- 1). Lay two timbers horizontal, parallel and 74 inches apart. Screw an 8-foot 2-by-6 board perpendicularly to the timbers so it is 8 inches away from the left ends of the set of timbers and there is 6 inches of overhang on both ends of the 2-by-6 board. Repeat this process with one more 2-by-6 board and your last two timbers.
- 2). Cut two 1-½-inch-wide notches that are 2 inches deep in each of the 2-by-8-inch boards. Use your hand saw and chisel to remove the wood, creating the notch. The notches should be on the same side, perpendicular to the 8-foot edge and 11-½ inches from the ends of the board. Cut another two notches with the same dimensions that are 4 inches from each end of the 2-by-8-inch boards.
- 3). Lift both sets of timbers upright so they are 81 inches apart. The 2-by-6 boards should be between the timbers and parallel. Set the two inside notches on the 2-by-8 boards over the 2-by-6 boards. Space them so they are 10-½ inches apart. Lift your last two 8-foot 2-by-6 boards underneath the empty notches that are on the outside of the timbers, one on each side of the pergola. Screw these 2-by-6 boards to the timbers.
- 4). Cut seven 1-½-inch-wide notches in each of your 2-by-4 boards, starting 4 inches from the end and spacing them 10-½ inches apart. The notches should be 2 inches deep and all on the same side. Set these boards on the 2-by-8 boards so the notches fit over them and the boards are perpendicular to each other. Space them 10-½ inches apart.
- 5). Cut your 40-inch board's ends at a 45-degree angle. The board should look like a trapezoid when lying flat, and the longest edge should still equal 40 inches. Screw this board to the 2-by-8 board and to the timber to provide support to the corner of your pergola. The angled top end of the 40-inch board should be flush with the top edge of the 2-by-8 board, and the bottom end should be flush with the outside edge of the timber. Repeat this process at each corner of your pergola with your last three 40-inch boards.
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