Pergola Depot Big Kahuna PLUS User manual

Assembly Instructions
Big Kahuna™ PLUS Covered Pergola Kit - Attached
Thank you for purchasing a do-it-yourself pergola kit from Pergola Depot!
Please carefully read these instructions entirely before beginning to familiarize yourself with the
whole process.In addition to these instructions, we have a variety of information and resources
available on our website under the Resources menu, including How to Measure for a Pergola
and Installation Information (including videos for some of the important steps in the installation
process).
Contact us if you have questions or need help!
Call: 1-877-563-0002
Email: [e-mail]
Visit: https://pergoladepot.com/
The Team at Pergola Depot

Assembly Instructions – Big Kahuna™ PLUS Covered Pergola Kit – 877-563-0002 – www.pergoladepot.com
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Tools and Supplies Needed
o Helpers - at least 2 recommended, especially for larger kits
o Tape measure (2 better), hammer, level, leveling string and stakes, sawhorses (2) or
substitute, clamp, and a few pieces of scrap wood for propping up beams for post
location (size and quantity depending upon rafter length and slope of installation
location)
o Spray paint, chalk, flags or other materials for marking post locations
o Ladder (tall enough to work the top of your pergola during assembly)
o Screw gun, power drill (min. 18V fully charged cordless) and power saw (skill saw min.
7 ½”blade) and hand saw
o Socket attachments, wrenches, drill bits:
o Supplied with Kit: Two star-drive bits (T25, T27) for 3” and 6” screws and one
nut driver bit (5/16”) for roofing screws
o 3/4” socket or open-end wrench for bolts
o 9/16” socket for angle brace lags – drill attachment preferred
o 1/4” drill bit for pre-drilling post at angle brace attachment
o 1/2” drill bit for pre-drilling angle brace to beam and rafter attachments
o 5/8” drill bit for installing rebar into post (if posts going into new concrete
foundations)
o For all kits using post bases on concrete: 5/8” masonry drill bit; and 15/16” socket
o For new footings: post hole digger, dry concrete mix, gravel, trowel, shovel and
mixing bin or wheelbarrow and concrete footing form tubes
o For Pressure Treated Pine kits using post bases on concrete: 5/32" masonry drill bit,
and #2 Philips bit or #2 Philips screwdriver
Kit Components

Assembly Instructions – Big Kahuna™ PLUS Covered Pergola Kit – 877-563-0002 – www.pergoladepot.com
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Reference the packing list that was provided with your shipment confirmation for a complete list
of kit components, including the piece count for each type of lumber and hardware pack
components. Here is a summary of the kit components:
o 2x8 Beams (2 for standard size kits)
o 2x8 Notched Rafters (# depends upon kit size)
o 6x6 Notched Posts (2 for standard size kits)
o 4x6 Angle Braces (4 for standard size kits) – 2 shorter (post to beam), 2 longer (post to
rafter)
o 2x2 Top Slats (# depends upon kit size)
o Metal Roofing Panels (# depends upon kit size)
o Hardware Pack (box) – see Pack List for detailed contents
o Post base mounting hardware if purchased (2 for standard sizes kits) and Tapcons (for
PT pine kits only) – for slab or footer post mounting
o Optional: post base trim
Instructions
For installations on top of new footings, allow the concrete to dry before completing the rest of
the pergola installation. This may require that you dig holes and pour footings a few days or
more prior to assembling the pergola depending upon the concrete used and climate.
Additional instructions are provided below.
For installations on top of new or existing concrete foundations, we supply post bases, anchors
and Tapcons as part of your kit if purchased with the option to be installed “on a concrete slab
or footer”.These materials can also be purchased as accessories from us or from your local
hardware store. Instructions for post base installation are provided below, and we have a video
on the Installation Information page on our website.
Please wait for the wood to dry completely before painting or staining a pressure treated
pine kit, which may take several months or more depending upon climate and weather
conditions.

Assembly Instructions – Big Kahuna™ PLUS Covered Pergola Kit – 877-563-0002 – www.pergoladepot.com
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Step by Step:
• Step 1 – Move all parts close to where you will be installing the pergola for easy access
during assembly.
• Step 2 – Place the ledger board against the wall exactly where it will be installed but
laying on the ground (with the x’s facing up) and make a pencil mark on the wall at each
end of the board. Once assembled, the ledger board will be installed higher than the
beams to create slope for water drainage. The height of the ledger board, and clearance
needed for the roofing structure will depend upon the beam side above ground post
height, rafter length and slope of existing ground surface as described below.
• Step 3 – Place beams on the ground (with the x’s facing up) parallel to the ledger board
and approximately a rafter length away from the wall as shown in the picture below.
• Step 4 - Slide two rafters over the two X marks on the beams just outside where “post” is
labeled on top of the beams – these are the second X marks in from the outside tips of
the beams, marked like this:IXI and resting on the same mark on the ledger board with
the flat end of the rafters against the wall.Have helpers lift the rafters and leger board to
allow the rafters to sit squarely over the beams (see table below for post and beam
height differential assuming level assembly surface) while remaining squarely against the
wall, then use blocks of wood to hold.You may also have to move the beams around a
little to get the rafters into place. Using 6” screws provided, temporarily screw each rafter
through the predrilled holes into the beams. Screw them in just enough to hold the rafter
in place.
• Step 5 – To ensure the assembly is square, hook one end of a tape measure on the
outside tip of the rafters and pull the tape to the opposite corner. Write down the
measurement. Then repeat for the opposite corner like this. This is easier if you and your
helper both have a tape measure and pull them across at the same time.

Assembly Instructions – Big Kahuna™ PLUS Covered Pergola Kit – 877-563-0002 – www.pergoladepot.com
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Move the beams from side to side until you have the same measurement both ways.
When you have the same measurement, it is perfectly square. Once square, make sure
the assembly does not move.
• Step 6 – To identify the location for each post hole or post base, look at the top of the
beams just inside the rafter where “post” is written with two lines on either side, like this:
IpostI. Ensuring the assembly does not move, use spray paint, chalk, flags or other
material to mark the ground or concrete surface at the center of the lines around the
words post and the mid-point between the two boards making up the beam assembly.
Unscrew and remove the rafters from the beams and move all the boards to the side.
Now you should be left with four marks where the post holes or post bases will be
located.
• Step 7 – If mounting posts using post bases on top of new footings, please ensure
adequate clearance for the ledger board and pergola roofing structure at the wall side.
The top of the ledger board when installed will need to be higher than the top of the
post and beam assembly as described in the step below.
When ready, dig holes with the center of the hole where marked, minimum 2’4” deep
(depending on the depth desired for frost line etc. – see our website under
Resources>Pergola Post Guide) and min. 16” diameter. Use concrete footing form tubes
and leveling line to ensure the top of each footing is level with each other and ground
level at the wall.Adjust footing if needed to accommodate ledger height requirements.
Pour in gravel to fill the first 4” of each post hole. Mix the concrete according to the
directions for the concrete purchased and fill the hole to about two-thirds of the way to
the top. Use a shovel or piece of rebar to eliminate air bubbles. Insert one piece of 18”
rebar supplied with the kit into the wet concrete so that it sits diagonally from the bottom
of one side of the hole toward the top of the other side. Pour in more concrete to cover
the rebar and until the concrete is level with the top of the form tubes. Work the top
portion of concrete to eliminate bubbles and smooth the top with a trowel or shovel.
Repeat for each footing. Allow concrete to dry completely, which will depend upon the
concrete used and weather conditions.
• Step 8 – This section will provide information and instructions of securing the posts to the
ground and achieving the proper roofing slope, (1) using post bases on top of newly
poured footings, (2) burying the posts into newly poured footings, or (3) using post bases
on top of an existing concrete surface (slab or footing).
To achieve the proper roofing slope, you will adjust the height of the ledger board and/
or the above grade post (and beam assembly) height by trimming the length of the posts
provided, by burying the posts to the appropriate depths, or a combination of the two.
For standard orders we provide posts in lengths of either 8’, 10’ or 12’ based upon your
specifications at the time of order.
! For orders specifying post base mounting on top of new footings or existing
concrete surfaces, we supply two posts at 8’ or 10’ (based upon your low side
preference).