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30 x 38 Full Circle Garage

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glentre

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May 21, 2016
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Gloucester, Virginia
Finished painting the walls. The top portion is a very light gray while the lower is a darker shade of gray with a slight blue tinge to it. I have samples of red vinyl stripe material coming in the mail and hope to order a roll by the end of the week. It should make a good contrast between the two gray colors. The unpainted area on the left rear wall is where my 7 ft high cabinets will be mounted to the wall.

My Rust Bullet shipment arrived but I am reluctant to start the floor because we still need a final electric inspection and the final inspection from the building department. Not knowing exactly when they will be showing up makes working on the floor before they are finished kind of iffy. Not that they will object to my working on the floor but I can't let anyone on the floor while the coating is being applied or before it has cured properly. Not cool to tell an inspector to come back another time because he can't walk on the floor.

I have released the cabinet order to the custom shop and they are saying they may be able to finish it by the end of this week if the laminate is in stock at their supplier. If not, it will be sometime next week. If the inspections drag on, I may end up picking up the cabinet parts and assembling them on the raw concrete floor and holding off on coating the floor until the cabinets are assembled and hung.

Glen
 

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glentre

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The electric inspector came this morning and approved the building after the required changes were made. The GC sent someone to bury the rear downspout drain pipe which could not be done until the power from the transformer was run. The power is about three ft underground while the downspout crosses over it and is only several inches below grade. To my knowledge, this is the last thing that had to be done for our final inspection which should be tomorrow or the next day. We are unsure about the heat pump, however. The GC was required to file for a HVAC permit but we are unsure if the unit needs to be inspected or not. It is nothing more than an overgrown window unit with no refrigerant piping or ductwork so I don't know why a self contained factory piece of equipment would need to be inspected. Busy work for county employees and fees to run the local government perhaps.

Still a lot of work to be done on my part before we can get any cars in the garage. While there is space now, I don't want to risk putting cars in as fresh oil drops on the concrete would not be wise just before finishing the floor.

Glen
 

mrekozz

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Dec 2, 2014
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I've been stalking this build for quite some time. Really into the 2 tone walls, my only change if I decide to do a simular build it is to opt out of the fluorescent lights, they still to this date bother my eyes :/.

Can't wait to see some cars in there!
 
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glentre

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Gloucester, Virginia
mrekozz,

Welcome to GJ and thanks for posting after lurking for some time. That's how most of us got started.

Interesting that fluorescents bother your eyes. What kind would you install in your build? I ask because I researched what type of lighting to use for some time. LED's were my initial choice but felt they would be a little harsh on my eyes. Besides, fluorescents have been a part of our lives for many years and I think we are accostomed to that kind of light. Easier to go with something known rather than unknown. I hope I have made a good choice but won't know until cars are in the garage and we start work.

Glen
 
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glentre

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Today we got our final building inspection and we passed. I asked about the requirement for tamper proof receptacles and was told that has been part of the Virginia code since 2008. Therefore, the electrician should have known that. He also should have known that any receptacles above 5.5 ft did not need to be tamper proof and that he did not need to change the outlets in the ceiling.

So, at this point, we are done with the county and free to move on to outfitting the garage. For those who have been following this thread, I hope my comments throughout the build regarding the construction have been interesting and helpful to anyone contemplating a similar build. For those interested in what happens after a build is turned over to an owner, please stay with us for posts on outfitting the garage over the next month or so. I'll try to keep it interesting and informative.

Glen
 

zmotorsports

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Glen, that is great news. Glad to hear your final inspection went well and you are ready to move in and get the shop outfitted to your liking.:thumbup:

Mike.
 

MacTexas

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Good to hear it passed and now after the fact you are up to speed on the Virginia electric code. Enjoy your posts, keep up the good work.
 
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glentre

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Mike,
Thanks for your comment. It has been a long process but starting the outfitting is going to be fun. I want to get it finished asap but a friend with a beautiful garage of his own wisely advised that this stage is the most rewarding and that I shoud be patient and take my time. I'll try but patience is not one of my virtues.

I read over your garage build and your coach thread....very interesting. You are one talented guy!

Glen
 

zmotorsports

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Mike,
Thanks for your comment. It has been a long process but starting the outfitting is going to be fun. I want to get it finished asap but a friend with a beautiful garage of his own wisely advised that this stage is the most rewarding and that I shoud be patient and take my time. I'll try but patience is not one of my virtues.

I read over your garage build and your coach thread....very interesting. You are one talented guy!

Glen

Thanks Glen, I appreciate that.

This construction thing is getting to me though. I'm a mechanic, NOT a carpenter nor contractor so I am way outside my comfort zone yet I find myself having to babysit the sub's constantly.

Like the old saying goes, if you want something done right, you have to do it yourself. I find my standards are a bit higher than many of the sub's I am seeing and have to keep on them constantly to ensure things are done the way I want.

I an NOT a patient person either and I expect when I am paying someone for a job they perform that job to my expectations both in quality and timeframe but I think that is too much to expect of many people these days.

Mike.
 
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glentre

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Mike,

I ran into the same problem in that I wanted my garage built the way I wanted but kept hearing "that's not the way we do it", or " this is the way we have always done it", or you don't need this or that", or "an owner doesn't need to micromanage", or worst of all, "you don't need to tell us how to do our work". The key is having good plans and writing a strict spec for all trades so exactly what you want is clearly communicated to a GC and all subs. I wrote a strict spec and scared away several contractors before finding one who understood that a tight spec helps both parties because it leaves nothing to argue about, results in few to no change orders and lets both sides know exactly what they need to do. You will rarely see a commercial construction project without a complete spec. My build has gone very smoothly because of the plans and specs and a cooperative relationship with everybody on the job.

A project without a good set of plans and spec is like a trip without a road map. You will eventually get there but there will be a lot of headaches along the way.

Glen
 
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glentre

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As I mentioned some time ago, we decided to dress up the rear blank wall of the garage. We can't see it since it's only a few feet from the property line but we thought it unfair for the neighbors to have to look at that ugly wall.

So, I installed fake windows and shutters by just screwing them to the existing vinyl siding. My wife applied reflective material to the inside of the glass to prevent a hot house effect with possible melting of the siding.

While the windows are not real, the neighbors are pleased with the look.

Glen
 

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glentre

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This morning, I applied the first coat of Rust Bullet on half the floor. I decided to do it in sections because I don't want to assemble my new lift on a freshly finished floor. This way, I can put the lift together on the unfinished area and just roll it over to the finished Rust Bullet section.

The application went pretty much as planned using the manufacturer's recommendations. I was going to use my mask from my architectural woodworking business but was worried the cartridges were too old and would not properly filter out the very strong vapors of the Rust Bullet. So, I bought a new one from the supplier and glad I did. It worked well to the point very little smell got by the mask. I would recommend anyone using this product to include this mask in your order and by all means, don't try to use a dust mask as these won't trap any of the fumes from the finish.

There have been many comments on the forum regarding how hard it is to not have roller marks with this product. My first coat shows only a little of the marks and I guess that's a result of using a proper roller, good coveage and back rolling each section.

My plan is to apply three coats of the base gray color followed by two coats of clear. Hopefully, I can do it all today and into the evening but I may have to lay down the next to last coat late tonight in order to apply the final coat early tomorrow morning and not exceed the 12 hr window for recoating.

I am now waiting for the first coat to set up and hope to get the second one on early afternoon.

Glen
 

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johnnyradiant

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Mar 27, 2017
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Service Guys still need plugs. They sometimes need to charge a battery or two. I normally get by on my stock but the guys I work with generally have one on the charge when we roll into a job. They didn't invest in as many batteries as I did.
 

C_F

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I agree, the floor looks great! So do the windows on the rear wall, they definitely add more character and appeal to it.
 
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glentre

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Third coat now drying so I thought I'd post the finished second coat. Looks like first clear coat will go down sometime after 11:00 tonight so I can lay on the last clear coat early tomorrow morning without going beyond the maximum 12 hr window for recoating.

Glen
 

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glentre

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So, on Tuesday night I applied the first coat of clear and finished up around midnight. The next morning, I laid down the final coat of clear. The photos below show the results of the final product.

The clear coat comes with an anti slip grit which sinks to the bottom of the can very quickly. It needs to be thoroughly stirred before each filling of the roller pan. Then in the pan, it sinks to the bottom fast so it is difficult to pick up any of the grit with the roller. You can't push the roller to the bottom of the pan to get more grit on it because it then picks up too much grit and you end up with a dark spot on the floor which needs to be rolled repeatedly to spread it out.

It was frustrating because I was worried I was not getting enough grit on the floor or that it was uneven. However, I am very pleased with the end result and somehow, there is a fairly even distribution of grit on the floor and it looks fantastiic.

We will be out of town for five days so there will be no activity on the floor while it cures. The big test is to see how it holds up to car traffic and abuse over the coming months.

Glen
 

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bimmer1980

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Hi Glen,
Nice Build!

I also have one of the Bard wall mount AC units. can you post a few more pics on how you hooked it up? Specifically on how you did the thermostat?

I got mine used from an industrial piece of equipment.
 
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glentre

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Brad,

Regarding how the unit is mounted to the wall, the Bard web site has good installation manuals you can download to construct proper support for the unit. It is fairly straightforward with minimal carpentry knowledge required.

As far as electric hookup goes, the installation manuals will help for the high voltage side. The low voltage thermostat hookup is a little more tricky and depends on the configuration of your unit. Is it straight cooling or a heat pump? Does it have auxilary electric heat? Economizer or ventilation package? Humidity controller? Dehumidification sequencer? Outdoor sensor? And, do you have a programmable or non-programmable thermostat?

I have a three ton heat pump with 10kw auxillary electric heat and a programmable thermostat. I can take a photo of that hookup if it would help you. Let me know. Give me some input on what installation information you have after looking at the Bard site, if you have any prior experience with thermostat wiring, which of the above features you have and what brand and model thermostat you have and we should be able to figure out a proper low voltage hookup. If you are uncomfortable with wiring it up, any local hvac service guy should be able to do it at a reasonable cost. That might be a better course of action since you have a used unit that might need some testing of the refrigerant circuit to determine proper charge and how much current the compressor and fans are drawing once the unit is fired up.

Glen
 
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glentre

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Yesterday morning I picked up the five cabinets and laid out the pieces in the garage ready for assembly. A busy schedule will prevent me from getting them all put together for another few days or so but I will post photos when they are done.

In the afternoon we picked up the two metal work benches from Home Depot. They are beefy buggers and I think they will take a lot of abuse. Didn't take but twenty minutes each to assemble.

Today we received our 44" Harbor Freight rolling tool cabinet. As many guys on the forum have commented, the quality of that unit was better than expected. The red color of that cabinet matches almost perfectly with the laminate we chose for the cabinets and is also very close to the 2" red vinyl stripe we will be putting on the wall between the two paint colors. As I knew they would from others who bought the same benches, their red is a bit darker than the other pieces but I can live with it.

My three sons and one son-in-law will be visiting over the Memorial Day weekend so I need to get the cabinets assembled before then so they can help mount them to the wall.

Glen
 

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bimmer1980

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Brad,

Regarding how the unit is mounted to the wall, the Bard web site has good installation manuals you can download to construct proper support for the unit. It is fairly straightforward with minimal carpentry knowledge required.

As far as electric hookup goes, the installation manuals will help for the high voltage side. The low voltage thermostat hookup is a little more tricky and depends on the configuration of your unit. Is it straight cooling or a heat pump? Does it have auxilary electric heat? Economizer or ventilation package? Humidity controller? Dehumidification sequencer? Outdoor sensor? And, do you have a programmable or non-programmable thermostat?

I have a three ton heat pump with 10kw auxillary electric heat and a programmable thermostat. I can take a photo of that hookup if it would help you. Let me know. Give me some input on what installation information you have after looking at the Bard site, if you have any prior experience with thermostat wiring, which of the above features you have and what brand and model thermostat you have and we should be able to figure out a proper low voltage hookup. If you are uncomfortable with wiring it up, any local hvac service guy should be able to do it at a reasonable cost. That might be a better course of action since you have a used unit that might need some testing of the refrigerant circuit to determine proper charge and how much current the compressor and fans are drawing once the unit is fired up.

Glen

Glen,
Thanks for the info. I did download the manual awhile back, but need to take a second look. I'm still a little ways out on mounting it to the wall, but that will be moving up the priority list as the weather continues to warm up. I'll try to get an actual photo of the tag as well. Mine is just the AC unit--no heater. Not sure on the other features....

Photos of your thermostat and wiring would be great.

Thanks for the insight.

Brad
 
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glentre

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Gloucester, Virginia
bimmer1980,

A photo of my thermostat hookup would not apply to your unit since mine is a programmable heatpump thermostat set up for one stage cooling and two stages of heat. You have a cooling only unit so the thermostat wiring should be easy. If you go to the Bard website, you will find your unit model and a wiring diagram for the cooling only unit. After doing that and you still have problems, let me know and I'll try to talk you through it.

Glen
 
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glentre

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This is a photo of the first cabinet dry fit just to check fitting of the parts before final assembly. There are five glue dowels inserted into each end of the top and bottom pieces along with four pocket screws per side to help draw the pieces together. Three 4" wide braces install between the sides, one at the top, one and the bottom and one in the middle. Once assembled, the 1/4" back slides into the dados in the sides and bottom to complete the assembly.

Glen
 

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glentre

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Here's another photo of the inside face of a door showing the machined pocket and screw holes for the hinges. The next two are of the front and rear of the assembled cabinet and the last shows the hinges in place ready to mount the door to the cabinet.

Glen
 

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glentre

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Today was a milestone! After almost a year of planning using suggestions and ideas from this forum and then five months of construction, we finally put our first car in the garage. I painted half of the floor two weeks ago with Rust Bullet and was reluctant to put a car on it until now to give it time to cure. Hope I didn't rush things but I think It'll be ok.

This weekend we have a family reunion with 18 of our children and grand children. With three sons and a son-in-law to help, we expect to get all of our cabinets up and secured to the wall with doors on. Then they can drink beer. Once the cabinet project is done, it's on to getting the lift in and assembled and that will be a real treat to have. Crawling under cars at my age is getting a little old.

Glen
 

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glentre

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Yesterday was another good day! With help from five guys from our family reunion, we got all of the cabinets hung on the wall and they look great.

I like the appearance of the flush look of the cabinets without pulls and will go with that unless it becomes too inconvenient. The doors are adjusted slightly lower than the bottom of the cabinet so they can be opened by placing a foot under them and pulling outward. I have the pulls and can install them later if I change my mind.

Since I have only gotten back into the car hobby during the last few years, I do not have a huge amount of tools collected over many years as is common with other guys on the forum. So, I should be able to get everything I have hidden away inside these cabinets for the clean and uncluttered look I want.

The back wall of one of them will be filled with hanging plastic parts bins. I priced several sources of the metal plates the bins hang on but the freight cost was almost double the cost of the plate. So, I will be making my own bin hanging rails using ideas seen on this forum but won't get to that for the next two weeks or so.

My Eagle lift was shipped and we expect to pick it up from the freight terminal sometime this coming week. I am anxious to get it assembled so I can finish the remaining section of the floor.

Glen
 

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JCQuick

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wow those cabinets are nice looking. The whole place is looking great I love the fake windows. I'm just catching up but I feel your pain on stupid electrical inspectors. My inspector wanted the outlets screwed to the cover plate( metal boxes on concrete wall) made no sense but I did it
 

jonesg

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Re: Full Circle Garage

This is a photo of the garage taken from the plan. It will be 30 x 38 with a 13 ft ceiling. Interior stairs up to second floor for storage now and possible living quarters in the future.

Glen

Lets be honest, thats a 3 bay house.:)
 
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glentre

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Thanks to all for the above comments. It is certainly a labor of love.

Nobody told me how hard it is to move from a two car garage full of car and house related stuff to a new garage dedicated, hopefully, to only car related stuff. While I'm in the process now, the old garage seems to be just as full as it was before. I'm trying to leave house related things like shelves full of paint and paint tools, carpentry tools, an old cabinet for house necessary tools, chain saws, wood storage rack, boxes of plumbing related parts & fittings, and a lot of other misc. stuff in the old garage but know I will have to find room for some of it in the new garage. My wife wants a garage space back for her van and room for a few file cabinets but a lot has to go before that is possible.

I'm sure I'm not the only guy who has ever faced this problem and part of the solution, of course, is to decide what I can't do without and make a decision to chuck some of it out.

My lift will be delivered this Friday so I'll worry about moving things from the old garage until the lift is assembled and functioning. Looking forward to it!

Glen
 
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glentre

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In my last post on 5/30, I said my new lift was going to be delivered on 6/2 which it was. My drive is too narrow and winding to get a 40 ft trailer to the garage and I don't have a fork lift anyway so the lift needed to be picked up at the terminal some 60 miles away. I contracted a roll-back tow truck guy to pick it up and drop it in my garage. Photo attached. The delivery went well and that afternoon I unpacked the 4 post lift myself ready to begin putting it together. It was than that I discovered it was not the lift I ordered. Instead of sending the model MS8000 XLT extra tall lift ordered, Eagle Equipment sent the smaller MS8000.

I immediately called Eagle customer service and after looking up the paperwork, they confirmed they had sent the incorrect lift. Since it was now after 5:00 pm on a Friday, they said they would get back to me on Monday morning after talking to management.

As promised, they called me on Monday and asked if I would keep the lift if they gave me a discount on it. I couldn't do that since my tall antique cars require the higher lift. After consulting with management, they asked me to re-crate it and they would pay transportation to get it back to Greensboro, NC. but this was impossible since all the steel straps had been cut, parts were spread all over the garage and I do not have any help available to re-pack it. Plus, the LTL haulers won't accept shipment of a lift in pieces. I suggested the best way to do the exchange was to have them send a closed truck with two men to pick up the pieces, hand load them and make the four hour return to their facility.

Perhaps because of the expense of getting the incorrectly shipped lift back to their place exceeded the money they had in the lift, they offered to let me keep it at no charge with the condition that the correct XLT be shipped without a power unit, casters or aluminum ramps, all of which could be used from the first lift. I accepted this offer as being fair to both parties. While I have room in my 3 car garage for a second lift, it is not needed and I would never have bought one. As it is, I will need to buy a power unit from Eagle to get the first lift operational and move a 7 ft diameter fan from the ceiling over the second lift. Plus, the shipping error has set me back two weeks or so in getting my garage to a point I can get the second half of the floor finished and start working on cars.

I am grateful to the management of Eagle for confirming their shipping error and quickly working toward a solution. Many companies would have dragged out this matter for weeks or perhaps longer and would have been uncooperative in their approach. But, I could not have asked for better people to work with than the folks at Eagle.

Glen
 

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C_F

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It's good to hear that your experience with Eagle has ended up as a net positive. As you said, it could have easily gone the other way, so it's nice to hear that they have great customer service!
 
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glentre

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It took a little longer to assemble the first lift since I was away for several days and I am doing all the work myself. Also, the lack of sufficient instructions meant I had to take the time to figure things out. Anyway, the lift is up and in place and the Chrysler is up in the air. After much thought on the subject, I have decided to change the position of the second lift from the left bay to the center one and next to the one already in place. The first one will be for storage and the second for work which leaves the left bay open for parking or general floor work since that bay is closest to the man door, tool and storage cabinets.

I will not be able to start assembly on the second lift until the week after next so have opted to wait to have it shipped until then. Assembly of that one should go quicker.

I also have not started the trim on the windows, the shoe molding around the floor or the entry doors and stairs. That stuff can wait until the garage related work is finished.

Glen
 

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