Pent Roof Garden Storage Shed Assembly Guide For OT0604 series If you have trouble reading printed guide, you can always contact your seller and get a digital version.
A message from the author Thank you for buying this shed. As a DIYer myself I understand that most people who are willing to buy a shed and assemble it personally are likely to be highly experienced in home projects. As a result, wordy manuals are not appreciated. Bearing that in mind, I finished the first version of the assembly guide in an IKEA way, that is, a guide with little or no word in it.
TOOLS M4 M6 2
PART LIST Some parts are stacked together for easier transportation. Occasionally two or more parts will stick together very firmly. As a result, you might think something is missing. But it is very likely that the missing part is just attached to another part.
PART LIST Some parts are stacked together for easier transportation. Occasionally two or more parts will stick together very firmly. As a result, you might think something is missing. But it is very likely that the missing part is just attached to another part. For better visibility, some parts are enlarged disproportionally in this manual.
WARNING Keep this guide for future reference. Read carefully. Safety Make sure you have access to all sides of the shed during construction. Ensure that all parts are present before starting assembly. Remove all parts from the box and sort them by number. Ensure that you have all elements required to build your garden shed. Always wear work gloves, long sleeves and safety goggles during assembly of the garden shed. Some components contain sharp edges and may cause damage.
LEGEND : marks a step. IMPORTANT: EXECUTE THESE STEPS IN NUMERICAL ORDER. A : marks a sub-step and the alphabetical order of executing these sub-steps. IMPORTANT: EXECUTE THESE STEPS IN ALPHABETICAL ORDER. DOOR [DL1] : marks the orientation of the shed. : marks a part. : marks a screw hole and the sequential order of fixing screws and panels. IMPORTANT: FIX SCREWS IN NUMERICAL ORDER. : marks a screw hole that SHOULD NOT be fixed. : marks an unacceptable layout. : marks an acceptable layout.
Foundation Foundation 1300mm Back 1950mm DOOR The site must be prepared so that the base of the shed is level all round. Checking with a spirit level is required. This shed must be secured onto a firm and leveled foundation, preferably concrete slabs. The foundation must have a minimum thickness of 10 cm. Allow cement to dry for at least 48 hours. The foundation can also be constructed using bricks or blocks.
GENERAL RULES GENERAL RULES: DOOR, BACK, LEFT, and RIGHT. Starting from Step 1.1 and throughout this manual, you will constantly see the location marks like DOOR/ BACK/LEFT/RIGHT, shown below. It tells the orientation of the shed. For better visibility, the shed will be rotated multiple times in this manual. As a result, you might find it hard to keep track of where the shed is facing. If this happens, try to find the location mark. Use the two illustrations below as a reference.
Outer Base For better visibility, illustrations of screws and bolts like [S3] are enlarged greatly and the color of some parts changes. [D1] x 1 [D2] x 2 [D3] x 2 [DL1] x 4 [D4] x 1 [S3] x 12 [DL1] [DL2] [D2] [DL2] x 2 [D1]/[D4] [D2] [DL2] [D4] [DL1] [DL1] [D3] [D3] [DL1] [DL1] [D1] [DL2] [D2] DOOR COMMON MISTAKE: Confusing Parts: [D1] and [D4] [D1] and [D4] are almost identical except that [D1] has a punched latch hole on it and [D4] doesn’t.
Inner Base [N1] x 4 [N2] x 2 [S3] x 8 [N2] [N2] [N1] [N1] DOOR [N1] [N1] DOOR Notice In this step, [N2] is inserted into [N1]. No screws are used. Only eight [S3] are used in this step. After the step is finished, there are some unused screw holes left on [N1] and [N2]. They are used for attaching optional floor base to the base, which is not included in this shed.
Securing The Base [S6] x 4 Use a marker to mark [DL1]’s hole onto the Foundation. THEN REMOVE THE BASE.
Securing The Base [S6] x 4 DOOR COMMON MISTAKE: [S6] [S6] consists of two parts, the yellow tube and the screw. As stated on the last page, you need to hammer the tube into the foundation, put the base back and fasten the screw into the tube. Sometimes a customer would hammer the whole thing through [DL1], and it is not correct. For better visibility, the Foundation will be hidden afterwards.
Securing The Base Don’t Do This It takes 48 hours for the concrete foundation to cure and in rare cases, a customer would choose to assemble the shed elsewhere and move the finished shed onto the foundation. Don’t do this.
GENERAL RULES GENERAL RULES: Wall Panels Remove the protective films first These are the wall panels you will be using. Wall Panels, except for [Q2], are symmetrical, meaning they don’t have predetermined top/bottom, or left/right. But they do have exterior and interior, with the exterior’s color being the color of the shed and the interior’s color a universal light grey. [Q2] does have a difference between its left and right, but no difference between its top and bottom. [S4] [S3] Starting from Step 2.
[Q2] [Q2] x 4 [S4] x 8 [S3] x 8 [Q2] [Q2] Door Right COMMON MISTAKE: [Q2] The four [Q2] can be assembled in whatever order. Use a step stool to temporarily support the assembled [Q2]. A [Q2] has four screw holes on each of its ends. In step [2.1], only two screw holes in the middle are used. The rest will be used in following steps. Also, pay special attention to the orientation of [Q2]. It is the side with three screw hole that is facing the door/back.
GENERAL RULES Top Aluminum Frames: [B1][B2][B3][B4][B5][B6] [B1] [B2] [B3] [B4] [B5] [B6] Take a close look at these frames. They are not the same and thus not interchangeable. They are not symmetrical either, so there is only one correct layout. Here are some general rules: 1. Look for the [Flat Surface] first. There are screw holes on the [Flat Surface]. These screw holes are used for the connection between [BL1] [BL2]and frames. 2.
Top Frames 1 [BL1] x 4 [BL2] x 2 [B1] X1 [B2] X1 [B3] X1 [B4] X1 [BL1] [BL2] [BL1] [B1] [B1] [B2] [B1] [BL1] [B2] [B2] [BL2] [BL1] [B4] [B3] [B3] [B4] [B4] [B3] COMMON MISTAKE: [BL1][BL2] Lots of mistakes can happen in this step, but are avoidable. It may seem to you that these frames can be connected with [BL1][BL2] in multiple ways. Truth is, there is only one correct method, which means you have to follow the illustrations precisely.
Top Frames 2 [B1]+[B2] [B4]+[B3] [S3] x 8 [B1] [B2] [B1] [B2] [B4] [B3] [B4] [B3] [S4] is not used here. Notice that [B3] and [B4] are quite special because they have no [Opening] but two [Flat Surface]. However only one [Flat Surface] has [Screw Holes] on it. If you are doing it right, the finished [B4]+[B3] will look like this. Anything different indicates something is wrong.
Top Frames 3 [S3]+[S4] x 8 [B3] [B4] [B1] [B2] DOOR This is the only correct layout of [B1][B2][B3][B4]. Similar to step 2.1, only two screw sets are used for each end of [Q2]. Notice that there Notice that there are four screw sets marked ▲ in the illustrations above. There are no corresponding screw holes on the top frames for the two screw sets. Check the next page for two mistakes before taking this step.
For better visibility, all other parts are hidden in this section. RARE MISTAKE:[B1][B2][B3][B4] [B1] [B2] Right Wall [B4] [B3] Right Wall We have some rare cases where customers assembled the top frames but could not continue in later steps. The two illustrations above depict what happened. Take a close look and it is obvious that the [Flat Surface] with screw holes are facing upward, which is wrong. Also the layout is different from what’s shown on the last page.
Top Frames 4 For better visibility, all other parts are hidden in this section. [S3] x 4 [B5] [B4] [B3] [B6] DOOR [B1] [B2] In this step, your task is to connect [B5] and [B6] to [B1]+[B2] and [B3]+[B4]. Leave [Q2] alone. COMMON MISTAKE:[B5][B6] [B5] [B6] Similar to what’s shown in step 2.4 RARE MISTAKE, we have two illustrations depicting what could go wrong. However this two mistakes are commoner. Still, the key is to look for the [Flat Surface] with screw holes.
GENERAL RULES Wall Panel Stacking Starting from Step 2.6 you will be stacking panels. These general rules apply to wall panels only. Stacking of roof panels will be talked about later. [Q3] [Q3] [Q3] [Q3] The picture above illustrate how two wall panels are stacked together, from a top to bottom perspective, outside the shed. As you can see, only one channel of each wall panel is stacked. It makes no difference which panel is on top.
GENERAL RULES GENERAL RULES: Single Wall Panel Nailing This illustration is taken from step [2.6] ⑤ ⑦ ⑧ ⑥ As stated before, a wall panel has no predetermined top/bottom end. It’s up to you to decide which end is the top or bottom. Once you have made the decision, follow the rules below. 1. Start from the screw holes at the bottom end. 2. At each end, start from the peripheral screw holes and move to the screw hole in the middle.
GENERAL RULES GENERAL RULES: Multiple Wall Panel Stacking and Nailing ⑤⑦⑧⑥ [Q1]-1 [Q1]-3 stacking [Q1]-2 stacking BACK ①③④② This is the illustration taken from step [2.11] “–1, -2, -3” indicates the order of nailing the wall panels to the rest of the shed. Please follow the exact nailing order. You don’t have to memorize the exact order of nailing these panels because detailed wall panel stacking layout will be illustrated in the following steps. This page serves as a reminder.
Side Wall 1 [Q3] x 1 [S3]+[S4] x 8 Fix the screws following the order of ①~⑧ Don’t be tempted to fix the screws that are not marked. This [Q3] can be stacked above or under [Q2]. ⑤ ⑦ ⑧ ⑥ There are no corresponding screw holes on the top frames for ⑥⑦⑧. Make sure that Screw ⑤ indeed goes into the screw holes on the top frame.
Side Wall 2 [Q3] x 1 [S3]+[S4] x 10 Fix the screws following the order of ①~⑩ The second [Q3] can be stacked above or under the first [Q3] and [Q2]. ⑥ ⑧ ⑩ ⑨ ⑦ There are no corresponding screw holes on the top frames for ⑥⑧⑩⑨. Make sure that Screw ⑦ indeed goes into the screw holes on the top frame.
Side Wall 3 [Q3] x 2 [S3]+[S4] x 18 [Q3] [Q3] DOOR Repeat Step 2.6 and Step 2.7 and finish assembling the left two [Q3] one by one.
Back Wall 1 [Q1] x 1 [S3]+[S4] x 6 ④ ⑥ ⑤ [Q1] stacking BACK ① ③ ② Fix the screws following the order of ①~⑥ The second [Q1] can be stacked above or under [Q2]. There are no corresponding screw holes on the top frames for ④⑥⑤.
Back Wall 2 [Q1] x 1 [S3]+[S4] x 6 ④ ⑥ ⑤ [Q1] stacking BACK Fix the screws following the order of ①~⑥ The second [Q1] can be stacked above or under [Q2]. ① ③ ② There are no corresponding screw holes on the top frames for ④⑥⑤.
Back Wall 3 [Q1] x 1 [S3]+[S4] x 8 ⑤ ⑦ ⑧ ⑥ [Q1] stacking stacking BACK Fix the screws following the order of ①~⑥ The last [Q1] can be stacked above or under the ① ③ ④ ② other two [Q1]. There are no corresponding screw holes on the top frames for ⑤⑦⑧⑥.
Door Support [S4] x 4 [S3] x 6 [LL] x 1 [LR] x 1 A [LR] [LL] DOOR Use a plier to bend [LL] and [LR] following step A. Notice that in Step B, the top end of [LL] or [LR] has two screw holes each. But only one needs a [S4].
[S1][S2][S4] [S1]+[S2]+[S4] x 12 DOOR After all wall panels (including [LL] and [LR]) are done nailing, find the screw holes in the middle of the wall panels and use [S1] [S2][S4] to enhance the overall steadiness of the shed.
Roof Supports 1 [L4] x 4 [S1]+[S2]+[S4] x 10 [FL] x 1 [FR] x 1 [L4] [SL] x 1 [SR] x 1 [L4] [FR] [FL] [L4] x 2 [FR] [FL] [SL] and [SR] is encased in [FL] and [FR]. [SR] [SL] Rare MISTAKE [FR] There is a rare mistake where a customer would mistake the upper edge with the lower edge of [FL] and [FR]. This mistake is easily avoidable if you make sure that [SR] is connected to [FR].
Roof Supports 2 [S3]+[S4] x 22 22 sets of [S3]+[S4] will be used in this step. Pay special attention to the six screw holes marked ▲ in the illustration below. Lift the [Roof Support] ([SL]+[FL]+[FR]+[SR] ) a little bit, you will find ▲ are the only six corresponding screw holes on the top frames. While nailing the [Roof Support] to the top frames, make sure that you fix ▲ first, and that the screws are indeed going into the holes on the top frames. The fixing order of the rest [S3]+[S4] is not important.
GENERAL RULES GENERAL RULES: Roof Panels Remove the protective films first These are the roof panels you will be using. [W1] x 1 [W2] x 3 GENERAL RULES: Single Roof Panel Nailing L-Channel U-Channel (Notice: The following rules apply to garden shed with pent roof only. We also have apex roof line, but the roof panels are quite different.) Take a look at the [W1] above. It is obvious that the left and right edge of the roof panel are quite different.
GENERAL RULES GENERAL RULES: Roof Panel Stacking Top Bottom Starting from Step 3.3 you will be stacking roof panels. The two pictures above illustrate how two roof panels are stacked together, from a top eaves to bottom eaves perspective outside the shed. As you can see, only one channel of each panel is stacked. Notice that the roof panel on the right has a U-channel while the one on the left has an L channel. It is always the roof panels with a U channel that is on top.
GENERAL RULES GENERAL RULES: Multiple Roof Panel Stacking and Nailing [W1]-1 [W2]-3 [W1]-4 [W1]-2 Fast-forward to Step 3.6 and you will find the illustration above. These are the four roof panels you will be using. “–1, -2, -3, -4” indicates the order of nailing the roof panels to the rest of the shed. Please follow the exact nailing order. You don’t have to memorize the exact order of nailing these panels because detailed order will be illustrated in the following steps. This page serves as a reminder.
ROOF PANELS 1 [W1] x 1 [S3]+[S4] x 4 For better visibility, wall panels and bases are hidden in the roof panel steps. [W1] BACK L-Channel Start from this [W1] first. Some key points: 1. Place the [W1] so that the L-channel points to the outside of the shed, not inside. This is important. 2. Only four sets of [S3]+[S4] are used.
ROOF PANELS 2 [W1] x 1 [S3]+[S4] x 4 [W1] L-Channel BACK L-Channel This step is similar to last step. Some key points: 1. Place the [W1] so that the L-channel points to the outside of the shed, not inside. This is important. 2. Only four sets of [S3]+[S4] are used. The order of fixing these four sets are irrelevant, but you need to make sure that the [S3] are indeed going into the screw holes on the triangular/rectangular panel or top frames. 3.
ROOF PANELS 3 [W2] x 1 [S3]+[S4] x 7 [W2] BACK [W1]-1 [W2]-3 L-Channel Right Wall [W1]-2 Left Wall Some key points: 1. Place the [W2]-3 so that the L-channel points to the Left wall (not your left hand) of the shed. This [W2]-3 is placed above the [W1]-1. – 1, -2, -3 indicates the order of roof panel. 2. Seven sets of [S3]+[S4] are used, four sets for nailing [W1] and three for roof panel stacking. The top two sets ①② are the most important and should be fixed first.
ROOF PANELS 4 [W1] x 1 [S3]+[S4] x 10 [W1] BACK [W1]-1 [W2]-3 [W1]-4 [W1]-2 Left Wall Right Wall Some key points: 1. L-Channel Place [W1]-4 so that the L-channel points to the Left wall (not your left hand) of the shed. [W1]-4 is placed under [W1]-2. [W1]-4 is placed above [W2]-3. 2. Ten sets of [S3]+[S4] are used, four sets for nailing [W1] and six for roof panel stacking. The top two sets ①② are the most important and should be fixed first.
EAVES 1 [L1] x 2 [S3]+[S4] x 2 [L1] [L1] Left Wall Right Wall BACK 42
EAVES 2 [L2] x 1 [L3] x 1 [S3]+[S4] x 1 [L3] Right Wall [L2] Left Wall BACK [L1] could be stacked under or above [L2]/[L3].
EAVES 3 [G4] x 2 [S3]+[S4] x 2 [G4] [G4] Right Wall BACK Left Wall [G4] 44
EAVES 4 [L2] x 1 [L3] x 1 [G4] x 2 [G5] [G5] Right Wall [S3]+[S4] x 3 [L2] [L3] Left Wall BACK Repeat Step 3.8 to 3.9 and finish step 3.
SCREW CAPS [S5] After all of the roof panels are nailed, go inside the shed and take a loot at the roof panels. You will find dozens of [S3] with their pointed tips. They are dangerous and it is necessary to seal the tips with [S5].
LEFT DOOR 1 [DBHG] X 1 [DBL] X 1 [DA] x 1 [DBL] [DA] Interior [DBL] [DBHG] This is the interior view of the Left Door. It is worth mentioning because [DA] and [DBL] have different interior and exterior. [DA] 1. [DA] and [DBHG] have no predetermined top or bottom. You can use whatever end Interior as the top or bottom. 2. [DBL] does have a predetermined top and bottom. Check the illustration above. There are three screw holes on the interior of each end of [DBL].
LEFT DOOR 2 [S8] X 2 [S9]+[S4] x 1 [S10]+[S4] x 1 M4 x 20 [DBL] [S2] x 2 M4 x 25 [DBHG] [S9]+[S4] [S10]+[S4] [S8] 1. Use [S9] and [S10] with [S2] and [S4]. 2. Use [S10]+[S4]+[S2] to connect two [S8]. 3. It doesn’t matter which [S8] is on top.
LEFT DOOR 3 [DBT] X 2 [S9]+[S4] x 4 [DBT] [S2] x 4 M4 x 20 1. [DBT] has no predetermined top or bottom. You can use whatever end as the top or bottom. 2. Notice the stacking order of [DBT], [DBHG]/[DBL], and [S8]. [DBHG]/[DBL] is above [DBT] and under [S8], i.e.
LEFT DOOR 4 [SPRING LATCH] [SPRING LATCH] x 2 TOP [S3] x 6 BOTTOM Some key points: 1. Notice that the orientation of the two [Spring Latch] is different. 2. [S4] is not used. 3. Each [Spring Latch] has four screw holes but only three are used. The unused one is marked as X. 4. Use some force while nailing [Spring Latch], because there are no corresponding screw holes on [DBT].
LEFT DOOR 5 1. Bend the [HG] hinge before nailing it to the door. No tool is required. 2. Take a closer look at [HG], which has two sides. The difference is that there are five countersunk screw holes on Side A. While nailing [HG] to the door, make [HG] x 2 sure that [S3] goes into the countersunk screw holes. No [S4] is required. [S3] x 4 [HG] [HG] Side A [HG] Side B [Countersunk Screw Hole] COMMON MISTAKE: [HG] Aside from the countersunk screw holes, there is another catch about [HG].
Right DOOR 1 [DBHG] X 1 [DBR] X 1 [DA] x 1 [DBR] [DA] Exterior [DBR] [DBHG] This is the exterior view of the Left Door. It is worth mentioning because [DA] and [DBR] have different interior and exterior. [DA] 1. [DA] and [DBHG] have no predetermined top or bottom. You can use whatever end Exterior as the top or bottom. 2. [DBR] does have a predetermined top and bottom. Check the illustration above. There are three screw holes near the middle of [DBR].
RIGHT DOOR 2 [S8] X 2 [S9]+[S4] x 1 [S10]+[S4] x 1 M4 x 20 [DBHG] [S2] x 2 M4 x 25 [DBR] [S8] [S10]+[S4] [S9]+[S4] 1. Use [S9] and [S10] with [S2] and [S4]. 2. Use [S10]+[S4]+[S2] to connect two [S8]. 3. It doesn’t matter which [S8] is on top.
RIGHT DOOR 3 [DBT] X 2 [S9]+[S4] x 4 [DBT] [S2] x 4 M4 x 20 1. [DBT] has no predetermined top or bottom. You can use whatever end as the top or bottom. 2. Notice the stacking order of [DBT], [DBHG]/[DBR], and [S8]. [DBHG]/[DBR] is above [DBT] and under [S8], i.e., [DBT] is covered by [DBHG]/ [DBR]. See the illustration below.
RIGHT DOOR 4 1. Bend the [HG] hinge before nailing it to the door. No tool is required. 2. Take a closer look at [HG], which has two sides. The difference is that there are five countersunk screw holes on Side A. While nailing [HG] to the door, make [HG] x 2 [S3] x 4 sure that [S3] goes into the countersunk screw holes. No [S4] is required. [HG] [HG] Side A [HG] Side B [Countersunk Screw Hole] COMMON MISTAKE: [HG] Aside from the countersunk screw holes, there is another catch about [HG].
FINISHED LEFT AND RIGHT DOOR [RIGHT DOOR] [LEFT DOOR] Interior Above is the finished layout of the right door and the left door. It is obvious that the layout of [S8] is different and only the left door has [Spring Hinges] nailed to it.
HINGES [S3] x 12 Bend the [HG] again so the wing part will touch the [LL]/[LR]. There are screw holes on [LL]/[LR] that match the countersunk screw holes on [HG]. No [S4] is needed.
LATCHES [LATCH] x 1 [S3]+[S4] x 5 This screw hole has no corresponding screw hole on the [DA], so use some effort while drilling.