Almost Heaven Saunas ® THE AUTHENTIC SAUNA EXPERIENCE Worthington Sauna Installation & Owner’s Manual
Read this entire manual through to the end before proceeding with the assembly. ELECTRICAL REQUIREMENTS All electrical wiring must be performed by A QUALIFIED LICENSED ELECTRICIAN. Because of the heat involved in the sauna, it is required that you use copper wire with 90ºC insulation. Do not use aluminum wire to make the connection. Consult with an electrician so you can determine the requirements for your particular situation.
STEP 1 - Locate the (3) bottom rails and position as shown. Overlap the corner joints and be sure the rails are square to each other. Drill a 1/8” pilot hole in the corner joints and secure rails to each other using a single 5x70 screw in each of 2 corners. STEP 2 - Locate the wood wall elements (sections). These will be inserted over the bottom rails as shown in the diagram.
STEP 4 - Verify that the element wall sections are square to the rails, perpendicular to each other, and that the flat top of the wall elements and corner posts align. Using a cordless drill with the appropriately sized bit (included) use 6x20 screws and secure the 90° corner post to the short and wide elements through the pre-drilled holes. NOTE: Because the elements utilize both vertical and horizontal boards, you will hear a “cracking” sound as you draw the elements tight with the screw.
STEP 7 - Continue the addition of wall elements by adding (3) of the wood wall element sections along the back rail. The wall sections will not screw together, but be sure they are level at the top and firm to each other by tapping in place with a rubber mallet. STEP 8 - Add the third 90° corner post and secure with 6x20 screws as with the other rear corner post. STEP 9 - Add a wall section on the left wall and attach to the 90° corner post with 6x20 screws.
STEP 10 - Add two more wood wall element sections along the left wall. The wall sections will not screw together, but be sure they are level at the top and firm to each other by tapping in place with a rubber mallet. STEP 11 - Locate the last 90° corner post that has clips on one side and a glass groove with 2 holes on the other. Be sure the holes are to the top and facing towards the inside of the sauna. Install according to the instructions in Step 6.
STEP 13 - You will now install the roof support rails. Locate the (3) roof support rails and cut to length. The left and right rails should butt up to the front corner posts and the rear wall. NOTE: BE SURE THERE ARE NO GAPS BETWEEN THE WOOD WALL ELEMENTS BEFORE TAKING YOUR MEASUREMENTS. Measure 1-1/2” down from the top of the wall element sections and pencil marks on each end the wall sections. Then screw the roof support rails to the wall element sections using 4x70 screws with the bit provided.
STEP 16 - Locate the glass wall header and position over the glass window sections. Lower the header over the glass so that the glass will fit into the grooves at the base of the header. Line up the pins of the header to the holes in the corner posts and gently tap into place with a rubber mallet. NOTE: YOU MAY NEED TO PULL THE LEFT AND RIGHT WALLS OUT SLIGHTLY IN ORDER TO FIT THE HEADER BETWEEN THEM. DO NOT USE GLUE WHEN TAPPING THE PINES INTO THE HOLES.
STEP 19 - You will now install the bench supports. Find the long bench support and cut to length so that it will go as far as the left and right walls. On the rear wall and from the floor measure 33” and make a pencil mark. Position the upper bench support at (just below) the mark and use a level to insure that the support is level to the ground. Then screw the upper bench support into the wall element sections using 5x70 screws. Do this with both the short right and left bench supports as well.
STEP 22 - Attached the metal post support bracket to the bottom of the upper side bench using screws included in hardware packet. Slip the metal support post over the bracket and secure in place with the hex screw located in the support bracket. STEP 23 - Place the upper side bench on the side bench support rail and line up to the upper rear bench. Using 5x70 screws secure the upper side bench to both the wall of the sauna and the upper rear bench from below.
STEP 25 - You will now install the lower bench back support. From the front of the two UPPER bench supports that you just installed, measure 1-1/2” back and make a mark. Then, install the two lower backrest supports (one on the left and right side of the sauna) to the sidewall element sections using 5x70 screws. STEP 26 - Position the lower back support (5-slats) against the vertical supports you installed in step 25.
STEP 28 - Assemble the lower bench by attaching the right and left framed leg supports to the bench and screwing into place with 4x60 screws. Be sure the two holes in the uprights are to the rear of the bench and the plastic floor protectors are down. Next, attach the angled support members so that the pins line up with the holes. Place a dab of wood glue (not included) in the holes before tapping into place. Secure the support members to the bench using 3.5x40 screws.
STEP 31 - Install the hinges onto the glass door and secure to the window. The hinge consists of the hinge bracket, hole spacers, bracket cleat and hex screws. Be sure the screws are snug before mounting the door. NOTE: There is an intentional gap between the bottom of the door and the floor as well as between the glass panels. A sauna must have airflow, which is why these gaps are intentional.
STEP 34 - Assemble the heater fence as shown. The heater fence may or may not be used depending on the type of heater that came with your sauna. STEP 35 (optional) - Install the light fixture in a location of your choosing. It is suggested that the light be approximately 12” from the ceiling. NOTE: A licensed electrician should do electrical wiring in the sauna. STEP 36 (optional) - Install LED light according to LED light instructions. See separate heater and light installation instructions.
OPERATION After the sauna has been installed, sweep down the inside to remove any sawdust and wood shavings, and then vacuum completely. Using a damp cloth and warm water, wipe down the entire sauna including the benches to remove any remaining dirt, dust and debris. Rinse off the sauna stones and install them in or on the heater in accordance with the heater manufacturer’s instructions. Improper placement of heater stones can result in lower than desired heat temperatures.
