2x12 Flat Top Louvered Pergola A B C A S S E M B LY G U I D E Model: Camelot D OPTIONAL ACCESSORIES A) Bolt Down Bracket Kit (4 for Pergola) B) Pergola Wall C) Pergola Planter D) Tall Base Molding E) Short Base Molding E www.newenglandarbors.com www.newenglandarbors.co.uk Ver 1.
Ta b l e o f Co n t e n t s PAGE 12 x 12 Flat Top Louvered Pergola Introduction & Overview……………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .………. . . . . . 3 Pergola Materials Overview………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . …. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pergola Materials Breakdown………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .…. . . . . . . . . . . . .
IInnttrroodduuccttiioonn && O Ove verrvviieew w (Camelot Pergola Shown) Getting Started First off, allow us to say thank you for the investment you have made in one of our fine pergola kits. This kit is designed to be assembled and installed ideally by two people with basic carpentry knowledge and tools. Do not attempt alone, especially during the installation stage.
Camelot Pergola Materials Overview www.newenglandarbors.com www.newenglandarbors.co.uk 1 2 3 4 5 6 7 11 8 9 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Turn Bar Holder (1) - 10957 - Found in Box 7 Post Caps (4) - 10699-1 12. Pre-assembled Louver Bars (Right) - With Long Louver Bar (3) - 10986 Main Column Tops (4) - 10930 13. Pre-assembled Louver Bars (Left) - With Long Louver Bar (3) - 10985 Post Trims (8) - 10698-1 14. Steel Holder Brackets (36) - 10937 Rafter & Beam Decorative End Caps (20) - 10829 15.
Camelot Pergola Materials Breakdown Check Boxes (Total of 7) for These Contents In the event of missing or defective parts please call our customer service dept. at 1 800 282 9346 (Mon. to Fri. 8:00 AM to 4:00 PM EST). (UK Tel: (44) 2038 687160 - Mon to Fri. 1:00 PM to 10:00 PM GMT). 1. Post Caps (4) - 10699-1 2. Main Column Tops (4) - 10930 3. Post Trims (8) - 10698-1 4. Rafter & Beam Decorative End Caps (20) - 10829 5. Main Support Beams (8) - 10983 6. Beam & Rafter Joiners (10) - 10820 7.
Pergola Additional Materials List www.newenglandarbors.com www.newenglandarbors.co.uk Hardware (in plastic bag) A All Screws Included with this Kit are Self-Auguring. A. Tube of Vinyl Weld Glue (2) - 20000 B C D E F G H B. 5/8” (16mm) Self-Auguring Stainless Steel Screws (72) - 20016 (to lock Louver Assembly to Steel Holder Brackets ) C. 1 1/2” (38mm) Self-Auguring Stainless Steel Screws (40) - 20005 - (for Beam and Rafter Joiners) D.
Wood Post Layout & Installation for In-Ground Application www.newenglandarbors.com www.newenglandarbors.co.uk This pergola can also be installed on a pre-existing wood or concrete surface using our bolt down bracket system with a 4x4 wood post (sold separate). See page eight for more details. Overhead View 1 135 1/2 in. 344.2 cm Post location and placement is the most critical step in the overall installation process.
OPTIONAL STEP Wood Post Layout & Installation Using Bolt Down Brackets for Concrete or Wood Surface www.newenglandarbors.com www.newenglandarbors.co.uk 1 * * 134 3/8 in 341.3 cm Note: for additional information on the bolt down bracket installation, refer to the bolt dow bracket instructions. * Orientate brackets accordingly to reduce offset motion of posts. (direction of arrows denote flange opening) 190 in (482.
STEP THREE *Ensure that predrilled holes at top of column are orientated correctly for future beam and rafter placement. Vinyl Column Assembly & Installation Over Wood Posts 1 Using the vinyl weld glue, insert the One Way 4”x4” Internal Wood Post Guide in the one end of the main column posts. This step is only applicable if your wood 4x4 post are embedded into the ground. If your pergola is going to be installed on wood or concrete surface, please dispose of these four pieces.
At this stage, the columns should be properly installed as per the following illustration, with the columns 134” in. (340.4 cm) apart. Also, notice that the holes at the top of each post should be facing the same direction. 134in. 340.4 cm. 134 in. 340.4 cm.
Main Support Beam Assembly 3 Using four 1 1/2” (38mm) screws provided, fasten the Beam Joiners, Main Support Beam, and Wood together as shown. 3 4 Now that the wood is secured in place, use the 1/2“ (13mm) predrilled holes as templates and drill 1/2” (13 mm) holes through the wood as shown. Make sure to drill straight through to the other side of the main support beam. Note: Do not pre-drill the 1/8" screw holes through the wood.
Rafter Assembly 2 Insert one of the notched 2x6x12 (5x15x300cm) pressure treated wood into a rafter section follow by the joiner and another rafter section. Make sure the notch is at the bottom as shown. www.newenglandarbors.com www.newenglandarbors.co.uk 3 Glue and attach the Decorative End Caps onto the ends as shown. 3 4 Using four 1 1/2” (38 mm) screws provided, fasten the Rafter Joiners, Rafters, and Wood together as shown. 4 5 Repeat for all six rafters.
STEP SIX Main Support Beams & Rafter Placement 1 Using a helper and two ladders proceed to complete the following steps: 1 Raise one Main Support Beam Assembly at a time and insert the 9” Bolt Assembly into the holes to hold into place as shown. Some force may be required to get the bolt through. Do not tighten the nuts until all four beams are in place, instead, simply hand-tighten them. Note: The 9" Bolt Assembly is used to properly position the main beams on the columns.
Main Support Beams & Rafter Placement 4 www.newenglandarbors.com www.newenglandarbors.co.uk 4 Fasten the Rafters to the Posts using the 4” (102 mm) screws provided (4 per post). 5 Note: The spacing between the rafters should be 42” (106.7 cm) as shown below. Fasten a 4” (102 mm) screw at each intersection where the Beams and Rafters intersect as shown. 24 screws will be needed. 5 5 *Important: Make sure the distances between rafters are 42” (106.7 cm).
Pre-Assembled Louver Bars with Long Louver Bar STEP SEVEN Louver Assembly 1 Note the difference in distance to the first Louver Bracket This kit contains four different pre-assembled Louver Bars as shown below and aside: 3 x Pre-Assembled Louver Bars (plain) 6 x Pre-Assembled Louver Bars with Long Louver Bar* 3 x Pre-Assembled Louver Bars with Short Louver Bar *) There are two variations of Louver Bar Assemblies with Long Louver Bar.
Louver S T E P Assembly EIGHT 2 Insert the Louver Boards one by one. Make sure each board is inserted completely into the brackets. 2 www.newenglandarbors.com www.newenglandarbors.co.uk 3 Attach the matching Pre-assembled Louver Bar. Pressure fit the boards one by one. 3 The ends of the louver bars with large space should be at the same end. 4 Ensure that the holes in the louver holder brackets are all on top of the louver bars assembly Repeat for all six sub-sections.
Louver Assembly 5 www.newenglandarbors.com www.newenglandarbors.co.uk Place twelve Steel Holder Brackets as shown below and carefully lower the Louver assembly onto the steel brackets. Do not screw the Steel Holder Brackets in place at this point. Steel Holder Brackets 6 Install in order (one row at a time) Fasten the Short Louver Bar using two nuts as shown. Do not over tighten. You will need to raise the middle section momentarily to do this step.
Louver Assembly 7 Slide the Steel Holder Brackets to a spot which will not interfere with the operations of the louvers. ‘Open’ and ‘Close’ the louvers to test and make sure the steel brackets are not constraining the operation. 8 From the top, fasten the steel brackets in place using 5/8” (16 mm) screws. A total of 12 screws will be needed. 9 Repeat for the underside of the steel brackets. Another 12, 5/8” (16 mm) screws will be needed. 7 8 9 Bottom View www.newenglandarbors.com www.
Louver Assembly 10 Repeat for other two rows. 10 11 Place the Post Caps onto the posts. 11 www.newenglandarbors.com www.newenglandarbors.co.
STEP EIGHT Turn Bar Holder Installation www.newenglandarbors.com www.newenglandarbors.co.uk The Turn Bar Holder is packaged in box 7 kit and is designed to provide a place to keep the Turn Bar when not in use. 1 Pick a location that is easily accessible and out of the way of the louvers operation. The post is recommended as the 2 1/2” (64 mm) screws are used to protrude into the wooden post, providing a secure mounting support. 2 Mount with the slot on the top and closer to the post as shown.
O P E R AT I O N S 1 1 To adjust the positions of the louvers, slide the Turn Bar in between two louver boards and turn in a circular motion to the desired position. Excessive force should not be required. 2 For best leverage, push with the arm of the Turn Bar as opposed to ‘prying’ with the Turn Bar Cap(see illustrations). 3 If operation proves to be difficult, this may be caused by nut(s) that are too tight.
M O D I F I C AT I O N The footprint of the pergola is 12’ x 12’ measured to the outside of the posts. If a smaller dimension is required, a few guidelines should be considered: 1 1 It is easier to shorten the pergola by the way shown - by shortening the lengths of the louver boards and the beams versus shortening the lengths of the pre-assembled louver bars. 2 Asthetically, it is best to cut all 84 boards equally so that they are even across the three rows.
M O D I F I C AT I O N S www.newenglandarbors.com www.newenglandarbors.co.uk Below is an example of resizing the pergola: [In this example, the new dimensions are 120” (10’) x 102” (8’-6”)] All 84 louver boards are cut down by 6” (15.2 cm) All 4 Beams are cut down by 9” (22.9 cm) 144 in (Distance to outside posts) 36 in 36 in 36 in 126 in (Distance to the outside posts) North America Toll Free Phone: 1 800 282 9346 United Kingdom Tel: (44) 2038 687160 www.newenglandarbors.com www.newenglandarbors.
