It's not as hard as it looks, and you'll be backyard lounging in no time.
POP Projects is a collection of new and classic projects from more than a century of Popular Mechanics. Master skills, get tool recommendations, and, most importantly, build something of your very own.
Pergola plans are an enduring favorite in Popular Mechanics (we’ve been publishing them since the 1920s), and it’s easy to see why. The finished product is a blissful addition to any yard, a shady place to sit and read, eat and drink with friends, or zone out on a summer day. From a DIY point of view, the return on investment is high: a small pergola can be built in a weekend and requires reasonably inexpensive materials—plus basic carpentry skills and tools.
A simple pergola consists of four parts fastened into a square or rectangle: posts, crossbeams, rafters, and lattice. Here we present eight essential building steps, as well as plans for a pergola to build—or just consider for inspiration. Either way, you win, because a pergola is as enjoyable to make as it is to simply behold.
Some Tools You'll Need
Craftsman 48-Inch Level
DeWalt Cordless Drill/Driver
Now 45% Off
The Plans
The Process
Step 1: After cutting the posts, crossbeams, and rafters to dimension, secure one crossbeam to two posts, driving a 4-inch decking screw through the beam into each post. this is a temporary subassembly, so it doesn’t pay to get too fussy with it. Just make sure that the top of the beam is nearly equidistant from the top of each post.
Step 2: Raise the subassembly, sliding the posts into 18-inch-deep holes. Attach 1x3 crossbraces (these are also temporary) to the posts using 1⁵⁄₈-inch drywall screws. As you can see in the photo, the crossbraces are secured alternately to the inside and outside of the posts to increase stability.
Next, drive a stake into the ground about 4 feet away from each post. Using a 4-foot level, plumb each post and fasten the braces to the stakes to hold the subassembly in place. Backfill the postholes. Repeat on the opposite subassembly.
Step 3: Place a 2x8 rafter upright on the crossbeams and strap the level atop the rafter with a bungee cord. Loosen the decking screw from the crossbeam to the post, and raise or lower the beam slightly until the rafter is level. Secure the crossbeam to the post with four decking screws, then slide the rafter over and repeat the leveling process at the adjacent post.
Next, add the remaining two crossbeams.
Step 4: Cut the posts to finished height with a reciprocating saw, using the crossbeams to guide the blade. This ensures a neat, flush cut.
Step 5: Attach each rafter with eight screws. Drive each decking screw at an angle through the rafter face into the top center of each crossbeam.
Step 6: Lay the 2x4 slats in place and secure them to the rafters with a pair of 3-inch decking screws at both ends of each slat.
Step 7: The lattice frame consists of two rectangular assemblies with the lattice fastened between them. The frame pieces that face the interior of the pergola are made with 1x4 lumber. This frame fits between the posts. On the exterior frame, the vertical members are 1x6s and the horizontal pieces are 1x4s. The extra width provided by the 1x6s creates a flange through which you drive screws to secure the frame to the posts.
To build the frame, crosscut the horizontal frame pieces to match the distance between the posts. Next, crosscut the vertical frame parts to length. Fasten the lattice-frame pieces to each other using 1⅝-inch deck-ing screws. Finally, place the frame between the posts, check it for level, and fasten the 1x6 frame members to the post with 1⅝-inch decking screws.
Step 8: Build the flower box and the bench. Level each using a 4-foot level, and attach them to the posts using 4-inch decking screws (and carriage bolts for the bench). Once the pergola’s construction is complete, apply two coats of semitransparent stain and commence the backyard relaxation.
Joseph Truini
Joe is a former carpenter and cabinetmaker who writes extensively about remodeling, woodworking, and tool techniques. He has written eight books and is a contributing editor to Popular Mechanics. He also appears on the Today’s Homeowner TV show, and co-hosts the weekly Today’s Homeowner Radio Show. Joe writes from his home in Roxbury, Connecticut.
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