Pergola Depot Big Kahuna User manual

Assembly Instructions
Big Kahuna –Attached Pergola Kit
Thank you for purchasing a do-it-yourself pergola kit from Pergola Depot. We appreciate your
business, and we are here to help you in any way possible. Read this entire Instruction sheet before
beginning so you can get a feel for what you will be doing. If you take your time and follow these
instructions, you can do it!
If you are installing this kit on a concrete patio or on top of concrete footers, we advise that you use a
6X6 Galvanized post base on each post secured with 5/8” red head concrete anchors, which can be
purchased from us or your local hardware store. You will need some additional tools for this. There
are instructions on how to install them included in this document, or watch a video on our website
under the help menu.
Call or email us with any questions.
Call: 1-877-563-0002
Email: [email protected]
www.pergoladepot.com

Tools Needed
oHelper
oHammer
oLadder
oScrew gun (with square drive bit supplied with kit)
oPost Hole Digger (If posts will be going in ground)
o¾” Wrench
oLevel
oTape measure
o6X6 Galvanized post bases if going on concrete
Kit Components
o2x8 Beams (2 for standard size kits)
o2x8 Notched Rafters (# depends upon kit size)
o2x8 Ledger Board (1)
o6x6 Notched Posts (2 for standard size kits)
o2x6 Angle Braces (4 for standard size kits)
o2x2 Top Slats (# depends upon kit size)
oHardware Pack
oOptional: Post Base Mounting Hardware; Concrete Footing Form Tubes
Reference the packing list that was provided with your shipment confirmation for a complete
list of kit components, including the number of each type of lumber and hardware pack
components.

Installation Steps
฀Step 1- Remove the wrapping from the outside of the crate
฀Step 2- Lay out all parts next to where you will be installing the pergola.
฀Step 3- Place the ledger board against the wall exactly where you would like it, 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.
฀Step 4- Place the front beams in place on the ground about where you think they will end up.
Slide one rafter on each of the outermost X marks and butt the rafters against the wall. Make
sure the end of the rafter that is against the wall is on top of the X mark on the ledger board.
Temporarily screw in the rafter to the front beam and to the ledger board.
฀Step 5- Step back and look to see how square everything looks. Take a tape measure and
hook it on the outside corner of one of the rafters, and pull the tape to the opposite corner.
Write down the measurement. Then hook it on the other corner and pull to the opposite corner
like this:
Move the front beam from side to side until you have the same measurement both ways. When
you have the same measurement, it is perfectly square. Hint: This is done easier if you and
your helper both have a tape measure and pull them across at the same time.

฀Step 6- Now you can see where you should dig your holes for each post. (Or mount your post
bases if you’re on concrete.) Look at the top of the beam just inside the first rafter where it
says post. If you are on concrete, make a mark on the ground directly in the center of the lines
where it says post on all both sides of the beam. If you are on grass or dirt, stick the flags that
are provided with the kit into the ground on both sides where it says post.
฀Step 7- Remove the rafters from the beams and move everything out of the way. Now you
should be left with two marks on the ground where your holes or post bases will go.
฀Step 8- Dig 2 or 4 foot deep holes (depending on the depth desired) or install your post bases
directly over top of your markers.
฀Step 9- Level up from the marks you made on the wall earlier to the desired height of the
pergola. Screw the ledger board to the wall with the 5/8” bolts supplied with the kit making sure
that the ledger board is perfectly level. If you are installing on a wood frame wall, you will have
to locate the studs behind the framing and drill into them with the provided wood lags. The
bottom of the ledger board will be the finished height of the bottom of the front beam. It should
now look like this:
฀Step 10- Lye the two posts on the ground with the bottoms at the edge of each hole, with the
tops facing away from the hole.
฀Step 11- Lay one beam down on the ground near the top of the posts. Slide the posts up and
onto the beam between the lines on the beam where it says post.
฀Step 12-Set the other beam on top sandwiching the post in between the two beams.

฀Step 13- Place 1 washer on each ½” bolt. Lift up the beam assembly enough to fit the bolts
between the ground and the beam and insert the bolts into the holes from the bottom. Hint:
You may want to use a block of wood to place on the ground under the bolt so you can push
the beam down to get the bolt to come up through the hole.
Place a washer and nut on each of the bolts and make them snug but do not tighten them
down yet.
฀Step 14- With one person on each side, tilt the assembly up and drop the posts into the
postholes (or into the post bases if on concrete). Have your helper hold the assembly plumb.
Refill the holes around the posts with dirt or dry concrete. If you are using concrete, do not
water it in yet. Check for level across the top of the beam and on the sides of the posts. If you
are installing the pergola on top of a concrete patio with post bases, you will need to prop the
assembly up so that it does not fall. Once you have the bottom of the posts in the post bases,
put one nail on each side to hold them in place, but do not let go of it! Someone must hold this
in place.
฀Step 15- Move your stepladder in between the beam and the wall. Take one of the end rafters
and slide it onto the outermost X mark on the beam just like you did on the ground and screw it
through the predrilled holes onto the top of the ledger. Now move to the opposite side and
screw the other end rafter in place. Now your helper should be able to let go of the assembly.
฀Step 16- Install the remaining rafters on the remaining X marks. Secure them to the beam and
the ledger with 3” deck screws through the predrilled holes in the top of the rafter. (Note: If on
concrete, now is the time to finish securing the posts to the bases.)

฀Step 17- Place the top slats into position in the layout lines across the top of the rafters, make
sure to have the same overhang on each side and screw them down. Start on one side and
make your way across to the other side screwing every other rafter. Stagger your screw
pattern, making sure that every top slat is screwed down on both end rafters, as pictured
below:
Be careful screwing the screws in because stainless steel is a soft metal and they strip VERY
EASILY! Push down hard, make sure your drill is straight, and that the square bit is seated all
the way down into the head while screwing them in. Use a moderate speed. Sometimes the
screws will break if you go too slow. There are extra screws in every kit just in case you strip
some, but if you need more you should be able to find them at any local hardware store.
฀Step 18- Install the Angle Braces. Slide the angle braces, with the long side towards the top,
up in between the two pieces of wood that make up the beam. Get it flush with the top of the
beam and push the bottom side against the post. Make sure everything is nice and flush to the
post and to the top of the beam. Screw in two 3” deck screws through the angle brace into the
post through the predrilled holes, then screw the top through the face of the beam into the
angle with 4- 3” deck screws. (Note: There are no predrilled holes in the face of the beam)
Repeat for each angle brace. This is what the angles should look like when installed correctly:

฀Step 19-Check the entire unit for level and plumb, tighten down nuts, and water in the
concrete or dirt. Be sure not to push the unit around while the concrete is curing (about 24
hours).
You’re Done!
Thanks again for your business. We really do appreciate our customers and their feedback on ways
to improve our products. So, after you’ve completed putting your kit together, sit down, have a cold
drink, and drop us a line via email to tell us what you think about our products. Any feedback on how
we can make our kits easier to install will be very helpful. Pictures are always welcome!
Crafted with pride in the U.S.A!
Pergola Depot
Call: 1-877-563-0002
Email: [email protected]