It is the responsiblity of the dealer / installer / homeowner to check with their local building code authorities and follow local codes and requirements, including permits if required, prior installing this product.

It is highly recommended that the Royal Gazebo be considered a two-person project as there are several large components to handle. Two adults can typically assemble this kit within four hours (not including drying and/or curing time for concrete footings).

*Although our exclusive overlapping roof panels have been engineered for an attractive and secure fit, the Royal Gazebo is not water-tight. We recommend that you cover or remove your valuable possessions during inclement weather.

Location of the posts is crucial for the successful installation of this Gazebo. Extra care and caution must be exercised to assure the posts are installed in the proper locations relative to each other and are plumb.

Distance Tolerances from post to post should not exceed 3/16". Posts should be plumb within 1/8" top to bottom. The rotated positions must be held to within 1/16".

Measuring Sticks

To make locating the posts faster, easier and more accurate, ijt is recommended that you cut the following measureing sticks from straight 2 x 4s. This eliminates the need for using a cumber-some measuring tape. The lengths required are:

126"
110-1/32"
101-5/8"
76-11/32"
39-3/8"

Carefully measure and squarely cut each end to the above lengths. (It is helpful to have more than one measuring stick for each length.)

Template

To make locating and setting posts much easier, we highly recommend that you build a template as shown here. (If a custom deck floor is to be build, you may substitute the deck frame for this template.)

Cut Lists:

8 pieces each 47 - 7/32" (Cut 22 - 1/2 degrees on each end.)

2 pieces each 111"

4 pieces each @ 42"

2 pieces each @ 24"

Make sure the template is cut and assembled accurately. You can check the accuracy of the template by measuring diagonally across the template from the opposite corners, making sure all dimensions are equal to each other.

Establishing Location

1) Place the template in the desired location and mark the center location of each hole as shown in Illustration #3. Small stakes work well. Remove the template without disturbing the stakes and set aside.

2) Dig all eight post holes 31" to 32" deep and 7" to 8" in diameter being careful to keep the center of the holes in the proper locations.

3) After all eight holes are dug, carefully place hte template back into its original position.

Mid Rails

Note: The mid rails will be installed at this point to help level the gazebo prior to securing posts with concrete.

1) Determine your dorway opening now. No mid or bottom rails will be placed in this opening. See Illustration #1.
NOTE: The tallest point of each post must be pointed toward the center of the Gazebo.

2) Place one post in each hole, noting the position of the doorway. No keepers should be on the sides of the posts that form the doorway. While keeping the posts close to plumb, you will install the mid rail keepers, sockets and rails.

Install Metal Keepers

3) Position metal keepers on the centerline of the indicated sides of each post at 81 - 1/8" from the top of the post side to the top

of the metal keeper. See Illustrations #4 and #5. Positioning the keepers at the proper height is very critical, as it will affect the vertical position of the posts in the future steps. Make sure the tallest point of each post faces inward.

4) Drill one 1/8" pilot hole through one hole in the keeper. Use only one #10 3/4" screw (provided) to attach the keeper at this point. Tighten snugly but not fully.

5) Align the keeper so it is plum. Drill the other three pilot holes, using the keeper as a guide. Install the remaining three screws and tighten all four screws. Use all four screws when attaching the keeper.

Assemble Rails

6) Assemble the seven mid rails (with picket holes on bottom) by placing one molded socket on each end of the mid rail. See Illustration#6.

7) The order o finstalling be mid rails is not critical except no rails will be installed in the doorway.

8) With a rubber mallet, lightly tap the molded sockets down until they bottom out on the keepers.

Secure Posts

1) After all seven mid rails are installed, use the template surfaces to act as the bottom guide for the posts, see illustration #3. Tap the upper parts of the posts with a white rubber mallet as required to plumb the posts. The rails will move in and out of the sockets enough when tapped to allow you to plumb the posts.

2) Use the measuring sticks previously cut to verify the locations of the posts in relation to each other. See Illustrations #7 - 12.

Some measurements are from "Point to Point"*. Use corresponding distances between posts that are "Flat to Flat" to assure the post has not rotated out of position. Posts rotated out of proper alignment will make installing the rails difficult if not impossible.

Determine Post Elevation

3) After the posts are all very close to position and plumb, use the 126" measuring stick to span between opposing mid rails to set hte height of each post. Establish one post at the final grade level and use that post for setting the elevation of all the remaining posts. The bottom of the vinyl post cover should be at or slightly below grade level.

4) To raise the elevation of a post, pour some gravel into the hole and then raise the post up and down until enough gravel is under the post to obtain proper elevation.

You can tap down on the rails close to the posts to lower the elevation slightly.

5) Recheck each post for plumb and elevation very carefully. This will require several checks on each post.

Terms

"Flat to Flat" = The dimension lines refer to one flat side of a post to the corresponding flat side of another post.

"Point to Point" = The dimension lines refer to the corner of a post to the corresponding corner of another post.

Pour Concrete

6) After all the posts are plumb and correctly positioned, fill the holes eith concrete one at a time. Continually check the posts to assure they haven't moved out o fposition or plumb. Post adjustments must be made prior to the concrete setting beyond the time when adjustments can be made.

7) Disassemble and remove template being careful not to disturb post and concrete.

Note

Please allow the concrete to adequately dry (per the manufacturer's recommendations) before continuing.

Install Post Skirts

1) The two-piece post skirt snaps together to form an octagonal trim at the base of each post. See Illustration #13.

Bottom Rails and Pickets

Note: Do not install bottom rails in the entrance section.

1) To make inserting pickets easier, remove the previously installed mid rails.

Note: Concrete footings must be secure or this step will shift posts out of position.

With a rubber mallet, lightly tap the mid rail (at the bottom of the vinyl socket) to lift the rail off the metal keepers and set aside.

2) Bottom rail keepers are installed in the same manner as the mid rail keepers. See Illustrations #4 and #5 for locations.

3 ) Assemble seven sections of bottom rails (with top picket holes) with the molded sockets. See Illustration #6 for orientation of sockets, rails and rail stiffeners.

4) With a rubber mallet, lightly tap the molded sockets down until they bottom out on the keepers.

5) Set the pickets into the precut holes in the bottom rail, one section at a time. Place one end of the mid rail onto a keeper and begin to feed the pickets, one at a time into the holes on the mid rail. See Illustration #14.

6) Secure the mid rails and pickets by lightly tapping the molded sockets until they bottom out on the keepers.

7) COmplete the remaining six sections of rails and pickets.

8) Your gazebo should now look like Illustration #15.

Header Keepers and Rails

Note: Header rials (without picker holes) are used between all eight top sections, including the entry section.

1) Make not of the poper sides of each post that will receive keepers and header rails. See Illustration #4.

Install Metal Keepers

2) Position each metal keper (See Illustration #4) on the post so it is 2" below the top of the octagon post.

3) After all 16 header rail keepers are installed on the proper sides of each post, assemble the eight top header rails by placing one molded socket on each end of a header rail. Make sure an aluminum stiffener is in each rail. See Illustration #6.

Install Header Rials

4) The order of installing the header rails is not critical though a criss-cross pattern wil make installing the last section easier. The molded socket may have to be adjested further on or off the end of hte rails in order to fit properly on the keepers attached to the posts. Adjust as necessary.

5) With a rubber mallet, lightly tap the molded sockets down until they bottom out on the keepers.

6) Illustration #16 shows the posts with all eight header rails installed.

Ridge Rail Assembly Sequence

After all the header, bottom and mid rails and pickets are installed, begin installing the RIdge Rails. See Illustration #1.

Note: The most important requirement is that all the Ridge Rails overhang the posts the same distance within 1/4".

The approximate overhang, as shown in Illustration #17 is 9 - 1/2 to 10 - 1/2". This dimension itself is not as critical as having ALL the Ridge Rails overhang the same distance. If this overhang is not close to being equal on all eight posts, you will experience difficulty when installing the roof panels. You will determine the exact measurement in the steps following.

1) Insert two Ridge Rail assemblies through any two posts opposite to each other.

2) Gather together the Roof Hub assembly, (See Illustration #18), four 3/8" x 1" bolts, nuts, flat washers and lock washers.

3) Locate the hub assembly in the approximate center of the Gazebo. Attach one of the RIdge Rails assemblies. Hand tighten the bolts.

4) Check the overhang of both Ridge Rails as shown in Illustration #17. Adjust until the overhang of both Rails is equal. You may have to jiggle the Ridge Rail some as it will bind in the post when its weight is resting on the post.

5) Continue the same process according to the sequences shown in Illustrations #23 - 26 until all eight Ridge Rails are positioned with the smae overhang. Tighten all bolts completely once the Ridge Rails are positioned correctly with an equal overhang.

6) Make sure you check the overhang continuously each time you add another pair of rails.

7) As soon as you determine what the overhang will be, attach the Ridge Rial Brackets (See Illustration #19). Position the bracket on the post and RIdge Rail. See Illustration #17 and #20. Drill 3/32"pilot holes using the bracket as a template. Insert a #6-32 x 3/8" screw (provided) through a flower washer (See Illustration #21) and fasten the Ridge Rail bracket in four places per bracket. Snap washer caps (See Illustration #22) on the flower washers after the screws are tightened.

INstall Hub Skirts & Caps

1) Prior to installing the roof panels, install the roof center hub skirts and caps. See Illustration #27.

2) Locate the four halves of the skirts (same part as used previously as a post skirt). Snap together to make two complete skirts.

3) Slide one skirt over the top hub as shown and secure with two #10 3/4" stainless steel sheet metal screws or other suitable screw (not included). See Illustration #28. Make sure the location of the screws will allow them to penetrate the vinyl skirt. (If you live in an extremely windy climate you may want to use four screws.)

4) Repeat the previous step to secure the remaining skirt on the bottom of the hub.

5) Using the provided PVC glue, put smal drops on the skirt of hte cap that goes inside the extended vinyl portion to the hub. See Illustration #29.

If you anticipate disassembling the Gazebo, use glue sparingly to make future removal easier.

Install the top cap with the ball and the bottom cap without ball in the same manner. See Illustration #27.

Install Roof Panels

1) Gather all roof panels in groups sorted by length.

Note: Use masking tape, duct tape or suitabl eclamps to temporarily hold panels in place so they will not fall out during installation. Be extra cautious during installation of hte panels as they can suddeny fall out prior to the roll pin being installed and cause injury. Be sure to remove the tape immediately after installation so it doesn't leave a residue on hte panels. Direct sun light can dry tape out very quicly!

2) Install the eight smallest panels by sliding them into the Ridge Rails as shown. Push them toward the center hub until they stop without forcing.

3) Install the second largest panels in the same manner. Make sure they are firmly seated but do not force them beyond hand pressure. Make sure they are fully locked into each other.

4) After installing the two smallest roof panels in all eight sections, measure from the bottom edge of each end of hte lower panels to the ends of the Ridge Rails. They should all be the same distance. Adjust as necessary by lightly tapping the lower side of the ends of hte panels that are too low.

5) After carefully adjusting the positions of the first two rows, install the third and fourth rows of panels. Check the distance from each panel's end to the end of the RIdge Rail. See Illustration #32 for measuring points.

Note: (See Illustration #33) Before installing the last two rows of roof panels, make sure the rectangular aluminum stiffeners are in the roof panels as shown with dotten lines.

6) Install the remaining panels, carefully measuring and adjusting each time two additional rows of panels are installed.

7) After all panels are installed evenly, install Roll pins as shown in Illustrations #30 and #31. Use a small hammer or mallet to tap the Roll pins into the pre-cut hole. Adjust so they are evenly centered through the Ridge Rail.

8) Install Rail End Cap after rof trim is installed. See illustration #31. Use the provided PVC glue to permanently attach.