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Dundalk LeisureCraft Cedar Assembly Instructions Manual

Barrel sauna
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Ver. 2.8
Dundalk LeisureCraft Cedar Barrel Sauna
Assembly Instructions
Please read and understand the complete instructions prior to assembly and use of your sauna. Customer agrees not to hold
Dundalk LeisureCraft Inc. and any of its authorized dealers liable for improper installation, maintenance and repair of this product
Requirements:
2 People (recommended)
* Carpenter's Hammer
* Step Ladder
* Cordless Drill (we supply the bit)
* Tape Measure
Carpenter's Level
* Rubber Mallet
View the assembly process on
ph: 519-923-9813 | info@dundalkleisurecraft.com| web: www.dundalkleisurecraft.com

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Summary of Contents for Dundalk LeisureCraft Cedar

  • Page 1 Please read and understand the complete instructions prior to assembly and use of your sauna. Customer agrees not to hold Dundalk LeisureCraft Inc. and any of its authorized dealers liable for improper installation, maintenance and repair of this product Requirements: 2 People (recommended) * Carpenter’s Hammer...
  • Page 2 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Index Sauna Base Preparation (Standard) – Page 3 Sauna Barrel Assembly (Standard) – Page 4 to 14 Standard Bench Installation (Standard) – Page 15 to 18 Signature Bench Installation (Option) – Page 19 to 24 Lounge Bench Installation (Option) –...
  • Page 3 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Sauna Base Preparation A solid base for your sauna is recommended and can be made from any of the following. Concrete Pad Wooden Deck Crushed Gravel Patio Stones/Paver Blocks (Refer to the below chart for minimum base requirements) It is recommended to build a base larger than required to provide a sitting area for cooling off during your sauna session.
  • Page 4 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions *Please note that the number of Barrel Cradles supplied depends on the overall length of the sauna. *Saunas with an overall length of 10’ (305cm) or greater have 3 cradles while saunas that are less than 10’...
  • Page 5 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Secure stave into cradle using 2 ½” (64mm) screws. Repeat for remaining cradles. *Always ensure that you have the correct screw length so that there will be enough thread to hold, and especially, so that the screw does not go all the way through the material and come out the other side.
  • Page 6 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Use rubber mallet to tap wall into back groove. Repeat this process to install the door panel on the front wall. Make sure the door is centered with the middle stave. Use the top stave to go from the front wall to back wall to help stabilize the sauna.
  • Page 7 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Install the front half moon side wall panels. Screw into place at the top and bottom with 2 ½” (64mm) screws. Repeat for back wall. * Note that the bench brackets face inside of sauna.
  • Page 8 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Install a few staves at a time, alternating sides. Secure every 2 stave on the bottom of the sauna with the provided 2 ½” (64mm) nails to hold staves in place. ( If required)
  • Page 9 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions When you reach the top, you will find that the last wall stave doesn't look like it fits properly, this is normal. Assemble the steel bands by sliding the rod with a nut on one end through the other and secure with a second nut.
  • Page 10 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Measure all around the sauna to ensure the measurement of the bands are consistent. Secure band in same manner as previous step. Snug up bands with the cordless drill. Use the rubber mallet to tap the staves out & in as needed to get the last wall stave and top stave to sit properly together.
  • Page 11 Adding a Spacer to the Top Sauna Stave In your sauna package you will find a spacer stave that is square on both sides that is only required If there happens to be a “gap” after installing all of the staves, (as in Fig.1) You will need to follow the following instructions to add this spacer to the top special stave.
  • Page 12 Making the Top Sauna Stave narrower In rare instances, your sauna staves will be too tight not allowing the staves to settle into position correctly. (as in picture) This doesn’t happen often and the sauna staves and bands are always better being as tight as possible. You will need to follow the following instructions to make the top special stave narrower.
  • Page 13 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions The front and back bands should be 2” (5cm) from the end of the staves. * Space out middle bands according to sauna size and how many bands are included. Tighten all bands as tight as possible.
  • Page 14 If ordered, Install the thermometer centered above the door using a 1 ½“ (38mm) screw. • The main structure of your Cedar Barrel Sauna is complete. • Please refer to each of the remaining sections to install the various upgrades and options chosen.
  • Page 15 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions The flat floor (If Purchased) Is shipped semi assembled. You will need to add the bottom support onto the floor before assembling the benches. Locate the flat floor (A) and bottom support (B).
  • Page 16 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions To begin, Bring in the long sauna benches. Place the long benches down on the wall brackets and then snug up against the back wall. Secure benches to wall supports by attaching with 1 ½”...
  • Page 17 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Screw the bench supports from the bottom up using 3- 1 ½” (38mm) screws in each support. Secure the support leg to the floor using a 2 ½” (64mm) screw in each support.
  • Page 18 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Secure the porch seat to the front wall from underneath using (3) - 2 ½” (64mm) screws. Screw the front of the porch seat into the wall from the outside using a 2 ½” (64mm) screw.
  • Page 19 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions The flat floor (If Purchased) Is shipped semi assembled. You will need to add the bottom support onto the floor before assembling the benches. Locate the flat floor (A) and bottom support (B).
  • Page 20 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Using the front enclosure as a guide, Install the wall brackets with 3 pcs 2 ½” (64mm) screws, again making sure they are level with the sauna walls or door and flush with the top of the front enclosure.
  • Page 21 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Place the 4 seat brackets under the benches lined up with the curved seat support bracket on bottom of bench. Using 1- 2 ½” Screwing from the (64mm) screw, bottom up into the...
  • Page 22 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Screw the seats in place using the same method as in 4 screws in each seat, 2 in front and 2 in the back. previous step. Screw between the seat boards to make the screws less visible.
  • Page 23 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions To install the porch signature bench, first position the floor making sure it is level. Secure the sauna floor to the sauna staves with 2 ½” (64mm) screws. Screwing between the floor boards will make the screws less visible.
  • Page 24 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Position the assembled bench on the porch floor and up against the front wall of the barrel Sauna. Using a level, make sure the bench is level and square to the porch floor..
  • Page 25 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions The flat floor (If Purchased) Is shipped semi assembled. You will need to add the bottom support onto the floor before assembling the benches. Locate the flat floor (A) and bottom support (B).
  • Page 26 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Install the flat floor in the middle of the sauna making sure it is level. Using the pre drilled holes, assemble the lounge bench support to the longer front lower bench wall using 2” (51mm) screws.
  • Page 27 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Ensure bench is flush with the bench support and secure with 2 ½” (64mm) screws in the pre drilled holes. * If sauna is purchased with wood burning heater, repeat process for opposite bench.
  • Page 28 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions If the porch option is selected, start by installing the floor ensuring it is level. Secure with 2” (51mm) screws between the floor boards into the barrel wall. Assemble the 2 pieces for the porch seat together using 2 ½”...
  • Page 29 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions The following installation instructions are for the Helo Cup (Saaku) electric heater. Always refer to the original sauna heater manual for confirmation. Always Read all instructions carefully. Measure the proper distances for the heater template according to the heater manufacturers instructions.
  • Page 30 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions The following installation instructions are for the Helo Cup (Saaku) electric heater. Always refer to the original sauna heater manual for confirmation. Always Read all instructions carefully. Hang the heater on the two upper screws.
  • Page 31 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Locate the pieces for your heater guard. The heater guard contains 2 Assembled side pieces,2 heater guard supports and hardware. Stand the 2 Assembled side pieces of the heater guard on edge with pre-drilled holes on the bottom.
  • Page 32 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions To install the wood burning heater, lift the heater into the hole in the back of the sauna. * Woodstove is very heavy and 2 people are recommended for lifting. Secure the wood stove with the provided 1 ½” (38mm) lag screws.
  • Page 33 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Insert the flanged end of the chimney head onto the elbow firmly. * Some finessing may be required. Ensure that the flanged end of the chimney is securely in place Rinse the rocks with water before placing in the heater.
  • Page 34 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Start by removing all protective film from stainless steel parts before installation. Install floor protecting sheet against back wall centered between benches. Install back wall shield centered over chimney hole with 1 ½” (38mm) screws.
  • Page 35 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Insert the Chimney adapter into rear hole tapping with a rubber mallet until it is snug. Bring stove into position, centered in front of hole, about 6” (15cm) away from wall. Place the short connector through the hole in the sauna from the outside.
  • Page 36 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Insert the “T” connector to the short connector ensuring it is straight. Secure with provided screws. Attach the chimney cover plates using 1 ½” (38mm) screws ensuring halves are level. *Top Plate should overlap the bottom plate.
  • Page 37 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Wrap the chimney support strap around chimney and use the provided nut and bolt to secure. *Snug up only hand tight Attach chimney support braces to the sauna using 1 ½” (38mm) screws.
  • Page 38 Generally, you have access to add a vent to your sauna once assembled if it is deemed necessary. Vent Kit Contents Stainless Steel 3”x 7” Grill (X2) Cedar Vent Cover 1 ½” Stainless Steel screws (X13) Tools Required Hole saw or drill bit to drill holes...
  • Page 39 (6pcs) Install the cedar vent cover over the outlet holes on the inside of the sauna with a 1 ½” screw. * Tighten screw enough that the vent cover still rotates smoothly.
  • Page 40 Sauna Light Assembly Instructions (Optional) If a light is ordered, Dundalk Leisurecraft supplies the light fixture only. The light switch and any other electric components need to be purchased separately and should be installed according to the light manufacturers instructions and by a licensed electrician.

  • Page 41: Product Maintenance

    Dundalk LeisureCraft Sauna Light Assembly Instructions (Optional) Recommend low profile "pancake box" rather than standard octagon box. This can be surface mounted flush inside of the sauna with light fixture fitting over the box. The best placement for your light would be to the side or above the door on the front wall.
  • Page 42 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Line up the cove pieces starting with the smallest pieces on the end and working towards the middle forming a semi circle. Place 2 ½” screws in the pre-drilled holes to assist in the assembly of the cove.
  • Page 43 Dundalk LeisureCraft Cedar Barrel Sauna Assembly Instructions Continue building the cove from the middle until the cove is complete. When installed, the cove should be centered and tight together and to the wall of the sauna. Enjoy your new sauna cove!
  • Page 44 Congratulations on the assembly of your new Western Red Cedar Barrel Sauna! For assistance in the assembly of your Barrel sauna please visit our support page at: https://www.dundalkleisurecraft.com/support/ Or to view the assembly process got to: https://www.youtube.com/watch?v=DxlQu6VUNT0 ph: 519-923-9813 | info@dundalkleisurecraft.com| web: www.dundalkleisurecraft.com...
  • Page 45 This natural weathering will not harm the wood or impair the sauna’s performance. If you wish to retain the natural color of your Dundalk Leisurecraft Sauna, there are many cedar stains on the market and almost as many opinions as to which is best.

  • Page 46: How To Take A Sauna

    Children must be supervised by an adult. WARRANTY Dundalk LeisureCraft Inc. warrants our saunas against defects in materials and workmanship under normal/residential use for a period of five (5) years, as applicable, from the date of receipt of the product by the original end-user consumer.