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Jeff's Old Shop to Not so Old Shop

sponaugle

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Dec 13, 2018
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368
Location
Portland, OR
Since I am starting the process of building a new house and shop, I thought I would post up a bit about my current shop. It serves as a template for some of the things I want in my new shop, and it was a fascinating project to renovate.

My current house was purchased in 2011, and at purchase there was an existing ‘shop’ composed of a steel structure with corrugated steel siding, no internal wall structure, and a concrete floor. This shop was built in the mid 50s by the homeowner at that time, and he worked in an area shipyard. I assume that connection made available the material for the shop, as everything in the shop is made of massive quantities of steel.

Here you can see the shop as it was at purchase:

Shop1.jpg


The building is 26'x54', with a small additional room off to the rear side.

The shop included a large hoist attached to the side of the building. You can see the pipe sticking out of the side of the building, and that material is what the entire building is built with. Much of the core structure is 6” steel tube, some with wall thickness of 1/2” or more.

Shop2.jpg

Shop3.jpg


Our first task was the strip off the outside sheathing and expose the internal structure.

Shop4.jpg

Shop5.jpg


You can see how the building is structured, with large steel posts going into the foundation, and lots of steel members connecting the sides and roof.

Shop6.jpg


We removed all of the siding, and discovered all of this siding was coated in an asbestos insulation spray. That required a dedicated ‘hazardous material’ crew to come onsite and remove the material and dispose of it.

Shop7.jpg


The foundation was a combination of concrete walls as well as some ‘steel’ pipe headers. The pipe in this lower part was surprisingly thick. I drilled into those pipes and the walls were 1/2” thick.

Shop8.jpg

Shop9.jpg

Shop15.jpg
 
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sponaugle

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Portland, OR
Next up was the floor. The floor was a concrete floor of unknown thickness, so I originally intended to have it removed. I had someone come out to cut the floor into pieces and start removing it. The concrete itself was in very good shape, but since I didn’t know the thickness and type I was unsure about using it for an automotive lift. When the guys came to cut the floor they started with a 4” deep cut, then a 6”, 8” and 10” before we decided to reevaluate. We did some test drills around the floor and the entire floor was at least 12” thick, and even thicker in some places. That is a lot of concrete for a floor… probably between 50 and 60 yards. While it would have been possible to remove the floor, it was going to take a lot of work. Since the surface condition was pretty good, I decided to keep the floor as is and use a floor cover decking material.

Once the all of the wall surfaces were exposed, we started building a wood structure around the steel one.

Shop10.jpg

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Shop13.jpg


One cool feature was this build in welding table. The top piece is a solid steel piece over 3” thick.

Shop14.jpg


Next up was the roof structure and the roofing material. We decided to do a green metal roof to match the main and guest house.

Shop16.jpg

Shop17.jpg


Once the exterior was finished, we moved to getting the interior ready.

Shop18.jpg

Shop19.jpg

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We added full insulation on all walls including the ceiling, did all new wiring with a new 200amp dedicated feed, welding plugs, alarm system, low voltage wiring for speakers, networking, etc.

The last thing to add was a new floor system. I used the tiles from Bigfloors.com and it turned out great.

Shop22.jpg

Shop23.jpg

Shop24.jpg

Shop25.jpg
 
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sponaugle

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Portland, OR
Once the building was completed and painted, it fit the rest of the property perfectly.

Shop26.jpg


I moved in all of my gear and got to work.

Shop27.jpg

Shop28.jpg

Shop29.jpg

Shop30.jpg

Shop31.jpg


The ‘attic’ space was not configured yet, so after a few months I started on that project. I added a set of stairs to climb into the attic.

Shop32.jpg

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I added sheathing on the floor, and gained another 1400sqft of storage space!

Shop34.jpg

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Last but not least, I added a hoist that ran along the upper beam so I could pull up heavy stuff through a large opening to the space below.

Shop36.jpg


Overall, I am really happy with the space. It is a decent sized space for the property size and location (West Hills or Portland Oregon). The lift has performed perfectly over the last 5 year.
 

JoeMcGov

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Location
Birmingham, Alabama
The quick 5 minute picture summary is great. But SOOOOO much thought, planning and decision making went into that remodel.

Excellent result.
 
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sponaugle

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Portland, OR
Wait...
So after finishing this fantastic shop, you’re moving ...???

Yea, that is what all my friends say! The reason for moving is really a couple of reasons. Our new house will be about 10 minutes closer into Portland and is on the same road we live on, but the new 'lot' is 20 acres compared to 1.5 now. 20 acres inside the city of Portland is pretty rare, especially a lot that can be built on. While the 10 mins is not a huge difference, it is 10 mins closer to my daughters school, and given she is in Kindergarten we have many many more years of that drive.

While planning the new house I was able to make it a similar overall size, and as a bonus it is part of the house itself. It total I'll have more overall space for car (room for 12 cars in total) with 2x 2 post lifts. As well because it is new construction I can do lots of cool home and shop automation, which will be sweet.

I will certainly miss this shop, but I hope whoever buys this house will have years of enjoyment with it.

Jeff
 
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sponaugle

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Portland, OR
The quick 5 minute picture summary is great. But SOOOOO much thought, planning and decision making went into that remodel.
Excellent result.
Thanks!

It did turn out ok, but certainly I was not entirely sure how it would work at the start! It was such an unusual home done structure. There was a 'fence' behind the shop that had the same steel poles buried into concrete, and when I had that removed it was almost unbelievable how much steel was involved. The posts were the same 6" diameter, 1/2" wall thickness pipes, and they were in the ground almost 8 feet. I have no idea why the original builder used so much steel... it must have been free!

Jeff
 
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sponaugle

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Nice transformation. Looking forward to the new one. Why ya moving?

The primary reason is the new land is much much larger (20 acres vs <2), and it is next door to my wife's parents. The building of a new shop was also appealing, just to see what could be improved, etc.

Jeff
 

C.L S2000

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May 3, 2017
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Location
LB, CA
There are some more details about the GTR in my new build thread:

(https://www.garagejournal.com/forum/showpost.php?p=7627986&postcount=154).

In the GTR world it is 'lightly modified', being at 1130whp.

Jeff

All I can say about that is … WOW! :thumbup: that is one beautifully put together vehicle. And having almost full internals, light porting and twin 5757 setup is a bit higher in the Honda guys world rather than being considered "lightly modified" hahaha. I likes alooot. I have a 01 S2000, which is (even in the Honda world) lightly NA modified.
 

Dmoen

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Aug 30, 2013
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maybe i missed it, but did you make the building shorter? first few pictures it look like quite a tall building and the finished phooto doesnt look nearly as tall
 
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sponaugle

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Portland, OR
maybe i missed it, but did you make the building shorter? first few pictures it look like quite a tall building and the finished phooto doesnt look nearly as tall



No, actually a tad taller because the new roof is sitting in top of the metal under structure, but it is also wider because the walls are built outside of the metal, so it looks fatter.


Sent from my iPhone using The Garage Journal mobile app
 

gasgas17

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Nov 7, 2009
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Location
Nova Scotia, Canada
That is a really nice space. What a nice size! One improvement I would suggest on your ladder to the attic , is to add blocking between all the rungs on the 2 rails up the wall. Those rungs are very prone to breaking unless blocked in between or notched into the rails.
 
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sponaugle

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Dec 13, 2018
Messages
368
Location
Portland, OR
That is a really nice space. What a nice size! One improvement I would suggest on your ladder to the attic , is to add blocking between all the rungs on the 2 rails up the wall. Those rungs are very prone to breaking unless blocked in between or notched into the rails.

Good idea. If I don't get it done, I'll pass a note to whoever buys the house as we will be listing this summer.

Jeff
 
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