2x12 SONORA GAZEBO Model # 1804524 Owner’s Manual & Assembly Instructions MED TER IA TE IN average 2 person assembly time 10 HO U RS assembly time may vary based on skill level Before you begin FOR QUICK & EASY ASSEMBLY FIND 3D INSTRUCTIONS FOR THIS PRODUCT IN DOWNLOAD THE FREE APP For the most up to date assembly manual, to register your set, or to order replacement parts please visit www.backyarddisovery.
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Owner’s Manual Please Read This Before Starting Assembly MISSING A PART? CALL US BEFORE GOING BACK TO THE STORE The store where you made your purchase does not stock parts for this item. If you have assembly questions or you are missing or have damaged parts, please call 1-800-856-4445 you can also visit www.backyarddiscovery.com or e-mail customerservice@backyarddiscovery.
Owner’s Manual Limited Warranty Please read entire booklet completely before beginning the assembly process Please retain these instructions and your receipt for future reference. Keep them in a safe place where you can refer to them as needed. In order to provide you with the most efficient service, it is required that you provide us with the part numbers when ordering parts. For Your Records: Please take time and fill out the information below. This information will be needed for warranty issues.
Owner’s Manual Safety Warnings and Maintenance Instructions WARNING IT IS IMPORTANT TO CHECK AND TIGHTEN ALL HARDWARE AT THE BEGINNING AND DURING THE SEASON AS THEY MAY LOOSEN DUE TO WOOD EXPANSION AND CONTRACTION. • DO NOT climb or walk on the roof for any reason • Requires two or more people to assemble safely period. • Check for underground utilities before digging or • Check all coverings for bolts and sharp edges twice driving stakes into the ground.
Owner’s Manual Instructions for Proper Maintenance Your Backyard Discovery structure is designed and constructed of quality materials. As with all outdoor products it will weather and wear. To maximize the enjoyment, safety and life of your structure it is important that you properly maintain it. About Our Wood Backyard Discovery uses 100% Cedar (C. Lanceolata) wood.
Owner’s Manual Assembly Tips Protrusion Hazard Incorrect Correct If you see exposed threads and your bolt protrudes beyond the T-Nut you may have over tightened the bolt. To eliminate this, remove the bolt and add washers to eliminate the problem. 1/8” Proper Hardware Assembly Bolt and T-Nut Assembly Tap T-nut into the provided hole. Insert your bolt through the lock washer and insert into the provided hole opposite from the T-Nut. Turn clockwise to thread into T-nut.
Owner’s Manual Assembly Tips ASSEMBLY TIP: Keep an eye out for these boxes which will contain helpful pictures and information making the assembly process as quick and painless as possible. Sorting Wood E1 E2 F1 F2 G1 G2 When removing the wood from the boxes we recommend arranging them by part number before you begin assembly. This will allow for faster assembly and easily identify any parts that may be missing or damaged.
Owner’s Manual Tools Required for Installation (These are the tools that are generally required for assembly of our outdoor products. These tools are not included with the outdoor product purchase.
Basic Setup Dimensions Install unit on level ground. Check carefully for overhead lines and ensure there is at least 6ft (2m) clearance from the roof to any overhead lines. 12'- 3/16" 13'-1 3/16" 6'-0" 12'- 15/16" 12'-0" 6'-0" 12'- 15/16" 12'-0" 10'-4 3/4" 9'-2 11/16" 7'-5 13/16" 10'-7 1/8" Important Assembly Notes 1) While assembling unit, take time before and after each phase to make sure unit is level. If unit is not level, assembly will be difficult and improper assembly may result.
Important Note: In the event the INK STAMP identifier is not easy to read or is missing from a wood component, match the unique geometric shape and dimensions of the wood component found in a specific assembly step to the PARTS IDENTIFICATION section when required. This will aid in identifying the part for assembly and (or) customer service issues.
Important Note: In the event the INK STAMP identifier is not easy to read or is missing from a wood component, match the unique geometric shape and dimensions of the wood component found in a specific assembly step to the PARTS IDENTIFICATION section when required. This will aid in identifying the part for assembly and (or) customer service issues.
Parts Identification Hardware (22) - LAG SCREW WH 5/16x3 BLK - H100206 (246) (3) (3) (4) - WASHER FLAT 1/2 BLK - H100755 - BOLT WH 5/16x1 1/2 BLK - H100407 - NUT BARREL WH 5/16x7/8 BLK - H100192 (96) - WASHER SPLIT 1/2 BLK - H100754 - SCREW PFH 8X3 BLK - H100362 (94) - NUT HEX 1/2 BLK - H100753 (101) - SCREW PFH 8x2 BLK - H100391 (22) - SCREW PFH 8x1-1/2 BLK - H100200 (17) - WASHER FLAT 8x19 BLK - H100630 (44) - SCREW PWH 8x1-1/4 BLK - H100536 (25) - WASHER LOCK EXT 8x19 BLK - H100198 (3)
Parts Identification Hardware (2) - T-40 TORX BIT - A100042 (2) - T-40 TORX WRENCH - A100041 (22) - BOLT HEX 1/2x11 BLK - H100751 (9) - BOLT HEX 1/2x9 1/2 BLK - H100756 (58) - BOLT HEX 1/2x4 BLK - H100752 (9) - BOLT HEX 1/2x2-1/2 BLK - H100763 (9) - LAG SCREW HEX 1/2x4 BLK - H100762 (52) - LAG SCREW HEX 1/2x2 BLK - H100758 12
Parts Identification Accessories (NOT TO SCALE) (1) (1) - BYD ID TAG (SMALL) WITHOUT AGES - A100241 - "A" REVISION TAG - A100314 (4) - L.
Parts Identification Accessories (NOT TO SCALE) (8) - 29 GA STEEL SHEETING - A4M00980 .014"x37.01"x77.75" (.
PT1 - POST - W2A02715 (2) 7"x7"x94 7/16" (178x178x2400) (4) - 7x7 POST FOOT - A6P00296 PT2 - POST - W2A02716 (2) 7"x7"x94 7/16" (178x178x2400) STEP 1 NOTE: DO THESE STEPS TWICE. TIP: FOR EASE OF ASSEMBLY WE RECOMMEND USING SAW HORSES FOR STEPS 1 THROUGH 3.
(1) D1 - BEAM - W4L11976 1 3/8"x5 1/4"x134 1/8" (36x134x3408) (1) D2 - BEAM - W4L11978 1 3/8"x5 1/4"x141 1/8" (36x134x3586) (2) D3 - BEAM - W4L11977 1 3/8"x5 1/4"x11 1/2" (36x134x292) (2) - GAZEBO BRACKET - A4M00969 (2) - L.
AB1 - ANGLE BRACE - W4L11988 (2) 1 3/8"x6 7/16"x40 13/16" (34x163x1036) (2) AB2 - ANGLE BRACE - W4L11989 (2) 1 3/8"x6 7/16"x40 13/16" (34x163x1036) D4 - BEAM - W4L11979 1 3/8"x5 1/4"x124 3/4" (36x134x3168) (2) - GAZEBO BRACKET - A4M00947 STEP 3 14 12 15 13 BOLT HEX 11 9 12 10 13 11 (4) 1/2x9 1/2 BLK BOLT HEX (8) 1/2x4 BLK 2 3 1 4 2 5 3 6 4 7 5 8 6 9 7 10 8 ! NUT HEX 1/2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 3 4 5 6 2 1 1 (12) BLK 23 22 21 20 19 18
PT2 - POST - W2A02716 7"x7"x94 7/16" (178x178x2400) (1) (1) - GAZEBO BRACKET - A4M00947 STEP 4 BOLT HEX (2) 1/2x9 1/2 BLK MAKE SURE YOU'RE BUILDING ON LEVEL GROUND AND YOUR STRUCTURE STARTS OFF BOTH SQUARE AND LEVEL. LAG SCREW (1) HEX 1/2x2 BLK WASHER (2) SPLIT 1/2 BLK NUT HEX 1/2 (2) BLK WASHER (5) FLAT 1/2 BLK •WITH A HELPER STAND UP ASSEMBLY AND MOUNT 3RD POST.
PT1 - POST - W2A02715 (1) 7"x7"x94 7/16" (178x178x2400) (1) - GAZEBO BRACKET - A4M00947 STEP 5 BOLT HEX 11 9 12 10 13 11 14 12 15 13 (2) 1/2x9 1/2 BLK 2 3 1 4 2 5 3 6 4 7 5 8 6 9 7 10 8 ! 19 20 21 11 12 13 14 15 16 17 18 8 9 10 3 4 5 6 7 2 1 1 22 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 LAG SCREW (1) HEX 1/2x2 BLK WASHER (2) SPLIT 1/2 BLK NUT HEX 1/2 BLK (2 PLCS) WASHER SPLIT 1/2 BLK (2 PLCS) WASHER FLAT 1/2 BLK (2 PLCS)
(1) D1 - BEAM - W4L11976 1 3/8"x5 1/4"x134 1/8" (36x134x3408) (1) D2 - BEAM - W4L11978 1 3/8"x5 1/4"x141 1/8" (36x134x3586) D3 - BEAM - W4L11977 1 3/8"x5 1/4"x11 1/2" (36x134x292) (2) (2) (2) - GAZEBO BRACKET - A4M00969 - L.
(2) D5 - BEAM - W4L11980 1 3/8"x5 1/4"x105 7/8" (36x134x2740) STEP 7 BOLT HEX 1/2x2-1/2 BLK (8 PLCS) BOLT HEX (8) 1/2x2-1/2 BLK WASHER FLAT 1/2 BLK (16 PLCS) WASHER SPLIT 1/2 BLK (8 PLCS) WASHER (16) FLAT 1/2 BLK WASHER (8) SPLIT 1/2 BLK NUT HEX 1/2 BLK (8 PLCS) NUT HEX 1/2 (8) BLK D5 D5 21
(6) AB1 - ANGLE BRACE - W4L11988 1 3/8"x6 7/16"x40 13/16" (34x163x1036) STEP 8 NUT HEX 1/2 BLK (12 PLCS) BOLT HEX (12) 1/2x4 BLK WASHER SPLIT 1/2 BLK (12 PLCS) NUT HEX 1/2 (12) BLK WASHER WASHER (24) FLAT 1/2 BLK (12) SPLIT 1/2 BLK BOLT HEX 1/2x4 BLK (12 PLCS) LAG SCREW (6) WH 5/16x3 BLK WASHER (6) LOCK EXT 8x19 BLK WASHER LOCK EXT 8x19 BLK (6 PLCS) LAG SCREW WH 5/16x3 BLK (6 PLCS) AB1 AB1 AB1 11 9 12 10 13 11 14 12 15 13 AB1 2 3 1 4 2 5 3 6 4 7 5 8 6 9 7 10 8 ! 21 19 20 1
(6) AB2 - ANGLE BRACE - W4L11989 1 3/8"x6 7/16"x40 13/16" (34x163x1036) 11 9 12 10 13 11 14 12 15 13 STEP 9 BOLT HEX (12) 1/2x4 BLK 2 3 1 4 2 5 3 6 4 7 5 8 6 9 7 10 8 ! 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 2 3 4 5 6 1 1 22 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 BOLT HEX 1/2x4 BLK (12 PLCS) WASHER FLAT 1/2 BLK (12 PLCS) NUT HEX 1/2 (12) BLK WASHER WASHER (12) SPLIT 1/2 BLK (24) FLAT 1/2 BLK WASHER SPLIT 1/2 BLK (1
(2) PT3 - POST - W2A02718 7"x7"x32 1/2" (178x178x826) (4) - GAZEBO BRACKET - A4M00968 15 13 STEP 10 LAG SCREW 14 12 LAG SCREW 13 11 12 10 11 9 4 2 5 3 6 4 7 5 8 6 9 7 10 8 ! WASHER (12) FLAT 1/2 BLK 2 3 1 (4) HEX 1/2x2 BLK (8) HEX 1/2x4 BLK 20 21 17 18 19 10 11 12 13 14 15 16 8 9 3 4 5 6 7 2 1 1 22 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 NOTE PILOT HOLES WASHER FLAT 1/2 BLK (12 PLCS) LAG SCREW HEX 1/2x2 BLK (4 PLCS) LAG SCREW HEX 1/2x4 B
(2) RP1 - END RAFTER - W2A02719 2 13/16"x5 1/4"x80 5/8" (72x134x2048) (2) RP2 - END RAFTER - W2A02720 2 13/16"x5 1/4"x80 5/8" (72x134x2048) STEP 11 WASHER FLAT 1/2 BLK (4 PLCS) LAG SCREW (4) HEX 1/2x2 BLK LAG SCREW HEX 1/2x2 BLK (4 PLCS) WASHER RP2 (4) FLAT 1/2 BLK SCREW PFH (4) 8X3 BLK RP1 RP1 RP2 NOTE: PLACE 1/2" BOLTS IN HOLES BEFORE INSTALLING WOOD SCREWS (TO ENSURE PROPER ALIGNMENT) SCREW PFH 8X3 BLK (4 PLCS) 25
(4) D7 - ANGLE BRACE - W4L11987 1 3/8"x5 1/4"x29 5/8" (36x134x751) STEP 12 BOLT HEX (8) 1/2x4 BLK WASHER NUT HEX 1/2 (8) SPLIT 1/2 BLK (8) BLK WASHER (16) FLAT 1/2 BLK LAG SCREW WASHER (4) WH 5/16x3 BLK (4) LOCK EXT 8x19 BLK BOLT HEX 1/2x4 BLK (8 PLCS) WASHER FLAT 1/2 BLK (8 PLCS) D7 D7 WASHER FLAT 1/2 BLK (8 PLCS) WASHER LOCK EXT 8x19 BLK (4 PLCS) WASHER SPLIT 1/2 BLK (8 PLCS) LAG SCREW WH 5/16x3 BLK (4 PLCS) NUT HEX 1/2 BLK (8 PLCS) 26
(2) (4) H2 - FASCIA - W4L11985 1"x3 3/8"x141" (24x86x3582) NOTE ORIENTATION 5/8 7/8 E1 - OUTSIDE RAFTER - W4L11982 1 3/8"x3 3/8"x76 3/8" (36x86x1948) (2) (8) H1 - RAFTER - W4L11983 1"x3 3/8"x127 1/16" (24x86x3228) E2 - RAFTER - W4L11981 1 3/8"x3 3/8"x76 3/4" (36x86x1948) STEP 13 SQUARE YOUR ROOF PANEL BY MAKING SURE YOU GET THE SAME MEASUREMENT H1 FROM CORNER TO CORNER AS SHOWN.
(8) STEP 14 E3 - SHEATHING BOARD - W4L11984 1 3/8"x3 3/8"x141" (36x86x3582) •DO THESE STEPS SCREW PFH TWICE FOR BOTH ROOF PANELS (48) 8x2 BLK SCREW PFH 8X2 BLK (24 PLCS) E3 E3 E3 E3 28
NOTE: USE THIS PAGE TO FAMILIARIZE YOURSELF WITH THE ROOF PANEL & ASSIST YOU IN THE COMING STEPS STEP 15 (PREPARATION) • The following pages will show only one side of the roof panel being built. You will follow these same steps to build the opposite side. • Due to the roof panels mirroring each other you will start the first roof panel working from left to right and the second roof panel working from right to left. PUT YOUR ROOF PANELS ON THE GROUND SO THEY MIRROR EACH OTHER AS SHOWN.
(4) - ROOF SPACER - A4M00975 (4) STEP 15 11 9 12 10 13 11 14 12 15 13 • ROOF PANEL MUST BE SQUARE BEFORE YOU START THIS STEP. • WITH A SQUARE ROOF PANEL PLACE BOTH SHEETS ON ROOF PANEL AND ALIGN THEM AS SHOWN. • AFTER BOTH SHEETS ARE ALIGNED WITH EACHOTHER AND ARE SET TO THE DIMENSIONS SHOWN, PLACE ONE SCREW IN EACH ROOF PANEL AND FINE TUNE THEIR ALIGNMENT BEFORE MOVING TO THE NEXT DETAIL STEP.
15 13 14 12 13 11 12 10 11 9 •FOLLOW THIS STEP WITH BOTH ROOF PANELS #10-16 X 1 1/4" 2 3 1 4 2 5 3 6 4 7 5 8 6 9 7 10 8 ! (32) WOODGRIP 21 20 17 18 19 15 16 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 22 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 STEP 16 SCREW MAKE SURE THE ROOF PANEL & STEEL SHEETS STAY SQUARE WHILE ASSEMBLING.
(4) STEP 17 - 29 GA STEEL SHEETING - A4M00980 .014"x37.01"x77.75" (.
(4) - DRIP EDGE 29 GA - A4M00956 STEP 18 (2) - DRIP EDGE 29 GA SPLICE - A4M00970 •FOLLOW THIS STEP WITH BOTH ROOF PANELS 1/4-14 x 3/4" SELF (18) DRILLING SCREW 1/4-14 x 3/4" SELF DRILLING SCREW (9 PLCS) DRIP EDGE 29 GA (2 PLCS) DRIP EDGE 29 GA SPLICE (1 PLCS) FLUSH NOTE: SLIP DRIP EDGE INTO SPLICE. ENSURE THAT BOTH ENDS ARE FLUSH WITH EDGE OF ROOF PANELS.
STEP 19 WITH AT LEAST TWO PEOPLE LIFT ASSEMBLED ROOF PANELS AND SLIDE THEM INTO THE TRACKS ON THE GAZEBO. •FOLLOW THIS STEP WITH BOTH ROOF PANELS TW O PERSON LIFT TIP: A THIRD PERSON IS HELPFUL TO ATTACH ROOF ONCE IT IS IN PLACE. PUSH ROOF PANEL FOWARD UNTIL KNOTCHES LAND ON 1ST RAFTER BEFORE INSTALLING SECOND ROOF PANEL. INSTALL A 1/2" BOLT INTO THE HOLE ON BOTH ENDS TO TEMPORARILY SECURE ROOF PANEL UNTIL NEXT STEP.
(2) - GAZEBO BRACKET - A4M00948 STEP 20 BOLT HEX (4) 1/2x11 BLK • USING A HELPER, HOLD AND ATTACH ROOF PANELS AS SHOWN.
(8) - ROOF BRACKET - A4M00961 STEP 21 SCREW PWH ROOF BRACKET (8 PLCS) (40) 8x1-1/4 BLK SCREW PWH 8x1-1/4 BLK (40 PLCS) NOTE BRACKET LOCATIONS. CENTER ON THE RAFTERS ON EACH ROOF PANEL AND ATTACH.
(4) STEP 22 D6 - ANGLE BRACE - W4L11986 1 3/8"x5 1/4"x31 3/4" (36x134x805) WASHER FLAT 1/2 BLK (16 PLCS) BOLT HEX 1/2x4 BLK (8 PLCS) D6 WASHER (32) FLAT 1/2 BLK BOLT HEX (16) 1/2x4 BLK WASHER (16) SPLIT 1/2 BLK NUT HEX 1/2 (16) BLK WASHER SPLIT 1/2 BLK (8 PLCS) NUT HEX 1/2 BLK (8 PLCS) NUT HEX 1/2 BLK (8 PLCS) WASHER SPLIT 1/2 BLK (8 PLCS) WASHER FLAT 1/2 BLK (16 PLCS) BOLT HEX 1/2x4 BLK (8 PLCS) D6 D6 D6 D6 37
(2) (1) - 6 X 6 HIP/RIDGE CAP SPLICE - A4M00955 - 6 X 6 HIP/RIDGE CAP 29 GA - A4M00954 STEP 23 #10-16 X 1 1/4" WOODGRIP SCREW (16 PLCS) CAUTION METAL CAN BE VERY SLICK. DO NOT STAND ON METAL WHEN DAMP. PROCEED WITH CAUTION. TIP: DUE TO MULTIPLE LAYERS OF METAL ON THE RIDGE CAP, IT IS RECOMMENDED THAT A 1/8" DRILL BIT IS USED TO CREATE STARTER HOLES. #10-16 X 1 1/4" (16) WOODGRIP SCREW 22 1/2 NOTE: INSTALL 4 SCREWS EVENLY SPACED DOWN EACH SIDE.
(8) (8) - STEEL POST PLATE - A4M00950 - STEEL POST ANCHORING PLATE WITH FLANGE - A4M00949 STEP 24 LAG SCREW (32) HEX 1/2x2 BLK WASHER (32) FLAT 1/2 BLK STEEL POST PLATE (8 PLCS) STEEL POST ANCHORING PLATE WITH FLANGE (8 PLCS) WASHER FLAT 1/2 BLK (32 PLCS) LAG SCREW HEX 1/2x2 BLK (32 PLCS) 39
(1) (1) - BYD ID TAG (SMALL) WITHOUT AGES - A100241 STEP 25 - "A" REVISION TAG - A100314 FRONT VIEW SCREW PFH (4) 8x1-1/2 BLK SCREW PFH 8X1-1/2 BLK (2 PLCS) REAR VIEW BYD ID TAG (SMALL) WITHOUT AGES (1 PLC) SCREW PFH 8X1-1/2 BLK (2 PLCS) "A" REVISION TAG (1 PLC) 40
NOTE: MANUFACTURER RECOMMENDS INSTALLATION ON CONCRETE SURFACE OR CONCRETE POST PADS. SEE BELOW. FOR INSTALLATION ON WOOD DECK, YOU MUST ENSURE THERE IS AMPLE STRUCTUAL SUPPORT UNDER DECK. STEP 26 WASHER (16) FLAT 8x19 BLK CONCRETE (16) ANCHOR 1/4" x 2" CONCRETE ANCHOR 1/4" x 2" (16 PLCS) WASHER FLAT 8x19 BLK (16 PLCS) PRE-DRILL HOLES FOR CONCRETE ANCHORS USING A 3/16" CONCRETE DRILL BIT.
