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| About
The Big Kahuna Instructions |
Thank
you very much 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. Make sure before you get started, you have:
a helper, a hammer, a stepladder, a screw gun, a pencil,
a posthole digger, a ¾” wrench, a level,
and a tape measure.
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 to
install them.
If you have any questions we are only an email
or phone call away.
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| Step
By Step Assembly Instructions for The Big Kahuna Pergola
Kit |
- Step 1 - Remove the top of the
crate with the square drive bit found in the hardware
bag with all of the screws.
- Step 2 - Lay out all parts next
to where you will be installing the pergola.
- Step 3 - Place one beam on the
ground (with the x’s facing up) exactly where
you would like the front of the pergola to stand.
- Step 4 - Place the other beam approximately
9 ft. behind the first beam.
- Step 5 - Take 1 of the rafters
and slide it down onto the outermost X marks on both
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
rafter may fit a little tight, so you may have to
stamp it down with your foot. The X marks look like
this lXl
- Step 6 - 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.
- Step 7 - 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.
- Step 8 - 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
in between the two boards that make up the beam, where
it says "POST". If you
are on concrete, take a pencil and stick it down in
between and make marks on the ground in the middle
of the space 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 9 - Take all of the rafters
off of the beams and move the rafters and beams out
of the way. Now you should be left with four marks
where your holes or post bases will go. Like this:

- Step 10 - Dig 2 ft deep holes or
install your post bases directly over top of all 4
of your markers.
- Step 11 - lay 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 12 - Lay the beams down on
the ground at the top of the two sets of posts with
the corresponding letters. Slide the posts in between
the lines on the beam where it says "POST".
- Step 13 - Take the carriage bolts
and hammer them through the predrilled holes. They
fit really tight sometimes so don’t be shy about
giving them a good smack.
- Step 14 - Take one of the corner
braces and slide the long side 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 other side against
the post. Screw it in through the predrilled holes.
Repeat for each post.
- Step 15 - With one person on each
side, tilt the assembly up and drop the posts into
the postholes. Place one washer and one nut on each
of the carriage bolts. Refill the holes around the
posts with dirt or 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 - Put a washer and nut
on the other side of all of the bolts that you hammered
through.
- Step 19 - Install all of the remaining
rafters on the remaining X marks. (If on concrete,
now is the time to finish securing the posts to the
bases.)
- Step 20 - Take the top slats and
place them into position in the layout lines across
the rafters. There are predrilled holes to screw them
down. 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 21 - Water in the concrete
or dirt
You’re
Done!
Questions? Contact
Us
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| Thank
You! |
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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

Florida |
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