PERGOLA "Plus" for my Charcoal Grill

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Project by FJPetruso posted 05-10-2012 07:48 PM 127216 views 17 times favorited 12 comments Add to Favorites Watch

We’re re-doing & repairing our patio this spring & as part of the make-over I decided to make a nice cover for my Bar-B-Que grill. I wanted to make it to match our patio cover which is made of heavy treated deck lumber & matches our ranch style home. The design I chose was to have two heavy posts supporting a cantilever type awning of a Southwestern Pergola style. Like our patio cover, I didn’t want just a pergola to provide shade from the sun. ( I can’t understand why people here in the midwest, where you can count on rain for any special weekend event, choose to build pergolas designed for shade only in an arid southwestern climate. So many people are worried more about how a pergola looks & design it only to be attached to the house & completely forget about placing the rafters in an alignment that provides shade at the time the sun is the highest & hottest. So many pergolas have the rafters aligned to let the sun shine THROUGH at noon to 3pm. What a waste.) So a corrugated tin roof added to a pergola type top to keep hot sunshine, pergola placement and sudden storms & rain a minor inconvenience. 6X6s are used for posts & 4X6s were used for a support arms & angle braces. 2X6s & 2X2s are used to construct the top. The support arms are 4 feet long & the posts are placed 8 feet apart. The top, made to have a 2 foot overhang on the ends & a foot on the front & back, was made 12 feet long by 6 feet deep. For joinery I used a combination timber framing & typical bolted construction as all joints were both mortised & bolted for strength. A section of lattice is used for a decorative touch. It’s finished just in time to smoke some ribs for Mother’s Day!

-- Frank, Florissant, Missouri "The New Show-Me Woodshop"

12 comments so far

View Jim Jakosh's profile

Jim Jakosh

27696 posts in 4560 days

#1 posted 05-11-2012 02:19 AM

That is really cool. It give me an idea for one on my deck. thanks for the project!!!!!!!!!!............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Craftsman on the lake's profile

Craftsman on the lake

3896 posts in 4893 days

#2 posted 05-11-2012 02:35 AM

Nice and functional.

I built one for someone a few years ago. I used some polycarbonate roofing from home depot. really thin but lifetime warranty and very strong. It’s smoked so it cuts the sunlight.

-- The smell of wood, coffee in the cup, the wife let's me do my thing, the lake is peaceful.

View FJPetruso's profile


334 posts in 5165 days

#3 posted 05-11-2012 04:34 AM

That’s a cool looking patio! From the photo it looks like your columns have a neat looking reveal or molding.

I like the idea of using polycarbonate or fiberglass to let the light through too. But my neighborhood has lots of trees. Some people in the area used these products for their awnings & patio covers but the problem is lots of maple trees with “helicopters”, pine needles & other trees that shed a lot & the covers get pretty nasty looking from below. That tree to the right of the pergola is a “Rose of Sharon”. It has beautiful flowers but the darn thing sheds lots of petals daily all summer long & have to be swept up every day or it gets slippery. My wife sez that if it wasn’t so attractive to the Humming Birds she’d have me cut it down. I really would have liked to use the polycarbonate too but I have to clean gutters twice a year already & didn’t want to have another couple of chores. That’s the reason I opted for the galvanized steel. When someone plans to build a patio cover, trees are just another nuisance to consider. (My wife likes to feed the birds too. If you know what I mean?! )

-- Frank, Florissant, Missouri "The New Show-Me Woodshop"

View Martyroc's profile


2712 posts in 3761 days

#4 posted 05-11-2012 04:44 AM

Thats nice, I am being asked by the Mrs, to do a pergola this summer, probably a little bigger than that one, but this came out great

-- Martin ....always count the number of fingers you have before, and after using the saw.

View craigo's profile


54 posts in 3786 days

#5 posted 05-11-2012 06:36 AM

I suppose the Lattice section blocks off any hungry neighbors aswell, nice touch!

-- making something from nothing, and making it your own... thats life.

View DocSavage45's profile


9071 posts in 4297 days

#6 posted 05-11-2012 04:14 PM

Gentlemen. Great job! When I started complaining about maintaining what I have built because I like building , not the maintenance my wife said “You built it!” LOL struck me as a wise statement. She was meaning to say be proud of it. I took it to mean I need to be responsible for it as well.

Built a heavy duty pergala style roof over the back of my shop door to keep snow and water from settling in. Rotted the door jamb! Catching the tree droppings from my walnut trees. Sigh! LOL

-- Cau Haus Designs, Thomas J. Tieffenbacher

View FJPetruso's profile


334 posts in 5165 days

#7 posted 05-11-2012 04:57 PM

WOW!!! I truly understand. Those walnut trees are great for beautiful wood, delicious nuts & powerful dye for cloth (& hands). I just don’t want those things near my house!!!!!

I’ll keep my shootin’ iron handy to keep the neighbors away from the BBQ. At least I don’t have to guard the Old Smoke House! Actually my hungry neighbor helped. So I guess I can spare him a hot dog. LOL

He helped me raise the posts. I made a simple jig… I used a sheet of plywood attached & squared to the two posts 8 feet apart… Attached & squared a 1X4 across the posts near the ground level mark… Then my neighbor & I raised the set-up upright & dropped the posts into the pre-dug holes… Then I shimmed under the ends of the 1X4 & leveled across the top edge of the plywood, which kept BOTH the posts level side-to-side. We then poured concrete into the holes while keeping the posts level front to back. Squaring the posts together like that really made it easier than using batter-boards & long bracing on such a short span.

-- Frank, Florissant, Missouri "The New Show-Me Woodshop"

View john_az's profile


105 posts in 3825 days

#8 posted 05-17-2012 05:22 AM

That is really nice! Let me know when the baby-back ribs are done!

-- John, Phoenix-AZ

View dmattox's profile


1 post in 2329 days

#9 posted 01-03-2016 10:18 PM

Very interested in doing this project. How can I get the plans an such? Thank you

View FJPetruso's profile


334 posts in 5165 days

#10 posted 01-04-2016 12:44 AM

Unfortunately the plans are out of my head & I never put them on paper. But it’s a pretty straight forward assembly. 6X6 posts, 4X6 horizontal support using a bridle joint to join, & 4X6 45 degree brace with a tenon on each end for joining to the post & horizontal support. The rafters have decorative “S” curve on the ends & are notched for attaching to the horizontal support. Some blocking to keep them squared up. 2X2s are attached to the rafters to provide a surface to screw the corrigated tin to. The posts need to be planted deep in concrete to compensate for the load of the roof hanging over to one side. Bolts secured the bridle joints. I also added long lag bolts to the mortise & tenon joints. Gravity keeps the mortise & tenon joints in place but the lag bolts are a safty in case of high wind.

-- Frank, Florissant, Missouri "The New Show-Me Woodshop"

View CeeGee's profile


1 post in 298 days

#11 posted 07-27-2021 04:23 PM

How has the project held up the past 5 years? Thinking of doing something very much like this for our new patio project. How tall is the pergola? or what size 6×6 did you buy? I thought I read you used a mortise and tenon joint for the 45 degree supports, I am not ashamed to say that is certainly out of my wheel house. Any suggestions on how to connect if not using the mortise and tenon joint? Thanks and I appreciate your help and advise.

View FJPetruso's profile


334 posts in 5165 days

#12 posted 08-07-2021 09:09 PM

Its actually been about 9 years now since I built it & its still very sturdy & hasn’t tilted a bit. (The smoker is now kinda rusty lookin’ though.) The 6X6s started at 12 feet long but had to be shortened because I ran into very hard clay when digging the holes for the posts & concrete. But there’s still enough head room under it for a 6’ 6” person to stand up straight under it. You could use long bolts or lag bolts for attaching the 45s but I would recommend the mortise & tenon method. They aren’t real difficult to make if you take your time & plan it out. I did all the joinery with the lumber setting on saw horses then raised the whole assembley up & set it in the holes. I actually screwed a full sheet of plywood across the back to maintain the same height for both sides & to prevent “racking”. And did the same on the horizontal arms to keep them square.

-- Frank, Florissant, Missouri "The New Show-Me Woodshop"

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