BARLOW TYRIE quality since Ref: x 3m - 12 x 10 Pavilion with Cabrio Folding Roof Step by Step Assembly Instructions
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- Chester Campbell
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1 Pavilions 3.66 x 4.5m - Step 12 x by 15 Step Pavilion Assembly Shelter Instructions with Double Rail Beams Ref: x 3m - 12 x 10 Pavilion with Cabrio Folding Roof Step by Step Assembly Instructions Product Ref: Before you begin These installation instructions will lead you through the process of installing your new pavilion. The installation of the pavilion requires special attention to certain detail. Before you begin you should: Check your order Make sure the contents of the carton match the product numbers on your order. Contact your dealer if there are any damaged, missing or incorrect parts. Pay attention to safety Because of the size and weight of certain parts, installation is recommended with no fewer than two people. Always maintain a clean, organized work area. Make sure you have the right tools and materials Barlow Tyrie supplies the appropriate fasteners upon request through your dealer for anchoring the pavilion securely to the ground. If you are unsure about the required anchoring system best suited for your pavilion consult your dealer for the proper fastening method. Review entire installation guide This step gives you the opportunity to contact your dealer to answer any questions before you begin. Assembly requirements Two people Spirit level Hand drill Screwdriver set Step ladder Long nose pliers Spanners Rubber hammer Tape measure Page 1 of 16
2 Assembly overview Page 2 of 16
3 Part list 2x B1 2x B2 4x P1 4x P2 1x L1 Beam 3 mtrs 10 feet (roof hinge side) Beam 3.66 mtrs 12 feet (transverse side) Triangular Corner Post Corner Post Cover Full Length Lever Arm 1x L2 Dummy Lever Arm 3x T1 2x T2 Transverse Roof Support (no grove) Transverse Roof Support (with grove) Cross-Sectional View Cross-Sectional View 4x T3 4x T4 Lower Truss with 5/16 dia hole about pivot point Middle Truss with 5/16 dia hole about pivot point T3 T4 T5 2x T5 Center Truss with plastic spring slide insert T4 4x R1 Flat Bar Roof Trusses T3 1x R2 Lever Arm Strap KC.02 (LHS KIT) KC.01 4x AL005 Post End Plate 1x KC.02L 1x PL005 16x 002 Plate Screw 1/4 x 13/4 Roof Hinge Inlcudes the following sub kits: Roof Hinge Cover KC.04-A 1x SKC x SKC x SKC x K4.01 Plastic Corner Bracket KC.03 (RHS KIT) 16x 015 Metal Screw #10-3/4 8x 025 Metal Screw #8-3/4 1x KC.02R 1x PL005 KC.05 Roof Hinge Roof Hinge Cover 10x PL007 Plastic Corner Insert Inlcudes the following sub kits: 1x SKC x SKC x SKC Page 3 of 16
4 Part list 2x SKC.03-1 KC.06 2x 001 Tab Washer 1/ x 003 Carriage Bolt - 5/16 x 2 2x 005 2x 008 1/4 Flat Washer 1/4 Lock Washer 16x 007 5/16 Flat Washer 2x 014 Hex Bolt - 1/4-20 x 5/8 16x 012 5/16 Nylon Lock Nut 2x 026 Roof Hinge Cover Screw #10-3/8 KIT x SKC x 002 Strap Screw - 1/4 x 13/4 2x 003 Carriage Bolt - 5/16 x 2 2x 018 1/4 dia Nylon Bushing 4x 006 5/16 Flat Washer 1x 005 1/4 Flat Washer 2x 009 5/16 Lock Washer 1x 010 Nylon Lock Nut - 1/4-20 2x 011 5/16 Nut 2x PL01 1 Lever Arm Fork 2x 019 Nylon Bushing - 5/16 1x PL012 Fork Installation Guide 2x SKC x 016 Self-tapping Screw - #12 x 13/4 5x x 006 5x 012 Hex Bolt - 5/16 x 31/4 5/16 Flat Washer 5/16 Nylon Lock Nut 2x PL010 2x 020 Hinge Box Side Cover 2x PL013 Plastic Finishing Hole Cap Lever End Cover 10x 019 Nylon Bushing - 5/16 MISC KC.07 PL101 Pulleys included with curtains 4x PL07 4x PL015 20x R3 Velcro Strips 4x PL014 4x PL016 #8 Square Head Screwdriver Bit 16x 002 Cover Screw - 1/4 x 13/4 #10 Square Head Screwdriver Bit Page 4 of 16
5 Getting started 1 P1 Secure the base plates (AL005) to the bottom of each of the aluminium corner posts (P1) using metal bolts (002) as shown in the diagram. (Repeat step for all four corner posts.) AL KC.02L B Install the two roof hinges on the beams (B1) by first inserting two tab nuts into the bottom interior groove of both beams. Then slide the tab nuts till the mid section of the beams. Install the roof hinges on both beams using bolts and washers shown in the above right hand side diagram. LIGHTLY TIGHTEN BOLTS. The hinge will be centered and bolts will be tighten in step 6. 3 On a flat surface, assemble all the beams together by fixing the aluminum corner bracket (K4.01) at each corner, using the metal scews (015) supplied, as shown in the diagram. You may use pieces of the cardboard box to protect the frame from scratches. View A-A K4.01 B2 B1 B2 015 Cardboard B1 A-A Roof will open from this side Page 5 of 16
6 Assembling the roof 4 Use a Rubber Hammer T1 & T2 PL007 Install the plastic corner inserts (PL007) at each end of the transverse roof supports (T1) and (T2) as shown in the figure above. You will need a rubber hammer to insert them properly A-A View A-A Use a Rubber Hammer Middle Truss Assembly Complete the assembly by inserting the trusses (T3), (T4) and (T5) at each end of the transverse roof supports as shown in the figure above. Again you will need a rubber hammer to insert them properly. 5 T3 & T4 Roof Truss Ends 019 Nylon Bushing On each end of the roof truss assemblies (T3) and (T4) install two plastic bushings as shown in the diagram Page 6 of 16
7 Assembling the roof framework 6 T3 T4 T5 T4 T3 B-B D-D C-C E-E Lay the trusses on top of the beam assembly in the order and orientation shown by the diagram above. Consult views B-B, C-C, D-D and E-E for specific detail. Then turn to the next page for a description on how to fix each trusses to the hinges. Install the middle plastic stub truss on the lower hole. The upper hole can be used in time if more pressure needs to be exerted by the middle truss onto the roof fabric. Holes used for Lever Arm and Dummy Lever Arm (see Step 9) View B-B View C-C Holes used for Lever Arm and Dummy Lever Arm (see Step 9) T2 View D-D View E-E T2 Transverse Support Groove Should be Facing Downwards Page 7 of 16
8 Assembling the roof framwork Install the trusses on the hinge using hardware shown in views B-B. Notice that only one side is shown. Repeat this step on the other hinge. KC.02L See Through View 002 View B-B (Hardware Installation) View B-B (TOP VIEW) 006 Center Hinge Assembly F-F F-F Once the trusses have been fixed properly to each hinge, center the roof assembly by allowing the protruding groove of (T2) to extend just beyond the edge of beam (B2) (see view F-F). Then tighten the hinge bolts as shown in the bottom right diagram. Transverse Support Groove Facing Downwards View F-F 014 Tighten Bolts (repeat on other side) Page 8 of 16
9 Installing the corner posts 7 G-G Flat Washer 012 Lock-Nut View G-G View G-G (TOP VIEW) Attach one of the four corner posts (P1) to each corner of the structure using hardware shown in the top right diagrams. This step may require a second person or a ladder to lift the roof assembly in order to fix all four corner posts (P1). See diagrams below for further assembly steps. P1 P1 P2 002 To complete the post assembly, snap together the corner post (P1) and corner post covers (P2). Repeat step for each corner. KC-07 Assembly Locking Key P2 Top View P2 Then fasten the top cover assembly (KC.07) on top of each corner post (P1) DO NOT OVER TIGHTEN SCREWS. The locking key can be in the unlocked position or removed from the cover assembly by turning then pulling it. Page 9 of 16
10 Anchoring the pavilion 8 Make sure the structure is well aligned and levelled with the floor as shown in the diagram below. Consult the section below for recommendations on the type of anchorage required for fixing the structure on the floor. L W D Dimensions inches (cm) C3 W 111 (282) C2 L 138 (350) D 177 (450) level C1 Remaining holes in plate (AL005) are used for fixing the structure on the floor C1 79 (200) C2 114 (290) C3 144 (366) Distances W, L, and D are calculated from centre to centre of plates (AL005) Ground Fixing OPTION A WOOD DECK/FLOOR OPTION B CONCRETE/CEMENT FLOOR Requirements: 8 (2 per plates) of each - 5/16" x 2" wood screws - 5/16" washers Requirements: 8 (2 per plate) of each - 3/8 x 11/2 expansion anchor * use 1/2 cement drillm bit WOOD CONCRETE SOIL The Permo Lock anchoring system is the recommended method that offers a strong permanent solution for anchoring your shelter and to protect it against the wind. See next page for instructions on how to install this anchor Page 10 of 16
11 Anchoring the pavilion Permo Lock Anchoring System x1 coupling x4 bolt x4 washer Packaging Contents One Permo Lock anchor comes preassembled and ready to use as shown on the right. Verify that the rod end is flush with the end of the anchor. x1 rod x4 anchor x4 lock washer Top View Position your assembled structure on the chosen location then mark the center of each corner plate 19¾ (50cm) Drill a 1 x 19¾ (2.5cm x 50cm) hole at each marked location using a percussion drill with a diamond tip masonry drill bit 3-1/4 (8.2cm) Insert the assembled Permo Lock anchor into the drilled hole Screw in the coupling nut without turning the rod and anchor. The maximum opening of the Permo Lock anchor occurs when the rod extends 3¾ (8.2cm) above the coupling nut Apply grease on threads Unscrew the coupling and rod completley from the fixed Permo Lock anchor and remove the two washers Place the corner of the structure over the anchor and afix it using the supplied ½ bolt and washers. Grease the threads of the bolt Page11 of 16
12 Final frame assembly 9 I-I H-H PL012 T4 PL01 1 Remove the guide after installing the fork. View H-H (step a) 016 View H-H (step b) Install the plastic fork on the (T4) truss assembly on the opening side. Locate the proper position of the fork by using the fork installation guide as shown in views H-H. Then use the self tapping screw (016) to fix the fork on the transverse truss member. Then insert the end of the lever arm on the fork and fix the lever using hardware shown in view I-I. Repeat step on other side for the dummy lever arm PL01 1 See Through View 003 View H-H (step c) L1 KC.02L 10 PL005 View I-I (TOP VIEW) L1 L1 To complete the roof hinge mechanism, install the plastic hinge cover (PL005) over the roof hinge using screws (026).Then install side cover (PL010) and the hole cap (020). Repeat step on both sides. PL Install the Plastic Finishing Cap Page 12 of 16
13 Final frame assembly Install the lever strap on the end of the lever arm using hardware shown in the left diagram. Then install the plastic cap (PL013) on the end of both the lever and dummy lever arm. PL013 R Insert velcro strips at every 16 in the top groove of the beams. Then fix the valance to the velcro strips (R3). Start from one end of the valance and work your way around the frame assembly. See adjacent diagrams for detail. TOP VIEW R3 Velcro Strip (top groove) 16 apart Valance Velcro Strip (top groove) Roof will open from this side Page 13 of 16
14 Installing the roof fabric 13 J-J K-K L-L M-M Install the roof fabric cover over the frame assembly with roof trusses down. Make sure that all 4 corners of the roof fabric are aligned properly. SIDE VIEW View K-K Roof Fabric View J-J Weld Line View L-L Roof Support Velcro Strip The next step will give instructions on how to fix the roof cover to the frame assembly. Slide the flat bars (R1) in the pocket of the fabric as shown in View M-M.Then raise the truss assembly and push the flat bar and fabric into the groove of the transverse truss (T2). Then fix the velcro strip around the 2 roof supports (T4). Note that the velcro should be fitted around the support as shown in views K-K (left hand side support) and L-L (right hand side support). Then raise the middle roof support (T5) in its upright position and fix the velcro around it as shown in view J-J. T2 View M-M (Step a) R1 Insert a flat bar on each end of the pocket View M-M (Step b) Page 14 of 16
15 Installing the curtains 14 PL101 Plastic Pulley Snap Pulley in place Metallic Eyelet Curtain Exterior Side Curtain (Exterior Side) Zipper (Interior Side) Profile View Install plastic pulleys (PL101) by snapping them in each metallic curtain eyelet. Use long nose pliers to facilitate this operation. Pulleys should be facing towards the curtain side on which the zipper is located (see above steps). Then install each curtain sections into the provided beam slots as shown by left hand diagram. After installing all pulleys, block the access with the screws (025) as shown in the diagram. Repeat step for each corner. See next step (15) for curtain installation example 025 Curtain Type Decorative curtains Mosquito curtains Acrylic curtains Plastic curtains Rail Inner or Outer Inner Outer Inner or Outer 15 Roof fabric and valence not shown for clarity outside rail curtains on inside rail inside rail TOP VIEW curtains on outside rail decorative curtains (installed using velcro strips on bottom beam groove) Velcro Strips Bottom Groove 16 apart The decorative curtains are installed using velcro strips (R3) inserted 16 apart in the bottom groove of the beams similarly to the valance in step 13. If you have purchased optional curtains (mesh netting, transparent plastic or acrylic fabric) install them on the inside or outside rail of the beams. Page 15 of 16
16 Installing the curtains 15 Install the decorative curtains on the iterior or exterior rail of the beams (B1) and (B2). If you have purchased optional curtains (mosquito netting, transparent plastic or acrylic fabric) install them on the inside rail of the beams. Barlow Tyrie Limited Braintree Essex CM7 2RN England t: + 44 (0) f: + 44 (0) Barlow Tyrie Inc 1263 Glen Avenue Suite 230 Moorestown NJ USA t: f: Page 16 of 16 Ref 3412
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