Note: Following are the complete step-by-step instructions for converting your fireplace into a precast-stone masterpiece. For further details, resource information and images, search for Weekend Handyman episode WKH-108. Print out this document and you'll be ready to do it yourself.
Materials for Complete Project: Redwood for frame and bench (varies according to frame dimensions)
3 pieces of 2" x 6" x 14"
2 pieces of 2" x 6" x 16"
10 pieces of 2" x 4" x 12"
5 pieces of 1" x 8" x 12"
3 pieces of 4" x 4" x 12"
Shade canopy with tracks
Inset deck lighting kit
Handsaw
Circular saw
Jigsaw
Forstner bitHand tools
Clamps
Measuring devices First, you'll need to gather your tools and materials, determine the size of the area to be covered and order the canopy. Building the Front Posts for Canopy Frame - Build a box to support the base post and mount into place.
- Clamp posts together and notch where the header fits.
- Make a series of parallel cuts to create a notch, break it off with hammer and clean up any ridges with a chisel.
- Create decorative edge on the header by tracing a desired decorative edge onto header board, cut with a jigsaw.
- Attach the front posts -- visually line up the posts where you want them, make mark and notch where you're going to put the post.
- Clamp a bock to the post that will sit on the deck and keep it at the right height.
- Raise the post and level it.
- Use carriage bolts to attach the post to the deck.
- Raise the other post (to level use sticker boards since the post doesn't touch the ground or have a box). Level post, clamp a 2" x 4" on one side angled to the ground for support and clamp another 2" x 4" in the other direction.
- Attach the double-sided header.
- Measure each side while on t he ground, make mark then transfer to other header board.
- Raise the first header board and bolt it on.
- Bring second header board up, clamp and bolt it on.
- Attach the return boards.
- Measure the distance between the header and the frieze board (board on house that return boards will attach to).
- Add however many inches you want to measurement for return to hang over the front to create the pergola style.
- Cut the boards and add a decorative edge if desired.
- Raise the boards, rest on headers and slide the return boards back to the freize board.
- Attach the return board with galvanized metal brackets.
- Square where the first return board meets the header and screw it in.
- Repeat for the other return board.
- Attach tracks to the frame for the shade.
- Use tracks that are pre-cut to length (we ordered ours).
- Mount the brackets for tracks under the return boards. Cut a little piece out of the molding, and space them far enough apart to allow for the roller mechanism on each side of the fabric.
- Install tracks with bolts, and attach one end of each track to the house and the other end to the header directly across.
- Install shades. The rollers are inserted into the tracks.
Add an Angled Back Bench - Remove the old railing.
- Decide where you want the two end brackets to go.
- Measure the space between to determine even spacing of brackets in-between, and fasten brackets with screws.
- Attach 2 x 4's to each support. First, cut an angle at the top of each board to create a level edge.
- Use sliding "t" level butted against support, match the angle and use that to adjust your circular saw at an angle. Cut the top of the 2x4's.
- Clamp the 2x4's to each support, level, then attach with bolts.
- Attach the boards for the seat of the bench. Level first board to be flush with end of the deck.
- For the top of bench, set the table saw for the same angle cut used on the support boards to create a level board to use for setting things on such as beverages.
- Clamp the cut board in place, using a framing square to make sure it's flush, and then screw it on.
- Put on the rest of the back bench boards and skirt.
Adding Lighting to Deck - Measure where to place the lighting.
- Use forstner bit to cut a 3" diameter hole that's 7/8" deep with a flat bottom -- not a through hole. Keep the bit perpendicular when drilling.
- In the center of the hole, drill a 7/8" inch through hole using an auger bit or spade bit.
- Snap the light into place.
- Hook the lead wires into your main power wire, wrap connections with electrical tape, pull wires under deck and attach them to the transformer.
| 
