How You Build a pergola.

Background

Instructions

1. Design the pergola.
   We selected 16 foot long 2X6 supports and 1X6 horizonatal supports. We wanted the horizontal supports to be continuous and not pieced. The largest size available was 16 foot at our local supply store so we decided not to special order anything longer and to just go with those. We decided to angle cut the ends of the horizontal pieces to add a little style.

   Gather the parts.

   
   

   Size	Description	Length	Quantity
   2X6	pressure treated lumber	16 foot	2
   4X4	pressure treated lumber	8 foot	6
   2X6	pressure treated lumber	4 foot	8
   6 foot kit - 2 three foot sections	footer cardboard		1
   5/16	screws	4.5 inches	12
   5/16	washers		12
   5/16	nuts		12
   	concret mix		1 bag
   	4X4 metal bracket support for footer		6

   
   

   Dig the footers.

   Use a post hole digger to dig each of the eight holes. We dug ours about eight to 10 inches deep and used one foot sections of the footer cardboard. Insert the footer cardboard supports into the hole.

   

   Pour the footers.

   • Mix the concrete mix with water as directed on the bag.
   • Shovel the mix into the cardboard footer supports until the concrete is level with the top of the footer cardboard support.
   • Insert the 4X4 metal support bracket.
   • Take care to ensure that the bottom surface of the bracket is level.
   • Also ensure that the bracket is parallel to the bracket in one direction and perpendicular to the bracket in the other.
   • Repeat these steps for all six footers.

   

   Stain the wood.

   I decided that it would be easier to stain the wood prior to assembly so I stained all sides of all of the wood.

   

   Precut both sides of the 45 degree angle for the 4 foot horizontal pieces of the pergola.

   These cuts are purely for aesthetic purposes. Pay attention to make the angle cuts in opposite directions or as desired.

   

   Notch out the top of each of the 4X4 vertical supports.

   Cut the notch about 1 3/4 inch wide to a depth of about six inches such that the 2X6 16 foot long sections will rest firmly on the notch. Repeat this for each of the 4X4 supports.

   

   Measure and cut the vertical supports.

   This was the most critical step in the assembly process. This step required a couple of helpers. Because my ground was far from level, each of the posts would need to be cut at a different length.

   • Turn one 4X4 notch down on the 4X4 support in one corner.
   • Have a helper do the same with another 4X4 in the adjacent corner.
   • Hold a four foot 2X6 piece against the 2 posts at the desired height.
   • Use a level to adjust the 2X6 piece such that it is level.
   • Mark each of the two 4X4 pieces at the point where the wood touches the 2X6.
   • Cut the 4X4 pieces at the location that you just marked. This will be the bottom of the post. The posts will be assemble notch up later. Keep track of which post belongs in which corner.
   • Repeat this process for the next nearest post to identify the location to cut.
   • Repeat this for all posts until all 4X4 posts have been marked and cut.

   

   Secure the header supports.

   • Start with one side of the pergola that will support one of the 16 foot headers. Insert the three 4X4 pieces notch up into the metal supports paying attention to the direction of the notch such that the header will rest on the notch. Insert one screw in each of the 4X4 supports for the moment; drill a pilot hole if necessary.
   • Place the 16 foot header such that it is resting on the notches on each of the three posts. Use your level to ensure that the posts are level and the header is level.
   • Temporarily secure the header in place with clamps if necessary and drill a hole through the header and the notched post for the 5/16 screws. You will put 2 holes in this post so drill this hole accordingly.
   • Put a washer on the screw and insert into the freshly drilled hole. Add a washer on the other side and secure with a nut.
   • Drill the hole through the header and the other two notched posts and assemble the hardware the same way.
   • Repeat this process with the other side of the pergola. At this point, you have the 2 sides of the pergola assembled but independent of each other.
   • Add more screws as necessary through the 4X4 metal supports.

   

   Cut notches in the horizonal supports.

   • Lay a 2X6 four foot section across the top of the 2 pergola sections and center it.
   • Mark the location where this piece of wood touches the 2 header supports. Make a mark on both sides of the header such that you know how wide to make your notch.
   • Cut at the marked location to the desired depth. I cut mine about 2 inches deep. so the horizontal pieces will rest securely on the headers.
   • Use a scroll saw to complete the notch.
   • Repeat this for each of the 8 horizontal supports. To make this faster, I secured several together and made the notch cuts all at one. Next, I used the scroll saw to complete the notch on these supports one at a time.

   

   Add the horizontal supports.

   • Place each of the horizontal supports over the 2 headers such that the notch rests on the headers.
   • Adjust the spacing between the horizontal supports as desired.
   • Toe in screws to secure the the horizontal supports to the headers. Drill pilot holes prior to adding the screws if necessary.

   

   Finishing touches.

   • Drill an additional holed in each of the header supports for the 5/16 inch bolts and secure the hardware as done previously.
   • Because my pergola is very close to my deck, I decided to secure it to the deck for added stability. Cut the scrap pieces of the 4X4 posts to the appropriate dimension and secure it between the deck and the pergola using the toe in method where the screws are angled in.
   • Touch up any staining as needed.