Richard L. Holt

Physicist, Oceanographer, Aerospace Technologist, Rancher, Land Developer and Lecturer

Professional Resume

Education

Military Service

Getting Started

Active duty - US Army

Naval Missile Test Center

Navy Dolphin Research

NASA

Cal Tech Jet Propulsion Labs

TRW

EG&G/Wolf

Natl Cancer Institute

Cancer Control Programs

SAIC

TRW II

Extracurricular Activity

Houston Black Angus Ranch

SCUBA - World Underwater

Flying Airplanes

Sports in my Life

Idaho Sage Mesa Ranch

Ranch & Land Development

Making of Subdivisions

Retirement Activities

My Family

Introduction

Pergola Building

Colorado Dreaming

Family History

Panama and Me

My Early Years

Maternal Ancestry

Paternal Ancestry

The Panama Canal

Panama Railroad

French Canal Effort

U.S. Construction

Construction Photos

Canal Operations

Panama Today

Panama Links

Panama Canal DVD

 
Building a Pergola in Ventura

My daughter Michelle and her "brown-shoe Navy" Chief husband Steve wanted a pergola over their patio in their back yard at their home here in Ventura.  So I planned and designed one to fit their wants and needs with their inputs, ordered all the material, and three weeks before Thanksgiving, we began the project.

The first job was to lay out the design on the large existing concrete patio.  We decided that we would have 24" high concrete post bases holding up 8' 6X6 posts.  Later we would build decorative boxes around these bases to hold planters, serving tables, etc.  I drew this all up on my drafting table at home and had large blue-line sheets printed up with the layout.

To hold the concrete bases in place, we drilled 2" holes in the concrete patio floor and placed 1/2" rebar set in epoxy glue into the holes.  The Sonotube concrete forms would then be placed over these rebar holders and filled with Quikrete 5000 high quality concrete mix that we would hand-mix and carefully pour into the Sonotube forms. 

On top of each base and set into the concrete would be CB66 6X6 column base steel holders that would hold the posts in place on top of the concrete.  These would be centered on each Sonotube form and set the correct distance apart to make the dimensions of the pergola. Using 2X6 lumber stretched between the concrete forms,  I nailed the CB66 column bases to these 2X6es exactly where they needed to be to center them in the poured forms.  The photos will make this clear as to how we did this.

Three levels of wood would make up the pergola.  The lower level, 8' off the ground would be 2X10's.  The next level set at right angles to this level would be pairs of 2X8's.  Both of these levels would be nailed and bolted to the posts.  We made up decorative supports that were nailed to the posts to set the first level down on them to get the right height.  We used a Acculine Laser Level to set the heights of the supports for the first level on all the posts. 

The top level would be 2X6's that would be notched and set down on the 2X8's held down with construction glue and toe nailed as well.

When finished, all of this would then be primed and painted at a later date.

We started the construction of the wooden portion early on Thanksgiving morning with the help of Mike, a co-worker of Steve's at Point Mugu (another brown-shoe Navy Chief, by the way).  We also had the help of Steve's dad who had driven up from Phoenix for the Thanksgiving holidays with his wife Helen and Steve's sister Ann Marie.  Steve's dad, Dick, followed along as the construction progressed, filling, sanding and generally getting the thing looking good so that when we were done a primer coat of paint could be applied.  And of course we also had the help of our two grandsons Shilo and Dakota who wanted to be in the middle of all the work.

We finished the project by 2 PM on Thanksgiving day and at 5 PM Michelle served dinner under the new pergola.  Quite a task and a wonderful piece of family work for the day.  Good Job!!!
The Finished Pergola
The finished pergola. The bases need to be painted the color of the gate in the right background, but except for that, all the painting is done. This provides a beautiful place to sit and eat, study, read, or just enjoy the Southern California climate which is mostly sunny and warm.
The grandsons thought the Sonotube was neat so they wore the individual lengths before we set them in place. These guys are so much fun for me to have around any time.
Shilo with his mischievous smile. We try to make it fun for the boys while they are working and learning how to do these kind of things.
Dakota took time from his duties to ride his bike around the block, so he is wearing his helmet
Rebar set in epoxy in 2" holes in the concrete deck to hold the 24" high post bases in place
Setting up the Sonotube post bases where they were to go over the rebar that is already imbedded in the concrete patio
The next step before pouring the concrete into the tubes is to build a holder around each tube to keep it in place while we are pouring in the concrete
Steve starting the building of these brackets built out of scrap 2X4
These are then nailed to the concrete slab with a nail gun to make sure they don't move
I'm setting up the nail gun for Steve who had never used one before. The brackets are in place to hold the Sonotube in place. This nail gun fires 3" nails through the 2X4 into the concrete. This works with a .22 cartridge and fires when you strike the top of the gun with a hammer. Exciting to use!
Getting ready to fire a few to show Steve how this thing works. You'll notice the gun in my left hand on top of the sonotube. The orange portion is what you hold in your hand and it contains the firing pin. The other end you hold against the board and it contains the nail to be fired.
The rebar inbedded in the concrete slab and tied into it with epoxy glue to hold the bases in place
The Sonotube filled to where we would next lower the CB66 column base into it and fill the tube to the top
Steve mixing each batch in our portable tub
As the concrete is placed into the Sonotube we tamp it to make sure it sets with no air pockets in it - note the rebar sticking up in the concrete mix
Cheryl controlled the amount of water used in each batch - note the CB66 column base bracket sitting on the double 2X6's to the left
Carefully placing the concrete into the Sonotube and making sure it is tamped properly
Another tube ready to have the CB66 column base put into it
Dakota taking his turn in mixing the concrete - the boys participated well in this effort
Showing Dakota how to properly tamp the mix in the tube
Not too early to learn how to do these things - Dakota is nine
We have the CB66 column bases nailed onto the pair of 2X6's at the exact distance they need to be to make sure the posts will be set at that exact location which was 16'
Now comes the chore of carefully filling the tube to the top around the CB66 base
Cheryl and Steve working at topping off a tube around the CB66 bracket
Cheryl is a fantastic construction worker - her dad was a commercial home builder and taught her well - a real asset in any building job
Steve trimming off the ends of the 2X6 boards that are holding the CB66 bracket before we put it down into the concrete in the tube. The little house behind us is the dog house I built for the two family dogs, Buddy and Bosley. They even have a window to view the yard!
My favorite position set up for me by Michelle so that Dad could rest his tired body once in a while. This was a tough day forcing me to do some work I didn't think I could, but thank God, I got the strength to do it to help Steve and Cheryl do the job. Thankfullly Steve's Navy Chief friend Mike came along late in the day and saved the day.
All the brackets are now in place in each of the six bases for the posts, all the proper distance apart. We now have to wait 21 days for the concrete to cure. In the foreground is Bosley with Buddy behind him and then Steve and the beautiful dog house for all three of them! ((-:
The concrete has set and we have peeled off the Sonotube. We've watered them every day to make sure the cure is right. Next comes the finish on the outside of each base
I'm applying a coat of Patchcrete to each post base to seal the outside. This will all be hidden when we build the box around each base
About now my back and knees are telling me they have had enough! Can you tell by the beautiful expression on my face? I broke my back many years ago and had a total replacement of both knees with titanium knee joints two years ago, and when I do this kind of work, they talk back to me!!
I couldn't quit until all six were done. This is called "pushing the envelope" for a 73 year old warhorse!
The arrival of the wood from Stock Lumber in Ventura three weeks after we had finished the concrete bases. This load had all the posts and lumber for all three levels of the pergola. It didn't look like much for all that it cost. Lumber has gone rocketing into space price-wise!
Signing off for the load
Off-loading in the street with Dakota and I watching
When the actual woodworking started on Thanksgiving morning, this was my assigned position with my plans and instructions and I was told by my wife and daughter not to move from this vantage point. I had already been told by my docs that I had to take it easy or else I was going to be in deep trouble.
The troops are on the scene to do all the work. Steve and Mike along with Cheryl made up the work crew. They did a fantastic job all day. Here they are starting by setting the 8' posts in place on the concrete pedestals, while Shilo is exercising by running along the top of the stone planter wall behind them.
Making sure they are plumb before drilling and setting the bolts at the bottom of the post. We had the shims already in place at the bottom to set the plumb as well as we could before they started with the long posts.
Two bolts per base. The guy helping Steve is another Navy Chief, Mike, who came along and spent the whole day on the project. He was a great help. We fed him too!! Couldn't have done without him. It was fun to hear two Navy Chiefs yelling at each other all day as if either one of them knew what they were doing!!
A double-check before tightening the bolts
Drawing the nuts up tight
Setting the prefabed supports at the 8' level to hold the first level of boards. Steve's dad Dick in this photo helping where he could as we went along.
Nailing in place - these hold the 2X10's until bolts are driven through the post
Making sure the top of the support is right on the line at the 8' level
Mike then set each support with 3" nails from the SN70 framing nailer. We used this nailer a lot on the construction of this pergola. Nice to have in our stock of supplies.
Setting the two 2X10's in place on each side of the post and fastening them with nails to hold them in place
The supports have been installed on the post and Chief Mike is ready to drill for a long bolt which will hold the 2X10 to the post. Mike is a terrific guy who has now retired from the Navy and has moved to Wyoming. We will miss him.
The two Chiefs, Mike and Steve, install the bolts at each post - the lower level of the pergola is going in place - note the support brackets I had Steve make to hold the boards in place in addition to the bolts and nails
The first level boards are in - now come the second level which are 2X8's. They will also be bolted in place on the posts. Note the angle brace from the post to the first level timber to add a significant strength to the structure for possible earthquake horizontal movement.
Steve's dad, Dick, doing an important part of the job, that of patching up all the cracks and holes getting the structure ready for painting
The first 2X8 goes up on the outside of the post held in place with a clamp. As soon as the second one is placed on the other side of the post, they are then bolted together and through the post.
The middle set of 2X8's in place on the second level - two smiling Navy Chiefs at work! These guys are great workers!
Mike and Steve placing the extra 2X6 braces between the 2X8 second level boards which are then nailed to the first level 2X10's making the structure very sturdy
A new position for me to supervise from - in the sun out on the lawn. In this photo if you look closely you can see the 2X6 braces we nailed securely from both sides between the second level 2X8's and then nailed to the lower level 2X10's. That secured the second level to the first. We did that everywhere the sets met.
Steve installing a pair of 2X8's on the 2X10 first level boards. These are then tied to the first level with a short piece of 2X6 which goes up between the boards and nails to the first level 2X10 making the whole structure very sturdy
Cutting the notches into the 2x6's that will sit on top of the 2X8's. This was done with a saw and chisels
Mike is sawing the notches and Steve is in the process of placing one of the prepared boards up on the top level. These two guys worked very well together. No wonder our Navy is doing great with guys like this running it.
Neither one of these guys had ever done a job like this, but they sure learned fast.
Third level 2X6's being place where they belong

Here are a few more photos, out of sequence maybe but show the completed pergola at the end as Steve and Michelle used it for serving Thanksgiving dinner the same day we built the thing.

This batch of photos above shows the most important part of the building of the wooden structure of the pergola, the setting of the posts and getting them absolutely plumb so that the entire structure would be square and level.  We had a short piece (3' long) of a 6X6 that the lumber company gave me and Cheryl and I went around a few days before we started the post setting and set this in place on every CB66 column base.  With aluminum shims that Steve provided, we plumbed each base to prepare it for the setting of the 8' posts.  We left the shims in place so that when the guys placed the long posts on the base, the plumbing was pretty much done.

It worked out exactly as we had planned it.  Steve and Mike did not have to do much to get each post set perfectly.  In these photos you can see the guys setting a post, using a level to get it plumb, then drilling the post for the two bolts that went through the post base and through the post itself.  It worked great!  We had no problems.  Then we could build the rest of the pergola without a concern for the squareness of the structure.
I stuck this photo in here to show the first two levels finished and Cheryl and I looking over the job so far before we begin the adding of the top layer of 2X6's.
All that's left at this stage is the addition of the top level of 2X6's then painting and the building of the boxes around the concrete bases.
Steve, up on a ladder looking at the placement of the top level 2X6's, the spacing of these as they are going up.
Putting construction glue in the notches before the board is turned over and pushed down onto the 2X8 holding it in place
Chief Mike, a great guy to work with soon to be retired from the Navy
The other Chief, my son-in-law Steve - a hard worker, ready to turn the 2X6 over to set it down onto the 2X8. Then toe nailing takes place to make sure it is well set.
Chief Mike when we were finished with the job - a real privilege to have worked with him. What a great guy to have around when there is work to do. We then had a great Thanksgiving feast seated around the table for dinner both inside and outside under the new pergola.
With my grandson Dakota out on the patio under the new pergola before the Thanksgiving dinner was set up.
A look at the finished product as the sun starts to set. The next morning a primer coat of paint was applied, and then two coats of a finish will go on. The boxes around the post bases will be painted green to match the trim on the house. The final step will be to tile the concrete floor of the patio.
Shilo and the dogs after dinner had been served and eaten. Decorative boxes are being built to go over each of the concrete post bases. These will hold pots with flowers, etc. to decorate the patio.
Steve and Mike putting in some lag screws in the braces to finish up the work.
Eating under the new patio pergola. In this photo are Steve, Michelle and Dakota along with Dick and Helen Geair, Steve's dad and step-mother. Mike the other Navy Chief is also filling up on the turkey and dressing plus lots of other goodies.
Dick, Steve and Shilo enjoying the warm fire under the brand new pergola at the end of a very long and tough day building this thing. We had Thanksgiving dinner right here as well. Quite a job well done.

Welcome to the second of my family photo albums, this one is the trip we all took to Colorado to help a friend build a back porch on his second home high in the mountains of Colorado.