SaunaLife Ergo-Series E6 Barrel Sauna
Dimensions: 59" D x 81" H
Note: Please read the full manual before construction.
Parts List
Key components and fasteners for assembly include:
- Base Components: Cradle parts (1, A), various staves (2, 3, 6, 6a-d, 10, 10a, 10c, 11), outer bands (B).
- Door Components: Door frame parts (20, 20a-d), door hinges/hardware (22).
- Roof Components: Roof shingles (25), roof trim pieces (N, O).
- Accessories: Vent assemblies (G - upper, F - lower), drain set (W, X, Y, Z).
- Hardware: Various brackets and connectors (DET series), screws (H, I, J, K, M), fasteners for bands (C, D, E), hammer (L).
Detailed dimensions for each part are available in the original diagrams.
Tools Needed
- Measuring tape
- Marker pen
- Circular saw
- Water level
- Hammer
- Ratchet strap
- Silicone gun (for glass-wall models)
- Drill
- Crescent wrench
- Utility knife
- Rubber mallet
- Assistance (referred to as "Extra hands")
Installation Steps
Step 1: Front Wall Base Assembly
Assemble the front wall's circular base structure. Attach components (S, T) to the base cradle (TL1) using screws (J). Part U is fixed diagonally for added rigidity.
Diagram Description: Shows the circular base components of the front wall being assembled with brackets and screws. Part U is depicted being attached diagonally for structural support.
Step 2: Back Wall Assembly and Mounting
Assemble the back wall's base structure using component U (TL1). Attach components (I, T) to the base. Mount the assembled back wall to the main sauna body using internal brackets and screws (H), pre-drilling holes (Ø5/32") first.
Diagram Description: Illustrates the back wall base assembly and its subsequent attachment to the main sauna structure. Includes details on pre-drilling and screw placement.
Step 3: Base Leveling and First Staves
Position the base cradle components (DET A) and ensure the overall base is level and square by checking diagonal measurements. Attach the first set of staves using screws (M).
Diagram Description: Depicts setting up the base cradles, verifying squareness with diagonal lines, and attaching the initial staves with screws and a water level.
Step 4: Securing Staves to Base Cradles
Center stave 2 on cradle 1. Position the cradle assembly (W, Y, Z, X) within the grooves of stave 2. Secure the stave to the base cradles using screws (M).
Diagram Description: Shows the alignment of a stave with the base cradles and its securement with screws. A close-up details the cradle components (W, Y, Z, X) and the "inch=inch" measurement.
Step 5: Adding More Staves
Continue attaching staves to the base structure, ensuring they are vertical and level using a water level.
Diagram Description: Illustrates the barrel sauna structure taking shape as more staves are added and secured with screws (M). A water level is shown to ensure verticality.
Step 6: Temporary Bracing and Band Gap
Drill holes (Ø1/2") through DET 2. Temporarily secure staves using brackets (DET 3) and screws (H). Use a water level. Crucially, leave a ~1/4" gap when tightening screws for outer band (B) adjustment.
Diagram Description: Shows drilling, attaching temporary supports (DET 3) with screws (H), and using a water level. A close-up highlights the importance of the ~1/4" gap for subsequent adjustments.
Step 7: Installing Outer Bands
Remove temporary bracing. Use straps to support boards during installation. Place the outer bands (B) around the barrel on the outer side of the cradle. Ensure the ~1/4" gap is maintained for adjustment.
Diagram Description: Depicts removing temporary supports, using straps for stability, and fitting the outer bands (B) with screws (H). A close-up reiterates the ~1/4" gap requirement.
Step 8: Assembling Roof Sections
Join two stave halves (e.g., 3 and A) to bridge the gap, making them approximately 1/4" wider than the gap. Trim if necessary. Fasten the joined halves with screws (4). Raise slightly before installing the combined roof section.
Diagram Description: Shows joining stave halves, trimming, fastening them together, and then installing the assembled roof section onto the sauna structure.
Step 9: Attaching Bands and Supports
Attach bands (DET B1, DET B) to the barrel structure using screws. Place bands on the outer side of the cradle.
Diagram Description: Illustrates the process of attaching the metal bands (DET B1, DET B) around the barrel, with details on screw placement and approximate measurements (~9 7/16").
Step 10: Installing Vents and Shelves
Remove all temporary braces. Install the upper vent (DET G) and lower vent (DET F) using screws (K). Install the internal benches using parts 10a, 10, and screws (H). Pre-drill holes (Ø5/32"). Note: 72" and 88" models use 4 pcs. of DET 10a.
Diagram Description: Depicts attaching the vent assemblies and the bench components to the sauna interior. Includes pre-drilling instructions and model-specific notes.
Step 11: Bench Assembly and Securing
Install bench components (10c) under the benches and secure them to the main structure using screws (H, M). Pre-drill holes (1/8"). Use a water level for accurate bench placement. Note: 72" & 88" models use four pieces of 10c.
Diagram Description: Shows detailed assembly of the benches, including pre-drilling and securing with screws. A water level is used to ensure the benches are level.
Step 12: Heater Support and Safety Rail Installation
Attach heater support components (DET 15a, 15b, 15c, 15d) using screws (H, J, I). If necessary, trim part 15A to accommodate the heater's size and manufacturer's recommended safety clearance. Mount the sauna heater before installing the safety rail.
Diagram Description: Illustrates attaching wooden supports for the heater and benches. Includes a note about trimming parts for heater clearance and the importance of mounting the heater first.
Step 13: Door Installation
Use a water level. Fasten the door frame components (DET 20, 20a-d) to the sauna wall from the inside using screws (M, J, H). Ensure the door frame is pressed tightly against the wall. Install the door hinges (DET 22). Note front wall thickness (X).
Diagram Description: Shows the step-by-step process of attaching the door frame and the door itself to the sauna opening, emphasizing fastening from the inside and using a water level.
Step 14: Roof Shingles Installation
Refer to the shingles package for detailed installation instructions. Overlap shingles on top. Cut the roof trim piece (DET N) into three equal segments. Cut the other trim piece (DET O) and use the appropriate end.
Diagram Description: Illustrates applying the roof shingles (DET N, DET O) to the curved roof of the barrel sauna, showing overlap and cutting details.
Step 15: Final Securing
Secure the entire structure by attaching the final components (DET 25) with screws (H). Remove any remaining temporary bracing (DET A).
Diagram Description: Shows the final exterior view of the sauna with all components in place, indicating final screw attachments and removal of temporary parts.
