Pergola for the spa

[handirifle]

Well, we finished building the house in 2010. A few months later I built my workshop, a 24x30x10ft stick built. At the same time the foundation for the shop was poured, I had a slab poured for a spa and pergola. I included post supports for 6x6 set in the concrete, when I poured this slab. I dug footings under each place a post support would set. So there is sat. I put the spa on it a couple months later, after running elec to the location. I pulled 80 amps, 50 for the spa and 30 for whatever else we might want to add.

This has been like this for about 2.5yrs now and we finally accumulated the funds to complete the project.

Sorry no TRUE before pic, only when I first started. This as close to BEFORE as I can get. Just eliminate the post, and there you have it.

Backtracking a bit is the 20ft flatbed loaded with most of the lumber (more on that later). Not sure of your prices, but that is $1300 worth of lumber. Sure doesn't look like a lot of wood.

See the first pic for the very beginning of the build.

There are 7, 6x6 posts. I left the front open and clear for a wide open entrance.

Here are the 4 corner posts, braced to hold plumb.

There is also 2 of the 8 2x10's I used as headers.

 

[handirifle]

I had some help on this project, but actually did most of it myself. If you look close at the posts, you will see a cross piece under the end of the 2x10. I would set one end up on this cross piece, and then clamp it in place. Then raise the other end overhead as I climbed a ladder and set it on the other pole cross piece. The worst part was getting the overhangs even. Took about 6-8 trips from post to post to get it right. I set 3 of the 8 by myself, and my son helped me set the remaining 4, and cut and mount the diagonal braces. He also helped me bolt all the big pieces together. My son came up a day early for a previously planned trip, to help me out. He lives about 4 hours away. A neighbor helped on the first one.

My brother in law also helped me set the first row of 2x8 rafters.

Here's all the headers set.

Here's a close up of the headers before trimming.

Trimming is definitely easier on the ground, but I wasn't sure what design I was going to use at the time.

Here's the AFTER shot of the trimming.

Nothing fancy on the trimming. You can also see the bolts in the last pic.

 

[handirifle]

I guess I need to mention some dimensions for this thing. Sorry about that. The spa in the shots is 7ft 3" square. The concrete pad is 18' x 18'. and the posts are 7' 5", outside to outside. Posts are 10' high, 6x6 doug fir (all wood is DF). Headers are 2x10 at 20ft long before trimming. Finished length is 19' 8" on the rafters.

Here's a shot of the FIRST mounting of the rafters.

Now, to explain. I said first mounting, because once it was up the wife decided it was orientated wrong. In the above pic, the front is in the right side as shown. The front faces due south, and I figured, well face it sound with the rafters running east to west for best shading. Nope! I guess the magnetic variance is enough to throw the shade pattern off a bit.

Sooooo, after much discussion and consternation, and grumbling on my part (wife told me it was wrong before I set them) I removed all the rafters ( I used deck screws on all). I didn't take shots of this little endeavor. I would place one end in a corner and stack the others on top of that board. The other ends of those boards were fanned out across the headers. I did this on opposite sides.

To replace them, I started at the top of the pile and worked them into position. Took a couple hours but it got done. Luckily this think is pretty square, cause the rafters are notched to fit over the double headers. Only minor trimming required to place them in new position.

Here is the first layer of rafters, in the new orientation. By the way, the second layer of 2x8's (14 of them) was NOT planned at first, nor was it covered in the $1300 load. They were $300 more.

I said first layer, because AFTER I moved them we decided one layer was not enough, because now they "looked funny". Personally I was happy with them, but I do have to admit the second layer did make it look better.

Here's the ALMOST complete project. I have some "booties" to put on the bottom of the posts, to make them match the house, and then it will be ready for paint.

I have all the scraps cleaned up and actually got in the spa last night. This has taken me about 1.5 weeks, not working on it every day, because some days were just too hot to get anything done, ie Saturday is was 105 here. It topped off at 82 today.

 

[handirifle]

Like I mentioned, the booties are to come, and so is a ton of landscaping and privacy screens. The fence behind it, is my north end boundary. There is a dirt road that goes back a few miles. About half dozen neighbors come and go on that road, so will have to block the "looky loos".

If anyone cares, the land on the other side of the fence belongs to Johnny Gallecki (Leonard on "Big Bang Theory"). I have 3 acres, he has 320. Pretty much an absentee neighbor though. But we have spoken a few times. I usually text him whenever something is going on at his place to make sure he is aware of it. Just being neighborly there, as we all do the same for each other around here.

 

[forgeblast]

Nice Job!!

 

[deerseeker001]

Looks good, enjoy.

 

[ace10]

Looks great.

For anyone else endeavoring to undertake a project like this... a good way to save a lot of dough is to go with some much smaller dimensional lumber on the upper row, assuming your lower layer is the one providing most of the shade, when you most need it.

Imagine the cost of doing that project in cedar or redwood! :shocked:

 

[handirifle]

Yea we talked about cedar, because the wife REALLY hates bugs and it's a natural repellant, but it wouldn't really fit the scheme of the rest of our buildings. I didn't even price cedar, but I am sure it would have doubled the cost, at least. We estimate at least $2000 so far.

As for the smaller wood on top, when we moved the rafters, I bought 2x2's to put up there, but if you look closely you can see the 2x10's stick above the base layer, and it looked kinda off, so to correct the "look" I added another layer of 2x8's that were also notched, so that put the top actually on top.

 

[handirifle]

Also like I told my wife in the beginning, if we want a lot of shade, just do a gable roof. I have never felt pergolas are good for shade, still don't. I had seriously consider a gable roof, with open ends like a beam type construction.

If I ever decide to enclose this thing (something else I have thought about) I might change it to a gable roof. Probably never happen though.

Now if I can just talk her into letting me add a big carport on the other side of the workshop.......

 

[handirifle]

I should also mention, the bolts are 10" long 1/2" bolts and nuts. That ought to have a decent amount of sheer strength. I have two bolts in every joint, except where the diagonals bolt to the headers. I still wonder if there should not be two there also.