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RioOutdoors 4F-PH Installation Instructions Manual

4x4 floating partial hexagon pergola kit
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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.
•
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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P a g e
Installation Instructions
4F-PH
4x4 Floating Partial Hexagon Pergola Kit
Pergola Kits
Figure 1: Items included in the kit, (
Items not included in this kit: wood, tools, some hardware.
).
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Summary of Contents for RioOutdoors 4F-PH

  • Page 1 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.
  • Page 2 1.12 P ARTIAL EXAGON ERGOLA SSEMBLY UTLINE ..............14 1.2 T ........... 4 OOLS REQUIRED 1.3 C # 4F-PH ........5 ONTENTS OF 1.4 O ....5 PTIONAL ECK SUPPORT RACKETS 1.13 A #4HL H . 16 1.5 L DDING...
  • Page 3 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.
  • Page 4 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...
  • Page 5 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.
  • Page 6 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. Total Item Item...
  • Page 7 1.6 GENERAL LUMBER REQUIREMENTS INFORMATION We have designed the corner elbow brackets to provide automatic alignment of the header 4x4s. By making certain all header 4x4s are of the same length and not warped, following the instructions properly, and securing the 4x4s to the elbow brackets as instructed, you will achieve a perfect octagonal shape for your pergola.
  • Page 8 To create a deck, you must add support beams every 24”, or less, to support the deck boards. You may toenail the support beams in place or choose an easier and more precise mounting method using our Beam Support Brackets (SKU# 24BS, available at RioOutdoors.com). P a g e...
  • Page 9 1.7.2 Floor Leveling and Preparation. Plan to assemble a floating pergola where you can excavate and create a level platform, 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 the posts of the pergola to prevent the pergola from sinking into soil.
  • Page 10 1.8 OVERALL PERGOLA SIZE We have designed the corner elbow brackets to provide automatic alignment of the floor floating 4x4s and the header 4x4s. By making certain all outer perimeter “Header Lengths” are of the same length, following the instructions properly, and securing the 4x4s to the elbow brackets as instructed, you will achieve a perfect hexagonal floating deck base for your pergola.
  • Page 11 1.9 SIDE ELEVATION DIAGRAM Based on the height of the post used, the diagram below provides the side elevation profile for this pergola system. POST HEIGHT DIM A (in.) (in.) 92 1/2 104 1/2 116 1/2 128 1/2 140 1/2 The Post Height, above, equals the outer height of the pergola.
  • Page 12 1.10 POSTS PREPARATION A total of five (5) posts of equal length are required to build this structure. Make certain that all post members are as straight as possible and they are of equal lengths. The lumber you acquired from the store shelf can vary in lengths. Measure all post lengths, first.
  • Page 13 1.11.2 Preparing lumber member “A.” Follow the steps, below. Cut and prepare four (4) identical lumber members to be used as item 1.11.3 Preparing lumber member “B” Follow the steps, below. Cut and prepare four (4) identical lumber members to be used as item 1.11.4 Preparing lumber member “C”...
  • Page 14 1.12 PARTIAL HEXAGON PERGOLA ASSEMBLY WORK OUTLINE 1.12.1 Brackets application depiction This image shows where all brackets are used. 1.12.2 Structure assembly outline 1. Lay out the two items “A,” two items “B,” and one item “C” in a rough partial hexagon shape, as shown below. 2.
  • Page 15 8. Check top of all floating 4x4s for level. Adjust and make level, as necessary. 9. Insert a vertical post inside all five post receiver tubes. Slide post all the way down. If you feel any resistance, tap the top of the post lightly with a hammer.
  • Page 16 1.13 ADDING FLOOR CORNER #4HL HEX ELBOW BRACKETS Before starting assembly work, measure the length of each perimeter 4x4 to verify that they are of equal length and make certain each member is straight (has no bow nor is warped). On the ground, mark the location of one corner post. Start assembly at this post location and continue assembling floor members and corner elbow brackets around the perimeter.
  • Page 17 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”...
  • Page 18 7. Use a ratchet driver and a 7/16” socket to drive one ¼” X 1-1/4” lag screw through the pilot holes you drilled. Total of four lag screws are required. One in each lower hole on the sides of the U-channels. 8.
  • Page 19 1.14 ADDING FLOOR #4C2L BRACKETS 1. At corner #5, slide one #4C2L elbow over two adjacent 4x4s so the U-channels in the 2-way elbow bracket are inverted and over the 4x4s. 2. Place two shims under each 4x4 near the 2-way elbow. 3.
  • Page 20 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”...
  • Page 21 8. Drive one ¼” X 1-1/4” lag screw through four pilot holes you drilled in the outer faces. 9. Repeate step 8 for the holes in the inner corner faces of the U-channels. 10. Repeat Steps 2 to 9 at corner #6 and add the second 2-way 90 degree elbow bracket. 11.
  • Page 22 1.15 POSTS INSTALLATION 1. Slide a 4x4 post inside the open vertical tube in all corners’ elbow brackets. If post resists sliding easily, tap top of post lightly with a hammer. Post must slide all the way down to the bottom of the square tube. 2.
  • Page 23 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. 4. Repeat steps 2 to 3 at all corners. Check top of floor 4x4s for level one more time and adjust as necessary to maintain level. 23 | P a g e...
  • Page 24 1.16 POST TOP #4HL ELBOW BRACKETS INSTALLATION 1. Slide a #4HL elbow bracket’s tube over the 4x4 post top after aligning the header receiver u-channels in the proper directions. Let gravity work and pull the bracket all the way down on top of the post. If you feel resistance tap lightly on top of the elbow bracket until it slides all the way down.
  • Page 25 3. Identify the four 5/16” holes which are on the sides of the gussets in the elbow bracket. 4. Drill 3/32” X 1-1/4” deep pilot holes at the center of four 5/16” Holes. Locate pilot holes at the center of each 5/16” hole.
  • Page 26 1.17 POST TOP #4C1L BRACKET INSTALLATION Slide a #4C1L bracket’s tube on the 4x4 post tops #5 & 6 after aligning the header receiver u-channels in the proper direction. Let gravity work and pull the bracket all the way down on top of the post. If you feel resistance tap lightly on top of the elbow bracket until it slides all the way down.
  • Page 27 Drill 3/32” X 1-1/4” deep pilot holes at the center of four 5/16” Holes. Locate pilot holes at the center of each 5/16” hole. Drive one ¼ x 1-1/4” Lag Screw through each 5/16” hole into the pilot holes you drilled in step 4, using a 7/16” Socket and Rachet driver.
  • Page 28 1.18 SECURING THE HEADERS 1.18.1 Header “A” Installation 1. Lift and place one “A” 4x4 header into the U-channels between post #1 and post #2. 2. Locate the two 5/16” holes on each vertical face of the U-channels holding the 4x4 header. Drill 3/32” X 1-1/4” deep pilot holes at the center of four 5/16”...
  • Page 29 3. Before driving lag screws, review the position of the header ends on both ends of the header. Make certain that it is conforming to the image, below. The mitered ends of the headers should touch the bracket’s corner square tube face or be close to touching the tube face.
  • Page 30 1.18.2 Header “B” Installation 1. Lift and place one header “B” between post top #3 & #4 and one header “B” between post top #2 & #5. The miter cut ends of header “B” are to be positioned against post #3 and post #2. 2.
  • Page 31 3. Drill 3/32” X 1-1/4” deep pilot holes at the center of 5/16” holes at both ends of the header and on both sides. Locate pilot holes at the center of each 5/16” hole. Perform this step for both “B” headers. 4.
  • Page 32 1.19 INSTALLING DECK BOARD SUPPORT BEAMS 1. Decide on which direction you would like the deck boards to run. Deck support beams run in a perpendicular direction to the deck boards. Support beams should be spaced, approximately, every 24” or less to support the deck boards. Using a pencil or marker, mark the center locations of each beam on the inside face of the floating 4x4s to which you will attach the beams.
  • Page 33 6. Secure the support beams to brackets using #6 x 1” SS wood screws. Two screws on each side of the Beam Support Bracket are required. 1.19.1 Installing Deck Boards 1. Plan and lay down your deck boards starting in the center of the pergola. Work outward from the center in both directions. Use the thick end of a wood shim as a spacer to leave an 1/8”-1/4”...
  • Page 34 2. When you approach the vertical post corners, create notches in the deck boards ends to fit around the corner post bracket and the gussets. The gussets are 1/8” thick. Make a cut the width of a carbide tipped circular saw blade to create a clearance slot for the corner gussets.
  • Page 35 Was it easy to do? Did parts fit easily and properly? Do you like the quality of our products and design styles? Is your pergola structure sturdy and strong? Please go to RioOutdoors.com and provide us with your review.
  • Page 36 Warranty protects against defect in manufacture only, unless herein specified otherwise. Any part(s) found to be defective during the warranty period as outlined above will be repaired or replaced at RioOutdoors.com’s option provided that the defective part is returned, if requested by RioOutdoors.com. Alternatively, RioOutdoors.com may at its own discretion fully discharge all its obligations under the warranty by refunding the verified purchase price of the product to the original purchaser.
  • Page 37 Parts where the RioOutdoors.com logo has been altered, deleted, removed, or made illegible will void this warranty. Minor movement, expansion and contraction of the steel parts is normal and is not covered under the terms of this warranty.