Almost Heaven Saunas Blue Ridge Installation & Owner's Manual

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Almost Heaven Saunas Blue Ridge Installation & Owner's Manual | Manualzz

Blue Ridge Sauna

Installation &

Owner’s Manual

Revised December, 2012

Read this entire manual through to the end before proceeding with the assembly.


Be sure to immediately check your boxes against your shipping list and bill of lading. Examine for any damage and and notify Almost Heaven Saunas if there needs to be a repair or replacement of damaged or missing materials.


All electrical wiring must be performed by A QUALIFIED LICENSED ELECTRICIAN . Because of the heat involved in the sauna, it is required that you use copper wire with 90ºC insulation. Do not use aluminum wire to make the connection.

Consult with an electrician so you can determine the requirements for your particular situation. All wiring must conform to all national, state and local codes and regulations and according to the instructions provided with the heater.


Your Blue Ridge Sauna is designed for indoor use. Be sure your sauna is installed on a floor that is firm and flat. Installing on carpet is not advised due to both the water that will be used in the sauna as well as the difficulty in assembly on a soft surface. A concrete, tiled or vinyl surface are recommended as ideal surfaces for installation.


You should use two people for the assembly of the Blue Ridge Sauna. The wall and roof sections are large and need two people to lift and hold in place during assembly.


You should have the following tools:

 Cordless drill for driving screws

 Stepladder or stool

 Rubber Mallet

 Claw hammer

 Screwdrivers (Phillips and Flathead)

 Framing Square

 Utility knife

 Level


Wall Support Rails

Connect Wall Support Rails

1. Locate the 4 WALL SUPPORT RAILS

The 4 rails are all identical and will be used to create the wall support. The rails will support the weight of the sauna but will not be attached to the floor or assembled sauna walls.

NOTE: Be sure your surface is flat before you begin assembly.


Connect the corners using a 2” screw through each of the 4 pre-drilled holes on the inside of the rail groove.

NOTE: Be sure that the rails are square and level and that the screw head does not protrude into the groove.

3. Position completed WALL SUPPORT

Place the completed wall support into position.

You will need at least 2’ around each side of the sauna to comfortably complete the assembly.

NOTE: Once finished it is possible but not easy to slide the sauna closer to a wall due to the weight of the finished sauna room.

Completed Wall Support

4. Position WALL SECTION A

Position Wall Section A on the left rear side of the sauna according to the guide on ILLUSTRATION

1 on following page.

NOTE: Wall A should only go as far back in the groove as shown so that the back wall section B can overlap the edge of wall A.

Position Wall Section A












The 8 wall sections, A– H, will be positioned in the grooves of the completed wall support section as shown.

5. Position WALL SECTION B

Position Wall Section B on the left rear of the sauna according to ILLUSTRATION 1.

NOTE: Wall Section B will overlap Wall A.

Position Wall Section B

Attach Wall Sections A and B

6. Attach Wall Section B to Wall Section A

Using 2” screws, connect Wall Section B to Wall

Section A using the pre-drilled holes.

NOTE: Be sure the wall edges and top edges align evenly.


Position Wall Section C

Position Wall Section D

Position Wall Section E

7. Position WALL SECTION C

Position Wall Section C on the right rear side of the sauna according to the guide on ILLUSTRA-


NOTE: Wall Section C will attach to Wall Section B by way of the tongue and groove profile but will not be fastened with screws.

8. Position WALL SECTION D

Position Wall Section D on the right rear side of the sauna according to the guide on ILLUSTRA-

TION 1. Using 2” screws and pre-drilled holes, fasten Wall Section C to Wall Section D.

NOTE: As with step 6, be sure the wall edges and top edges align evenly.

9. Position WALL SECTION E

Position Wall Section E on the front right side of the sauna according to the guide on ILLUSTRA-


NOTE: Wall Section E will attach to Wall Section

D by way of the tongue and groove profile but will not be fastened with screws.

10. Position WALL SECTION F

Position Wall Section F on the right front of the sauna according to the guide on ILLUSTRATION

1. Using 2” screws and pre-drilled holes, fasten

Wall Section F to Wall Section E.

NOTE: As with step 6, be sure the wall edges and top edges align evenly.

Position Wall Section F


Install filler strip to Wall Section F

11. Install FILLER STRIP

Screw the filler strip to Wall Section F to fill the gap between Wall Sections F and H. Optional trim pieces will later be installed over this joint.

NOTE: Due to the inherent variations in lumber dimensions, this gap may not be completely filled by the filler piece. This will be addressed later.

12. Position WALL SECTION G

Position Wall Section G on the left front side of the sauna according to the guide on ILLUSTRA-


NOTE: Wall Section G will not attach to Wall

Section A.

Position Wall Section G


13. Position WALL SECTION H

Position Wall Section H on the front left side of the sauna according to the guide on ILLUSTRA-

TION 1. Using 2” screws and pre-drilled holes, fasten Wall Section H to Wall Section G.

NOTE: Wall Section H will not attach to the filler strip previously attached to Wall Section F.

Position Wall Section H


Find the pre-drilled wall connector. Place the wall connector on the top of the front wall edge, bridging walls H, the filler strip, and wall F.

Screw it into place with 2” screws.

Attach wall connector



Assemble 4 roof support rails in the same way you assembled the wall support rails in step 2.

NOTE: Be sure that the rails are square and level and that the screw head does not protrude into the groove.

Completed Roof Support

16. Attach ROOF SUPPORT over walls

Position the completed Roof Support over the wall sections. Once in place on all 4 sides, use 2” screws to attach Roof Support to wall sections.

NOTE: Tap the Roof Support firmly in place with a rubber mallet so wall sections are fully inserted into the groove before screwing into place.

Attach Roof Support over walls

17. Position ROOF SECTIONS

Place two Roof Sections on top of Roof Support, nesting the tongue of one section into the groove of the other. Measure around perimeter before fastening to be sure distance from edge is equal.

NOTE: Finished side of Roof Sections are to face the interior of the sauna.

Position Roof Sections

Fasten Roof Sections to Roof Support


Using 2-1/2” screws, fasten Roof Sections to Roof

Support using pre-drilled holes.

NOTE: Be sure to keep even distance from edge of Roof Section edges and Roof Support edges around perimeter of sauna as measured in step 17.


19. Attach ROOF TRIM

Find the package of 4 Roof Trim pieces and attach to the raw edge of the Roof Sections with 1-1/2” screws or finish nails.

NOTE: The trim pieces are not pre-drilled. You may install using screws or finish nails, whichever style you prefer.

Attach Roof Trim pieces

20. Attach EDGE TRIM - Optional*

You can cover the corners of the sauna with Edge

Trim. There are 4 pieces: 4-narrow and 4-wide.

Attach with 1-1/2” screws or finish nails, using one narrow and one wide piece for each corner.

Attach the narrow piece first and then overlap with the wide piece.

Attach Edge Trim: OPTIONAL

21. Attach WALL TRIM - Optional*

There are 6 pieces of wall trim. These can be used to cover the interior and exterior wall joints between Wall Sections D and E, Wall Sections H and F, and Wall Sections A and G. Attach with 1-

1/2” screws or finish nails.

Attach Wall Trim

* The use of the Edge Trim and Wall Trim is optional and will not adversely affect the structure or performance of the sauna if not used. Some people prefer the exposed countersunk screw heads on the edge corners and would rather not have the additional trim. This is completely discretionary and should be based on your aesthetic tastes. The Wall Trim may be desired if there is a slight gap between the walls, which can be caused by expansion and contraction of the lumber. Again, it is your choice and will not affect the performance of the sauna. If you choose not to use the trim we suggest you keep it stored in case you decide you want to use it at a later date. Also, we have provided 1-1/2” screws or finish nails. You can use whichever best suits your tastes!



Using 2” screws, attach the Top Bench Supports into Wall Sections A and D using the pre-drilled holes in both the Bench Supports and Wall Sections.

Attach Top Bench Supports

Attach Top Bench

23. Attach TOP BENCH

Using 2” screws, attach the Top Bench to the To

Bench Supports using the pre-drilled holes in the

Top Bench.

NOTE: The Top Bench is slightly wider than the

Bottom Bench.


Using 2” screws, attach the Bottom Bench Supports into Wall Sections using the pre-drilled holes in both the Bench Supports and Wall Sections.

Attach Bottom Bench Supports

Attach Bottom Bench


Using 2” screws, attach the Bottom Bench to the

Bottom Bench Supports using the pre-drilled holes in the Bottom Bench.

NOTE: The Bottom Bench will overlap two wall sections on each side of the sauna.


26. Attach Washer to VENT COVER

Put a 2” screw through the hole of the vent cover and then place the washer over the screw as shown.

Attach Washer to Vent Cover

27. Attach VENT COVER

Screw the Vent Cover over the vents on Wall Section B using the pre-drilled hole.

NOTE: Tighten only enough so vent cover will turn freely over vents.

Attach Vent Cover

Attach Door Handles


The door handle assembly will consist of the following components: 2-Door handles, 1- Male machine screw, 1-Female machine screw, 2-Square

Wooden Spacers, and 2-Round Wooden Spacers.

Locate the single hole in the glass door. Push one machine screw through one of the pre-drilled handles, through a round wooden spacer, through the glass, and into the other machine screw, which has already been pushed through the other door handle and another round wooden spacer. Tighten the screws to a point where the handle is secure on the door, but still rotates freely. With a level, position each of the handles so that they are horizontal and then screw the end of the handles into the hinge board that is attached to the glass door with the wood screws. Now tighten the long machine screws. TAKE CARE THAT YOU DO NOT



Heater Fence Assembly

29. Assembly HEATER FENCE

The Heater Fence consists of four precut, vertically notched posts and six horizontal rails that must be assembled before it is installed to the wall adjacent to the heater.

The vertical fence posts have slots cut into them for the rails. The two vertical fence posts that go against the wall have slots on just one face, as well as counter-bored screw holes for attaching them to the sauna wall.

The two fence posts that sit away from the wall will have slots cut into two of their faces.

Note the beveled ends on the fence rails that go into the corner posts. The ends of the rails that go into the fence posts that attach to the wall are square. Assemble the fence before attaching it to the wall by placing the rails into the slots in the posts and using the supplied 1” nails as shown.

You may want to put a small amount of wood glue into the slots. Be sure to nail at an angle so that the points will not go through the post. Countersink all nails. Once the fence is assembled, attach it to the wall behind the heater using the supplied wood screws.


Mount the heater as shown in the manufacturer's instructions. The heater should be mounted on Wall Section E, over the vents and 6” from the floor of the sauna.

All the necessary hardware is supplied with the heater.

Drill a hole below and behind the heater to run the wire and/or conduit according to local electrical codes. The heater will be hard-wired according the specific wiring requirements for your heater.

Heater Installation

Do not attempt to wire the heater yourself. Contact a licensed electrician in accordance with your local electrical codes. Heater brand may vary depending on where the sauna was purchased. Install sauna stones in accordance with heater manufacturer instructions.

Typical wiring requirements for up to 30 feet distance from the breaker box are as follows:

4.5kw-6.0kw heaters require 10-2 w/ground, copper only wire, and 30amp non-GFCI breaker.

8.0kw and 9.0kw heaters require 8-2 w/ground, copper wire only, and 40amp non-GFCI breaker.


Attach Light Fixture


Have a licensed electrician mount and wire the light fixture (on a separate circuit) into the electrical box mounted in the sauna’s back wall.

Do not install your light switch inside the sauna.

Rather, install the switch inline outside of the sauna. If a switch is desired inside the sauna, then it is recommended that you order the special light upgrade from Almost Heaven Saunas that has an integral switch. A standard incandescent bulb will be sufficient, but the heat of the sauna will shorten the life of a normal bulb. An appliance bulb, such as those used in a kitchen oven, will last longer than a standard bulb. Most people prefer subtle, low wattage lighting in the sauna. Do not exceed the wattage recommended by the light’s manufacturer. Do not use compact florescent blubs (also known as CFL bulbs), as the heat of the sauna exceeds the temperatures recommended by florescent bulb manufacturers.

Heater Installation

Floor Sections

32. Duckboard FLOOR SECTIONS

There are 4 floor sections that can be placed in the sauna. These will lay directly on the concrete, tile or vinyl floor that your sauna rests on.

The floor sections will sit loose for ease of removal. Position them so that any gap between the floor section and wall will be hidden on the back wall and below the benches.


Adjust tension with hex wrench


The tension on the sauna door hinges needs to be set in order for the door to close on its own. Look for the small hinge box that is included with your sauna kit. The hinges have been installed on the sauna, but the box contains both the hex wrench and set pins needed to adjust your door tension.

After the sauna is assembled, and with the door closed, take the hex wrench and insert it in the top of the hinge. Once the wrench is fitted into the hex opening, turn the hex wrench clockwise

(toward the wood wall and away from the glass) to tighten the hinge tension. You will feel the tension as you tighten. While leaving the hex wrench inserted and the tension held in place, insert the set pin into the hinge as shown. Repeat the process with the other hinge as each hinge must be tightened to the same degrees of tension.

The door should close gently on its own without slamming shut. If it does not, then repeat the process to each hinge to increase the tension further.

Save the hex wrench for future adjustment.

Insert pin and relax tension to hold



Western Canadian Red Cedar is naturally resistant to the elements and will retain its natural color when not in direct sunlight. If you wish to stain your sauna, your local paint store can recommend a stain for Red Cedar. A stain with a UV inhibitor will retain the full natural color of the cedar and is recommended if the sauna will be exposed to sunlight, say, when located by a window or slider door. Be sure to follow the directions from the stain manufacturer for application instructions. Never treat the inside of the sauna, and never use varnish or paint on the exterior of the sauna.


After the sauna has been installed, sweep down the inside to remove any sawdust and wood shavings, and then vacuum completely. Using a damp cloth and warm water, wipe down the entire sauna including the benches to remove any remaining dirt, dust and debris. Rinse off the sauna rocks and install them in or on the heater in accordance with the heater manufacturer’s instructions. Improper placement of heater rocks can result in lower than desired heat temperatures. The first time you turn the heater on, set it to the maximum setting and operate it for about 30 minutes with the door propped open. Then close the door and allow your sauna to come up to the desired temperature.

Since you most likely will use your sauna as both a "wet sauna" and a "dry sauna", you should install the sauna rocks that have been included with the heater, following the manufacturers instructions. These stones are necessary if water will be sprinkled on the heater to create the

"wet sauna", and they will produce more consistent heating in the dry mode (without the use of water). It is common for a stone to occasionally crack during initial heating. If excess amounts of water are used during sauna, prop door open to let the humidity escape. Not much water is necessary to achieve a “wet sauna”.

The amount of ventilation in the sauna can be adjusted by means of the vent located toward the top of the sauna. It is important to have adequate fresh air flowing through the sauna, and this flow can be adjusted with the movable vent cover.



 Mount the thermometer on the opposite wall as the heater and 6" from the top of the ceiling.

 A wooden bucket and ladle are provided for you to sprinkle water over the hot sauna rocks.

 Optional accessory kit available.

Mailing Address

P.O. Box 190

Macatawa, MI 49434

Almost Heaven Saunas, LLC

Shipping Address

HC66, Box 465-A

Highway 219 North

Renick, WV 24966

Sales 888-355-3050

Service 304-497.3991

Email [email protected]



The sauna as we know it comes from Finland. Taking a sauna bath induces excessive perspiration, which cleanses the skin. It stimulates circulation and reduces muscular tension. It can also be an excellent relaxational or social activity.

Not to be confused with a steam bath, a sauna is a dry heat bath. The relative humidity rarely exceeds 30% even in a wet sauna. This is because the sauna is made of porous wood and absorbs moisture. This makes higher temperatures more tolerable.

Shown below are the steps that are involved in taking a traditional bath. You may or may not want to adhere to this regimen.


STEP #1 - Set your heater so that the sauna room achieves the desired temperature, usually between 150º F and

170º F. As a novice, you should begin at the lower end of this range and work your way up to the higher temperatures over several sauna baths.

STEP #2 - Remove all clothing (except maybe your swimsuit), eyeglasses, contact lenses, jewelry, etc. Take a quick shower with warm water and soap, or a quick dip in your hot tub.

STEP #3 - Enter the sauna initially for about 5 to 15 minutes. Bring a towel into the sauna onto which you can sit or lay. Leave the sauna room once you have begun to perspire freely.

STEP #4 - Now you may take a cold plunge in your swimming pool, shower or snow bank. After that, relax and cool down for another 10 to 20 minutes.

STEP #5 - Re-enter the sauna. On this return visit you may wish to sprinkle small amounts of water onto the rocks creating bursts of steam. If the water spills through the heater and onto the floor, you are using too much, although this will not hurt the heater or the sauna.

STEP #6 - After your final visit to the sauna, relax for at least 20 minutes. Shower with soap and warm water.

Finish your shower with cooler water to close the pores of your skin. Dress only after you have cooled down completely.

NOTE: Whatever your sauna regimen, it is important that you keep your self hydrated by drinking plenty of water!



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