Walkway Pergola
Extend your outdoor living with a shaded seating area
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Extend your outdoor living with a shaded seating area.
The main posts of this treated-pine pergola are anchored in concrete. The frame is constructed the old-fashioned way, with tenons and housings cut into the timber with a circular saw and handsaw. It’s easier to apply the first coat of stain while the components are flat on the ground. Keep the stain handy throughout assembly to apply on all cut ends and inside joints.
Download Walkway Pergola project PDF
DIY lingo
Arbour, A stand-alone lattice framework covered with vines.
Pergola, Covered, trellised area supported by columns or posts.
Gazebo, A small roofed structure screened on all sides.
Cutting tenons
Side beams are tenoned at each end to fit mortices on the posts. Cut the beams to 1080mm and square a line around each end, 70mm in. Mark the tenon on each end with a marking gauge set at 45mm. Set a circular saw to 45mm and cut the shoulder with several relieving cuts across the beam from both sides. Remove the waste and clean up the faces of the tenon with a chisel.
STEP 1
Cut the posts
Use a circular saw to crosscut the housing, making several relief cuts across the post. Break out waste and clean up with a 25mm chisel. Cut a mortice in the remaining section of the post (see Diagram 5). Place the post, housing-down, on sawhorses and rip lengthways. Drill several 10mm holes through the post and clean out with a chisel to the same depth as the housing. Check for square then secure the posts with crossties. The post holes should be 1350mm apart for the front and back, 1050mm apart for the sides, 400mm deep and 300mm wide.
STEP 2
Secure the posts
Stand the rear assembly with the housing to the outside. Use a spirit level to plumb the posts before securing to the temporary braces fastened to the pegs. Level the horizontal ties at the bottom with levelling shims. Stand the front post assembly and fasten to the rear assembly with horizontal side supports, checking the posts are parallel and square (add additional braces if necessary). Use a spirit level to check the posts are the same height.
STEP 3
Concrete the posts
Pour mixed concrete into each hole and pack around the posts with scrap timber. At ground level, batter the concrete surface to allow for runoff and prevent water from pooling. Allow to set for a few days.
STEP 4
Lock in the side beams
Cut a tenon at the end of each beam to match the width and depth of the post mortices (see Diagram 5). Remove braces and place side beams on posts. Lock with 75mm x 10g galvanised screws angled from above.
STEP 5
Front and back beams
Front and back beams require housing at each end to fit around the top of the posts (see Diagram 5). Secure the beams on sawhorses and cut housings with a circular saw set to 70mm. Break out waste, clean up with a chisel and smooth with a coarse file.
STEP 6
Position the beams
Lift the beams onto the posts and push back until they’re flush with the face of the posts. Adjust housing if required or tap into place with a block and hammer. Fasten with 75mm x 10g screws angled from the top.
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