This step by step diy woodworking project is about a 16×40 lean to pavilion roof plans. This is PART 2 of the large pavilion project, where I show you how to build the lean to roof structure and how to attach the decorative trims. This pavilion is sturdy, but you could increase the slope of the roof to comply with the local building codes. Take a look over the rest of my woodworking plans, if you want to get more building inspiration. Premium Plans for this project available in the SHOP.
When buying the lumber, you should select the planks with great care, making sure they are straight and without any visible flaws (cracks, knots, twists, decay). Investing in cedar or other weather resistant lumber is a good idea, as it will pay off on the long run. Use a spirit level to plumb and align the components, before inserting the galvanized screws, otherwise the project won’t have a symmetrical look. If you have all the materials and tools required for the project, you could get the job done in about a day.
Projects made from these plans
Building a Lean to Roof for a 16×40 Pavilion
- G – 23 pieces of 2×6 lumber – 234″ long RAFTERS
- H – 4 pieces of 3/4″ plywood – 48″x48″ long, 20 pieces – 48″x96″ long, 5 pieces – 42″x96″ long, 1 piece – 42″x48″ long ROOF SHEETS
- I – 8 pieces of 1×8 lumber – 120 ft long, 2 pieces – 91 1/2″ long, 2 pieces – 8 ft TRIMS
- J – 1000 sq ft of tar paper, 1000 sq ft of asphalt shingles ROOFING
- PART 1: 16×40 Lean to Pavilion Plans
- PART 2: 16×40 Lean to Pavilion Roof Plans
How to build a 16×40 picnic shelter roof
Use 2×6 lumber for the rafters. Mark the cut lines to the rafters and then get the job done with a circular saw. Smooth the edges with sandpaper. Make the notches into the rafters, so you can fit them into place tightly.
Fit the rafters to the top of the pavilion, using the information from the diagram. It is important to space the rafters properly (every 24″ on center), otherwise you won’t be able to attach the roofing sheets. Use rafters ties to lock the beams into place.
Use 3/4″ plywood for the roof of the pavilion. Cut the sheets at the right dimensions and then lay them to the top of the pavilion. Leave no gaps between the sheets and then insert 1 5/8″ screws, every 8″ along the rafters, so you can secure them into place tightly
Fit 1×8 trims to the front and back of the pavilion roof. Align the edges with attention and insert 2″ nails to lock them into place tightly.
Fit the 1×8 trims to the sides of the pavilion. Make the angle cuts to the trims before locking them into place with 2″ nails.
Cover the roof with tar paper and then install the asphalt shingles. Make sure you also install the appropriate drip edges, so you can seal the shed roof. Read the manufacturer’s instructions for a tight fit.
Fill the holes with wood putty and let them dry out for a few hours. Smooth the surface with 100-200 grit sandpaper and remove the residues with a damp cloth. Apply a few coats of stain or paint to enhance the look of the pavilion. Make sure you take a look over PART 1 of the project, where I show you how to build the frame of the pavilion.
Fill the holes with wood putty and let them dry out for a few hours. Smooth the surface with 100-220 grit sandpaper and remove the residues with a damp cloth.
Top Tip: Apply a few coats of paint or stain to the components, to enhance the look of the project. Make sure you take a look over the rest of my pergola/gazebo/pavilion plans HERE. See all my free woodworking plans (over 1000) HERE. Premium Plans for this project available in the SHOP.
This woodworking project was about 16×40 outdoor pavilion with lean to roof plans free. If you want to see more outdoor plans, check out the rest of our step by step projects and follow the instructions to obtain a professional result. Feel free to SHARE my plans with your friends.