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The Basics
Most projects only need a few simple guidelines to turn an idea into a solid, well-built structure. The recommendations below are meant to serve as general guidance, since every build, environment, and use-case is a little different. While there will always be exceptions, these tips help the vast majority of customers confidently plan their project. If you don’t see your specific question answered here, feel free to reach out—we’re always happy to help!
Tip # 1 - Sketch it!
This might sound a little old-school, but starting with some grid paper can make a huge difference. Sketch out a simple top-down view of your build and use the grid to play with spacing and overall size. This helps you visualize how everything comes together before you start cutting or buying materials. It also makes it much easier to figure out how much lumber you’ll need, how long each piece should be, and which brackets are required. And if you ever want a second set of eyes, a quick sketch helps us point you in the right direction fast. Once it’s on paper, your build usually starts to click into place.
Tip # 2 - Know Lumber Limits
One of the most common questions we hear is, “How big can I build my pergola?” The short answer: as big as you’d like.
That said, wood does have its limits. As a general guideline, we recommend keeping horizontal timber spans to 12 feet or less unless you add additional vertical support. This helps reduce the chance of wood sagging over time and keeps your structure feeling solid for the long haul.​
The good news is this doesn’t have to limit your design. While our standard pergola, lean-to, and gazebo kits are designed around a 12' × 12' footprint, larger builds are absolutely achievable. By using extender kits, adding sections where available, and mixing in individual brackets, you can scale your structure to match the size, layout, and look you’re going for.
Tip # 3 - Suggested Heights
Our height recommendations vary by structure type. For pergola kits, we suggest a maximum post height of 9 feet. For lean-to shelter kits, the high side should stay at 10 feet or less. For gazebo kits, we recommend vertical posts no taller than 7 feet, even though the overall structure will be taller due to the gabled roof.
These guidelines are mainly about stability—especially in windy areas, where taller structures experience more movement. If you’d like to build taller, you can add stability by using gusset brackets at each corner, adding extra vertical posts or sections, or setting your posts in concrete (we recommend burying them at least 18 inches).
Tip # 4 - Louver Spacing
Louver spacing is largely a matter of personal preference, since it doesn’t significantly impact structural strength—but we do have some recommendations based on look and function. If you’re using our 45-degree louvers and want to maximize shade, we suggest spacing them 4"–6" apart. For a more open, airy feel, spacing them 8"–10" apart works well.
For our top-mount louvers, we recommend a consistent spacing of 8 inches between each louver for a clean, balanced look.
Tip # 5 - Roofing options
When building with a pergola kit, lean-to shelter kit, or DIY gazebo kit, it’s best to plan your roof material early. The type of roof you choose affects how the structure needs to be supported, so a little planning up front goes a long way.
For pergolas, the most common options are shade sails, followed by louvers. Every Bjorn pergola kit includes shade sail brackets at each corner for a simple install, while louvered roofs require louver brackets and additional lumber.
Lean-to and gazebo structures typically use solid roofing such as polycarbonate, steel panels, or corrugated tin. In these cases, we recommend using Bjorn joist hanger brackets with joists spaced 12"–16" apart for proper support.
Shade sails and roofing materials are readily available at most local hardware stores.
Tip # 6 - Where to buy Lumber
One of the most common questions we hear is, “Where’s the best place to buy lumber for my build?” The answer usually depends on what’s available locally, but most builders have a few good options.
Major hardware stores like Home Depot, Lowe’s, and Menards are convenient and allow you to buy everything in one trip, often without pre-ordering. The downside is higher prices, limited selection, and in-store lumber lengths that are commonly capped around 10 feet, which may not work for builds requiring 12-foot timbers.
Local lumber yards are ideal for custom lengths or specific wood species and typically offer the highest quality, but they’re usually more expensive and require pre-orders.
Building supply companies like Builders FirstSource often provide the best balance of price, selection, and availability—including higher-grade lumber—and usually don’t require an account to order.
Still unsure what brackets you need to build your dream structure?
We can help! Submit your sketch to us at support@bjornwoodworks.com or messaging us through our contact us section below.