RioOutdoors 4F-DH User manual

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Installation Instructions
4F-DH
4x4 Floating Dual Header Raftered Pergola Kit
Pergola Kits
WARNING: If the information in these instructions is not followed exactly, weakening or failure of the erected
structure may result causing property damage, personal injury, or loss of life.
All brackets designed and sold by RioOutdoors.com are to be used for building pergolas only and are not to be used for
other structure construction purposes.
Figure 1: Items included in the kit, (

 ).
Items not included in this kit: wood, tools, some hardware.
•
Thoughtfully engineered
Brackets eliminate all
wood-joinery skills
requirements.
•Skills required: leveling
ground, drilling pilot
holes, and driving lag
screws into lumber.
•Easy lift and place U-
channels eliminate
need for lifting
equipment. Super-
easy assembly work.
•Self-aligning design
squares up structure
automatically.
•Estimated Assembly
Time is less than 2
hours (not including
deck).

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Table of Contents
1.1 SAFETY AND WARNING INFORMATION ................3
1.2 TOOLS REQUIRED...................................................4
1.3 CONTENTS OF KIT #4F-DH ......................................5
1.4 OPTIONAL DECK SUPPORT BEAM BRACKETS .................6
1.5 LIST OF MATERIALS THAT YOU WILL SUPPLY,OR ARE
RECOMMENDED................................................6
1.6 FLOATING SYSTEM .................................................7
1.7 SIDE ELEVATION DIAGRAM .......................................9
1.8 ASSEMBLING FLOOR CORNER 2-WAY ELBOW BRACKETS .10
1.9 POSTS INSTALLATION ........................................... 14
1.10 POST-TOP DUAL HEADER BRACKET INSTALLATION ....... 15
1.11 HEADERS PREPARATION ........................................ 18
1.12 HEADERS INSTALLATION ....................................... 23
1.13 INSTALLING THE RAFTERS ...................................... 27
1.14 INSTALLING DECK BOARD SUPPORT BEAMS ................ 30
1.15 INSTALLING DECK BOARDS .................................... 31
2.1 CONDITIONS ...................................................... 34
2.2 EXCLUSIONS....................................................... 34
2.3 LIMITATIONS OF LIABILITY ..................................... 35
2.4 HOW TO OBTAIN WARRANTY SERVICE ..................... 35
Proper pilot hole diameter and hole depth for various lag screws and wood types
Lag Screw Type
Wood Type
Pilot hole drill diameter and hole depth
¼” X 1-1/4” Lag Screw
McMasterCarr.com SKU 92351A546
Soft Wood 3/32” drill bit diam., 1-1/4” depth
Hard Wood 3/16” drill bit diam., 1-1/4” depth
3/8” X 3” Lag Screw
McMasterCarr.com SKU 92351A636
Soft Wood 11/64” drill bit diam., 3” depth
Hard Wood ¼” drill bit diam., 3” depth
A properly sized pilot hole must be drilled before you attempt to drive lag screws into any pergola lumber member.
See Table, below. Driving lag screws into lumber, without first drilling a pilot hole, can prevent the lag screw from
driving fully into the wood or can lead to crack formation while driving the lag screw in, or later, as the wood dries
naturally. This can result in a weakened pergola structure.

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GENERAL INFORMATION
1.1 SAFETY AND WARNING INFORMATION
1.1.1 Building Permit & Inspection Requirements
We recommend that you consult with your local building permit office and obtain advice and any required building permits and
inspection approvals from the local building inspection department or the local authority over building codes.
1.1.2 Other Cautions
CAUTION: Adhere to all safety requirements. Wear safety glasses/goggles when working. Wear safety gloves
when handling brackets, hardware, and lumber. Wear hearing protection when using a circular saw, miter
saw, table saw, or hammer drill.
INSTALLER: Leave this manual with the consumer. CONSUMER: Retain this manual for future reference.

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1.2 TOOLS REQUIRED
Listed below, are common tools required for pergola projects. These tools are not included in this kit. Your pergola project may
not require all tools. Select and acquire the tools for your project from the “Required for” column in this table.
Description
Tool Purpose
Required for
Reference Image
Tape
Measure
Measure and verify
lengths. All pergola types
Framing
Level Verify Level/Plumb All pergola types
Hammer
Drill
Drill holes in concrete
pads or concrete
footing for securing
floor anchor brackets.
Drill pilot holes for lag
screws.
All pergola types
Ratchet
Socket
Driver
Drive lag screws into
Pergola lumber
members.
All pergola types
7/16” Hex
Socket
Drive ¼” X 1-1/4” Hex
Hd. lag screws. All pergola types
9/16” Hex
Socket
Drive 3/8” X 3” Hex Hd.
lag screws.
Raftered pergola (single,
dual, quad headers)
3/32” Drill
Bit
Drill pilot holes for ¼”
lag screws in soft
wood.
All pergola types
11/64” Drill
Bit
Drill pilot holes for 3/8”
lag screws in soft
wood.
Raftered pergola (single,
dual, quad headers)
½” X 4”
Masonry
Drill Bit
Drill ½” X 2” deep holes
in concrete pads or
concrete footings.
Surface Mount styled
pergola
#2 Phillips
Screwdriver
Bit
Attaching pergola
rafter ties to rafters
and headers.
Raftered pergola (single,
dual, quad headers)
Circular
Saw/Miter
Saw
Cut headers to length;
cut rafters to length. All pergola types
Jig Saw
Cut rafter tail designs.
Raftered pergolas
Image not available.
Crescent
Wrench
Tighten down nut on
concrete anchors. FLOATING Pergolas Image not available.
Hammer Various. All pergola types.

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1.3 CONTENTS OF KIT # 4F-DH
The contents of this kit are shown in the table, below. Before you begin your project, take an inventory of all items that you
received from us. If any items are missing, contact us directly via email at [e-mail]. Include your name and
shipping address and your order number, if available. We will respond within 24 hours with a resolution to your problem.
Item SKU #, Description
Item Qty
Item Image
Post-Top Dual Header Bracket
SKU# 4DH 4
4x4 Post-Top/Floor 2-way Elbow Bracket
SKU# 4C2L 4
Rafter Tie Bracket
SKU# 68RT 18
¼ x 1-1/4” SS Lag Screw
McMasterCarr.com SKU 92351A546 160
3/8 x 3” SS Lag Screw
McMasterCarr.com SKU 92351A636 16

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1.4 OPTIONAL DECK SUPPORT BEAM BRACKETS
If you wish to build a wooden deck as the floor for your floating pergola, you may wish to use our deck beam support brackets,
SKU #24BS. This bracket can support 2x4 or 2x6 beams. You can order the required number of brackets at RioOutdoors.com.
Deck Beam Support Brackets (Qty 2 every 24”)
RioOutdoors.com SKU# 24BS
6 for 8 ft.
8 for 10
ft.
10 for 12
ft.
1.5 LIST OF MATERIALS THAT YOU WILL SUPPLY, OR ARE RECOMMENDED
This is the list of required materials which are not included in this kit. You will acquire these items locally for your project. Use
this table to help you calculate your total project budget.
Item Description Item Qty
Item
Cost
($)
Total
Item
Cost
($)
Item Image
4x4 Post Lumber
(You determine
length)
4
4x4 Floor Floating
Lumber (You
determine length)
4
2x6 or 2x8 Header
Lumber
(12 ft. max 2x6, 16
ft. max 2x8)
4
2x6 or 2x8 Rafter
Lumber
(You determine
length)
16” centers. 9
for 12 ft.
header, 11 for
16 ft headers.
¼” X 1-1/4” x 7”
Wood Shims One Pack
Tape, for marking
drill bit depth 2” NA
Grand Total Cost ($)
NA

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1.6 FLOATING SYSTEM
1.6.1 What is a floating system?
Floating means that the vertical posts for the pergola are secured to 4x4s that are laid on the ground and floating; employing 2-
way elbow brackets to secure the posts to the floating floor 4x4s. You may choose to create a wooden deck within the pergola
walls. To do so, you must add 2x4 beams every 24” to support the deck boards. You may toenail the 2x4 beams in place or
choose an easier and more precise mounting method using our 2x4 Beam Support Brackets (SKU# 24BS, available at
RioOutdoors.com).

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1.6.2 Floor Leveling and Preparation.
Plan to assemble a floating pergola where you can excavate and create a level platform with, at least, the overall outer dimensions
of the pergola. If soil type is sandy, soft, or wet, you must consider adding concrete blocks or pier blocks under corners of pergola
to prevent sinking into soil.
1. Excavate enough dirt to create a flat and level platform.
2. Spray Roundup weed killer herbicide on the excavated area to prevent weed growth inside your pergola area.
3. Lay thick weed control fabric over the entire pegola platform. Overlap the fabric at least 6 inches where they join. Use U-
shaped lanscaping fabric nails to anchor the fabric to the ground.
Alternatively, you can excavate deeper, about 3 inches, lay the weed control fabric at the bottom and fill the excavated
area on top of the fabric with gravel up to your desired height.
4. Layout the four floating floor 4x4s in the intended shape and orientation on top of the leveled area.

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1.7 SIDE ELEVATION DIAGRAM
Based on the height of the post used, the diagram below provides the side elevation profile for this pergola system.
Dim A, above, is the height of the post used. Dim B is the inner ceiling height of the pergola. Dim B is measured to the bottom
surface of the header member.
Post Height
Dim
A
Dim B
96
96
92 3/4
108
108
104 3/4
120
120
116 3/4
132
132
128 3/4
144
144
140 3/4

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1.8 ASSEMBLING FLOOR CORNER 2-WAY ELBOW BRACKETS
We have designed the corner elbow brackets to provide automatic squaring and alignment of the floating 4x4s. By following
the instructions properly and securing the 4x4s to the elbow brackets as instructed, you will achieve a perfectly squared
floating deck base for your pergola. All you have to do is determine the size you desire for the length and width of your
pergola.
We recommend a maximum header length of 12 feet for 2x6 headers and 16 feet for 2x8 headers. The recommended rafter
lengths are 12 feet for 2x6 rafters and 16 feet for 2x8 rafters. We further recommend that you allow for 18” of overhang
beyond the posts on each side for the headers and 18” overhang beyond the headers on each side for the rafters. Before
you start assembly, study the table, below, and determine the length of bottom 4x4s you will need.

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1. Starting in one corner, slide one 2-way elbow over two adjacent 4x4s so the U-channels in the 2-way elbow bracket over
the 4x4s.
2. Place two shims under each 4x4 near the 2-way elbow.
3. Push 2-way elbow bracket downward until the horizontal part of the U-channels touch the 4x4 top surfaces.
4. Slide 4x4s all the way in towards the center square tube in the 2-way elbow bracket.

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5. Wrap a piece of electrical tape around the drill bit, spaced 1-1/4” from the drill bit tip. This will act as a hole depth
indicator when you drill each pilot hole. Pilot holes should be drilled at least 1-1/4” deep. A little bit deeper is acceptable
but do not drill less than the required 1-1/4” depth.
6. Drill 3/32 X 1-1/4” pilot holes through the lower holes in the U-channel’s sides. Only use the lower holes to anchor the
floor 4x4s to the U-channels.

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7. Drive one ¼” X 1-1/4” SS lag screw through the pilot holes you drilled.
8. Repeate steps 8 and 9 for the other side of both U-channels.
9. Repeat Steps 5 to 9 for the other three corners.
10. Remove all shims from under the 4x4s.
11. Tap top of 4x4s with a hammer to settle the 4x4s into the ground fabric.
12. Using a 4 foot framing Level, check top surfaces of all 4x4s to see if they are level. Use shims as you see necessary to level
all four 4x4s that are sitting on the ground.

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1.9 POSTS INSTALLATION
1. Slide a 4x4 post inside the open vertical tube in all four corners’ 2-way elbow bracket.
2. Identify the 5/16” holes in the inner faces of the 2-way elbow’s vertical tube. Drill 3/32” X 1-1/4” pilot holes in the center of
all four 5/16” holes.
3. Drive one 1/4x1-1/4” SS lag screw through each pilot hole you drilled and tighten down using a ratchet and 7/16” socket.
Repeat steps 1 to 3 at all corners. Check top of floor 4x4 for level on more time and adjust as necessary to maintain level.

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1.10 POST-TOP DUAL HEADER BRACKET INSTALLATION
1. Slide one Post-Top Dual Header Bracket over the 4x4 post top after aligning the headers receiver u-channels in the
proper direction. Let gravity work and pull the bracket all the way down on top of the post.
2. Identify one 5/16” hole which is located at the center of the top surf ace of the dual header bracket.

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3. Wrap a piece of electrical tape around the drill bit, spaced 1-1/4” from the drill bit tip. This will act as a hole depth
indicator when you drill each pilot hole. Pilot holes should be drilled at least 1-1/4” deep. A little bit deeper is
acceptable but do not drill less than the required 1-1/4” depth.
4. Drill a 3/32” X 1-1/4” deep pilot hole at the center of the 5/16” Hole.

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5. Drive one ¼ x 1-1/4” SS Hex Lag Screw through the 5/16” hole into the pilot hole you drilled in step 4, using a 7/16”
Socket and Rachet driver. Tighten down the screw.
6. Repeat steps 1 through 5 for each post-top dual header bracket.

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1.11 HEADERS PREPARATION
We recommend a maximum header length of 12 feet for 2x6 headers and 16 feet for 2x8 headers. The recommended rafter
lengths are 12 feet for 2x6 rafters and 16 feet for 2x8 rafters. We further recommend that you allow for 18” of overhang
beyond the posts on each side for the headers and 18” overhang beyond the headers on each side for the rafters.
1.11.1 Header and Rafter Tail Designs Cutting
Visit www.https://riooutdoors.com/rafter-tail-designs to see our collection of Rafter Tail designs. Based on your cosmetic
preference and woodworking skill level, select a rafter tail design shape that you plan to cut yourself or you plan to outsource the
design cutting. You may have your own design that you wish to apply to the rafter tails. The possibilities for rafter tail designs are
endless, and a minor change in detail can add a dramatic flair to your pergola design. Be creative.
1.11.2 Rafter Tie Brackets Installation
For a dual header pergola system, rafter ties are required to be installed on both top headers on each side of the pergola. The
rafter ties are to be installed in an offset pattern between the two headers, as shown in the image, below. This offset pattern
helps prevent warping of both headers and further helps to stiffen the pergola structure and prevents swaying motion.
OUTER HEADER
INNER HEADER
NOTE THE OFFSET
MOUNTING PATTERN FOR
THE RAFTER TIE BRACKETS

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After you determine the lengths for the headers, it is time to prepare two headers to install the rafter tie brackets on. We have
designed the rafter tie brackets to be auto aligning and simple to locate precisely. Follow these steps for easy rafter tie
placement:
1. On the ground, place two headers with the top edge of headers facing upward. Butt two headers together and align their
ends flush.
2. Clamp headers together using a C-clamp or other vice.
3. Measure and find the center along the header length. Mark a pencil line at the center point on both header top surfaces.
The rafters may be spaced apart 12” or 16”. 12” rafter spacings will shield sunlight longer in the morning as the sun rises in
the sky and earlier in the afternoon as the sun starts to sink in the sky as compared to using 16” spacings. Here, we assume
that you selected 16” spacings for the rafters. Adjust the mark location if you choose 12” rafter spacings.
4. Measure outward 16 inches, incrementally, and mark a line at each 16” point out from center until you reach the end of the
header on each side.
5. Separate the two headers by removing the clamp.
6. Starting with the outer header, place one rafter tie bracket on top of the center-most pencil mark on the outer header, as
shown below. See the “Right View,” below, and make certain the Rafter Tie Bracket is properly oriented towards the inside
area of the pergola. Look through the rectangle slot in the Rafter Tie. Slide the Rafter Tie until you can see the pencil mark
line you marked on the header top surface in the rectangle slot.

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7. On the outer header, starting with the center pencil mark, add one rafter tie then work outward, skip every other pencil
mark, and place a rafter tie on alternating pencil mark points.
8. On the inner header, place a rafter tie at the first pencil mark on each side of the center-most pencil mark. Then skip every
other pencil mark, and place rafter ties on alternating pencil mark as shown in the image, below.
SKIP EVERY OTHER
PENCIL LINE MARK
PLACE RAFTER TIES
ON THE INNER HEADE R
PLACE RAFTER TIES
SKIP EVERY OTHER
PENCIL LINE MARK
ON THE OUTER HEADER