Page 1
6 1/2 x 6 1/2 Wood Grain
Flat Top Pergola
ASSEMBLY GUIDE
OPTIONAL ACCESSORY
• Bolt Down Bracket Kit
Page 2
Table of Cont e n t s
Th e 6.5 x 6.5 Wood Grain Fl at To p Pergola
Introduction & Overview……………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .………. . . . . .
6.5 x 6.5 Flat Top Wood Grain Pergola Materials Overview……………………… . . . . . . . . . . . . . . . . …. . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 x 6.5 Flat Top Wood Grain Pergola Materials Breakdown……………. . . . . . . . . . . . . . . . . . . . . . . . . . . …. . . . . . . . . . . . . . . . . . . . . . . .
Pergola Additional Materials List………………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wood Post Layout & Installation for In-Ground Application………………………………. . . . . . . . . . . . . . . . . . . . .
Wood Post Layout & Installation using Bolt Down Post Brackets for Concrete or Wood Surface……………
Vinyl Column Installation Over Wood Posts………………………. . . . . . . . . . …………………. . …………. . …
Main Support Beam Assembly . . . . . . . . . . . . . . . . ………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Support Beams & Rafters Placement . . . . . . . . …………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening Decorative Caps . . . . . . . . . . . ………………………………. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shade Slat Assembly & Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAG E
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4
5
6
7
8
9
10
11
12
12
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6.5 x 6.5 Wood Grain Flat Top Pergola
Page 3
Introduc tion & O ver vie w
Getting Started
First off, allow us to say thank you for the
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. Should you decide to
moderately modify the dimensions of your pergola from the standard kit size,
a circular saw with a sharp fine-tooth blade is all that is needed to cut, shorten
or modify the vinyl components. When assembling components place on a
non-abrasive surface (ie: shipping box) to avoid scratching. We recommend
a 15’x15’ (4.6m x 4.6m) area for unneed to use excessive force when
obstructed assembling. You should not
investment you have made in one
assembling any components.
Planning & Preparing
Because this project is made to stand independent of your home, you can
either locate it near your house or let it stand alone in the garden. By keeping
it unattached from your hom
gutters or matching eave heights. If you plan to build your pergola close to
the house, please keep the outer extremities of the pergola a minimum of 4
inches (10.2 cm) back from your eaves.
What looks like the toughest part of this project is actually the easiest, the
graceful , solid-looking columns. We’ve designed these columns to simply be
slipped over treated 4x4 wood posts that are either embedded in concrete or
directly mounted to a concrete or wood surface using our bolt down brackets.
See pages 7, 8 and 9 for more details.
e you will not have to deal with moving existing
Restriction of Use
This product is not designed to carry additional
loads such as swings, people or other objects.
Please take the time to read this instruction
thoroughly prior to the construction of your pergola. If
you have any questions,
feel free to contact us.
weight
guide
It is critical before you start that you consider the current slope of elevation
where the pergola is planned - if there is any. Also utility or sprinkler line
location is important to identify prior to excavating holes if necessary.
You should also check to verify
hood covenants, or height restrictions regarding this type of structure.
local building codes, ordinances, neighbour-
6.5 x 6.5 Wood Grain Flat Top Pergola
3
Page 4
6.5 x 6.5 Wood Grain Flat Top Pergola Materials Overview
1
2
3
4
5
6
7
1. Rafters ( 7) - 14001
2. Shade Slats (7) -14002 Including
3.
Rafter & Beam Decorative End Caps
4. Post Caps (4) - Top 14004 & Bottom 14005
5. Posts (4) - 14009
6. Main Support Beams (2) - 14008
7.
Rafter Brackets
(10) - 14006
81.5 in
207 cm
Decorativ e End Caps
(18) - 14003
(14) - 14007
110.5 in
280.7 cm
95.25 in
242 cm
110.5 in
280.7 cm
12.3 in
31.25 cm
Front View
87.125 in
221.3 cm
4
78 in
198.1 cm
Top View
6.5 x 6.5 Wood Grain Flat Top Pergola
78 in
198.1 cm
88 in
223.5 cm
Side View
Page 5
6.5 x 6.5 Wood GrainFlat Top Pergola Materials Breakdown
(Accessories Not included)
C heck Boxes (Total of 4) for These Contents
In the event of missing or defective parts please call our customer
service
dept
1. Rafters
2. Shade Slats (7) 1.5” x 1.5 “x 94” (3.8 cm x 3.8 cm x 238.8 cm) - 14002
3.
4. Post Caps (4) - Top 14004 & Bottom 14005
5.
6. Shade Slat Decorative End Caps (14) - 14007
7. Main Support Beams with pre-drilled holes (2) 1.5” x 5.5” x 94.” (3.8 cm x 14 cm x 238.8 cm) - 14008
8. Posts (4) 5” x 5” x 94“ (12.7 cm x 12.7 cm x 238.8 cm) - 14009
( 7) 1.5” x 5.5 “x 94” (
Rafter & Beam Decorative End Caps
Rafter Brackets
(10) - 14006
3.8 cm
x 14 cm x
(18) - 14003
238.8 cm)
14001
-
1
2
8
3
4
5
6
7
Not to Scale
6.5 x 6.5 Wood Grain Flat Top Pergola
5
Page 6
Pergola Additional Materials List
Hardware (in plastic bag)
NOTE: WE HAVE INCLUDED 10% EXTRA SCREWS
BEYOND WHAT IS IDENTIFIED BELOW.
All Screws Included with this Kit are Self-Auguring.
A. Vinyl Weld Glue (2) - 20029
B. 3/4” ( 1.9 cm)
C.
3/4“ (1.9 cm) Self-Auguring Screws (8)
D.
4” (10.2 cm) Self-Auguring Screws with Nylon Washer (49) - 20026
E. 4” (10. 2 cm)
and Rafters to posts)
F. Snap Caps
Extra Materials You will Need
(Purchase separately from retailer of our products)
If Mounting Pergola on Concrete or Wood Deck (Not intended to be
installed on concrete pavers, patio stones, or interlocking bricks)
J.
4x4x4' (10.2 cm x 10.2 cm x 122 cm) Pressure-Treated Wood Posts (4) (purchase
at local building center)
K. 4x4 Bolt Down Bracket Kit
Refer to bolt down bracket instructions for hardware requirements, as they
pertain to your application:
If mounting pergola onto an existing concrete surface:
L. 1/2“ x 3 1/2” x 12“ (1.3 cm x 9 cm x 30.5 cm) Wood Shims (32) (see page 8)
M. 1/4” x 2 3/4“ (0.64 cm x 7 cm) Cement Screws - Countersunk Head (12)
N. 3/16” (0.48 cm) Concrete drill bit. Minimum 3“ long (1)
If mounting pergola onto a wooden/composite deck with
AN ACCESSIBLE UNDERSIDE:
O. 1/2“ x 3 1/2” x 12“ (1.3 cm x 9 cm x 30.5 cm) Wood Shims (32) (see page 8)
P. 1/4” x ?“ (0.64 cm x ? cm) Bolts and Nuts - Countersunk Head (12) (Length
depends on thickness of blocking material)
Q. 1/4” (0.64 cm) Washers (12)
R. 1/4” (0.64 cm Wood drill bit. Minimum 3“ long (1)
If Mounting Pergola in Ground
Self-Auguring Screws (40) - 20025
- 20025 (to secure Posts to Wood Posts)
Self-Auguring Screws with Nylon Washer (32) -20026
(129) - 20027
(for screw heads)
(purchase from a retailer of our products)
(for Rafter Brackets)
(for Shade Slats)
(to secure Beams
A
B
J
C
D
E
F
L
L.
4x4x8' (10.2 cm x 10.2 cm x 243.8 cm) Pressure-Treated Wood Posts (4)
local building center)
M.
Concrete Ready Mix (4) (purchase at local building center)
Tools You Will Need
• Level
• Hammer
• Tape Measure
• String Line
• Wood Stakes (4)
(temporary support for string line)
• Step Ladders (2)
• Cordless Drill
Tools You May Need
• Circular Saw with Fine Tooth Blade
• Framing Level
• Framing Square
6.5 x 6.5 Wood Grain Flat Top Pergola
6
(purchase at
Purchase Separately
K
Purchase Separately at:
www.newenglandarbors.com
www.newenglandarbors.co.uk
Purchase Separately
M
CONCRETE - Ready Mix
Purchase Separately
Not to Scale
Page 7
Wood Post Layout & Installation
for In-Ground Application
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.
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.
STEP ONE
Measure and mark out the location of the pergola posts using
string line and temporary wood stakes. Diagonal distances must
be the same to ensure a square installation. Adjust string lines
accordingly. The inside corner of the string lines will be the post
location.
Please Note:
Should you decide to moderately modify the dimensions of your
pergola from the standard kit size, a circular saw with a sharp
fine-tooth blade is all that you need to cut, shorten or modify the
vinyl components.
1
from corner of woodpost to corner of wood post.
Overhead View
78 1/4 in.
198.76 cm.
110.66 in. (281.08 cm.)
78 1/4 in.
198.76 cm.
STEP T WO
Install Wood Supporting Posts Directly into the Ground
1
After you have determined where the posts will be located,
excavate 10” (25.4 cm) diameter x 36” (91.5 cm) deep post holes.
2
After holes are dug and cleaned, place the 4x4 wood post into
a hole ensuring it’s level and square to string lines. The final post
height should be about 60” (152.4 cm) out of the ground.
3
Fill the vacant hole with pre-mixed concrete all the way
to
within 3” (7.6 cm) of the top of the hole. After the concrete
has set, back
fill & compact the 3” (7.6 cm) space with soil.
4
Repeat for all four posts.
2
1
60”
152.4 cm
10”
25.4 cm
3
36”
91.5 cm
3”
7.6 cm
6.5 x 6.5 Wood Grain Flat Top Pergola
7
Page 8
OPTIONAL STEP
1
Wood Post Layout & Installation
Using Bolt Down Brackets
for Concrete or Wood Surface
Note: for additional information on the bolt down bracket
installation, refer to the bolt down bracket instructions.
1
Mea
sure and
using string or chalk line. Measure from the edges of the
base plates (not the vertical side walls). Diagonal distances
must be t he same to ensure a square installation. Adjust
string lines
will be the
Mark out the location of bolt down brackets as illustrated
Using a 3/16” (0.48 cm) masonry drill bit,
deep holes to allow installation of 2 3/4” (7 cm) concrete
mark out the location of the bolt down brackets
accordingly. The inside corner of the string lines
location of the inside corner of the base plates.
2
3
drill 3” (7.6 cm)
screws (Not included)
4
*
78 3/8 in
199.1 cm
* Orientate brackets
accordingly to reduce
offset motion of posts.
(direction of arrows
denote flange
opening)
.
*
110 11/16 in (281.5 cm)
From corner of bracket
to corner of bracket.
(Bottom base plates)
2
Marker
78 3/8 in
199.1 cm
*
*
Proceed to install three 2 3/4” (7 cm) concrete screws into the
bottom
Concrete patios generally have sloped surface for water run-off.
If this is the case, when you secure the bolt down bracket to the
concrete, the bracket may be at an angle. This can be corrected
for level using galvanized steel washers (not provided), acting
as shims underneath the base to level - VERY IMPORTANT OR
PERGOLA BEAMS
base of the bolt down bracket (Not included)
Please Note:
AND
RAFTERS WILL NOT BE LEVEL.
5
With the four post brackets installed plumb, proceed to set
the 4x4 x4’ wood post in place. Secure using the same concrete
screws included in the kit.
Repeat for all 4 posts.
6
Posts should be approximately 48” (122 cm) height.
7
In order to create a snug fit between the wood posts and
inner cavity of the vinyl posts, it will be necessary to ‘build out’
the 4x4 posts near the bottom and the top using 1/2” x 3 1/2” x
12” (1.3 cm x 9 cm x 30.5 cm) shims on all four sides (not supplied).
the
Level
3
3“ (7.6 cm) (Deep)
48”
5
6
4
7
Note: Shims can be cut from 1/2" (1.3 cm) plywood and secured to
the wood posts using wood screws or nails (purchased separately).
6.5 x 6.5 Wood Grain Flat Top Pergola
8
1/2”x3 1/2”x12”
shims on all
four sides
near bottom
and the top
Page 9
STEP T H REE
Vinyl Column Installation
Over In-Ground Wood Posts
1
Using a step ladder, guide the vinyl column over the top of the
wood post down into position. Ensure that holes at top of
column are orientated correctly for future beam and
rafter placement as per illustration.
Please Note:
If you installed your wood posts directly into the ground, please
proceed to position the vinyl column tight to the inside corner of
the wood posts as illustrated below. NO SHIMS REQUIRED.
Wood post inside
the vinyl post.
Ensure that holes at top of column
*
are orientated correctly for
future beam and rafter placement.
Vinyl Columns should be tight to the inside
corner of wood posts as illustrated.
NO SHIMS REQUIRED with in-ground installation.
2
Finally, adjust post heights accordingly to ensure future level
installation of beams and rafters as necessary. If slope is severe
causing a height difference between the posts, you may need
to trim down the bottom of two or more of your vinyl columns
as necessary.
3
Securethevinyl columns to the wood posts using 1 - 3/4” (1.9 cm) screw
at 8” (20.3 cm) up from the bottom and 1 more approximately 36” (91.4
cm) high. Cover the screw heads with provided snap caps.
36“
Slope?
1
Shims to
“build out”
the 4x4 posts
on all four
sides
2
91.4 cm
8“
20.3 cm
3
46 in
116.8 cm
Vinyl Column Installation Over
Wood Posts with Bolt Down Brackets
1
The process for posts installation over the bolt down bracket is
identical as shown aside.
6 in
15.2 cm
1
6.5 x 6.5 Wood Grain Flat Top Pergola
9
Page 10
At this stage, the columns should be properly
installed as per the following illustration,
with the columns 78 in (198.1 cm) apart.
Also, notice that the holes at the top of each
post should be facing the same direction.
78 in.
198.1 cm.
78 in.
198.1 cm.
STEP FOUR
Main Support Beam Assembly
1
Lay out two 94” (238.8 cm) beams (part 7) as shown. Align and
fasten mounting brackets to the pre-drilled holes on top of the
beams using the 3/4“ (1.9 cm) screws provided. Cover the screw
heads with provided snap caps.
STEP FIVE
Main Support Beam & Rafters Placement
Using a helper and two ladders, proceed to complete the
following steps
2
Slide the main support beam with rafter clips pre-installed through
both holes of the vinyl column (overshooting), and then back
through both holes of the opposite column. Repeat for
opposite beam.
Please note:
The top of the vinyl columns may need to be tensioned in opposite
directions to each other to allow the beams and rafters to be
installed on a slight angle. The vinyl columns naturally allow for
some measure of flex.
3
Stop when the end of the main support beam measures 3” (7.6 cm) from
the outside edge of the post. Fasten both ends of the beam to
the posts as illustrated using four 4“ (10.2 cm) screws per post.
Cover the screw heads with provided snap caps.
Repeat step 2 for the remaining posts and main support beam.
1
2
3”
7.6 cm
3
10
6.5 x 6.5 Wood Grain Flat Top Pergola
Page 11
4
Slide the two outer
(overshootin g) and then back through both holes of the opposite
column. Stop when the
rafters throu gh both holes of the vi nyl column
end of the
from the outside edge of the post.
beam measures
3”
(7.6 cm)
5
Using 4" (10.2 cm) self-auguring screws, lock the beams and rafters
into position inside the posts by driving in 2 screws on each face of
the posts. Cover the screw heads with provided snap caps.
6
Place the remainder five rafters in the front and rear rafter brackets.
7
Complete a final adjustment of all beams and rafters. All spacing
should appear equal to the eye.
8
Using 3/4” (1.9 cm) self-auguring screws, attach the pergola
rafters to the
rafter brackets. Cover the screw heads with
provided snap caps.
5 6
4
7
8
6.5 x 6.5 Wood Grain Flat Top Pergola
11
Page 12
STEP SIX
Fastening Decorative Caps
1
Glue the post caps top and bottom using vinyl weld.
Glue the postcaps onto the posts.
2
Install decorative pergola end caps using vinyl weld.
1
2
STEP SEVEN
Shade Slat Assembly
1
To assemble the shade slats, glue th
end caps onto the end of the filters.
e 1 1/2” (3.8 cm) square pergola
Shade Slats Installation
Shade slats are designed to extend approximately 7 1/4” (18.4 cm)
past
the last rafter. Measurement includes the pergola
Your g oal is to ensure that all the shade slats overhang
equally to the eye.
2
Install first and last shade slats 2“ (5.1 cm) away from the posts.
3
Install the rest of the shade slats
at
10.5” (26.7 cm) spacing.
4
Install one 4” (10.2 cm) screw at each intersection of rafter and shade slat. Cover
the screw heads with provided snap caps.
1
end caps.
2
4
6.5 x 6.5 Wood Grain Flat Top Pergola
3
10.5”
26.7 cm)
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