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Above 1200 Sq/FT 1898 Ohio Post and Beam Barn rebuild - 6784

Wokspaces above 1200 squarefeet.

STINEY

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Joined
Jan 23, 2009
Messages
279
Location
Bucyrus Ohio
Several guys have asked if I had a thread on my 1898 Barn that I am turning into a shop complete with parts storage, kids hangout area, and wife's storage area (all in haymows)

I will be adding to this as I gather old pictures, so it may not be all in correct order timewise, but here is the largest chunk.


Front before. New gutters/downspouts were done a couple of weeks before.

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Front with roof painted.

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Front view with one side done.

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A view from the other end.

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Roof painted. The old boarded-over sliding door is also being blocked up here, making the foundation all one height. I don't need or want that door as there is already one like it on the opposite side facing the driveway. The blocks are filled, and prior to that, re-bar was drilled into the concrete threshold. Its essentially a solid foundation wall now.

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End wall of the "Straw-shed" part of the barn. This end had lots of openings to allow for filling all the way to the top with straw or hay.



Inside of same wall. That weird large truss in the haymow will soon be history too, it was apparently built to allow the ground level to be free-spanned, but was pushing the end wall to bow out from the load with no bottom chord. Bad design, but interesting idea. We added posts back in at ground level after jacking the beams up 4". The weird truss thing has been removed - maybe room for a basketball court in the near future?

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You can see one of the new posts in this picture, and some of the cabling I had added to temporarily pull the wall back in with come-alongs. Worked well as a temporary fix, moved the wall back in over 6" that way. It had moved enough to start dropping floor joists, that's when I noticed the problem.

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Lots better.

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Other side.

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New door has a "rubrail" so it does not ding the siding up when opening it. (That's the white horizontal piece)

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Inside of sliding door. Someday when I pour concrete back here I can bring it right up to the new door and have a nearly weather-tight seal.

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Three openings are all framed up for overhead doors as well.



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Stuck up sections of the old doors, they stopped some of the weather until the overhead doors showed up a couple days later.

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Lots of progress on the front.

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Finished end wall of hay shed back section of barn.

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Nearly finished other end wall. Some trim and soffits left.

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The small single overhead opening is all framed now. Finish siding and some more trim, then doors. The small opening we reverse calculated in order to get the door & track as close as possible to the overhead beams, then measure downwards in order to raise the threshold as far as possible for drainage. This is as good as it gets, I had planned on a small retaining wall and 2 levels on the front, now I know exactly where they have to go.

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All trimmed up.

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Front is done. Just waiting for doors now, those are the old sliders just screwed to the inside to block the opening temporarily.

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Finished! (Is there ever really such a thing as finished?)

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Need to dig out and pour a threshhold here. I intentionally waited until the door was in (we crammed it UP as far as possible, let the bottom fall where it will as long as it is UP as close to the ceiling beams as it can go). Am planning on a 10' apron in front as well. Will have to get creative where the ioutside elevations change from the big doors to the smaller one.

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STINEY

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Joined
Jan 23, 2009
Messages
279
Location
Bucyrus Ohio
Re: The Barn Shop

This concrete was poured with a "bump" intentionally, in order to give support to the sliding doors against the winds.

I have 3 of these.

Overhead doors will be going in soon......these bumps need to be flat.

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Asked the local rental gal if they had anything for this job, she instantly said "scarifier".

Here it is. Unloaded it with the engine hoist, thing weighs about #350.

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And the business end of it.

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Took from 6:30 to 9:45 to do all three, had to dodge a wind/rain storm and hail flying into the shop.
Worked pretty well, it self-levels the area as it rolls on 4 wheels that set the grinding height. Crank it till it just kisses the surface of the flat part of the floor that you want the high spots to be flush with, then move it around on the high spot until you hear no more kissing. That is the short version, and the quiet one.

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Bye-bye bumps! Total cost was $58.13 for a 1.2 day rental.

The rental people have a diamond polisher I might use later to give it a nicer surface, but this got the floor all ready for the overhead door guys to do their thing.
 
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STINEY

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Jan 23, 2009
Messages
279
Location
Bucyrus Ohio
Re: The Barn Shop

If you look close at these pictures, you can see that one of the "bays" has nothing to attach a ceiling to.

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I have a cure for that.

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One step closer to an insulated ceiling.
 

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STINEY

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Bucyrus Ohio
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STINEY

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279
Location
Bucyrus Ohio
Re: The Barn Shop

Some drainage tile work I did to stop the downspouts from dumping on the surface, and giving them access to the field tile.

The front.

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And the rear.

This actually picks up the downspouts from all 3 barns.

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Don't mind the pile of rubble. At the same time we did a lot of work on the house, removed 2 chimneys and lowered the basement floor 2', the old cement floor and steps joined the chimneys in this pile until repurposed as clean fill to help contour for drainage.

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STINEY

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Jan 23, 2009
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279
Location
Bucyrus Ohio
Re: The Barn Shop

I put in a new 200 amp electrical service to replace the old 60 amp the house came with.

Since everything was going to be changed anyways, I took the meter off the side of the house and put it on a pole in the yard across the driveway.

And ran from a combination panel separate feeds to the house and barn.

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Passed inspection with flying colors. The inspectors were very professional and helpful.

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nsula_country

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May 23, 2013
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1,534
Location
Northwestern Louisiana
All I can say is WOW! What a transformation.

Any new updates on this?

When I was designing our shop, I used the red/white color scheme to resemble an "Old Red Barn."

CT
 
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STINEY

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Jan 23, 2009
Messages
279
Location
Bucyrus Ohio
Thanks.

Have been planning and saving for a new roof. The one on there is solid, but has lots of tiny leaks. I've been trying to chase them down and fix them, but that is easier said than done, lol. They are rather elusive little buggers.

A friend recently finished his truck and I snapped a picture with the barn.

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LXCam

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Apr 23, 2013
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Location
AZ
That's a hell of a job you've done so far, looks great! What did you do with all the old siding, I hope you kept it?
 

Adk Mike

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Jan 13, 2014
Messages
331
Location
upstate NY
Those types of barns are called drive through hay barns. They drove the team of horses in and unloaded the loose hay off the wagon. where I live they have been torn down or fell down. They are often built from American Chestnut. Those trees died off in the early 1900's
You did a great job and a great save. Nice !!
 
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STINEY

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Messages
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Bucyrus Ohio
That's a hell of a job you've done so far, looks great! What did you do with all the old siding, I hope you kept it?

Thanks. The old siding is still there, the metal went on over it after some minor surface leveling work.

From the inside its hard to tell there is metal siding on it. Overhead doors are the only real giveaway.
 
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STINEY

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Messages
279
Location
Bucyrus Ohio
Those types of barns are called drive through hay barns. They drove the team of horses in and unloaded the loose hay off the wagon. where I live they have been torn down or fell down. They are often built from American Chestnut. Those trees died off in the early 1900's
You did a great job and a great save. Nice !!

Bingo :thumbup: You know your barns. I still have the hay track/trolley and hook. In cleaning the haymows out it was like an archaeological dig....small square bales, loose hay, SMALL ROUND BALES, more loose hay. Intermingled with several old beer bottles and cans. Ever see a STEEL budweiser can? Lots of Bohemian Beer bottles - must have been real good or real cheap?
 

madoc1

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Dec 11, 2012
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Location
spicewood, tx
wow, 119 years old and still standing straight! except for that truss mess up they sure knew how to build a barn. does it have a concrete all the way around? nice job on the outside. anymore pics of the drive thru hay attachment? nice work.:beer:

jim
 
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STINEY

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Bucyrus Ohio
Thanks madoc1.

The foundation is a patchwork. The rear straw shed has a good stem wall on a footer below frost level.

Now the front main barn.....on the north (left) wall it has a mortared stone foundation that is somewhat below frost level. It was leaning out very badly when we bought the place, the barn was jacked off the leaning stone foundation, and the foundation was rebuilt under before setting the barn back down on it.

The front had the vertical bents (main upright beams) sitting on large horizontal beams, which were sitting on large rocks approximately 3'-4' in size. The old wooden floor had been removed (likely it collapsed from a tractors' weight as mechanization hit rural America in the 30's -40's, these wooden floors were designed for horses and wagons) and the "floor" recreated with dirt hauled in.

Naturally the dirt against the horizontal beams caused them to rot, and the front of the barn had sagged downwards 14" in the center 3 bents. With the help of a few I-beams and a couple of 20-ton bottle jacks I was able to dig out directly underneath the vertical beams (all the way to undisturbed soil), pour a concrete footer pad and block up with solid concrete blocks to meet the non-rotted part of the horizontal beam. Then sit the beam back down.

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Removing the old fill and getting back to undisturbed soil.

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Did the above routine to 12 beams on this barn alone. So part of the new "foundation" is beams-on-blocks-on-footer. I dug the rest of the "fill-dirt floor" out and filled with compacted gravel and 6" of concrete. The floor is independent of the support system though.

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The south side was good and I didn't need to do anything other than repoint in a few places. Of course, it had the milking parlor in it, and its likely that foundation was redone in the 40's with the advent of the new-at-that-time milk inspection requirements. To be able to sell a certain grade of milk commercially there were new sanitary requirements needed to pass inspection, such as concrete floor, solid ceiling, painted walls and ceiling, etc. So its quite likely it went through an extreme make-over at that time.

Neat footnote. I work at a local CaseIH dealership, and our semi-driver used to run a milk route in the 60's. Part of his route included our house, and he lifted many a steel milk can from that concrete chilling tank to the left of the man-door of the barn.

We cleaned the junk out of it, filled with topsoil and raise strawberries in it now.

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STINEY

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What is the estimated ground floor sq/ft? Looks like 5000+

CT

The front part of the barn is 52x32 = 1664

The back straw shed is 48x36 = 1728

So according to the county tax records its 3392 total. On the ground level. So I suppose doubling that space isn't being unrealistic, since there are haymows above the entire floor area.

Did I mention that taxes on an original barn of this vintage are basically nill? While it may not make sense at first glance to pour money into an obsolete structure, especially when building new would save a few dollars, the tax savings over time more than make up for the difference.
 
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STINEY

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This old homestead is kind of unique in our area as it has twin barns and a baby. Someday we would like to give the other big barn the same siding treatment. Its all jacked up and foundation reworked for now though, that's a good start.

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Farmall450

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Marengo, Illinois
That looks great, it's nice to see these barns being saved. Unfortunately by me they were all dairy barns with low ceilings so mostly useless in today's world.
 
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STINEY

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I use the milking parlor area as a workshop for the drillpress, table saw, large workbench with vise. The ceiling is only about 7.5' so its limited, but works nice for smaller stuff.

The other areas work great for stuff like this.

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And I'm in seventh heaven having a concrete floor of my own to work on. Too many years of shadetree wrenching.

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STINEY

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Moved some snow off the drive in front of the barn, pushed it back to make plenty of room for the next round.

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Been enjoying working on various projects. Its amazing how much nicer it is inside without all the gaps in the old siding letting the wind blow right through the building, lol.

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STINEY

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Thank you. It has been a lot of work....have a lot of ideas on more I would like to do.

New roof and more concrete in the back half are on the front burner.
 

jhark123

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Any chance you could re post some pictures? I’d love to see them.


Sent from my iPhone using Tapatalk
 
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STINEY

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I believe I have found a cure for the PB blues.

You guys let me know if you still cannot see any of the pictures, ok?


Some of them have become duplicated. My fault from too much moving and shuffling, lol.
 
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STINEY

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Bucyrus Ohio
I have been wanting to pour a threshold under the overhead door in this section, mostly to keep the groundhogs from coming in and trying to burrow under my main concrete floor.

The opportunity presented itself recently.

Empty room, jackhammer out old concrete livestock waterer base, mark for concrete depth and compact 411 floor.


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First couple wheelbarrow loads. Truck chute could have reached the back, but my guys are so good that they prefer to use wheelbarrows. Their reason is it is not as sloppy and they can place it more accurately with less water.




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Halfway there from the other end of the room.

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I love my dog, God bless her simple soul. Son came out later in the evening to use the drill and dog came with him. He never even thought of the concrete, and the dog had been curious all day, though confined to prevent incidents. Oh well, they are light depressions, not nearly as deep as they look in this picture.


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And time to fill it back up.


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Guess that ended up as more than a simple threshhold. Ah well, a little overkill never hurt anything.
 
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PatrickM

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Portland, Oregon
I love the barn, the Jeep, the VW Beetle, VW buggies(Manx-es), the dog and the property. I grew up just outside of Youngstown. The only thing missing from this Taj Mahal is a Mail Pouch sign on the side. Kudos for bringing that old barn back to the living.

-Patrick
 
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STINEY

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Bucyrus Ohio
Thanks guys. Its nice to know others are into these old barns, it helps put more motivation into the work they take.


The lower part of the rear straw shed part of the barn had turned into a "catch-all" for the other work around the place. Really a cluttered up mess with a damp floor. Time for that to change.

Emptied it out, made the yard look like a junkyard.

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Halfway there.


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jollygreengiant

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Ontario, Canada
Thanks guys. Its nice to know others are into these old barns, it helps put more motivation into the work they take.


The lower part of the rear straw shed part of the barn had turned into a "catch-all" for the other work around the place. Really a cluttered up mess with a damp floor. Time for that to change.

Emptied it out, made the yard look like a junkyard.

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Halfway there.

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Was there supposed to be pics with this post?
 
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