CABRIO Retractable Classic Roof / Double Rail System Step by Step Assembly Instructions Before You Begin These installation instructions will lead you through the process of installing your new shelter. The installation of the shelter 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. Jardin de Ville supplies the appropriate fasteners upon request through your dealer for anchoring the shelter securely to the ground. If you are unsure about the required anchoring system best suited for your shelter, 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 Persons Hand Drill Ladder Wrench Kit Tape Measure Level Rubber Hammer Screwdriver Set Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 1 of 15 Model # Cabrio 1.0
Assembly Overview Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 2 of 15 Model # Cabrio 1.0
Part List (1 of 2) 2x B1 10 Side Beam (roof hinge side) 2x B2 4x P1 4x P2 12 or 14 Front Beam (transverse side) Triangular Corner Post Corner Post Cover 1x L1 Full Length Lever Arm 1x L2 Dummy Lever Arm 2xTF1 Transverse Roof Support with groove Cross-Sectional View 3xTF2 Transverse Roof Support (no groove) Cross-Sectional View 4xTS1 Lower Truss with 5/16 dia hole about pivot point 4xTS2 Middle Truss with 5/16 dia hole about pivot point 2xTS3 Center Truss with plastic spring slide and corner inserts TS1 TS2 TS3 TS2 2x R1 Flat Bar Roof Trusses TS1 1x R2 Lever Arm Strap KC01 1x KC02 4x LA3002 Post End Plate 16x 002 Plate Screw 1/4 x 1-3/4 1x KC.02L 1x KC.02R KC04 Roof Hinge (left) Roof Hinge (right) 4x PL102 Plastic Corner Beam Inserts 2x KC03 8x 025 Metal Screw #8-3/4 1x PL005 Roof Hinge Cover KC05 Inlcudes the following sub kits: 8x PL007 Plastic Corner Insert 1x SKC03-1 1x SKC03-2 1x SKC03-3 Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 3 of 15 Model # Cabrio 1.0
Part List (2 of 2) 2x SKC03-1 KC06 2x 001 Tab Weld Nut 1/4-20 16x 003 Carriage Bolt - 5/16 x 2 2x 005 9/32 x 5/8 Flat Washer 16x 007 5/16 x 1-1/2 Flat Washer 2x 008 5/16 x 1/2 Lock Washer 16x 012 5/16 Nylon Lock Nut 2x 014 Hex Bolt - 1/4-20 x 5/8 KC07 2x 026 Roof Hinge Cover Screw #10-3/8 4x PL07 4x PL015 2x SKC03-2 4x PL016 4x PL014 2x 003 Carriage Bolt - 5/16 x 2 16x 002 Cover Screw - 1/4 x 1-3/4 6x 006 2x 009 5/16 x 3/4 Flat Washer 5/16 x 5/8 Lock Washer KC08 1x 002 Strap Screw - 1/4 x 1-3/4 2x 011 5/16 Nut 2x 018 1/4 dia Nylon Bushing 2x 019 Nylon Bushing - 5/16 1x 005 9/32 x 5/8 Flat Washer 2x SKC03-3 1x 010 Nylon Lock Nut - 1/4-20 5x 004 Hex Bolt - 5/16 x 3-1/4 2x PL011 Lever Arm Fork 10x 006 5/16 x 3/4 Flat Washer 1x PL012 Fork Installation Guide 5x 012 5/16 Nylon Lock Nut 2x 016 Self-Tapping Screw - #12 x 1-3/4 10x 019 Nylon Bushing - 5/16 2x PL010 1x PL013 KC31-SS 2x 020 Hinge Box Side Cover Plastic Finishing Hole Cap Lever End Cover 2x LT-A49 MISC 12x 040 Stainless Steel Secure Latch Self-Taping Screws #8-3/4" K.PL101 Pulleys included with curtains KC32-S 16x CAP.01 Plastic Caps K.APL001 Velcro Strips #8 Square Head Screwdriver Bit* #10 Square Head Screwdriver Bit* *Provided for European model only Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 4 of 15 Model # Cabrio 1.0
Getting Started 1 Post end with holes P1 002 LA3002 Cross-Sectional View Secure the base plates [KC01.LA3002] to the bottom of each of the aluminum corner posts [P1] using metal bolts [KC01.002] as shown in the diagram. (Repeat step for all four corner posts.) Insert the bolts with a small angle towards the wall. LA3002 002 2 KC.02L 001 005 B1 008 014 Install the two roof hinges on the beams [B1] by first inserting two tab nuts [001] 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 tab nuts, bolts and washers from kit [SKC03-1] 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 inserting the plastic corners [KC04.PL102] at each end. Once fully inserted, lock in place the plastic corners with supplied screws [KC04.025], as shown in view A-A. You may use pieces of the cardboard shipping box to protect the frame from scratches. View A-A B2 B1 025 PL102 B2 Cardboard B1 A-A Roof will open from this side Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 5 of 15 Model # Cabrio 1.0
Assembling the Roof 4 Use a Rubber Hammer TF1 & TF2 PL007 Install the plastic corner inserts [KC05.PL007] at each end of the transverse roof supports [TF1] & [TF2] 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 [TS1], [TS2] and [TS3] 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 TS1 & TS2 Roof Truss Ends 019 Nylon Bushing On each end of the roof truss assemblies [TS1] & [TS2] install two plastic bushing [SKC03-3.019] as shown in the diagram. Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 6 of 15 Model # Cabrio 1.0
Assembling the Roof Framework 6 TS1 TS2 TS3 TS2 TS1 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. View B-B Holes used for Lever Arm and dummy Lever Arm (see Step 9) View C-C Holes used for Lever Arm and dummy Lever Arm (see Step 9) TF1 View D-D View E-E TF1 Transverse Support Groove Should be Facing Downwards Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 7 of 15 Model # Cabrio 1.0
Assembling the Roof Framework Install the trusses on the hinge using hardware from kit [SKC03-2] shown in views B-B. Notice that only one side is shown. Repeat this step on the other hinge. Nylon bushing 019 KC.02L 006 004 See Through View 012 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 [TF1] 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) Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 8 of 15 Model # Cabrio 1.0
Installing the Corner Posts 7 G-G 003 007 Flat Washer 012 Lock-Nut View G-G (TOP VIEW) Attach one of the four corner posts [P1] to each corner of the structure using hardware from kit [KC06] 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 To complete the post assembly, snap together the corner posts [P1] and corner post covers [P2] using a rubber hammer as shown in the diagrams above. Repeat step for each corner. 002 KC07 Assembly Locking Key P2 Top View P2 Then fasten the top cover assembly [KC07] 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. Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 9 of 15 Model # Cabrio 1.0
Archoring the Shelter 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 C2 C3 level C1 Remaining holes in plate [LA3002] are used for fixing the structure on the floor See ANNEX 1 for measurements Dimensions given from center to center of plates [LA3002] Structure Anchorage System Recommendations 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 plates) of each - 3/8" x 1-1/2" expansion anchor * use 1/2" cement drill bit CONCRETE WOOD SOIL PAVER/GRASS This anchoring system is the recommended solution for anchoring your tent on other surfaces than wood or concrete such as paver or grass. Consult your dealer for more information on this fastening method. Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 10 of 15 Model # Cabrio 1.0
Final Frame Assembly 9 I-I H-H PL012 TS2 PL011 Remove the guide after installing the fork. View H-H (step a) 016 View H-H (step b) Install the plastic fork [KC08.PL011] on the [TS2] truss assembly on the opening side. Locate the proper position of the fork by using the fork installation guide [KC08.PL012] as shown in views H-H. Then use the self tapping screw [KC08.016] 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 from kit [SKC03-2] shown in view I-I. Repeat step on other side for the dummy lever arm. 011 009 006 019 See Through View 003 PL011 KC.02L 10 View H-H (step c) PL005 L1 View I-I (TOP VIEW) L1 L1 To complete the roof hinge mechanism, install the plastic hinge cover [KC03.PL005] over the roof hinge using screws [SKC03-1.026]. Then install side cover [KC08.PL010] and the hole cap [KC08.020]. Repeat step on both side. PL010 026 020 Install the Plastic Finishing Cap Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 11 of 15 Model # Cabrio 1.0
Final Frame Assembly 11 018 010 005 Install the lever strap on the end of the lever arm using hardware from kit [KC08] shown in the left diagram. Then install the plastic cap [PL013] on the end of both the lever and PL013 R2 002 12 Roof Support TS1 040 B2 Center Line Locate the center distance of beam [B2].Then install the stainless steel latch [KC31.LT-A49] using the self-taping screws [KC31.040] on the roof support [TS1] and beam [B2]. Make sure the latch parts are fixed apart correctly such that it can be closed as shown in the adjacent diagram. Repeat step on other side. The stainless steel latch is used along with the corner locking mechanism (shown in step 7) to secure the roof truss in place. B2 LT-A49 Closed Latched 13 Insert velcro strips at every 16 in the top groove of the beams. Then fix the valance to the velcro strips [MISC K.APL001]. Start from one end of the valance and work your way around the frame assembly. See adjacent diagrams for detail. Inside view, facing B2 & TS1 TOP VIEW K.APL001 Velcro Strip (top groove) 16 apart Valance Velcro Strip (top groove) Roof will open from this side Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 12 of 15 Model # Cabrio 1.0
Installing the Roof Fabric 14 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 [TF1].Then fix the velcro strip around the 2 roof supports [TF2]. 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 [TF3] in its upright position and fix the velcro around it as shown in view J-J. TF1 View M-M (Step a) R1 Insert a flat bar on each end of the pocket View M-M (Step b) Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 13 of 15 Model # Cabrio 1.0
Installing the Curtains 15 K.PL101 Plastic Pulley Snap Pulley in place Metallic Eyelet Curtain Exterior Side Curtain (Exterior Side) Zipper (Interior Side) Profile View CAP.01 Install plastic pulleys [MISC K.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 caps [KC32-S.CAP.01] as shown in the diagram. Repeat step for each corner. See next step (16) for curtain installation example. 16 Roof Fabric & Valance Not Shown For Clarity outside rail inside rail curtains on 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 [MISC K.APL001] inserted 16 apart in the bottom groove of the beams similarly to the valance in step 14. If you have purchased optional curtains (mesh netting, transparent plastic or acrylic fabric) install them on the inside or outside rail of the beams. Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 14 of 15 Model # Cabrio 1.0
Installing the Curtains 17 Complete installation of each curtain sections at each corner. Installed curtains should resemble the above diagram. Distributor: ShadeScapes Americas 970.527.7070 cuscini.shadescapesamericas.com info@shadescapesusa.com support@shadescapesusa.com Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 15 of 15 Model # Cabrio 1.0
Annex 1 - Step 8 Measurements Dimensions given below are from center to center of plates [LA3002]. Internal Dimension 10x10 Model inches (cm) W 111 5/8 (283.5) L 111 5/8 (283.5) D 157 7/8 (401.0) C1 80 (203.2) C2 114 (289.6) C3 148 (375.9) Internal Dimension 10x12 Model inches (cm) W 111 5/8 (283.5) L 138 3/4 (352.4) D 178 1/8 (452.4) C1 80 (203.2) C2 114 (289.6) C3 148 (375.9) Internal Dimension 10x14 Model inches (cm) W 111 5/8 (283.5) L 161 3/8 (409.9) D 196 1/4 (498.5) C1 80 (203.2) C2 114 (289.6) C3 148 (375.9) Distributor: ShadeScapes Americas cuscini.shadescapesamericas.com 970.527.7070 Supp. of 15 Model # Cabrio 1.0
Architectural Testing TEST REPORT Report No.: C0993.02-109-44 Rendered to: CUSCINI DESIGN, INC. Mirabel, Quebec CANADA PRODUCT TYPE: Fabric Covered Garden Pavilion with Convertible Roof SERIES/MODEL: Cabriolet Shelter Reference must be made to Report No. C0993.02-109-44, dated 08/31/12 for complete test specimen description and detailed test results.
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Page 1 of 5 1.0 Report Issued To: Cuscini Design, Inc. 12015 Arthur-Sicard Mirabel, Quebec J7J 0E9 CANADA 2.0 Test Laboratory: Architectural Testing, Inc. 130 Derry Court York, Pennsylvania 17406-8405 717-764-7700 3.0 Project Summary: 3.1 Product Type: Fabric Covered Garden Pavilion with Convertible Roof 3.2 Series/Model: Cabriolet Shelter 3.3 Compliance Statement: Results obtained are tested values and were secured by using the designated test method(s). Test specimen description and results are reported herein. 3.4 Test Date: July 24, 2012 3.5 Test Record Retention End Date: All test records for this report will be retained until August 31, 2016. 3.6 Test Location: Architectural Testing, Inc. test facility in York, Pennsylvania. 3.7 Test Sample Source: The test specimen was provided by the client. Representative samples of the test specimen(s) were not provided to Architectural Testing, Inc. from Cuscini Design, Inc. 3.8 Drawing Reference: The test specimen drawings have been reviewed by Architectural Testing and are representative of the test specimen(s) reported herein. Test specimen construction was verified by Architectural Testing per the drawings located in Appendix B. Any deviations are documented herein or on the drawings. 3.9 List of Official Observers: Name Company Jean Bourque Michel Bourque Paulo Medeiros Thomas Lawlor Michael D. Stremmel, P.E. Emily C. Riley Cuscini Design, Inc. Cuscini Design, Inc. Cuscini Design, Inc. Architectural Testing, Inc. Architectural Testing, Inc. Architectural Testing, Inc. www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Page 2 of 5 4.0 Test Procedure: The test specimen was subjected to a dynamic wind test. Winds were produced by an engine-driven fan located approximately 7 feet from the test specimen. The wind was directed to the front leading edge of the pavilion and subsequently at the corner of the pavilion (45 angle). Tests were conducted starting at 50 mph wind speed and increased in 10 mph increments without a relaxation period between wind speed increments. Each wind speed increment was maintained for thirty seconds. Wind speed increments continued until the maximum capacity of the equipment was reached. 5.0 Test Specimen Description: 5.1 Awning Size: 10' x 14' 5.2 Frame Construction: Frame Member Material Description Side beams (4) Aluminum Extruded Corner posts (4) Aluminum 6063 T6 Extruded, capped at bottom end using an aluminum base plate secured to the post with four 1/4" x 1-3/4" long Robertson flat head screws. Capped at top end using plastic cover assembly, secured using four 1/4" x 1-3/4" long Robertson flat head screws per post. Extruded aluminum cover plates were snap-fit to each post. Side beams Corner posts Joinery Type Square-cut N/A Detail Secured using plastic corner keys and two #8 x 3/4" long Robertson pan head screws per corner Secured to the beam corners using two 5/16" x 2" long carriage bolts, washers, and lock nuts 5.3 Roof Construction: Roof Member Material Description Transverse supports (2) Aluminum Extruded, constructed of three members each Trusses (3) 6063 T6 Extruded, constructed of three members each Transverse supports and trusses Joinery Type Mitered Detail Secured at corners with metal and covered in plastic keys and secured to hinges at each end using one 5/16" x 1-3/4" long hex bolt with washer, nylon bushing, and lock nut www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Page 3 of 5 5.0 Test Specimen Description: (Continued) 5.4 Curtain Assembly: Description Quantity Location Secured to groove in transverse Roof cover 1 supports and using Velcro straps around the transverse supports and trusses Curtains 4 Secured to roof beams using snap-fit plastic pulleys located at each metal eyelet in curtain 5.5 Hardware: Description Quantity Location Roof hinge 2 Secured to roof beam at midspan using two 1/4"-20 x 5/8" hex bolts, lock washers, flat washers, and tab washers per hinge Lever arm 1 Secured to center truss using a plastic fork and one #12 x 1-3/4" long selftapping Robertson flat head screw Lever strap 1 Secured to lever arm end using one 1/4" x 1-3/4" long Robertson flat head screw with nylon bushing, washer, and lock nut Plastic strap secured to transverse support at midspan using one 3/4" flat Plastic strap with locking head Tek screw. Plastic hooks secured 2 hooks to transverse support and roof beam using two #8 x 1-1/2" long self-tapping Robertson pan head screws each 6.0 Installation: The specimen was installed onto a concrete pad. Each frame leg was secured to the concrete using one 3/8" x 1-1/2" expansion anchor with bolt and nut. www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Page 4 of 5 7.0 Test Results: 7.1 Test #1: Pavilion curtains open Wind Speed Observations 50 mph No damage 60 mph No damage 70 mph No damage 80 mph No damage 90 mph No damage 100 mph Curtain pulled off pulleys at one corner 110 mph No additional damage 120 mph No additional damage 130 mph No additional damage Note: At the conclusion of the test, it was observed that the Velcro ties released along the truss furthest from the wind source and at the midspan of the center truss. 7.2 Test #2: Pavilion curtains closed Wind Speed Observations 50 mph No damage 60 mph No damage 70 mph Zipper broke on the font panels 80 mph No additional damage 90 mph No additional damage 100 mph No additional damage 110 mph No additional damage 120 mph No additional damage 130 mph Plastic strap released on the back side Note: At the conclusion of the test, it was observed that the Velcro ties released along the truss furthest from the wind source and at the midspan of the center truss. www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Page 5 of 5 Architectural Testing will service this report for the entire test record retention period. Test records that are retained such as detailed drawings, datasheets, representative samples of test specimens, or other pertinent project documentation will be retained by Architectural Testing, Inc. for the entire test record retention period. This report does not constitute certification of this product nor an opinion or endorsement by this laboratory. It is the exclusive property of the client so named herein and relates only to the specimen(s) tested. This report may not be reproduced, except in full, without the written approval of Architectural Testing, Inc. For ARCHITECTURAL TESTING, Inc. Emily C. Riley Technician Michael D. Stremmel, P.E. Senior Project Engineer ECR:dem Attachments (pages): This report is complete only when all attachments listed are included. Appendix-A: Photographs (2) Appendix-B: Drawings (9) This report produced from controlled document template ATI 00479, issued 01/27/12. www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Appendix A Photographs Photo No. 1 Test #1 Set-Up and Application of 50 mph Wind Load Photo No. 2 Test #2 Set-Up and Application of 50 mph Wind Load www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Photo No. 3 Test #2 Application of 130 mph Wind Load www.archtest.com
Test Report No.: C0993.02-109-44 Report Date: 08/31/12 Appendix B Drawings www.archtest.com