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Assembly Instructions
Big Kahuna™ PLUS Covered Pergola Kit
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: info@pergoladepot.com
Visit: https://pergoladepot.com/
The Team at Pergola Depot
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Summary of Contents for Pergola Depot Big Kahuna PLUS
- Page 1 Assembly Instructions Big Kahuna™ PLUS Covered Pergola Kit 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...
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Page 2: Tools And Supplies Needed
Tools and Supplies Needed Helpers - at least 2 recommended, especially for larger kits 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) Spray paint, chalk, flags or other materials for marking post locations... - Page 3 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 (4 for standard size kits) o 2x8 Notched Rafters (# depends upon kit size) o 6x6 Notched Posts (4 for standard size kits) o 4x6 Angle Braces (8 for standard size kits) –...
- Page 4 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 all four beams on the ground (with the x’s facing up) exactly where you •...
- Page 5 Step 4 – 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.
- Page 6 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 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.
- Page 7 Post height differential required = 4 ½” (for 12’ rafters per table). Upslope post length requirement = 8’ or 96” (downslope post length) + 4 ½” (post height differential) = 100 ½”. Place 10’ posts on sawhorses, measure 100 ½” from the top (notched end) of the posts down and mark a line toward the bottom across two opposite sides of the posts.
- Page 8 For example: Assume pergola size 20x20 (20’ rafter length), desired 10’ above ground post height at shorter/ downslope side, using four 12’ posts supplied, 4” of height differential for slope of existing ground surface, and minimum post depth of 2 feet or 24 inches (varies depending upon your situation for frost line etc.).
- Page 9 This will allow for small adjustments in the placement of the post in the base on the rafter side of the structure. Then, square each base to the outside edge of the pergola footprint. To square bases, lay one of the beams or rafters (depending upon length needed) on the ground directly outside two of the post bases, then rotate the post bases until the outside edges of each base are touching and square with the board and the side walls are parallel with the rafters.
- Page 10 Step 13 - With one person at each post, tilt one assembly up, lift and drop the posts • into the postholes, or into the post bases if on concrete. Have your helper(s) hold the assembly plumb. If posts are going into footers, check to ensure the ground lines marked toward the bottom of the posts are level with the tops of the holes.
- Page 11 the corresponding X marks on the other side of the beam assembly (second X marks in from the tip of the beams). Adjust as described above as needed. Now your helpers should be able to let go of the assembly. Leaving the outermost rafters for later, install the remaining interior rafters over the “X”...
- Page 12 Repeat for the remaining angle brace to beam attachments. For the angle brace to rafter attachment, place one of the longer angle braces with predrilled side towards the post and long side against the inside of the outer rafter (there will be one more rafter mounted on each side of the beam that will become the outermost rafter in a later step).
- Page 13 Step 17 - Install the remaining two rafters over the two outermost X marks on the • beam assemblies. Secure each rafter to the beams using 6” screws provided with your kit through the predrilled holes. Step 18 - Place the top slats into position across the top of the rafters between the •...
- Page 14 Please let us know if you have any questions or feedback on the instructions, products or our support process. We always appreciate receiving photos of the build and finished spaces! Congratulations and thank you for being a Pergola Depot customer! Hand made in the U.S.A! Call: 1-877-563-0002 Email: info@pergoladepot.com...