Suncast CA3500 User manual

© 2011 Suncast Corporation, Batavia, IL 0660091C
CA3500 / CAS3500
Classic Arbor
OWNER’S MANUAL
WARNING
• Repair or replace broken parts immediately.
• Suncast is not responsible for damage caused by weather or misuse.
• Avoid excess heat from any auxiliary source.
Before you begin...
Read instructions prior to assembly. This product contains parts that can be damaged if incorrectly assembled. Once assembled, the unit cannot be
taken apart without breakage. Please follow instructions. Suncast is not responsible for replacing parts damaged due to incorrect assembly.
Avoid scratching nish. For steps where parts are placed upside down, place parts on a smooth surface to avoid scratching finish. Flatten cardboard
from carton to create a smooth work surface.
Avant de commencer...
Lisez les instructions avant de procéder au montage. Cet article comporte des pièces qui risquent d’être endommagées si ces dernières ne sont pas
installées correctement. Une fois assemblé, l’unité ne pourra pas être démonté sans l’endommager. Veuillez suivre les instructions. Suncast ne peut
être tenu responsable en cas de perte de pièces suite à un montage incorrect. Évitez de rayer le ni. Lors des étapes où les pièces doivent être placées
à l’envers, placez les pièces sur une surface lisse afin d’éviter de rayer le fini.
Aplatissez le carton de la boîte afin de créer une surface de travail lisse.
Antes de empezar…
Lea las instrucciones antes de comenzar a armar. Este producto tiene piezas que pueden dañarse si se arman incorrectamente. Una vez armado, la
unidad no se podrá desarmar sin dañarla. Por favor, siga las instrucciones. Suncast no se hace responsable de piezas dañadas debido a un armado
incorrecto. Evite rayar el terminado. Para realizar las operaciones en las que las partes deben colocarse con la superficie terminada hacia abajo,
coloque las partes sobre una superficie suave para evitar rayar su terminado. Aplane el cartón de la caja de embalaje para crear una superficie de trabajo
lisa y suave.

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• Consult your local authorities for any permits required to construct arbor.
Prior to the construction of your arbor, check with the local building code official to review any required permits or building limitations.
• COMPLETE SITE PREPARATION AND FOUNDATION CONSTRUCTION BEFORE UNPACKING ALL PARTS.
A level and sturdy foundation is required before arbor construction can begin.
• Read instructions thoroughly prior to assembly.
This kit contains parts that can be damaged if assembled incorrectly or in the wrong sequence.
• Please follow instructions.
If you have questions or concerns with this product DO NOT return to store. Assembly questions? Missing parts? Call 1-800-846-2345
or 1-630-879-2050.
• Assistance is required.
Due to the size of the parts, at least two people are required to handle, fit and secure arbor components.
• Foundation mounting hardware varies with each application.
Read manual first and contact your local building supply retailer for recommendations for your application.
Before You Begin...
 •Donotstand,sit,orstoreitemsontopofarbor.
•Donothangplantsorheavyitemsfromstructure.
 •Repairorreplacebrokenpartsimmediately.Call1-800-846-2345 or 1-630-879-2050 for replacement parts.
•Suncastisnotresponsiblefordamagecausedbyweatherormisuse.
 •Atregularintervalsinspectyourarbortomakesurethatassemblyintegrityhasbeenmaintained.
 •Periodicallycheckthatthelocationyouhavechosentosetyourarborisstilllevel.
 •Avoidexcessheatfromanyauxiliarysource.
 •Railingisnotintendedasaseat.
 •Anyadditionalholesdrilledintopartscouldcauseunsafeconditions.
•Followmanufacturersafetyinstructionswhenusingladder.
 •Donotanchortopaverbricks.Foundationmustbeasolidsurface.
 •Exercisecautionusingalawnmower,edgetrimmerorotheryardequipmentneararbor.
CAUTION
TOOLS REQUIRED
• Screw Gun or Drill with Screw Bit or Phillips Screwdriver
• Hammer
• Ladder
• Rubber Mallet
• Assistance is required during assembly.

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AB
DE
C
FG
HIJK
LMN
PARTS
AA BB CC DD
HARDWARE
ANCHOR BRACKET
#0630632
2 1/2" Screw
x50
#0630635
2" Screw
x12
#0630635
2" Screw
x16
#0630636
Angle Bracket
x4
#0630637
Stake
x4
#0630633
3" Screw
x26
CA3500 - #0W00174
CAS3500 - #0W00174S
Handrail
x2
CA3500 - #0670064
CAS3500 - #0670119
Beam
x2
CA3500 - #0670060
CAS3500 - #0670122
Post
x4
CA3500 - #0W00176
CAS3500 - #0W00176S
Spindle
x12
CA3500 - #0W00165
CAS3500 - #0W00165S
Rafter
x7
CA3500 - #0670061
CAS3500 - #0670118
Arch
x2
CA3500 - #0670063
CAS3500 - #0670120
Post Trim Ring
x4
CA3500 - #0W00175
CAS3500 - #0W00175S
Railing Support
x4
CA3500 - #0670062
CAS3500 - #0670121
Post Top Trim
x4
CA3500 - #0W00173
CAS3500 - #0W00173S
Rail
x4
CA3500 - #0W00166
CAS3500 - #0W00166S
Arch Support
x4
#0630634
1.5" Finishing Nail
x16

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1. Openthebox.Removeandorganizetheparts.
ASSEMBLY PROCEDURE
2. Locate the two Arches (A) and the four Arch Supports (B).
On a smooth floor or surface, take one Arch and two Arch
Supports and arrange as shown. Align edges to create a
smooth seam.
A
B
D
E
C
F
G
H
I
J
K
A
A
BB
B
smooth seam

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3. Attach each Arch Support to Arch using one 3" Screw (AA),
through the pre-drilled hole, at location and angle shown.
4. Locate two Posts (C) and two Post Trim Rings (D). Slip one
Post Trim Ring over the long board on each Post, as shown.
5. Take one Post, with Post Trim Ring, and insert the long board
into the notch of the arch assembly with trim ring flush
against arch and beam receptacle facing up.
Attach Post to arch assembly with three 2" Screws (CC)
through pre-drilled holes in positions shown.
NOTE: Do not sink screw heads into wood.
x2
x3
x2
CC
AA
AA
C
D
long board post ring
notch
long board
beam receptacle

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6. Repeat step 5 on second post of arch assembly.
7. On both sides of arch assembly, center Arch Support
on Post and attach each with two 3" Screws (AA)
through pre-drilled holes in positions shown.
8. Repeat steps 2 - 7 to assemble second arch.
x2
AA

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9. Locate one Beam (E). With at least two people, stand one arch assembly
upright. Insert the tongue, on the end of one Beam, into the receptacle on the
Post (C).
From the inside of Arbor, secure Beam to Post with one 2 1/2" Screw (BB)
angled through Beam and into Post. See Illustration.
With assembly still upright, repeat with second Beam on opposite side of
arch assembly.
10. With at least two people, stand remaining arch assembly upright.
Insert loose ends of both Beams into Post receptacles and secure
with one 2 1/2" Screw (BB) in each Beam in the same manner as
step 9.
E
BB
E
C
insert tongue into receptacle
top view of screw angle
EC

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11. Locate one Rail (F) and one Handrail (G). Center the Rail
on the flat side of the Handrail.
Secure with three 2 1/2" Screws (BB) inserted through
pre-drilled holes in cutouts of Rail, in positions shown.
12. Locate the four Railing Supports (H). Align the end of
railing assembly (F/G) 1 3/4" from the top and centered
over the pre-drilled holes in the notched end of one
RailingSupport.Seephotoforexactpositioning.
Fasten Railing Support to railing assembly with four 2
1/2" Screws (BB) in pattern shown.
G
F
H
G
F
BB x4
BB x3
H
1 3/4"
at side
F
G

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13. Repeat step 12 for the other side.
14. Locate the twelve Spindles (I). Stand railing assembly on
endandinsertsixSpindlesintothecutoutsintheRail,as
shown. I
H

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15. Take a second Rail (F) and insert top ends of Spindles into
cutouts in Rail, as shown. If necessary, use a rubber mallet,
to fully seat Rail and Spindles.
16. Center Rail on both Railing Supports (H) and attach with two 2 1/2"
Screws (BB) through pre-drilled holes on each side in locations
shown.
17. Repeat steps 11 - 16 to assemble second railing.
F
H
BB x4

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18. Position arbor assembly on a smooth flat surface.
Under the Beams, center railing assemblies on
Post and set flush to bottom of post.
19. Attach railing assemblies using four 2 1/2" Screws
(BB) through pre-drilled holes in each of the four
Railing Supports, as shown. BB BB
BB
BB
x16
left side right side
center on post
ush to post
under the beams

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20. Locate the seven Rafters (J). Align the two cutouts on each
Rafter with the cutouts on the Arches.
Attach each Rafter with one 3" Screw (AA) through pre-drilled
holes at each cutout, as shown. J
AA x14
align cutouts

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21. Locate the four Post Top Trim (K) pieces. Take one Post Top
Trim and place over a Beam positioned with short leg facing
the interior of Arbor. Slide down on Beam until short leg rests
on Post and long leg rests on Post Trim Ring. See photos for
correct placement.
22. Attach Post Top Trim to Beam with four 1 1/2" Finishing Nails
(DD) through the pre-drilled holes at positions shown.
K
short leg
short leg
post
DD
x4
long leg
K
K
post trim ring

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23. Repeat steps 21 - 22 to install remaining three Post Top Trim
pieces.
24. This Arbor includes brackets to anchor the Posts. The Arbor must be installed on a firm, level surface.
Attach Angle Bracket (M) to bottom of Post using two 2" Deck Screws (N). Attach Bracket to floor, foundation, or
the ground using appropriate fasteners.
NOTE: Use 2" screws if foundation is wood or composite material. If foundation is concrete or other hard
surface, use hard surface fasteners purchased separately. Use Stakes (L) if anchoring to ground.

15

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Suncast Products and Replacement Parts
To purchase Suncast replacement parts and learn about other Suncast products visit us online or call.
www.suncast.com
24 hours a day, 7 days a week, 365 days a year.
1-800-846-2345 or 1-630-879-2050
Mon - Fri 6 am - 8 pm, Sat 8 am - 5 pm, Sun Noon - 5 pm CST