2x24 Flat Top Louvered Pergola A B C A S S E M B LY G U I D E Model: D Bristol Grande OPTIONAL ACCESSORIES A) Bolt Down Bracket Kit B) Pergola Wall C) Pergola Planter D) Tall Base Molding (2x 4pc Kit) E) Short Base Molding (2x 4pc Kit) F) Pergola Privacy Trellis E www.newenglandarbors.com www.newenglandarbors.co.uk F Ver 1.4.
Ta b l e o f Co n t e n t s PAGE 12 x 24 Flat Top Louvered Pergola Introduction & Overview……………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .………. . . . . . 3 Pergola Materials Overview………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . …. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pergola Materials Breakdown………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .…. . . . . . . . . . . . .
IInnttrroodduuccttiioonn && O Ove verrvviieew w 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.
Pergola Materials Overview www.newenglandarbors.com www.newenglandarbors.co.uk 4 7 1 9 2 3 5 6 13 8 10 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Pergola Materials Breakdown www.newenglandarbors.com www.newenglandarbors.co.uk Check Boxes (Total of 13 ) 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 (6) - 10699-1 2. Main Column Tops (6) - 10930 3. Post Trims (12) - 10698-1 4. Rafter & Beam Decorative End Caps (24) - 10829 5. Main Support Beams (12) - 10983 6.
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 (4) - 20000 B C D E B. 5/8” (16mm) Stainless Steel Screws (144) - 20016 (to lock Louver Assembly to F G H I J Steel Holder Brackets ) C. 1 1/2” (38mm) Stainless Steel Screws (96) - 20005 - (for Beam and Rafter Joiners) D.
Wood Post Layout & Installation for In-Ground Application www.newenglandarbors.com www.newenglandarbors.co.uk Post location and placement is the most critical step in the overall installation process. Please double check for the possibility of any underground utilities such as sprinkler, gas or telephone lines. Overhead View 1 135 1/2 in. 344.2 cm 135 1/2 in. 344.2 cm 191 5/8 in (486.7 cm.) from corner of wood post to corner of wood post. 191 5/8 in (486.7 cm.
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 six 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. 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 (4x15x300cm) pressure treated wood into a rafter end section follow by the joiner and a rafter middle section. Make sure the notch is at the bottom as shown. www.newenglandarbors.com www.newenglandarbors.co.uk Rafter Middle Section Rafter End Section 3 Glue and attach the Decorative End Cap onto the one end as shown. 3 4 Using four 1 1/2” (38 mm) screws provided, fasten the Rafter Joiners, Rafters, and Wood together as shown.
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 six 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.
3 Place the rafter sections onto the main support beams as shown. www.newenglandarbors.com www.newenglandarbors.co.uk 3 Install the rafter face joiners against the post as shown below. Fasten with 4” (102 mm) screws through the face as shown. Fasten the top and bottom with 1 1/2” (38 mm) screws as shown.
5 www.newenglandarbors.com www.newenglandarbors.co.uk A To install the rafter joiner, temporarily lift and place the inside rafters sections on its side as shown. B Join the two rafter sections with a rafter joiner as shown, and fasten with four 2 1/2” (64 mm) screws as shown. C Replace the rafter assembly into place and repeat for second inside rafter.
6 Fasten the Rafters to the four corner posts using 4” (102 mm) screws provided (4 per post). www.newenglandarbors.com www.newenglandarbors.co.
7 Fasten a 4” (102 mm) screw at each intersection where the Beams and Rafters intersect as shown. 36 screws will be needed. www.newenglandarbors.com www.newenglandarbors.co.uk Note: The spacing between the rafters should be 42” (106.7 cm) as shown below. 7 *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: 6 x Pre-Assembled Louver Bars (plain) 12 x Pre-Assembled Louver Bars with Long Louver Bar* 6 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 twelve 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 6 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.newenglandarbors.
Louver Assembly 10 Repeat for other five rows. 10 11 Place the Post Caps onto the posts. www.newenglandarbors.com www.newenglandarbors.co.
STEP EIGHT Turn Bar Holder Installation 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. Fasten with two 2 1/2” ( 64 mm) screws provided.
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 foot print of the pergola is 12’ x 24’ 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 168 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 126” x 283” ] 283 in (Distance to outside pots) All 168 louver boards are cut down by 6” (15.2 cm) All 12 Beam Sections are cut down by 9” (22.9 cm) 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.co.
