PUT UP A PAIR OF PERGOLAS Gather your supplies ■ Posts 200 x 100mm x 3m treated pine sleepers (16)
■ Outrigger blocks From 200 x 100mm x 3m treated pine sleeper
■ Outrigger arms 140 x 45mm x 4.8m H3 treated pine (16)
■ Battens 42 x 42mm x 4.8m treated pine (14)
■ Screen frames 90 x 45mm x 5.4m treated pine (5)
■ Screen surrounds 42 x 18mm x 5.4m treated pine (8) ■ Matrix Woodland Décor Screen Panels in Charcoal (4)
You’ll also need Stringline; wooden pegs; set-out paint; post-hole digger; 175mm batten screws for treated pine; drill; spirit level; quick-set concrete (3 bags per hole); 12mm x 10m plastic tube; power saw; handsaw; sliding bevel; protractor; hammer; sharp chisel; 100mm batten screws for treated pine; Cabot’s Exterior Stain and Varnish in Acorn; painting equipment; metal primer; 375 x 275 x 75mm T shape mending plates (16); black spray paint; M10 x 40mm galvanised coach screws and washers; 900 x 600 x 3mm MDF; exterior undercoat; low sheen exterior acrylic paint in black; nail gun and galvanised nails, to suit
When using power tools, wear all safety gear required. For more information, refer to your equipment instructions.
A water level is a 12mm clear plastic tube filled with water, with air bubbles removed. With a person at each post holding tube, the person at marked post moves tube until water settles at marked point. Person at other post then marks post where water level is in tube at their end.
Here’s how STEP 1 To set out pergola, set up 5m-long parallel stringlines, 5m apart. This will be position of inside faces of posts. Use set-out paint to mark positions of post holes (4 along each stringline). Make distance between centres of posts 1.4m. Ensure posts are opposite the one on other side. Dig a 350mm-wide hole 700mm deep for each post.
STEP 2 To make each post, stack 2 sleepers and join using 175mm batten screws. Place a post in a hole so inside face meets stringline. Make plumb and concrete in position. Repeat to install remaining posts.
STEP 3 Starting from shortest post, mark a level line across posts on that side with a spirit level. Use a water level (see Notes, left) to transfer level to other pergola and draw level line along posts. Use power saw to cut top off all posts along level line. As saw won’t cut through full depth of posts, use handsaw to finish cut.
STEP 4 To mark out 45mm-deep notches on top of post, on inside face of post, mark a point 120mm down from top of post. Set sliding bevel to 8° using a protractor. Place against 1 side of post so blade meets marked point and slopes down towards outside face of post. Repeat to mark notch for other side of post.
STEP 5 Set power saw to cut 45mm deep and make multiple passes through post for notch. Reset saw to cut full depth and cut down vertical
lines of notch. Knock out waste timber with a hammer and make smooth using chisel. Repeat Steps 4 and 5 for remaining posts.
STEP 6 To construct an outrigger, cut 3 outrigger blocks from sleeper. Make blocks 140mm high and width to suit width of post remaining between the 2 notches. Position blocks flush with each end of 1 outrigger arm, screwing together with 100mm batten screws. Put third block so centre of block is 850mm from 1 end of outrigger arm. This will be the top end of the outrigger. Repeat to construct 7 remaining outrigger armand-block assemblies for remaining posts.
STEP 7 Apply 1 coat of stain to assemblies and remaining outrigger arms. Apply stain to posts. Let dry.
STEP 8 Put a stained outrigger arm on top of outrigger arm-and-block assembly and screw together. Repeat for all outriggers.
STEP 9 Trace shape of a mending plate on MDF and cut out, retaining outer ‘stencil’. Set aside. Apply primer to mending plates, let dry then spray with black paint. Let dry.
STEP 10 With a helper, lift an outrigger over an end post of 1 pergola so pair of outrigger arms sit either side of notch in top of post. Make bottom end of outrigger 600mm from outside face of post. Screw through outrigger arms into post to secure. Tip
Loosen screws at bottom end of outrigger to make it easier to get outrigger over post. Tighten after installation.
STEP 11 Place 1 mending plate over a join between outrigger and post. Predrill then use coach screws to fix in place. Repeat to install mending plate on other side of post.
STEP 12 Repeat Steps 10 and 11 to install outrigger at other end post. Have your helper look along top of first outrigger to ensure top of second outrigger is in line prior to screwing mending plate to posts.
STEP 13 Set up a stringline between bottom ends of outriggers. Install outriggers on remaining posts so they meet the stringline. Look along tops of outriggers before fixing mending plates to ensure they are all in line. Install mending plates.
STEP 14 Repeat Steps 10–13 to install all outriggers on second pergola.
STEP 15 Place MDF stencil over a mending plate on post. Using the MDF to protect against overspray, spray paint heads of screws and touch up mending plates. Repeat for all mending plates.
STEP 16 To determine batten length, measure distance across outriggers on 1 pergola. Cut battens so they are 120mm longer than this measurement. Undercoat then apply 2 coats exterior acrylic in black, allowing to dry after each coat. Repeat for second pergola. STEP 17 Place a batten at top end of outriggers so it overhangs 60mm at each end. Use a 150mm spacing block to position batten 150mm from top. Nail in place. Fix 3 more battens to top of outriggers using block to maintain an even gap. At bottom of outriggers, place a batten in line with centre of mending plate. Place battens on either side using spacing block to separate. Repeat for second pergola. STEP 18 To construct frame for decorative screen, measure between posts and cut screen frame pieces for top and bottom of frame. Cut uprights for frame 1810mm long. Position uprights between top and bottom of frame so gap between them is 910mm and is centred on top and bottom pieces. Screw through top and bottom pieces into uprights. Apply 1 coat of stain to frame and let dry. Undercoat then paint screen surrounds in 2 coats exterior acrylic, allowing to dry after each coat. Cut to fit around inside of frame and nail in place so edge of surround is flush with edge of frame on 1 side. Place decorative screen inside frame so it sits on surround. Run more surround around screen to hold in place. Repeat to make 3 more screens. STEP 19 Put screens between posts, flush with outside faces. Screw through top and bottom of frame into posts to secure.
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Post Screen Outrigger Batten Mending plate FOR PROJECT SUPPLIES, SEE STOCKISTS PAGE