The Luxury Pergola Modern DIY Louvered Pergola Instruction Manual

Tool List: Required For Assembly

• Safety Goggles

• Screwdriver

• Hearing Protection

• Work Gloves

• Caulk Gun

• Painters Masking Tape

• 72” Level

• 25’ Tape Measure

• Paper Towels

• ½” Combination Wrench

• Ladders

• Shop Vacuum

• Cordless Impact Drill

• ½” Rotary Hammer Bit

• Sawhorses

• Wire Strippers & Crimpers
  

• Rotary Hammer

• Quick Clamps

• Utility Knife

• 10″ Magnetic Bit Holder

Important Safety Instructions:

Symbol Explanation:

This warning triangle calls attention to hazards that can lead to death or to severe injuries or which are important for the functioning of the pergola.

This sign identifies important notes.

Safety Instructions:

To install this pergola technical knowledge is necessary. Do not mount this pergola yourself but contact a professional workman for help if

• you are unsure if the pergola can be mounted on the place you chose for installation.
• you do not understand the instruction manual or parts of it.
• you do not have necessary tools available.
• you do not have necessary technical knowledge

A minimum of three healthy adults are required to move and install the pergola

The product is big and heavy. Do not try to install the pergola alone. If the pergola falls, it could cause damage and serious injury. Contact us for help.

Do not install the pergola when you find damage parts are that parts are missing. Contact Us

Keep children and pets out of the working area during assembly and adjustments.

Aluminum shards will come off of the unit during drilling and screwing. Wear eye protection to avoid being potentially blinded.

All extrusions have sharp edges and can cause severe lacerations to your hands, face,eyes, and any other exposed surface.

Do NOT climb on the unit. It is not built to hold someone on top. It can collapse potentially causing severe injury or death.

The parts in this unit are heavy. Do not attempt to assemble it if you have to strain to move it. Potential strains can cause serious injury.

Install the unit exactly as described. Improper installation can result in the unit’s collapse causing severe injury or death.

The impact driver used can heat up and twist causing twisted wrists or severe burns on hands or exposed skin.’

Collect ALL parts and screws that fall on the ground. Failure to do so may result in tripping, falling, or puncturing your feet, hands or body.

Wedge anchors must be tightened completely. Wedge anchors without base trim extrusions also can be a tripping hazard.

Careful pulling low voltage motor line to avoid cutting or abrading it. Replace it if you scar or cut into any of the wires.

Wear a mask when using touch up paint and always do so outside. Failure to do so could result in light headedness, fainting, or death.

Careful hammering the wedge anchors down. Missing the anchor could cause broken hands, fingers, toes, and feet.

Do NOT get Novaflex sealant in your eyes or mouth. Follow manufactuer recommendations for Hazardous chemicals if you do.

Do NOT operate the louvers in winter when snow is on top or its frozen. Doing so could break parts of The Luxury Pergola and result in louver collapse causing serious injury or death.

Do NOT put your hand between louvers. Doing so could pinch skin and bruise it and break fingers or hands.

Pro Tip: Avoid galvanic corrosion. Any steel that will be in direct contact with the Aluminum components should be galvanized or well painted .

Installation Steps:

Plan Ahead

Carefully review these instructions and review your job specific plans before installation. You MUST watch the installation videos located at as well for further guidance.

Pro Tip: Use care in handling! Finished surfaces can be easily scratched.Use duct tape or other surface protection on tool surfaces (saw bases, jigsaw footplate, clamp surfaces, etc), and cover working surfaces such as sawhorses and tables that Luxury Pergola components will be in contact with to help avoid scratching.(If you do scratch them – hide them behind gutters or face up and away from common view)

Note: #14 (larger) TEK screws are for frame-to-frame connections. #10 (smaller) TEK screws are for the the pivot strip and gutter.

1. Determine the location of the pergola on the patio. Ensure the post base holes will hit concrete on each open hole for the given size.
2. Determine the location of the electrical control box given the 25’ plug in power cable and 25’ line to the motor. Keep in mind the line must go up a 9’ post and then usually another 4’-8’ to the motor.
3. Determine direction of louvers (Typically they close towards the North or East)

Unpackaging The Unit:

What is Included:

• (4) 2”x10” beams of varying lengths to fit your kit labeled A, B, C, and D
• (4) Gutters of varying lengths to fit your kit labeled A, B, C, and D
• (4) Posts cut at roughly 9’ in height (One is drilled for electrical, one is drilled for drainage. The larger hole is for drainage)
• (12-25) Louvers included size and quantity depending on kit size.
• (24-50) End caps
• (4) Stainless Steel Post Bases
• (48-100) End Cap Screws
• (12-25) Push Nuts
• (1-3) Retainer Strips
• (4) 6.5” U Channel Connectors
• (4) Beam to Beam Connectors
• (4) Beam To Beam Connector Sleeves
• (1-2) Link Bars
• (100) #10 Tek Screws (Color Matched)
• (100) #14 Tek Screws (Color Matched)
• (3) Tubes of Novaflex Sealant (Color Matched)
• (2) Cans of Touch Up Paint
• (1) Motor
• (1) Motor Assembly Kit
• (1) Electrical Control Box with 24’ Plug in Cable and 25’ landscape line.
• (1) Remote
• (16) ½” Wedge Anchors
• (1) Electrical Connection Assembly For Motor
• (1) Bundle of Composite Shims
• (1) Allen Wrench

1. As you unpackage the larger extrusions, set them on sawhorses. (2) Sets are ideal, but the unit can be assembled without them.
2.  The extrusions will be assembled in the following order if you’re going to stack them on top of one another they should order as follows from top (easily accessible) to bottom (installed last):
   a. Posts
   b. Beams
   c. Gutters
   d. Louvers
   e. Retainer Strip & Link bar
   f. Trim (if applicable)

Step 1: Posts and Wire

The Goal:
To have all four posts up and ready for beams and the wire run for the motor.

Step 1:1
Slide the posts onto all the post bases and slide them into generally the correct area of the patio. Slide the Base Trim extrusions

Step 1:2
Place the #14 screws in all open drilled locations. (If applicable) Slide the base trim extrusions down the post.

Step 1:3
Ensure the outflow hole for the drainage lines up with the post base and that post is in the correct area of the patio for drainage.

Step 1:4
On the post with a hole drilled at ½” lean it back down and throw the landscape wire up the post. Usually, one person feeds from one end and the other pulls with a long and hooked object. When lifting the post back up, hang the excess wire out (at least 4’) and tape it to the post.

Step 1:5
Assemble the (4) Beam to beam connectors with the (4) Gutter Connectors and the (4) 6.5” U Channel Inserts using (8) #10 Tek Screws.

Step 1:6
Lower the entire assembly into each of the four posts orienting the gutter connector bent portion to the inside of the unit. Pull the landscape wire through the gutter connector drilled out for the wire. Ensure the gutter connector drilled for drainage is attached to the drainage post. Hang the excess wire out of the gutter connector and tape it to avoid it falling back down.

Step 1:7
Use (4) Wedge Anchors, a hammer drill, hammer, and ratchet set or wrench to attach one post of your unit to the patio. This will hold the unit in place during assembly.

Pro Tip: Ensure you hold the hammer drill straight up and down to avoid drilling at an angle. Blow or vacuum out the dust to give the anchor room.

Step 2: The Beams

The Goal:
To have the perimeter frame assembled.

Step 2:1
Lift B wall up and place it on the posts with the holes lining up. Place (4)

14 Tek Screws through the Beam To Beam connector and into the insert on each

side.

Step 2:2
Repeat Step 2:1 for A wall, C wall, and D wall.

Step 2:3
Place the two missing screws on the interior of the unit through the gutter connector and into the unit.

Step 2:4
Slide the Beam To Beam Connector Sleeve over the outside of each connector and screw it down with (4) End Cap Screws

Step 3: The Gutters, Square & Plumb

The Goal:
To set gutters and plumb/square the unit. Anchor down the remaining posts.

Step 3:1
Lower each gutter labeled correctly into their appropriate spots between the gutter connectors. Place #10 Tek screws in each drilled location. (“A” gutter goes on “A” Wall, etc.)

Step 3:2
Measure the unit for square and check the posts for plumb with a level. Use the post that is anchored already, ensuring its plumb as you plumb the post on the opposite corner. Measure from the post on the inside to the post on the inside. The number should match those below. Composite shims provided may need to be used to hold the unit plumb.

• 8 x 8 Unit: 9’ – 7 15/16”
• 10 x 10 Unit: 12’ – 5 15/16”
• 12 x 12 Unit: 15’ – 3 7/8”
• 12 x 16 Unit: 18’ – 4 7/16”

Step 3:3
Once the unit is square and plumb. Lift up the post base if applicable and clamp, tape or hold it in place as you drill out the (4) holes on each post. Insert and tighten all anchors ensuring the posts remain square and plumb.

Step 4: Seal The Unit

The Goal:
Seal the unit

Step 4:1
Seal in each corner the locations shown below with the Novaflex sealant included in the box. Paper towels and mineral spirits are helpful to get it off your hands as you tool it into the spaces.

Step 4:2
Seal the interior of the gutter conectors on each up leg and on the bottom of each gutter where it rests in the connector.

Step 4:3
Seal the gutters to the beams with the Novaflex Sealant. After running the bead above the gutter, tool the bead with your finger or a tool.

Step 5: Louver Preparation & Installation

The Goal:
Prepare and lower in the louvers.

Step 5:1
Remember which way you want the louvers to close. Typically, the overhang portion of the louver with the pile weather strip faces North or East. Begin screwing on your end caps with (2) End Cap Screws per louver. Pro Tip: Don’t overtighten the end cap screws, or you’ll risk splitting the end caps from the tension.

Step 5:2
As you screw on the end caps, lower the louvers into place in the slots aligned on each side. Set one side and then lower in the other. It is easier to lay them in from the open side to the side it closes towards. As you lay them in, lower them in closed and hook the louver on the prior louver.

Step 6: Retainer Strip & Link Bar & Trim

The Goal:
Place and screw on the retainer strip. Place the link bar and fasten with push nuts.

Step 6:1
Place the L shaped retainer strip labeled on each side for the letter on the unit and screw it on with the pre-drilled holes.

Step 6:2
Repeat Step 6:1 for the opposite wall on all strips.

Step 6:3
Place on the link bar, slotting the circular holes on the nub closest to the pile weather stripping on each louver. The slot should slot over the nub closest to the short side.

Step 6:4
As you place on the link bar, place the push nut on the nub, angling it at 45 degrees until it bites into the nub and holds itself in place. Use a ½” combination wrench to push on the push nut.

Pro Tip: Once you place the push nut on the end cap, they will not come back off, so ensure you’ve laid out the link bar from one end to the other correctly. If you’re not sure, pause and delay the push nuts. If you need to take them off, you’ll likely have to cut them off or pry them off and buy replacements.

Step 6:5
If applicable, lift the pre-mitered trim pieces for each wall and match the letters with the corresponding beams. “A” wall beam with “A” wall trim. Line up the screw holes on the trim piece with those on the beam and drive #10 Tek screws into each open spot.

Step 6:6
Repeat 6:5 for all walls around the unit. Check that each corner lines up well.

Step 7: The Motor Assembly

The Goal:
To install and wire the motor.

Step 7:1
Lower in place the motor assembly connection to the link bar and bolt it in place with the provided parts.

Step 7:2
Thread 10mm shoulder bolt through the front of the motor shaft and into the motor assembly connection, linking it together with the lock nut on the other side. Tighten this with the ½” combination wrench and an Allen Wrench.

Step 7:3
Screw down the motor mounting plate in the corresponding holes for that side of the unit.

Step 7:4
Pull open the louvers until the back of the motor reaches the motor mounting plate and push the 10mm clevis pin through the mounting plate holes when the motor’s back end lines up.

Step 7:5
Place the cotter pin in the open hole of the clevis pin and bend it to keep it from coming back out.

Step 7:6
Take the Electrical Connection Assembly and place it on top of the beam behind the motor.

Step 7:6
Take the wire on the motor and pull it into the Electrical Connection Assembly on one end and screw the wire down on the plastic terminal labeled for red and black.

Step 7:7
Feed the wire that is going up the post over and up to the Electrical Connection Assembly. After pulling through the open end, strip and screw down the wires on the correct terminals.

Step 7:7
Tighten the openings where the wires come in, screw down the lid, and glue the box down to the beam with some Novaflex.

Step 8: Plug In And Test

The Goal:
Get it working!

Step 8:1
Place the electrical control box where you want it, and then plug the box into an open outlet.

Step 8:2
Check with the remote that the unit opens and closes. If you want to reverse the buttons on whichbutton opens or closes, you can swap the red and black lines from the motor into the electrical connection assembly.

Step 9: Enjoy!

Technical Support

Detailed Technical Support is available here and online on “The Luxury Pergola’s” main page at https://www.youtube.com/channel/UCsJ6svDi2ae- IAClU243Mcg

Further support is ongoing and will be detailed here over time. Full technical detail support is not available over the phone now due to the lean size of our team. Staffing up for support would add cost to the product that we do not want to do at the moment.

The Luxury Pergola Install Guide | info@theluxurypergola.com

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