Barry Builds His Dream Shop

[Bib Overalls]

My friend Barry is a master fabricator/welder/machinist. He is also a marine surveyor and refloats or salvages boats blown about by hurricanes. His forte is building stainless steel tanks for agricultural use. Just about every crop duster in this area has one of his mixing tanks. He also builds custom trailers, fixes busted up agricultural equipment, and changes the wheel base on trucks. To long and he will make it short. To short and he will make it long. You get the idea.

After years of working out of a shop in town he has decided to build one on his family place in the country. Because he is a metal man by trade this will be a welded up metal structure. I have seen the steel beams he will be using for the frame and this is going to be one solid building.

He started with an old equipment shed his father put up 40 years ago. I would have taken it down but Barry has a plan that will incorporate the old shed into the new structure.

Work started, as it always does, with dirt. The addition is about 2,500 square feet and all of it is placed on fill.

Notice the nearly flat shed roof. There is no ridge cap. The panels run from one side to the other with a "buckle" at the top. The old building will be tied into the new structure. I was thinking he would have a flat, wet valley where the new and old join. Barry is to smart for that. You will see his solution a post or two down.


Barry's Shop 01 by Bib Overalls, on Flickr

 

[Bib Overalls]

With the dirt work done it was time for concrete.

 

[Bib Overalls]

And more concrete.

 

[Bib Overalls]

Now for that pesky roof. Since the roof panels are one piece from eave to eave Barry simply raised one side to achieve a level plane that drains to the outside.

 

[Zeke]

I know you're still in the middle of posting but I have to say you tell a great story and 'Barry' has more energy than 10 of me.

 

[Bib Overalls]

And all stitched together with some old fashioned stick welding.

Vertical construction started today. I'll post some pictures of that in a day or two.

 

[Bib Overalls]

I know you're still in the middle of posting but I have to say you tell a great story and 'Barry' has more energy than 10 of me.

Barry is an amazing, self reliant guy. And being a country boy he has access to a lot of equipment that most of us can only dream about. Like a forklift, back hoe, mobile crane, dump truck, and bob cat. And, of course, he has talented friends like Paul, Roger and Howard who can always find a bit of time to help.

 

[Bib Overalls]

Today's mission. Erect the "red iron" frame for the machine shop portion of the project. About 24' x 30' in size and tied in to the existing equipment shed. Lots of cutting, fitting, fabrication, and welding. Having the right tools and equipment makes a big difference.

Barry has been bargain hunting for materials and with his abilities he can make odd sizes work. He also has the truck and trailer needed to haul heavy stuff home. He found some material locally and made a marathon run to Muscogee, OK for a load of red iron and enough exterior sheet metal to close in the entire building.

 

[Bib Overalls]

I was amazed at how much we got done today. Two walls framed and five purlins positioned. If we were stick building or effecting a metal building "package" that would not be much to brag about. But when you are cutting and fitting every piece and tying in to existing work and doing it with salvage steel it makes for a long day. Barry finished up the last weld as the sun was setting.

 

[Bib Overalls]

Work continues. The building will have a high bay and a low bay. The high bay is all new construction. The low bay is the original shop building extended 25' in the back for the machine shop.

The high bay will have a pair of overhead lifts on a trolley beam down the center. To support the weight some rather heavy beams have been used as posts and rafters.

Heavy. But with a crane and fork lift on site the job is doable.


Barry's Shop 056 by Bib Overalls, on Flickr


Barry's Shop 057 by Bib Overalls, on Flickr


Barry's Shop 059 by Bib Overalls, on Flickr


Barry's Shop 062 by Bib Overalls, on Flickr


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Barry's Shop 065 by Bib Overalls, on Flickr

 

[Bib Overalls]

Once the first heavy rafter is set work starts on the purlins and second heavy rafter. In the back, the original shop roof structure is tied into the new work and the redundant (old) corner post is removed.


Barry's Shop 066 by Bib Overalls, on Flickr


Barry's Shop 067 by Bib Overalls, on Flickr


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Barry's Shop 072 by Bib Overalls, on Flickr

 

[Bib Overalls]

With the walls and roof framed it was time to lift the 1,000#(+/-), 40 foot lift trolley track into position and weld it place. The job, from placing the sling to finishing up the initial welds took less than an hour. We were rained out today and it does not look good for tomorrow. Next up is bracing the track, painting and then tying in the rest of the old shop framing to the new work.


Barry's Shop 073 by Bib Overalls, on Flickr


Barry's Shop 075 by Bib Overalls, on Flickr


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Barry's Shop 077 by Bib Overalls, on Flickr

 

[Bib Overalls]

Today we started on the roof. The first section put down is over the machine shop. Essentially and extension of the existing equipment shed. With the roof in place we were able to open up the end of the shed. Looks kind of messy. And it is. Most of what you see is headed to the recyclers. The end result will be 3,750 sq feet of open work space with two posts.


Barry's Shop 080 by Bib Overalls, on Flickr


Barry's Shop 081 by Bib Overalls, on Flickr


Barry's Shop 082 by Bib Overalls, on Flickr


Barry's Shop 083 by Bib Overalls, on Flickr

 

[Bib Overalls]

Work on the walls and roof sheet metal is continuing. The 75' long by 18' high South wall is fully sheeted now and work has started on the high roof. Weather has been a problem with wind and rain closing the site down for a couple of days. We are hoping to be closed in by this weekend.


Barry's Shop 084 by Bib Overalls, on Flickr


Barry's Shop 085 by Bib Overalls, on Flickr


Barry's Shop 086 by Bib Overalls, on Flickr


Barry's Shop 087 by Bib Overalls, on Flickr

 

[Joe13]

Very cool build so far! His talents and resourcefulness are definitely paying off. My only concern, a little more safety gear! I see a lot of missing ear protection, eye protection, shorts with a chop saw! I know you are all older, but please be careful!

 

[Punchwood]

So, as I see it, there's no bolts at all, other than anchors in the floor, and this whole thing is welded solid? If that's correct, I pray that you guys never have an earth quake down there. Where did he come up with his weld sizes? Did he use 7018? Was it from new cans ( unopened ), was a rod oven used? Sorry to be so negative, but this is very scary on many levels.

I'm sure that your friend is a very talented man, but doing something like this with zero engineering involvement is absolutely NOT the way to go about this.

 

[MagKarl]

Awesome build. Barry has my respect, great eye for possibility and repurpose of material.

 

[joe49]

So, as I see it, there's no bolts at all, other than anchors in the floor, and this whole thing is welded solid? If that's correct, I pray that you guys never have an earth quake down there. Where did he come up with his weld sizes? Did he use 7018? Was it from new cans ( unopened ), was a rod oven used? Sorry to be so negative, but this is very scary on many levels.

I'm sure that your friend is a very talented man, but doing something like this with zero engineering involvement is absolutely NOT the way to go about this.

do you have a stamp?

 

[davo727]

Very nice! Im also going to be using some surplus steel in my build.

Funny post above from the new York guy, we don't need engineering plans to get out of bed down here.

 

[Bib Overalls]

Barry overbuilds everything. He has been welding for 30 years and knows how to do it right. All of his welds are made using fresh rods out of sealed containers.

Construction in unincorporated areas of our county do not require permits or inspections. Barry is following usual and customary building practices in our area.

I agree about the safety gear. I just take the pictures.

 

[55chevy]

Thanks for posting this interesting build. It is cool to see a talented man do his thing.

 

[Punchwood]

do you have a stamp?

Yes. I figured that people would argue and say that everything is fine and that no engineering is required. Hey, carry on, no skin off of my hiney. Good luck ever getting it insured or anything covered if something goes wrong.

 

[Biff Lungren]

My first post to say this is Crazy Awesome! Thanks for sharing!!

 

[Biff Lungren]

Dang, killed a thread with my first post? that's a record for me...

 

[Bib Overalls]

No, no it ain't dead.

Over the past couple of days we have been "tinning out" 28' x 75' high bay roof. The last panel was screwed down about 3 pm today. Having the crane on site made a big difference.


Barry's Shop 088 by Bib Overalls, on Flickr


Barry's Shop 089 by Bib Overalls, on Flickr


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Tomorrow a couple of us will finish the knee wall that connects the high and low roofs and take down the old shop wall immediately below.

 

[Bib Overalls]

Sunday work commenced on the knee wall.


Barry's Shop 094 by Bib Overalls, on Flickr

At the same time I started removing the wall between the old shop and the addition.


Barry's Shop 095 by Bib Overalls, on Flickr


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Barry's Shop 097 by Bib Overalls, on Flickr

With that accomplished we finished closing in the front sheet metal and tying it into the old work.


Barry's Shop 098 by Bib Overalls, on Flickr


Barry's Shop 099 by Bib Overalls, on Flickr


Barry's Shop 100 by Bib Overalls, on Flickr

The last panel was screwed of about 7 pm. Where is Daylight Savings Time when you need it?


Barry's Shop 101 by Bib Overalls, on Flickr

Today we finished off the machine shop walls. It will turn cold tomorrow. So Barry will start building the doors for the high bay at his old shop.

 

[Bib Overalls]

After the full court press to get the structure up and closed in Barry took a little time off. Sort of. He had to make a run across the state to get a load of foam insulation for the ceilings in the old equipment shed and the new machine shop. And there were a couple of jobs for good customers that needed to be done as well.

Today we started on the sliding doors for the high bay. There will be two doors; one 4'6" wide and one 10" wide. Both doors will be 16'6" tall and roll on a track imbedded in the concrete apron.

Material is 2" x 3" 11 gauge rectangular steel. The outsides will be covered with the same white material used on the exterior walls. The interior side will be plywood. 3" thick ridged foam will be sandwiched in between. The doors will seal up tight to keep vermin out and heat in during the winter.

We got the small door framed and the metal for the large door cut today. With any luck we should be test fitting tomorrow.


Barry's Shop 104 by Bib Overalls, on Flickr


Barry's Shop 103 by Bib Overalls, on Flickr


Barry's Shop 102 by Bib Overalls, on Flickr

 

[plow]

Subscribed!

 

[Tunajoe]

Sweet!
Is this in Jonesboro?

 

[Bib Overalls]

Actually it is on the ridge above Bono. I am about one mile from the Jonesboro municipal line and he is about five miles out. Right now we are iced in. The paved streets are cleared. The dirt roads are snow over ice.

Friday we went over to the Tennessee side of the river and picked up some industrial machinery Barry bought at a plant closing auction. One LeBond 16" lathe, two mills, chain hoist, air compressor, 25 hp three phase motor, three phase panel with breakers, five lathe chucks and a bunch of other stuff. We are hoping the roads will be clear Tuesday so we can go back and get the 8' power break, the 25' overhead track with power hoist, the stationary grinder, electrical conduit, etc. Barry buys ans sell this kind of equipment all the time. I think he will be keeping the LeBonb lathe and the mill. I'm hoping to work a deal for the very nice Bridgeport he has. We will see.

The project lost some energy over the holiday. Starting to pick up. Barry went to the other side of the state and picked up a load of 3" thick closed foam sheets. These will be used to insulate the ceiling over the machine shop and the ceiling and wall in the old shop. Barry also box plated one of the "C" channel beams that originally just held up one end of the old shed roof. It now carries the machine shop roof. The boxing should double the beam's strength.

Next up; finishing the doors and the insulation. This will be followed by machine spotting. With the machines in place we will start hanging lights,
wiring and running air lines.


Barry's Shop 105 by Bib Overalls, on Flickr


Barry's Shop 106s by Bib Overalls, on Flickr


Barry's Shop 107s by Bib Overalls, on Flickr

 

[Bib Overalls]

We were planning on going back to the auction site yesterday but weather precluded that. Just too much ice and snow. We didn't get the trailer unloaded until today. We have plans to go get the second, and final load, tomorrow.

Here is a look at the haul.


Barry's Shop 108 by Bib Overalls, on Flickr

Berry really likes that welder.


Barry's Shop 109 by Bib Overalls, on Flickr

25 HP three phase motor. Will be used as a rotary converter in the new shop.


Barry's Shop 110 by Bib Overalls, on Flickr

My new Bridgeport. Needs a "Y" axis lead screw assembly. Ya got one for me?


Barry's Shop 111 by Bib Overalls, on Flickr

Three phase electric panel with breakers. For the new shop.


Barry's Shop 112 by Bib Overalls, on Flickr

Five lathe chucks, a steady rest, two face plates, drive dogs, and dead centers.


Barry's Shop 113 by Bib Overalls, on Flickr

Quincy duplex compressor.


Barry's Shop 114 by Bib Overalls, on Flickr

Burr King parts cleaner and polisher with media.

 

[Bib Overalls]

Part 2.

Five tool posts including one Aloris.


Barry's Shop 116 by Bib Overalls, on Flickr

Band saw blade welder.


Barry's Shop 117 by Bib Overalls, on Flickr

1.5 ton chain hoist.


Barry's Shop 118 by Bib Overalls, on Flickr

Miller welder with cart. The cart has a tank for coolant and a boom for a second wire feed. Berry will use this in the new shop to build boats and trailers.


Barry's Shop 119 by Bib Overalls, on Flickr

The Kingston mill comes off. This will be an upgrade for the Pilgrim that he currently uses and plans to sell.


Barry's Shop 120 by Bib Overalls, on Flickr

Barry rigs the 16" LeBlond lathe. This is another replacement for two lathes that he has under power in the old shop.


Barry's Shop 121 by Bib Overalls, on Flickr

Things are not looking good at this point.


Barry's Shop 122 by Bib Overalls, on Flickr

Actually just a little imbalance caused by the off set motor. It landed just fine.


Barry's Shop 123 by Bib Overalls, on Flickr

We used the fork lift to move the lathe inside the shop. The lift was willing but it would not steer without some additional weight out back. I also took the ride.

More when we get back from our run tomorrow.

 

[sunsation288]

Thanks for sharing so many picture , i like to see different kind of build ,please keep the picture coming

 

[Bib Overalls]

Thanks for sharing so many picture , i like to see different kind of build ,please keep the picture coming

Happy to oblige.


Barry's Shop 124 by Bib Overalls, on Flickr

Today we went back to the auction site and picked up the rest of Barry's "winnings."

This is the crown jewel, an 8' hydraulic brake press. Looks a bit scabby but it is all there and runs.


Barry's Shop 125 by Bib Overalls, on Flickr

Loaded up and ready to go. In addition to the press brake we brought back a 25' overhead hoist track, a 1.5 ton electric hoist and trolly, another chain hoist, and trolly, a surface grinder, two heavy duty tables with hydraulic set ups (purchased for materials), a surface grinder, a pallet of flexible plastic conduit, and a surface grinder. A heavy load but no where near the estimated 8 tons we brought home in the first run.

 

[Bib Overalls]

The Thanksgiving holiday, and a week chasing down equipment followed by a week of unseasonable cold weather stalled the project a bit. With good weather breaking through it is time to get back at it.

Today, we started hanging the sliding shop doors.


Barry's Shop 126 by Bib Overalls, on Flickr

The first task was hanging the top track. Yesterday Berry made these brackets out of stainless steel scrap.


Barry's Shop 127 by Bib Overalls, on Flickr

On the left side of the doors the track extends beyond the building.


Barry's Shop 128 by Bib Overalls, on Flickr

The bottom track is a piece of 1"x1"x1/4" angle iron welded in to a 2"x1"x1/4" channel iron. The channel was set in the concrete apron in front of the building. It was leveled using a surveyors transit.


Barry's Shop 129 by Bib Overalls, on Flickr

The top track is a channel bent up from 14 gauge galvanized steel sheet. Guide pads made out of UHMW keep everything in proper alignment.


Barry's Shop 130 by Bib Overalls, on Flickr



The first door up was 4'6" wide and we were able to stand it up with muscle power. Actual placement was made using a forklift.

The second door was 10'6" wide and way to heavy for us. So we used the crane to lift it off the trailer and carried it into position with the forklift. This was a tricky deal. With Barry on the forklift Paul and I pulled the bottom of the door out. We then guided the top into the upper track as Berry lifted. With the door in the top track the bottom was brought forward and the wheels were set on the lower track. Setting both doors took about 20 minutes.


Barry's Shop 131 by Bib Overalls, on Flickr

The door frames are easy to move. Tomorrow they will be insulated and covered with the same metal used on the rest of the building. When all of the trim and seals are in place the doors will seal up tight and be secure.


Barry's Shop 132 by Bib Overalls, on Flickr

 

[crawler07]

The garage is looking great! Cant wait to see how he seals the doors up..

 

[ADSR]

Pretty damn cool shop!

 

[Bib Overalls]

Barry's Shop 133 by Bib Overalls, on Flickr

Every fabrication shop needs a good welding table. If you are lucky, you can find one at a machinery auction. Admittedly, this does not look like a welding table but there is one lurking under all of that tooling on top.


Barry's Shop 134 by Bib Overalls, on Flickr

There is no telling what all of this cost when it was made in 1993. Certainly a lot more than the $90 that Barry paid.


Barry's Shop 135 by Bib Overalls, on Flickr

This Hoffman box is 30" tall, 24" wide and 10" deep. These things are pricy.


Barry's Shop 136 by Bib Overalls, on Flickr

Not to mention the once state of the art electronic controls.


Barry's Shop 137 by Bib Overalls, on Flickr

Just about everything stripped off is on this pallet. Lots of project material. There are two sizable ground plates, a hydraulic cylinder, several large blocks of steel, about $100 worth of grade 8 socket head cap screws, and a three phase to single phase transformer/converter. If you need any of this let me know.


Barry's Shop 138 by Bib Overalls, on Flickr

With everything stripped off it looks like a welding table.


Barry's Shop 139 by Bib Overalls, on Flickr

The top is 4' by 4' square and 1" thick. The surface has been ground flat. There are numerous holes tapped 1/2" x 13 TPI. Perfect for holding down work. All this puppy needs is a little cleaning and rubbing on top and it will be ready to go.

 

[stacerbob]

More

 

[supperfly17]

yes moree pleasee