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Assembly Instructions
Big Kahuna™ PLUS Covered Pergola Kit - Attached
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 - Attached 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 (2 for standard size kits) o 2x8 Notched Rafters (# depends upon kit size) o 6x6 Notched Posts (2 for standard size kits) o 4x6 Angle Braces (4 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 the ledger board against the wall exactly where it will be installed but •...
- Page 5 Move the beams from side to side until you have the same measurement both ways. When you have the same measurement, it is perfectly square. Once square, make sure the assembly does not move. Step 6 – To identify the location for each post hole or post base, look at the top of the •...
- Page 6 For orders specifying buried posts (posts installed into concrete foundations), we supply two posts at lengths of 12’. All standard kits are designed for a slope of ½” for every 12” of total rafter length, making the height difference between the post and beam assembly and the ledger board greater for longer rafter lengths, as follows: Rafter Length Post to Ledger Height...
- Page 7 measure the height differential between the outside post location and ground level at the wall, then adjust for that difference to the required post height differential from the table above. For example: Assume pergola size is 18x20 (18’ rafter length), desired 9’ above ground post height, two 10’...
- Page 8 For posts being installed into concrete footings, we recommend inserting one piece of supplied 10” rebar into the bottom of each post. Locate and mark a spot at the center of each post approximately 10” below ground level. Using a 5/8" drill bit, drill a hole through the post at the desired mark on each post.
- Page 9 Step 12 - 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”. Set the other beam on top sandwiching the post in between the two beams. Step 13 - Place 1 washer on each ½”...
- Page 10 existing ground as required). Holding the ledger board in place exactly where it will be installed, ensuring that the board is level, mark with a pencil through the pre-drilled holes in the ledger board. If installing on a concrete wall, using a 5/8" masonry drill bit, pre-drill holes in the masonry wall to a depth of at least 4 1/2".
- Page 11 placement or height of either the post and beam assembly or ledger board. Please contact us as needed to assist. When the first rafter fits squarely, secure the rafter to the beam and ledger using 6” screws provided through the predrilled holes in the rafter onto the top of the beams. Then move to the opposite side and secure another rafter into position over the corresponding X marks on the other side of the beam assembly (second X marks in from the tip of the beams) and ledger board.
- Page 12 Then, mark another spot down two inches from the top of the beam (where the angle brace meets the top of the beam) and in the center (side to side) of the angle brace – avoid the rafter as shown in the picture below. Ensuring the beams and angle brace do not move, pre-drill through the beam and angle brace at the marked spots using 1/2”...
- Page 13 Step 19 - Install the remaining two rafters over the two outermost X marks on the • beam assemblies. Secure each rafter to the beam and ledger board using 6” screws provided with your kit through the predrilled holes. Step 20 - 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...