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| About
The Big Kahuna Instructions |
Thank
you for purchasing a do-it-yourself pergola kit from
Average Joe’s Pergola Depot. We appreciate your
business, and we are here to help you in any way possible.
Read this entire Instruction sheet before beginning
so you can get a feel for what you will be doing. If
take your time and follow these instructions you can
do it. We have faith in you!
If you are installing this kit on a concrete patio,
we advise that you use a 6X6 Galvanized post base on
each post secured with ½” red head concrete
anchors which can be purchased from your local hardware
store. You will need some additional tools for this.
Ask your hardware salesman for instructions on how toinstall
them.
If you have any questions we are
only an email
or phone call away.
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| Kit
Components & Tools Needed |


Here is what you will need:
- Helper
- Hammer
- Ladder
- Screw gun (with square drive bit supplied with
kit)
- Post Hole Digger (If posts will be going in ground)
- ¾” Wrench
- Level
- Tape measure
- 6X6 Galvanized post bases if going on concrete
If you have any questions we are
only an email
or phone call away. |
| Step
By Step Assembly Instructions for The Big Kahuna Pergola
Kit |
- Step 1- Remove the wrapping from
the outside of the crate
- Step 2- Lay out all parts next
to where you will be installing the pergola.
- Step 3- Place all four beams on
the ground (with the x’s facing up) exactly
where you would like the pergola to stand like so:

- Step 4- Slide one of the rafters
down onto the outermost X marks on the beams. You
may have to move the back beam around a little to
get it into place. Make sure you have the rafter on
top of the same mark on both beams. The X marks look
like this: lXl
- Step 5- Take another rafter and
slide it down on the next X mark to the inside. Keep
placing rafters on the x marks until all rafters are
resting on the beams You should now have this lying
on the ground:

- Step 6- Step back and take a look
to see how square everything looks. Take a tape measure
and hook it on the outside corner of one of the beams,
and pull the tape to the opposite corner. Write down
the measurement. Then hook it on the other corner
and pull to the opposite corner like this:

- Move the back beam from side to side until you have
the same measurement both ways. When you have the
same measurement, it is perfectly square.
- Helpful Hint: This is done
easier if you and your helper both have a tape
measure and pull them across at the same time.
- Step 7- Now you can see where you
have to dig your holes for each post. (Or mount your
post bases if you’re on concrete.) Look at the
top of the beam just inside the first rafter where
it says post. If you are on concrete, make a mark
on the ground directly in the center of the lines
where it says post on all four corners. If you are
on grass or dirt, stick the flags that are provided
with the kit into the ground on all corners where
it says post.
- Step 8- Take all of the rafters
off of the beams and move everything out of the way.
Now you should be left with four marks where your
holes or post bases will go.
- Step 9- Dig 2 or 4 foot ft deep
holes (depending on the depth desired) or install
your post bases directly over top of all 4 of your
markers.
- Step 10- Lye the four posts on
the ground with the bottoms at the edge of each hole,
with the tops facing away from each other. Like This:

- Step 11- Lay one beam down on the
ground near the top of the posts. Slide the posts
up and onto the beam between the lines on the beam
where it says post.
- Step 12- Set the other beam on
top sandwiching the post in between the two beams.
- Step 13- Place 1 washer on each
½” bolt. Lift up the beam assembly enough
to fit the bolts between the ground and the beam and
insert the bolts into the holes from the bottom.
- Helpful Hint: You may
want to use a block of wood to place on the ground
under the bolt so you can push the beam down to
get the bolt to come up through the hole.
- Place a washer and nut on each of the bolts and
make them snug but do not tighten them down yet. Now
you should have this:

- Step 14- slide the corner braces,
with the long side towards the top, up in between
the two pieces of wood that make up the beam. Get
it flush with the top of the beam and push the bottom
side against the post. Make sure everything is nice
and flush to the post and to the top of the beam.
Screw in two 3” deck screws through the angle
brace into the post through the predrilled holes,
then screw the top through the face of the beam into
the angle with 4- 3” deck screws. (There are
no predrilled holes in the face of the beam) Repeat
for each angle brace.
- Step 15- With one person on each
side, tilt the assembly up and drop the posts into
the postholes (or into the post bases if on concrete).
Have your helper hold the assembly plumb. Refill the
holes around the posts with dirt or dry concrete.
If you are using concrete, do not water it in yet.
Check for level across the top of the beam and on
the sides of the posts. If you are installing the
pergola on top of a concrete patio with post bases,
you will need to prop the assembly up so that it does
not fall. The crate that the kit came in works well
for this purpose. Once you have the bottom of the
posts in the post bases, put one nail on each side
to hold them in place.
- Step 16- Repeat step 15 for the
other side.
- Step 17- Move your stepladder in
between the two sides. Take one of the rafters and
slide it onto the outermost X mark on the beams just
like you did on the ground. Now move to the opposite
side and slide another rafter into position on the
outermost X mark. Now your helper should be able to
let go of the assembly.
- Step 18- Install all of the remaining
rafters on the remaining X marks and secure them to
the beam with 3” deck screws through the predrilled
holes. (If on concrete, now is the time to finish
securing the posts to the bases.)
- Step 19- Place the top slats into
position in the layout lines across the rafters labeled
with an S and screw them down to the rafters. Make
sure you have the same overhang on all of the top
slats. Be careful screwing the screws in because stainless
steel is a soft metal and they strip VERY EASILY!
Push down hard while screwing them in. There are extra
screws in every kit just incase you strip some, but
if you need more you should be able to find them at
any Ace Hardware, Home Depot, or your local hardware
store.
- Step 20- Check for level and plumb,
tighten down nuts, and water in the concrete or dirt.
You’re
Done!
Questions? Contact
Us |
| Thank
You! |
| Thanks again for
your business. We really do appreciate our
customers and their feedback on ways to improve our
products. So after you’ve completed putting your
kit together, sit down, have a cold drink, and drop
us a line via email
to tell us what you think about our products. Any feedback
on how we can make our kits easier to install will be
very helpful. Pictures are always welcome! Don’t
forget to check back often for new outdoor living structure
kits coming soon!
Crafted with
pride in the USA
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