Yesterday we put another productive day into the Pergola. Dave and Pete came back out, and our friend Dan also came over to lend a hand. The first order of the day was to saw a decorative angle into both ends of all 18 of the 2x10 rafters.
Once all the boards had been sawn, we started putting the first ones up. We used z-shaped deck hangers on the posts to support these first beams and keep them level while we centered them with the same amount sticking out past the posts at both ends. Once they were centered, we tacked them in place with 16p nails.
With the outside boards nailed in place, we drilled a guide hole through the posts. Once we got through, we held up the inside boards and marked them with the drill also. Then we used another drill with a 5/8" spade bit to widen all the holes to fit the bolts.
Every aspect of putting up these (very heavy) boards was complicated by our need for ladders. Here Dave, Pete & Dan work together to bolt the second inside board into place.
The second layer of rafters rest on top across the first layer, and to complicate matters they are notched to fit. This requires lifting the boards into place, marking them, lifiting them down, cutting the notches, and then lifiting them back into place again. I guess that probably explains why my torso muscles are all so sore today!
We called it a day at this point, with three of the end sets done & bolted into place. This is a lot of work to build, but I am really pleased with the results. I love the scale of it, it doesn't look like a regular "backyard" pergola, it looks like something you might see at a public park or a resort - it's heavy duty! Cary was pleased to note that it holds his weight just fine. This is good, since I'm sure it will be very popular with local hairless monkeys, at least until the vines grow over it.
Hopefully we'll find some time mid-week to continue working on this project, but if not I'm sure we'll finish building it next weekend, and then move on to putting down some pavers of some as-yet-undetermined kind for the floor of it. The fun just never stops around here!