Pergola Project

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Steliz

Camberwell Carrot
Joined
11 Dec 2017
Messages
512
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252
Location
Hungary
My big summer project this year was to build a Pergola next to my house. I had the area concreted over last October to make an area where we can sit out and enjoy the view and get a bit of shade in summer (be aware, this post will contain gratuitous pictures of the lovely view from my house). I haven't taken pictures of every step but here is the general build.

So, I bought a pile of wood.
P1-min.jpg

Then I started processing it, cutting it to length and planing, routing a mitre on the edges and sanding it.
P3-min.jpg

I cut the braces all at once from a 6m length of 150mm x 150mm.
P2-min.jpg

I managed to arrange my workshop so that I could run the 2.5m posts over my planer.
P4-min.jpg

Then they were stained.
IMG_20200829_121220-min.jpg

All the other components were cut to size and stained.
IMG_20200829_121229-min.jpg


All that processing took quite a long time as the wood was rough sawn to begin with and, because of the lengths involved, I was restricted to working outside mostly. There were also a lot of summer storms which meant delays while waiting for the wood to dry out.

So, on with the build. I started by fixing a supporting piece to the garage wall which I notched to accept the side beams. I then fitted the metal 'feet' and put the posts in place and braced everything together.
IMG_20200909_141504-min.jpg

I had a little help from a friend who helped me get all the cross beams up and fixed in place.
IMG_20200915_125651-min.jpg


It was at this point that I realised my first error. I had orientated the metal feet in a way that I thought would provide the most resistance to the wind (probably unnecessary considering the size of it) but I hadn't accounted for fixing the lower rail to the post which I now couldn't. It was too late to change so I just plowed on regardless.

I had previously made some decorative frames for the house balcony rail and I decided to use the same design to compliment it.
IMG_20201019_140257(1)-min.jpg

Joined with half laps and third laps (no idea what the correct name is).
IMG_20201019_140221(1)-min.jpg
 
And ready for a coat of lacquer.
IMG_20201027_092433-min.jpg

I installed the front panels and rails which was made easier by the fact that I could fix the bottom rail to the post.
IMG_20201101_123233-min.jpg

IMG_20201101_123049-min.jpg

I then installed the rest but, although I got a tight fit between the posts, the top rail is the only part that is fixed to anything.
IMG_20201104_150829-min.jpg

To fill in the gaps and provide more strength I made up some more panels starting with the usual wood processing.

48 identical pieces.
IMG_20201105_115047-min.jpg

All the half laps cut.
IMG_20201107_133003-min.jpg

It was right after taking this picture that I noticed that the half lap in the middle was off centre. It wasn't meant to be. I had measured it wrong and transferred the error to every piece. I stood in my workshop with my head in my hands and thinking that I was going to have to do it all again and at that moment my wife walked in. I told her what had happened and she looked me right in the eyes and gave me these words of sympathy - "You're not buying any more wood!"

As luck would have it, because I had made an identical mistake on all of the pieces they still fit together! Yay! So I got them all glued up, stained and fitted.

And here is the finished result.
IMG_20201114_123835-min.jpg

IMG_20201114_123900-min.jpg

IMG_20201114_124007-min.jpg
 
Excellent job, and good write-up. Enjoy the view!

"Third laps" are bridle joints, I think.
 
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