrel Bolt
1 Shingle Spacing Template - 1/8” x 7 1/2” x 40”
U
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 Walls - 18 1/2” x 62 1/2”
D 2 - Rear Walls - 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 (left / 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 - Roof Plywood - 5/8” x 21” x 44”
U 1 Sheet of Roofing Paper
V, 27 - 16” long x 5 1/2” wide Shingles
W 5 - 16” long x 2 3/4” wide Shingles
X 8 - 8 1/2” long x 5 1/2” wide Last Row Shingles
Y 1 - 8 1/2” long x 2 3/4” wide Last Row Shingle
Z 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.

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 (DD) 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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(EE) Barrel Bolt
1”
Utility Knife
Page 3
1/8” & 3/8” Drill Bits
1 1/2”
Bolt with Black Head, Silver Nut and Washer

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 attachments. 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 sits
flush with front and side. Have helper hold Side Wall while
Rear Wall is positioned on Floor.
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.

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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.
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.
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
Do Not Attach Walls
To Floor until Step 8.
Rear Wall
approx. 1/2” gap

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Page 6
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. When all walls are attached together, check alignment with the floor. When positioned
correctly, fasten bottom wall framing to floor using 2 - 2 1/2” screws per wall panel.
Optional - Caulking
seams will help prevent
moisture from entering
at seam. Caulking not
included in kit.
Caulking

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Page 7
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.
11. Place Plywood Roof (F) on Wall Framing and Door Header. Align evenly from side to side. At the
front, recess Roof slightly. See Step 12 for close up of front Roof alignment. When correctly positioned,
screw to framing with 6 - 1 1/4” screws. Note: Be sure screws do not come through Door Header.
Plywood Roof (F)
You will want Front Corner Trim (P) to cover
screws in Step 24. Use Trim to confirm screw
location.
1 1/4” screws

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Page 8
12. Locate both Angle Cut Gable Siding Pieces (G). There are left and right side pieces. Starting
with the left side, place above Side Wall so lap sidings fit together.
Left Side Angle Cut Gable Siding (G)
13. Align Gable Siding flush at rear with Wall Siding and flush with top of Plywood Roof. Secure with
7 - 1 1/4” finishing nails. Make sure to nail into edge of Plywood Roof at top and into wall framing at
bottom. Hammer at slight angle to contact wall framing. Align right side Angle Cut Gable Siding Piece.
Plywood Roof and Angle Cut Gable
Siding Flush with each other.
Siding
aligned
at rear
14. Complete right side Angle Cut Gable Siding Piece as per Step 12-13.

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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Page 9
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. Tighen #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
Door Trims.
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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Page 10