Eric Lindner Woodworks: How I made an Outdoor Covered Wood Pergola

This blog is about how I made a beautiful custom Pergola in the place of what was originally an old shed:

I first started by researching different images of what a good pergola looks like. Then I had to remember how to frame a roof. I found this helpful website: (click here for link). At Lowes I learned about Ondura corrugated roofing material made out of tar, more pictures on that later.

In the afternoon I tore down the old shed. I used a recirculating saw to cut through the metal and then remove the old shed.

Hidden from view on the back part of the rooftop I found the inscription: May 13 1972. The little shed did good for being 43 years old!

Now all that remains is a scrap heap of metal for recycle.

The vacant slab of concrete exposed a very dirty wall.

After giving it a good power wash I used Drylok exterior masonry waterproofing paint to give the wall a new look.

I also used cement patch up mix to repair some of the lower part of the wall.

I used a 3/8" cement drill bit to drill and anchor 1/2" lag screws about 6" from each corner.

With the four brackets in place I screwed in the 4 x 4 post and then attached an 8 foot long 2 X 6. Using the level I realized there was a one inch slant to the concrete slab below. But that was okay because I actually cut the post a couple inches longer than eight feet just in case.

I used the 2 X 6's for the sides as braces to hold the post steady until I was ready to permanently nail them up.

In order to make sure I cut my rafters correctly I used scrap pieces to make test cuts. Then I used them as patterns for the real rafters.

I temporarily screwed to the front and back fascia boards a piece of wood for the center beam to sit on until I could nail all the rafters in place. After I removed the temporary pieces the resulting look produced a nice center floating beam effect.

Even with all the practice cuts I couldn't get the "perfect" joints. Later I thought of a way to improve the look.

In the meantime, I cut some scrap 2 X 6's on a 45 degree angle to provide a back brace for the posts.

To give even more structural support I made screw pockets in 2 X 4's and attached them at 45 degree angles from the facia boards to the post beams.

I used my Kreg Jig K4 and Ryobi clutch drill to make the pockets. I think the pockets provide the strongest joint for this application.

Pictured below is a window where the grill will be. So I made the brace a little higher than the others to avoid head banging.

I installed across the top of the rafters 1 X 2's to support the roofIng and give me something to nail it too.

I also cut the end of the rafters at a 45 degree angle for a "pergola" style look.

Now it was starting to take shape, except I was having a hard time with the center beam sticking out and what to do with it.

Eventually I angled 2 X 4's to add design to the look of the entrance. Then I had to cut and attach more 1 X 2's on the roof.

I also cut the bottom of the center beam on a 45 degree angle to match the rafters.

Here is a view from below.

In order to cover the sloppy joints mentioned earlier and give even more strength to the structure, I used lag screws to make a decorative joint on the front.

I used more lag screws around the facia boards and fastened them to the 4 X 4 beams for added strength.

I used Behr premium wood finish, cedar natural tone to paint the wood.

The corugated roof sheets were 4 feet by 6 so I had to cut about a foot off of them. In order to cut them you use a regular circular saw but have to flip the blade around. It reminds me of the same method used for cutting plastic siding.