Pergola Day 15 - Structure Complete

 Steve and Ryan came over and helped finish the structural elements of the pergola. I started out by cleaning up the area and laying out the tools while Jack supervised.

Once Steve and Ryan arrived we installed the second beam. The next step was to install the joist that goes along the north side of the pergola and provides the support for the floating corner. The corner is held together with timber screws and a L bracket.

After that, we installed one of the posts that will support the joist. 

This turned out to be a little more complicated than I thought. I mis-measured the beams and as a result the joists were sitting on the brick instead of the railroad tie. This wasn't a big deal except for the fact I had planned to screw the base into wood, not brick. I took a trip to OB Hardware to purchase some concrete screws and masonry bits. After some drilling we were able to get the posts installed. 

Once the post was bolted into the joist, Steve decided to strength-test the structure by hanging on it. The structure passed.

The next step was to install the remaining joists. We started on the south side and worked north. The first was held in with timber screws. Two of us would hold the joist up while the third made sure the board lined up with the beams and installed the timber screws.

The joists in the middle were installed using brackets. I would climb up the ladder to install the brackets, then Steve and Ryan would lift the joist up so I could measure the necessary length. The joist was removed, cut to the correct length, and then reinstalled and screwed in.

Once the six joists were installed, we then installed the second post on the mini-wall that supports the floating corner.

I purchased the correct masonry bits from the store so the second time around went a lot faster. At that point we were finished for the day!

For fun, we threw some of the cedar boards up on the pergola so we could experiment with how far apart we wanted the boards spaced. I like how they look 2-3 inches apart.

The next step is to decide upon how far the cedar boards will be spaced and how much we want the boards to overhang from the end. Once we decide that, we will make a run to Home Depot to purchase a box of screws and start screwing the lattice down. I think we are three or four days away from being finished!

Pergola Day 14 - Electricity

 I applied a couple of coats of paint to the last two support posts but other than that I spent the day re-wiring the pergola. I took a trip to Home Depot to purchase some supplies, came home and started re-installing the electrical outlet only to realize I forgot a couple of parts. I had to drive back to Home Depot for a second time today to purchase some brackets .I finally put everything together.

Then I turned on the low voltage lights to test them and immediately started seeing smoke. After examining the situation I realized that by coincidence, one of the screws I used to attach the electrical conduit went through one of the wires that I had installed in the post, shorting it out. So I had to rip the remaining wiring out of the post, re-install new low voltage wiring, and then re-wire the transformer. 

After that I had to apply wood putty to hid the new wiring. 

Obviously I wasn't too stoked about the mistake. Oh well. Tomorrow I'll sand and repaint it.

Pergola Day 13 - Patch, Paint, & Prep

 I spent a couple of hours prepping for the install of the second beam on Saturday. I patched some holes in the beam we installed a few days ago and touched up a few areas. Everything is looking nice!

I also sanded and primed the last two pieces of wood we need to paint. The 4x4 is the last post we will use in our decorative walls. The smaller piece is a "knee joint" we will use to help support the 4x4 beam that connects to our "floating corner". 

While I was in the backyard I noticed a visitor in the avocado tree. I can't remember the last time we saw a squirrel in the backyard. I think he entered our backyard by jumping from our neighbor's garage to our fence where he climbed down and did some exploring.

I enjoy watching the birds (and squirrel) chilling in the yard.

Pergola Day 12 - First Beam Installed

 We brought the neighborhood over today to help hang the first beam. Benton, Henry, Oliver, and Ryan met up at our house at 1:00 PM. We started off by carrying the beam over to our neighbor's yard. From there we spent some time talking about the best strategy for lifting the beam into the air.

We came up with the idea of pre-drilling a hole at one end and lifting up one corner and temporarily bolting it. 

The project took a lot of coordination and patience. Part of the challange was moving the beam up and down over the fenceline.

We had a team of people holding the beam while I used the impact wrench to drive large bolts through the posts and into the beams.

After a couple of tries, we were able to successfully mount the first of the two beams. 

The next step is to to prep the support posts and joists along the north side of the pergola. Once these are ready for install, we will calendar a time for the team to come back and help install the second beam along the west side. In some ways it should be easier because there is no fence to deal with. But it may be a little more complicated because of the floating corner we have in the design. Hopefully we have the entire substructure completed by next weekend.

Pergola Day 10 & 11 - Posts Are Up & Joists Are Finished

This post combines a couple of days together. We finished routing the posts and installing the wires. First I feed the wire through the back of the post to the front and tie it off.

This photo shows the wiring for the lights running from the base of the post down to where the wire crosses over the center of the post to the frontside where the fixture will be mounted.

Here is a closeup of where the wire turns 90 degrees and goes through the post to the other side. You can see the tiny nails I used to hold the wire in place.

After applying and sanding the wood putty, I repainted the posts. Now the wiring is discretely hidden inside the posts.

Michelle finished painting the joists on Day 11. They are now ready for installation, along with the two posts on the ground to the right.

We were able to finish installing all five posts. It was harder than I thought. I learned the hard way that the best way to install the posts was to place them in the existing brackets, use a level to make sure they were standing up correctly, and then tracing holes where the bolts go prior to installing the post. 

Of course I didn't do this...I thought I would be smart by using the old posts as templates for the new ones and tracing the existing holes onto the new boards. What that doesn't take into consideration is the slight variations that exist between the old 4x6 posts and new 4x6 posts. This led to a lot of minor adjustments on 3 of the 5 posts. They eventually went in though.

This post bolted into the existing brackets correctly the first time. It was the only one of the four to do so.

The top of this post has a bundle of wire that will eventually be used to power the ceiling lights on the pergola.

Here is a close up of one of the posts with the wiring exposed for the light fixtures that will eventually be installed.

Next step? Install the first beam. Hopefully that happens tomorrow!

Pergola Day 9 - Painting and Installing

 So Day 9 started off with a trip to Home Depot. I purchased the hardware needed to bolt our pergola together. Everything I bought was made with galvanized steel which will help the bolts withstand the weather as well as the pressure treated lumber. Its amazing how much a box of bolts can cost.

While I was gone, Michelle got started on applying primer to the joists. Each 2z6 joist is around 10 feet long. Michelle applied two coats on the top side. 

We will apply two coats to the bottom tomorrow, and then two coats of the final color to each side. I have to admit I'm tired of painting wood.

I started drilling holes into the posts so they could be mounted. I also drilled holes for where the light fixtures will be installed. We knew we needed to "hide" the wires to on the two poles that will face the avocado tree so I used the center post along the back as a "prototype". The back posts will have their wires on the outside of the posts (to provide easy access) but the wires will be hidden against the fence. But the center post needs wires run to the top to provide power to the lights that will hang from the top of the pergola. I used the router to carve a groove in the back of the post. From there I ran wire along the grove and backfilled it with wood putty which I will eventually sand flat.

I fell into a good routene for drilling holes. I would start the hole with a 1/4" bit. I would then use a 3/8" extended bit to run the hole through the board. For holes for lights, that was the end of it. But for holes where the mounting hardware would go, I then expanded the hole with a 1/2" extended bit, and then finish it off with a 5/8" bit. The 5/8" bit isn't long enought to go through the 4x6 so I had to drill it from both ends.

I was in middle of drilling a hole with the 3/8" extended bit when the battery on my drill died while the bit was in the wood. I replaced the battery and attempted to keep drilling but the force in the hole sheered the bit leaving the tip in the hole.

I had to use nails, a Dremel, and a couple of pairs of pliers to dig the broken bit out of the wood.

After 45 minutes I was able to dig the bit out.

Lesson learned...if you stop drilling in the middle of a hole, reverse the tool and back it out a little before continuing.

We were able to install one of five posts today. It was nice to see some lumber standing upright for the first time!

The second post is going into an existing hole. I cut out the plants around the hole and treated the end of the cut wood with a treatment that protects the wood and allows it to be surrounded by dirt.

We should have at least two of the other posts installed tomorrow. The remaining two need wood putty and paint. I'm not sure how long that will take so it could be one or two days before they are installed.

Today was another milestone. I finally almost "blew out" the pair of flipflops I purchased the day after I retired. Time to order another pair!

As always, Jack and Diesel were keeping an eye on our homestead. They are always making sure we are safe!