OLT Garden Chalet 4x2 User manual

Outdoor Living Today www.outdoorlivingtoday.com [e-mail]
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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Page 2
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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Page 4
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

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 4 - 1”
screws. Important - Drill Pilot Holes first to prevent splitting of wood.
Left Door
Left Door
Hor. Door Trim
21. Position Upper Rear Horizontal Trim (L) on top lap of Rear Wall Panels evenly from side to side.
Nail Trim into Wall Framing and Roof edge with 6 - 1 1/4” finishing nails
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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Page 11
Flange may
need 2
additional 1”
screws from
front to
strengthen.

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 1/4” nails.
Place 2nd Filler Trim directly above and secure with 3 - 1 1/4” nails. Complete both sides.
Filler Trims (O)
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 1/4” 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 1/4” nails.
Side / Rear
Corner Trim (Q)
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Page 12

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Page 13
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 1/4” nails.
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 1/4 nails.
Front Door
Header Trim (T)
28. Unfold Sheet of Roofing Paper (U). Place on Plywood Roof evenly and nail down with
4 - 7/8” nails. Position nails to penetrate through Plywood Roof into wall framing.

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Page 14
29. Locate 16” long x 5 1/2 and 2 3/4” wide Shingles (V, W). Starting with a 5 1/2” wide Shingle on the
left side, align first Shingle on front left corner to overhang the Front Door Header Trim and Front / Side
Corner Trim by 1 1/2”.
1 1/2”
1 1/2”
31. With 1st row of Shingles spaced correctly from side to side and overhanging the Front Door Header
Trim by 1 1/2”, secure each Shingle with 2 - 7/8” nails. Place 2nd row of shingles directly on top of first
row except use a 5 1/2” wide shingle on the right side and a 2 3/4” wide shingle on the left . Secure both
outside Shingles with 2 - 7/8” Shingle Nails 8” from their butt.
1/8” to 3/8”
gap between
Shingles.
Nail 2 1/4” from front edge
Important-
Butt (thick) end of
shingle will be facing
towards front
Butt End
2 1/4”
5 1/2”
2 3/4” wide x
16” long Shingle
30. When first 5 1/2” wide x 16” long Shingle is correctly aligned, nail down to Plywood Roof with 2 - 7/8”
shingle nails 2 1/4” from front edge. Position and secure a 2 3/4” wide x 16” long shingle on opposite corner.
Drill pilot holes first when nailing 2 3/4” wide Shingle to roof. Space remaining 5 1/2” wide x 16” long shingles
between both outside shingles leaving an 1/8” to 3/8” gap between each Shingle.
2 3/4” wide 5 1/2” wide
8”
3 Extra 5 1/2”
wide Shingles
and 2 - 2 3/4”
are included in
kit.

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Page 15
32. Choose remaining 2nd row of
5 1/2” wide Shingles and place on top
of 1st row. Position and secure as per
Step 31.
33. Tack Shingle Spacing Template
(7 1/2” high) with 2 - 7/8” shingle nails flush with
front of shingles. Position and attach 3rd row of
outside Shingles as per Step 30. Use 5 1/2” wide
on left and 2 3/4” on right side to start.
Shingle Spacing Template
3rd Row of Shingles
34. Position and secure remaining 3rd row of shingles as per Steps 31-32.
Shingle Spacing Template
8 1/2” Long Shingles (X &Y)
35. Re-position Shingle Spacing Template as per Step 33. Locate 8 1/2” Cedar Shingles (X &Y) and
position as per Steps 31-34. Position 2 3/4” wide shingle on left and 5 1/2” wide shingle on right. Nail 7”
from the Butt of the 8 1/2” shingles with 2 - 7/8” shingle nails per shingle.
Nail 8” from Butt of 3rd row shingles
Nail 8” from Butt
7 1/2”
5 1/2”
2 3/4”
Shingle Spacing Template
5 1/2’ wide
Nail 7” from Butt

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Page 16
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 (AA). 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 (AA)
36. Center Roof Ridge Cap (Z) 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.
Roof Ridge
Cap (Z)

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Page 17
38. Locate 1 Shelf Support (BB) 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 attaching. Attach 2nd
Shelf Support to Side Wall framing as described above. Place
Shelf (CC) on top of Shelf Supports.
Shelf
Support
(BB)
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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Page 18
41. Attach Interior Door Stop to Floor with 2 - 1 1/4” screws. To align correctly, close Doors in best
close Door position. Mark and attach. Drill pilot holes to prevent splitting.
42. Install the Barrel Bolt Plywood Spacer 3/4” from bottom 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 on Interior Door Stop to mark location. Open Door and Drill with a 3/8” bit.
Right Door
43. Attach Door Handles (DD). Handles are positioned on top section of each door and mounted with
3/4” Black Screws. Attach Black Barrel Bolt (EE) 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.
Mark first and
then drill hole
with 3/8” bit.
Important: Drill shallow Pilot
Holes to prevent splitting
Install 3/4”
from bottom
of Door.

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. Freight Delivery
4. Quality of Materials
5. Assembly Manual
6. Overall Satisfaction.
Please call, write or email us at:
Outdoor Living Today Partnership
P.O. Box 96
Sumas, Washington
98295
Toll Line: 1.888.658.1658 | Fax: [phone] | [e-mail]
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 its
use creates a false or misleading statement or
impression as to the positions, statements or actions.
Page 19
Congratulations on building
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 stain.
You may also wish to paint 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.