Construction - electrical run through channels routed on top of beams, then covered with aluminum c-channel (available at Home Depot and Lowes) then caulked with Solar Seal (don't use any of the caulks at Home Depot - they crack after 2 years). GFCI. Indoor switch to turn off all electricity to pergola.
Construction - inner beams. 4"x10" (3 1/8" x 9" actual after processing through planer and jointer), up to 20' long. Notched 3", and resting on beams that were each notched about 3/4". Hoisted in place using Genie lift.
Outdoor-rated fan. Mounted a stainless circular metal plate between fan bracket and beam so the fan's canopy wouldn't get water in it. Note to self: next time route the remote-control antenna OUTSIDE the box and seal with caulk, because remote doesn't work well inside an all-metal enclosure.
Construction - cutting final radius. Note the radius guide clamped to center beam behind fan. A long piece of lumber was attached to a thin piece of peg board to which a large-blade circular saw was mounted. Saw had to cut through the vertically oriented 2x4's.
Construction - curves cut using router with circle guide. Beams 3 1/4" thick. Routed taking multiple passes using a long 1/2" dia straight router bit (under $30 from Lowe's). Required choking down on the router bit shank. The DeWalt router did not have 3 1/2" of travel, so started the cut with the router motor set higher in its base, enough for the bit to clear the top of the material. After 8 passes, the motor was set fully down in the router base, and the remainder of the passes were…