To avoid these ads, REGISTER NOW!

16x32 Gambrel Barn Workshop

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
I am building a workshop for my father to spend his retirement days in. Dad needed a nice place to go to get away from the house and all the crazy that goes on there. I also needed a place to spend my spare time and keep all my tools organized. My 10x16 shed is chock-a-block full of equipment and tools and the disarray is driving me nuts. I had planned on building a man cave for quite sometime but the old ball and chain would drain our funds and make it impossible to have any money left over for anything extra. I had some choices to make, either live in ******* my whole life, or cut off the leeches with a knife and escape the POW camp RAMBO style.
SO, this now newly single man and his father got together and decided to build a nice place for them to spend their time.

Okay so my plan was to follow the shed building plans that I bought of the internet. Which I must admit, its easy to get scammed these days. I did find a really good plan set with material list and such for several different size sheds. The largest being 16x32 gambrel. My construction background is non existent at this point in my life. I just built a nice 10ft deck for my walmart pool before summer started. It turned out great. With that confidence boost, I figured I could finish this shed very quickly. I ordered all my material from the local yard, a few nail guns from Amazon, and a cement mixer from Lowes.

Here is the rundown on my building specs and materials:
-16' x 32' 2 story gambrel shed
-The foundation with be 3ea treated 4x6 beams sitting on 15ea concrete piers, 5 per 32ft beam
-The floor is 2x8 treated joists with 3/4" treat plywood deck
-7' x 7' double door on one end, no windows at first.
-Double bubble foil radiant barrier all around the walls
-LP smartside reverse batten exterior panels over studs
-Radiant barrier OSB on the roof and shingles on top
-2nd story or Loft floor built with 2x8. should have 7' head clearance

Having never built anything before, I'm terrible at estimating how long my projects will take to complete. I guessed that 2 days was enough to finish this shed, maybe 4. Which would be possible with a few friends.
The fine print:
-I will be building this shed by myself. The ex scared away most of my friends over the course of our marriage, and I haven't built that core group back up yet, and my friends that I still have, have back problems or live too far away.
-So of course that 2 day estimate seems freaking ridiculous. I had 2 weeks off of work to complete it.
-I had all the wood and materials dropped off at the build site by the lumber store. This was my first time getting materials delivered and its much easier than picking through lumber. I just had to accept the fact that a lot of it would be crooked and figure out what a professional would do in that situation.

Enough BS-ing. You came to see the pics of my build, so here you go.


View media item 54224This is where I will build the shed. It's only 50 feet from the service pole which will save money on wire. I measured and marked out where I would set the 15 pier concrete post. Then started post hole digging, always tons of hand blistering fun.


View media item 54225Here we have the crooked 4x6 beams. I thought about calling and getting them replace but there just isn't any good lumber out there anymore and I wasn't about to waste any time sorting through 16ft 4x6 beams. I set out all the blocks and got them level, then set the beams on top.


View media item 54226So by now I am cursing these crooked beams that lean left on one side and left right on the other side. I just made do, and moved on.


View media item 54227Built the Rim joists and started to nail the beams to it.


View media item 54228View media item 54229All of the floor joists are installed, then I leveled the floor based off of the joists. I decided to do it this way because the beams were just atrocious, and there isn't any way to straighten them, not that I would if there were.

It took me 2.5 days to get to this point. I took 2 days off to spend time with the family and rest. I would restart on Monday.


View media item 54230Hey Look!! It rained!! YAYYYYYY!!! :mad::mad:
After some youtube research, I sucked the water out of the pier holes with a shop vac. Then I drove to Lowes and bought a cement mixer, which I had never used in my life. I can give some advice on this, if its rated for 4 bags of cement, only mix 3 at a time. Also, you need to tilt the mixer very slowly when pouring it, because once the weight shifts you can't react fast enough and catch all of the cement in your arms to prevent it from spilling onto the ground. 40 bags of cement later, the holes are filled.
Why did I buy a cement mixer? well I had enough cash to buy a cement mixer OR a wheel barrow. I bought a mixer and a 5 gallon Lowes bucket. Pouring cement in a 5 gallon bucket is very do-able and I actually recommend it you anyone, and after you try it, tell me about it and we can laugh about how that was the worst idea ever. :lol_hitti


View media item 54231Next day, nailing on the plywood floor. I was literally going to do this with a hammer. My friends advised against it and I got a nail gun. Best decision I ever made.


View media item 54232Here you can see my pier post and beam connection. You can't go wrong with Strong ties. And you can never install too many of them. From my extensive research, I knew I needed a continuous load path and I will use hurricane 2.5AZ for all the other connections. Simpson's strongtie catalog is awesome and will show you cool things even a wizard wouldn't know.


View media item 54233Floor is done. That was fun. I'd continue to rhyme but I don't have time.


View media item 54234Lets cut some truss boards. The dewalt Miter saw and the big stand it sits on came in handy. I just cut my first truss board, and set the stops on the stand up for the rest. So no measuring every board. I was able to cut 100 boards in an hour. I AM A MACHINE!!!!!!!


View media item 54235Flash forward to the next day, I forgot to take pics of the complete truss build. I put two boards together on the floor and built a jig. I assembly the 100 boards until I had 50 1/2 trusses. The shiny piece attaching the truss boards is Radiant barrier OSB. I am using this for the roof and could have saved $2 on the 3 sheets I used to mend the truss boards together by buying regular OSB, but I did not think about it at the time.


View media item 54236Here is my pile of 1/2 trusses. Lets put them together and they will give birth to a full size Truss.


View media item 54237Its easy, put the boards in until they **** up.


View media item 54238Then put 8 or 10 or 20 nails into each side. I must admit that using the nail gun is really fun and I like trying to see how fast I can set 8 nails. The greater the speed the lower the accuracy, hence the more nails I used. So, nailing speed is directly proportional to the amount of nails used. Its almost Linear.
 
To avoid these ads, REGISTER NOW!
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
View media item 54239This picture is crooked for your viewing displeasure. So the plans called to build the Gambrel roof ends on the floor and lift them out of the way to build the walls. I've made some poor decisions in my life, but that was a big one. I was going to need help to install this beast on the roof. WTF was I thinking!!! I guess some people aren't born with ignorance, it must be learned.


View media item 54240Now that its out of the way, time to build a wall. I cut all of the wall boards that I needed and set them to the side. I put the sticks down in place and nailed the top and bottom cords. Then I layed the foil insulation down on the studs and taped the seams. Finally I layed the panels down and nailed them. I was able to lift this wall by myself and tack it down.


View media item 54241View media item 54242View media item 54243I must admit, thats a nice looking wall. I learned something about radiant barriers that day, they work well at reflecting radiant sunlight. These 4 walls would toast me like burnt popcorn over the next few days. If only science could come up with some type of cream I could use to protect my skin from UV rays.

All four walls go up, I was too busy to take pics. I ran out of insulation on the last wall. Poor job planning on my part. My calculator must have had a glitch that day, or I screwed up. pick one.


View media item 54244So how am I gonna get this gambrel in place? Family member to the rescue.

View media item 54245 We used a tractor in a very unsafe manner that I have a video of. I am very embarrassed that I didn't have a plan for this part of the construction, but we got it up there and everyone is still above ground.


View media item 54246Starting to install the Trusses. I used all of the left over stud pieces to get the Trusses spaced perfectly 16"oc. Installing these by myself was a lot up and down ladders and cursing because I didn't bring nails up there with me. The trusses weren't too heavy and I was able to set them on top with a little finagling.


View media item 54247The next day, more trusses.


View media item 54248More trusses....


View media item 54249yup. you guessed it. trusses


View media item 54250Done with Trusses. If it looks like the trusses are crooked, its an optical illusion from the camera angle, probably. Maybe. don't judge me. Moving on


View media item 54251This brings us to the final picture. I started installing the roof sheathing and had to call it quits so I could pack my bags for my business flight the next day. i would be gone for 2 weeks and had to leave it in this state with no roof on. Its a little obvious that I exceeded my 2-4 day build estimate. Holy Sh*t!! why didn't someone correct me on that, because now I can see that doing this in two days is not possible when working alone.

From start to finish, it took me 12 days to get to this point. The only help I got was lifting the other three walls and installing the Gambrel end. All in all, my 31 year old body feels 100 years old. My hands and arms are numb, my back is sore, my hands look like I stuck them in a blender, and my energy has left my body without a notion about when it shall return. On the bright side, I feel like I learned a lot and have a new sense of victory by getting this far on my own.

In conclusion, I have been at work for the past 2 weeks and I will be traveling back home tonight, then I have another 2 weeks to complete everything else. I should have the shingles installed in a week, maybe.




"Good judgment comes from experience, and most of that experience comes from bad judgment"


My Build Thread Here http://www.garagejournal.com/forum/showthread.php?p=5208475&posted=1#post5208475
 
Last edited:

dreasoner

Well-known member
Joined
Jul 2, 2015
Messages
177
Location
Indianapolis, IN
Is purple, pink or mauve (not sure which), your favorite color? I was just curious on the colored framing members. That is an impressive project for a solo effort.
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
So my initial cost calculation on this build was $5000. That included everything I needed to black it in. Blacking in the workshop is the first phase of the project.
The second phase includes
-decking the loft floor with 3/4" T&G.
-building full size stairway to loft. I want it to be easily accessed by my dad.
-flashing the doors. There are better ways to trim the doors to prevent water intrusion. I didn't build it that way. I got in a hurry and negligent.
-install batt insulation on walls
-7/16" OSB will be installed on the interior walls. Then painted white or a light color for good light deflection throughout the room.
 

sublime68charger

Well-known member
Joined
Sep 9, 2014
Messages
5,415
Location
SW Wisconsin
nice job so far,

I find for time to get anything done I figure out what I think it should take me,

and then x3 that figure and I might be close to being half done by that point.
it never seems to go as fast as I think it should.
 

Kevin54

MEMBER EMERITUS
Joined
Jan 12, 2005
Messages
29,341
Location
Urbana, Ohio
Is purple, pink or mauve (not sure which), your favorite color? I was just curious on the colored framing members. That is an impressive project for a solo effort.

That's one of those sheds you see in magazines where they show each member of wood a different color :lol:
 

jim whitney

Well-known member
Joined
Sep 30, 2015
Messages
113
Location
Winchendon ma.
Nice job for one man ! It,s not as easy as it sounds when you start actually doing every single part of the labor required. I did a 28x32 gambrel with a second story at age 45 , with 4' foundation .( New England) it took me a year to finish and believe me at the end I had enough! You,ve done a good job and have something to be proud of , knowing you did it all yourself . Now sit back ,have a beer ,and brag to all your friends
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
Nice job for one man ! It,s not as easy as it sounds when you start actually doing every single part of the labor required. I did a 28x32 gambrel with a second story at age 45 , with 4' foundation .( New England) it took me a year to finish and believe me at the end I had enough! You,ve done a good job and have something to be proud of , knowing you did it all yourself . Now sit back ,have a beer ,and brag to all your friends

Thank you Jim. I do plan on setting up a brew station and beer fridge inside somewhere.
 

pipeman

New member
Joined
Sep 21, 2010
Messages
4
If you put batt insulation in the walls it will prevent the radiant barrier from working . It must have at least 3/4" space between it and anything else. unless you are going to air condition the space you don't need batt insulation.
 
To avoid these ads, REGISTER NOW!
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
If you put batt insulation in the walls it will prevent the radiant barrier from working . It must have at least 3/4" space between it and anything else. unless you are going to air condition the space you don't need batt insulation.

I do plan on putting a/c inside. The radiant barrier is kind of loose against the sheathing and somewhat maintains an air space between. I think the air space is required if you are using the radiant barrier as your only insulation. I'm just using it to stop the sun radiation from heating up the interior. I am assuming it is doing the same at the OSB plywood with radiant foil on one side. That has been shown to drop attic temps from 130 to 100.

I rebuilt an engine and transmission for my Volkswagen in a homedepot shed that wasn't insulated and the summer temps got up to 130. The new shed will have air conditioning for sure. It will be my summer heat escape.
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
I got a lot done the last couple of days. Here are the pics.


It seems like 2 days of rain has molded some of the wood ceiling joists. Any idea on what I need to do about that?
View media item 54514View media item 54517View media item 54519View media item 54518


Started to lay some felt down. This is not easy to do by myself. I wanted to cut the pieces into 32 foot lengths and install all at once but with the wind it was impossible. so I cut it into 19 foot strips and overlapped the two pieces 6 feet.
View media item 54515


So I built this little helper to hold up the whole roll of felt. this worked a lot better and I could lay a full 32ft length.
View media item 54537


I left this slot on top for a ridge vent
View media item 54538


Just a pick of the me on the roof
View media item 54539
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
I had some more wood delivered today. T&G flooring for the loft floor, and 2x4s for the other gambrel roof end.
View media item 54516


I started laying down the shingles. I have never installed shingles before but a little research and I was good to go. The package that the shingles came in had really good instructions and pictures. I decided to go with a 6 nail pattern even though I have 7 nails in this one shingle.
View media item 54540
View media item 54541
View media item 54542

The front side is done. the back side will not be easy because the scaffolding does not fit back there. So it was me and a 12 foot ladder.
View media item 54543

Here is my little helper again. Holding up the shingles for me.
View media item 54544

This is as far as I got Friday. I'm taking the weekend off due to a big storm rolling in. I was able to get the peak of the roof closed in with felt paper. I only have two days left to finish the shingles. hopefully I can get it done Monday and Tuesday.
View media item 54545
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
Are you installing any windows or a fan for cooling or air movement ?

My original plan was to insulate the bottom floor and have an air conditioner, probably a window unit. Install 2 windows on the side of the building and a window on each gable end. I would build stairs going to the second floor and block it off with a door.
But I am considering insulating both floors and having a central air conditioning unit to cool everything off. I would use the 1st floor for a wood workshop and the second floor would be an office/man cave/storage.
I'm still not 100% sure what I should do.
 

Motoman1100

Well-known member
Joined
Oct 2, 2014
Messages
443
Location
GA
Excellent job... and by yourself... Wow, a lot of work.

About the mold, I guess I wold just hit it with some diluted bleach and see what happens. Should kill off the mold and that new roof should keep it from coming back.

Good luck with the rest of the build and be safe!
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
Now that everything is blacked in, I am starting to plan the layout of the inside. I decided to put the stairs to the 2nd floor on the north side so I can install windows on the south side towards the driveway.
The stairs needed to be:
1. large enough for my father
2. strong enough for my father
3. safe enough for my father.

He and I are both large people so I made the stairs 4 foot wide. I made stringers out of 2x12's. For the treads I used 2x6 and for the risers I plan on ripping some left over flooring plywood. I used this same setup for a pool deck and it was very strong. I don't like boards flexing under my feet and 5/4 deck boards just don't hold me up.

I marked the outlines of the stairs with chalk lines to get an idea of where I would need to cut the ceiling joists.
View media item 57548
I calculated the stringers here. BlockLayer.com
Great website with construction calculators and its easy to understand.

View media item 57551
View media item 57552
View media item 57553
Then I built a wall across the floor joist and cut the joist above the stairs for headroom.
View media item 57554
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
Installing the electricity. Based on my calculations, 100amp service would be enough for me. I put the breaker under the stairs. It just seemed like the best place.

View media item 57556
View media item 57555
View media item 57558
Removed the meter and was afraid I would get complacent and grab the leads. I taped some cardboard over the hole to make me feel better.
View media item 57564
I had to run the electric wire 90 feet to the shed. I used 3awg wire that I got for really cheap at WireAndCableToGo.com

Damn trench filled up with water. I was able to keep water out of the conduit though so I was happy about that. I dug my trenches more than the required 18in. As you can see, the "licenced electrician" that installed the 1 inch line to the left barely buried the conduit 4 inches below the ground. NEC states 18in. :shocking:
View media item 57565
View media item 57563
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
I was trying to figure out how many shop lights I would need to get the required about of lumens in my new workshop. According to a calculation I found somewhere, I would need at least 87,000 lumens for my 512 sq ft shed.
T-8 bulbs are available with 3000 lumens per bulb. That would require me to get at least 16 fixtures with 2ea 48in bulbs per fixture. The cheapest fixtures alone would cost $320 for 16 of them. Add the bulbs to that. Then I thought about where I would put them. I am already a little less than 8 feet of head room.

I was really interested in the LED versions of the shop lights. These come in right at $35. Way too much cash for me to dish out. I could buy tools with that money.

So I found these lights on amazon. LED Lights LEDMO 5630
They come in 16ft rolls for 10 bucks. The plus side? I would only need to install 13 16ft sections to get my 87,000 lumens. LEDS run cooler and use less juice. If a section goes out, it's only $10 for a new set.

Next is how to power them. They need 12volts to run.
You can purchase a power supply to feed power to them. Its the same size as a laptop charger. But at $10 a pop for a 60w charger, I new I could do better than that. It comes out to 16 cents per watt. Also a few shaky amazon reviews of them burning up cured me of that idea.

I work around a lot of automation and PLC controls so I knew there were cheaper power supplies to be had. Meanwell to the rescue. They make a power supply at every level you can imagine. They also make power supplies just for LEDs. Although, they are more expensive, and to me, 12volts is 12volts and the LEDs don't know any different either.

I went with these at around 12 cents per watt. MeanWell LRS-350-12
It has its own cooling fan and power management protection that is exactly what I was wanting. Pulling around 7 amp at 120volts max, I could put 2 per 20 amp breaker. It may never pull 7 amps but I error of the side of caution. I purchased 4 units which will give me enough space to power 16 light strips 16ft long.

Enough introduction. Here are the pictures.

Mounting the power supplies. Probably just temporary until I come up with a better mounting solution.
View media item 57557
Next idea I had, how will I mount the LED strips to the ceiling. If I put them on the bottom of the ceiling joists, I will hit them with something by accident, a board of plywood. So I needed to find a way to protect them. Aluminum c channel came to mind. But it would take $2000 worth of it. So next idea. What if I routed a channel in the ceiling joists for them to slide into. VOILA!!!!
I walked around Lowes router bit section and saw the 1/2 dovetail bit. It would have worked great. But I went with this instead. Keyhole bit
I just needed to make a jig with some angle iron so my router would pass down the center of the joists.
View media item 57571
Side view
View media item 57572
Here is the final result. It was a tight fit. I would like to try the dove tail bit to see how it would be.
I didn't install a light in every joists, but I think I will go back and do that to make it even brighter.

View media item 57560
View media item 57569
Pulling the lights into the groove
View media item 57570
View media item 57562
View media item 57568
View media item 57567
I don't have any install in the back corner yet so it is still dark back there.

View media item 57573
View media item 57577
After I install the interior walls and paint everything white, it will be much brighter too.



I have more information on my setup if anyone wants it. I can go further into detail on how I wired up the power supplies to the light switches and what size wire I used for the LEDS.

_
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
Cool building. You are packing a lot in a small well laid out space!


Regards,
Jeff

Sent from my bag phone...

Thanks Jeff,
I haven't made drawing plans of how I will setup my space yet. I am hoping for wood storage on the south wall in front of the stairs, a large work table in the center with a table saw, some wood working tools on the north wall, cabinets and work surface below the cabinets also on the north wall. I'll add a pic of a sketch when I make one.
 
OP
G

gnarlyleech

Well-known member
Joined
Oct 20, 2015
Messages
79
Location
Southern Louisiana
Pintrist has some awesome ideas for wood storage that hangs off the wall on hinges. Check it out.


Regards,
Jeff

Sent from my bag phone...

Pinterest is my favorite place for genius ideas like this.
plywoodcart.JPG


and this

FH00SEP_4GARAG_22.JPG


Some combination of the two is what I will likely do.
 
To avoid these ads, REGISTER NOW!
Top Bottom