Its Pergola Season! Tips To Building Your Own

Still my favorite...our barn pergola

Still my favorite…our barn pergola

The very first pergola we ever built.

The very first pergola we ever built.

Strong posts, like these 6 x 6's make for a strong pergola

Strong posts, like these 6 x 6′s make for a strong pergola

3 finished kits are loaded and ready to go!

3 finished kits are loaded and ready to go!

There is no mistaking it – we are in full-blown “pergola building season” at the farm.  Ever since building our own and then a few more for friends and family a few years back – our “hobby” has grown to making quite a few each year  ( See : Building Our Farm One Pergola At A Time)

Another one of our favorites - love the way they decorated to make it their own!

Another one of our favorites – love the way they decorated to make it their own!

Posts can easily be secured with anchors to a concrete pad

Posts can easily be secured with anchors to a concrete pad

A pergola adds an "outdoor room" to your landscape

A pergola adds an “outdoor room” to your landscape

We have been so fortunate to have met a lot of wonderful new people through the process – and, more importantly, it has really helped to build the farm  and fund projects like the sensory garden and new chicken coop.

So for today’s Sunday Farm update, we thought we would share some of the picture, tips and hints that we have learned when it comes to building a beautiful and durable outdoor garden pergola.

A Strong Base Is The Key To A Strong Pergola:

With any outdoor structure, everything starts with the base.  To put it simply, don’t skimp on your posts.

When working with wood,  a 4 x 6″ or 6 x 6″ post is your best choice for long-term durability.  4 x 4″ posts – although much less expensive than the thicker ones, simply won’t hold up over time.  They will begin to bend and bow – and within a year or two – your structure can start to look more like a curvy art sculpture than an outdoor oasis.

Choosing The Type And Thickness Of Wood:

There are a lot of choices when it comes to what species and thickness of wood to use.  It really comes down to personal preference.  We build all of our beams and top purlin boards from 2″ thick lumber. Although there are thinner and less costly options - the 2″ thickness gives the piece long-term strength and durability.

Almost all of our pergolas are made from treated lumber.  It’s a great choice when looking to handle harsh outdoor conditions.  It’s also very versatile – you can leave it to weather to a natural grey patina – or paint or stain it to match almost any wood species or decor.

Cedar is another viable option, but the cost of cedar is becoming astronomical, and it is very hard to find in  2″ thickness.  No matter the wood species, thinner boards tend to end up like the thinner posts, bowed and curvy over time.

Securing The Structure:

A lot of people ask us if its better to bury the posts, or to mount them on a concrete pad or footer.  It really comes down to personal preference, as both work well.

If you have an existing concrete patio – then by all means securing your posts with a bracket is the way to go.  You can find simple plate anchors (Simpson ties, etc.) at most home improvement and hardware stores that do an excellent job of securing posts to concrete.

If you choose to bury your posts – make sure to dig down deep enough to get below the frost line and prevent it from heaving out of the soil.  For ours on the farm we buried our posts 24″ and then back-filled with packing limestone gravel and dirt.

Quite simply, the important thing is to definitely secure it!  If it’s not secured, all it can take is one little serious windstorm to turn your beautiful little paradise into a pile of toothpicks.

Jim and Mary

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Creating Your Own Outdoor Paradise

This space has become a great place for the couple that purchased this one to enjoy their morning coffee and watch their fish swim in the ornamental fish pond they installed

Creating An Outdoor Room – We were blown away when we saw what Robin and her husband created with the pergola

Beyond getting to meet so many spectacular people – one of the most rewarding aspects of building our pergolas is knowing that they become a special place for people from all over to enjoy their own backyard space.

I am always amazed at the creativity of people and how they can take something and make it completely their own.  Although the basics of how we build our wooden pergolas are the same – each and every one looks completely different once someone takes it into their own space.

This past week we received an email from one such couple that truly blew us away with the space they created.  Robin and her husband contacted us back in the early summer after building a patio from reclaimed brick, and wanted an outdoor pergola structure to go over it.  So, over the next few weeks, like we so often do, we traded emails and pictures and worked our way through the design and size of it.  It ended up being a large pergola –  16′ x 14′ with 12′ posts to be sunk in the ground. On a sunny Sunday in early July, they came down and picked up their pergola kit.   What they did with it from there is simply amazing – building an outdoor paradise – complete with curtains, lights, tables and chairs.
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Our Garden Pergola - the very first one that started it all

Our Garden Pergola – the very first one that started it all

It’s neat really to think sometimes where all of the pergolas have ended up.   They have been installed on the top of a 40 foot deck overlooking a small forest – on top of a loft in the middle of Cincinnati -and in backyards across Ohio, Kentucky, Indiana and Pennsylvania.  We never get tired of getting pictures back from those that have purchased – telling us how they have “made it their own”.   We love the stories of enjoying their morning coffee outside, having  an outdoor dinner, or enjoying a glass of wine at night under the stars.  It makes us happy to see others enjoying their own “little slice of heaven” – just like we enjoy ours at our farm.

Jim and Mary

Landscaping and Extra Features Can Make All The Difference

Our Finished Barn Pergola And Patio

Our Finished Barn Pergola And Patio

Building Our Farm One Pergola At A Time

The very first pergola. Hand built in the driveway before transporting out to the farm.

It’s a bit funny how it all started.  I would love to tell you it was a grand business scheme complete with well thought out ideas, a marketing plan, and great advertising.  A grand plan to build a business that would allow our farm to earn an income, and create a more self-sufficient farm and life.

It was however, all by chance.  You see, after clearing the land for the first time and putting in the raised bed gardens – we sat in lawn chairs in the upper northwest corner of the “farm” and took in the view.   While sitting, Mary simply said…”wouldn’t it be nice to have a place to sit and enjoy the garden and look out at the barn and farm”.

Early spring…the farm pergola with the barn being constructed in the background. Its a great place to sit when you need a rest!

We both liked the look of a pergola over other choices of garden structures like a gazebo or canopy.  The rustic and beautiful lines of a pergola just fit the theme of what we wanted our Old World Garden Farm to be about. Over the course of the next few weeks we looked everywhere to buy our dream pergola.  The problem was, we couldn’t find one we liked. We seemed to have two choices –  flimsy metal canopies that came with a not so flimsy price –  or ultra expensive wood kits on the markets that required the equivalent of a house payment.  So we decided on a third option…design an old world pergola and build it.

This was the view Mary loved of the fence and garden from the first time we sat in the lawn chairs with just an open field.

With no power still at the farm, and much like our chicken coop – we built our farm pergola in the driveway of our suburban neighborhood.  We cut our own pattern for the edges from a piece of cardboard until we liked the curves – then proceeded to cut out the purlins with an old jigsaw.  Looking back now – I laugh thinking how long it took to cut those boards – having to stop every 15 minutes just so the ol’ jigsaw would stop smoking from overheating.  We cut every curve and notch by hand – even cleaning out the notches with a hand chisel to get “just the right look”.    At the end of a couple long days – there she stood –  our “old world” garden pergola – an all wood, all natural hand-built pergola erected in our driveway.  We celebrated by heading out to a local dining establishment for a celebratory beverage and meal.

It took FOREVER to cut these notches the first time with our old jigsaw!

And then it happened  - Mary’s phone rang, and our little business started.  The call was from  parents of our neighbors down the street.  They had just driven by our driveway while we were at dinner and the pergola caught their eye.  She innocently asked where we had purchased it , because like us – she had been looking for a “real wood” pergola.  We laughed and said we looked too, and finally had just built one.  Before we both knew it – we were building another for them.   We built that one in the driveway too – and during the process a note appeared on the half-built pergola asking if we would build another….and then another.  That year, in just a few months we built and sold 15 pergolas…and every single bit of the profits were poured back into our farm.  It was our way to start building the dream.

Our first “sold” pergola.

And so it continues, we built a small website to showcase some of what we build (www.owgarden.com). We added a few more sizes, and a new style of a pergola that celebrates our love of old barn structures that we call the Garden Structure.  We have one simple rule.  Keep it fun and keep it simple.  We still build them one at a time – and always will, although we did purchase a new saw and a few new tools that makes all that cutting a little easier!  We will never build more than 50 a year – so that we can continue to enjoy time with our family and continue to build our farm.  We practice responsible building by using only FSC certified wood.    Forest Stewardship Council (FSC) is a non-profit organization devoted to encouraging the responsible management of the world’s forests. FSC sets high standards that ensure forestry is practiced in an environmentally responsible, socially beneficial, and economically viable way

One of our favorites!  A pergola we built for a couple in Ohio.

One of our favorites! A pergola we built for a couple in Ohio.

So whether it’s a CSA,  selling canned or baked goods, raising livestock, growing cash crops, making your own wine or beer – or building pergolas – there is always an opportunity to do things you love and to make a good simple living at it.  We still both have our days jobs – with no immediate plans to stop.  But our ultimate goal, is to have a completely self-sufficient little farmstead.  A little vineyard, an orchard, a full garden, chickens, with hopes of more future livestock as well.  And ultimately – a little bed and breakfast to share it all with others.  For now, our little business is helping us build it that much quicker, one pergola at a time.

- Jim and Mary