time, materials and tools

Compound Mitre saw
Power drill
Orbital Sander with 80 to 100 grit sand paper disc
Angle Grinder with metal cutting blade
Paint spray gun or paint by hand
Adjustable shifting spanner
Size 19 Spanner
Hand wood chisel
Pine timber
4 x TP 69×69 x 2.4 PAR (Posts)
9 x TP 32 x 144 x 3.0 PAR (Roof slats)
2 x TP 32 x 220 x 3.0 PAR x (Side Structure)
1 x TP 32 x 94 x 3.0 PAR (45-degree Angle braces)
1 x 12mm x 1m threaded rod
16 x 12mm nuts
16 x 12mm washes and spring washes
Exterior wood stain 3 to 5 Litres
18 x Long wood screws 6.0 x 75mm
16 x long wood screws 6.0 x 60mm
4 or 5mm wood drill bit
12mm wood drill bit
Pencil and tape measure
Speed Square and clamps
Safety gear and a ladder
PREP WORK befor your start making your Pergola
4 x TP 69×69 x 2.4 PAR (Posts) kept as is
9 x TP 32 x 144 x 3.0 PAR (Roof slats) cut off 2mm of the ends
2 x TP 32 x 220 x 3.0 PAR x (Side Structure) cut to 2.8m in length
1 x TP 32 x 94 x 3.0 PAR (45-degree Angle braces) cut at a 45-degree angle with 500mm in length on the shorter angled side, point to point.
How to build your DIY Pergola
Step 1
Cut the ends
Use the Compound Mitre saw to cut millimetres off the two ends of all the pine timber to remove the course painted yellow ends. Because the pine timber is so long, make use of a saw horse to prop the other end up, at the same height while cutting with the compound saw.
Step 2 :
Sand down all the wood surfaces down with an orbital sander.
In this project the Pine timber was stained and protected before the build as to protect the wood from the weather as there was not adequate covering to protect the bare pine wood. One can paint and stain the structure before the build or once the structure is up and fully assembled.
Step 3 :
Stain and paint
To help with saving time a paint spray gun was used to apply the exterior wood stain to all the pine timber to be used. Another option is to use a paint brush and sponge roller manually to apply the stain.Raise the pine timber over a big drop cloth and cover one side of the pine timber at a time, allowing drying time between coats and allow to fully dry for handling a full 12 to 24 hours.After assembly touch ups with a paint brush can be done.
Step 4
Assemble the two side structures. ( Part 1 )
The side structure of the pergola is made up of 2 posts TP 69×69 x 2.4 PAR bolted to the side of the pine timber TP 32 x 220 x 3.0 PAR. Measure and place the posts 2.8 m apart on the 3m pine timber TP 32 x 220 x 3.0 PAR. Make sure the posts are perpendicular and straight by using a speed square. Mark measurements for 2 equally drilled holes on the surface area the pine timber crosses and are to be joined. These measurements must be exact on wither side where the posts are to be adhered and exactly equally on the side timber as threaded bolt has to go through.
Step 4
Assemble the two side structures. ( Part 2 )
To help with this process a measured template on cardboard was used to mark the same measurements on all four post joins to the side timber to make sure all measurements are exact. See image. Divide 220mm in half (110mm) on the surface of the 220mm width and length of the 69mm width pine timber, draw a horizonal line and create two equal squares and cross the corners with diagonal lines and those center crossings is where the drilled hole with the 12mm drill bit will be made.
Step 4
Assemble the two side structures. ( Part 3 )
Once the holes are drilled, cut 6 x 140mm lengths of threaded rod with an angle grinder, and insert them in the drilled holes, 2 at each post join, add the washer, spring washer then a nut on either side and tighten with the spanners on each end. Two side structures are now assembled with posts secured on either side.
Step 5
Cut notches (Part 1)
Measure and mark half way point (72mm) on the pine timber roof slats (9 x TP 32 x 144 x 3.0 PAR) and mark a width of 35mm enough to fit on to the wood thickness of 32mm of the Pine wood side structures (2 x TP 32 x 220 x 3.0 PAR). A marked-out notch on either side of each the roof slats is how the pergola rood slats will be secured in place to the side structures. We marked the notches 2.8m apart, with a 60mm overhang on one end and 140mm overhang on the other end, on the larger overhang of 140mmm, this was enough space to cut a 45-degree cut at 70mm from the bottom end of the roof slat and then space the notch 70mm from the 45 degree angle cut for aesthetic purposes for a classic Pergola look.
Step 5
Cut notches (Part 2)
Instead of marking the measurements out on every 9 x roof slats of the Pergola, a template was made to mark out these notches on each end of each slat. Once the notches are marked out, use a jigsaw, chisel, clamps and speed square to neatly to cut out the marked notches on the ends of all the wood roof slats (9 x TP 32 x 144 x 3.0 PAR).
Step 6
Place and secure roof slats
Once all the equally measured notches have been cut out, with extra hands, help and using a ladder, hold the two side structures up right and place the two end roof slats first, to create a square shape and an easier structure to work around while adding the remaining roof slats.Equally space the inner roof slats, in the project they were spaced 350mm apart.Use the 4 or 5mm wood drill bit to drill a pilot hole on top of the notch now resting on the side of the side structures, making sure these roof slats are straight and at the 35mm spacing marks, then drive in a long wood screws (75mm) with a power drill to secure.
Step 7
Add the 45-degree angled braces
Cut 4 x TP 32 x 94 x 3.0 PAR (45-degree Angle braces) cut at a 45-degree angle with 500mm in length on the shorter angled side, point to point.Secure these with 2 x long wood screws (60mm) on either end to the post and roof slats, this angled pine timber will make the structure stronger and sturdier.
Step 8
Touch up with the stain and decorate.
Make touch ups with the wood stain and a paint brush. One can sink and cement the bottom of the posts into the ground, or one can surround the bottom of the posts with brick work and cement for a more fixed structure, or as in the project it can be left above the ground as the property rules state no fixed structures were allowed.For shade or rain cover, one can leave the pergola as is or add a fitted sun shade sail, or canvas material or even polycarbonate corrugated roof sheeting. Or for a greener shaded look add a trellis and vine growing plants that will take to the roof and sides of your DIY pergola the choice is yours.