dirt_dobber
Well-known member
way to go doing it in Feb. - eat that elephant one bite at a time!
Above 1200 Sq/FT Barn Workshop build
- Thread starter ururk
- Start date
Wokspaces above 1200 squarefeet.
Wednesday, March 29: Moved the pump jacks to the other side:
The housewrap is in tatters - I didn't staple it down very well, and it would have held, except we had a wind storm come though a week or so ago - I think 60mph+ winds. My goal this weekend is to get the side eave finished, and do as many roof panel as possible. Once done, I will be putting the tarp on and then restapling the housewrap.
When I made the eave on the other side, I made twice as many pieces of wood as I needed - and as I installed the horizontal furring, I figured out a few ways to improve my methods. So... what I'm saying is I expect a productive weekend
.
Weather is starting to get nice - high 40's, low 50's... should be seeing frequent updates soon!
The housewrap is in tatters - I didn't staple it down very well, and it would have held, except we had a wind storm come though a week or so ago - I think 60mph+ winds. My goal this weekend is to get the side eave finished, and do as many roof panel as possible. Once done, I will be putting the tarp on and then restapling the housewrap.
When I made the eave on the other side, I made twice as many pieces of wood as I needed - and as I installed the horizontal furring, I figured out a few ways to improve my methods. So... what I'm saying is I expect a productive weekend
.Weather is starting to get nice - high 40's, low 50's... should be seeing frequent updates soon!
Sunday, April 2: Finished filling in all panels, and finished the eave off as much as possible.
I also trimmed the boards sticking out of the bottom of the eave.
I feel like I got a lot done this weekend - due to many different factors. I optimized the construction order, did all cuts on the ground instead of in the air, had (almost) enough wood for the entire two days, and knew which proper cuts to make. Oh, and I was able to use the same jig to cut the angled pieces with a few tweaks. And two beautiful days at the perfect temperature.
Because this week will be another horrible rainy week, I probably won't get much done. However, I'm going to prototype out the front eave construction and possibly cut all the wood for the front and back, with the goal to finish those this next weekend (currently a 10% chance of rain), measure the roof, and put a semi-temporary tarp on while I get metal roof material quotes.
I also trimmed the boards sticking out of the bottom of the eave.
I feel like I got a lot done this weekend - due to many different factors. I optimized the construction order, did all cuts on the ground instead of in the air, had (almost) enough wood for the entire two days, and knew which proper cuts to make. Oh, and I was able to use the same jig to cut the angled pieces with a few tweaks. And two beautiful days at the perfect temperature.
Because this week will be another horrible rainy week, I probably won't get much done. However, I'm going to prototype out the front eave construction and possibly cut all the wood for the front and back, with the goal to finish those this next weekend (currently a 10% chance of rain), measure the roof, and put a semi-temporary tarp on while I get metal roof material quotes.
FTWingRiders
Well-known member
Thanks for the update! Looking forward to seeing what this year will bring you.. how soon do you hope to finish the outside? Any damage to the foam sheets over the winter?
smschriefer
Well-known member
Looking good! I know you can't wait until the roof is done. If the weather permits, do you thing you'll have the roof done in April?
fergus
Well-known member
Man, this building is gonna outlive you for sure. Built like the proverbial brick lavatory.
Keep at it.
Keep at it.
Foam: It held up fine, flashing tape did too. The only damage is some mold on the upper part right under the eaves - when I put the roof on I'm going to spray a fungicide. But, otherwise it held up.
I'm hoping to order the metal roof this month, probably the end of the month. It really depends on how much rain we get, and if I can figure out a safe way to work on the front and back from a ladder. Right now I have some ideas on how to get the front eave put together, but I have to test out my tallest ladder first to see how safe it is. Ultimately, my plan will involve safety straps on the top rung of the ladder, but I might just break out the roofing safety harness for myself.
Provided I can get the roof on without renting the machine, I will probably do the siding and trim from the machine, and paint and do some repairs on the house. I saw a smaller tracked unit on a local tree service truck, and I'm going to see if I can find that unit as I don't need the same reach as before.
I'm hoping to order the metal roof this month, probably the end of the month. It really depends on how much rain we get, and if I can figure out a safe way to work on the front and back from a ladder. Right now I have some ideas on how to get the front eave put together, but I have to test out my tallest ladder first to see how safe it is. Ultimately, my plan will involve safety straps on the top rung of the ladder, but I might just break out the roofing safety harness for myself.
Provided I can get the roof on without renting the machine, I will probably do the siding and trim from the machine, and paint and do some repairs on the house. I saw a smaller tracked unit on a local tree service truck, and I'm going to see if I can find that unit as I don't need the same reach as before.
Saturday, April 7: The week was either very cold or rainy - this weekend, however, was beautiful.
To give an idea of the process, after measuring the angle and cutting a board to fit against the roof edge, I marked positions of each 2x4:
After screwing on the individual pieces, I then carried it up to the roof and screwed it in several places:
Where the angles meet, I screwed a "plate" on so that the outer board doesn't warp over time:
That's where I left it for the day:
To give an idea of the process, after measuring the angle and cutting a board to fit against the roof edge, I marked positions of each 2x4:
After screwing on the individual pieces, I then carried it up to the roof and screwed it in several places:
Where the angles meet, I screwed a "plate" on so that the outer board doesn't warp over time:
That's where I left it for the day:
Sunday, April 9: Another beautiful day - moreso since I had enough supplies for the day for once
Just a photo of eave construction, did the back side today:
Also, this is how I trimmed the end of 2x4's off (note: safety equipment isn't visible, I need to get my hair cut - I have in-ear protection+bluetooth, and safety glasses):
And where I left it:
So, I have to do all four corners now, plus the lower 2x6 end boards. Then the lean-to.
Just a photo of eave construction, did the back side today:
Also, this is how I trimmed the end of 2x4's off (note: safety equipment isn't visible, I need to get my hair cut
- I have in-ear protection+bluetooth, and safety glasses):
And where I left it:
So, I have to do all four corners now, plus the lower 2x6 end boards. Then the lean-to.
Sunday, April 16: Happy Easter. Oh, and evidently Menards was open today - made a quick run to buy some screws and wood for the lean-to on the back.
Didn't get a whole lot done today - between having company over, and having to go to Menards, I only finished the last corner:
Didn't get a whole lot done today - between having company over, and having to go to Menards, I only finished the last corner:
Monday, April 17: Took the afternoon off to start the rear - it's going to rain Wed/Thu so I wanted to get as much done as possible.
Sides are finished:
The front should be fairly simple. I ran the boards long and will trim them in the air. I'm not certain *how* I will do the outer corners as the tallest step ladder I have is just shy of a safe working height, though I probably can just lean over, carefully. Or I guess put a ladder against the eave, hrmmm.
Anyhow, I have to install a slightly-massive 12" (11" when beveled) header along the back of the lean-to. This will allow me to install some long screws into a girt at the top, securing it both at the bottom of the board as well as the top. My best guess is that this will be much more difficult than I envision.
Sides are finished:
The front should be fairly simple. I ran the boards long and will trim them in the air. I'm not certain *how* I will do the outer corners as the tallest step ladder I have is just shy of a safe working height, though I probably can just lean over, carefully. Or I guess put a ladder against the eave, hrmmm.
Anyhow, I have to install a slightly-massive 12" (11" when beveled) header along the back of the lean-to. This will allow me to install some long screws into a girt at the top, securing it both at the bottom of the board as well as the top. My best guess is that this will be much more difficult than I envision.
A side note about the tattered housewrap, and next steps. We keep having massive windstorms, and I've given up any hope of having a semblance of protection on the outside walls. I'm pretty beat, and really just want to finish this project
So, next steps once the rear is finished:
1) Measure roof for metal and trim
2) Get quotes - two or three metal suppliers, two or three roofing contractors. However... the last ballpark construction quotes I got were too expensive, so I probably will do this myself
3) Put tarp on roof
4) Install trim (if I go with Azek / Hardie / Boral)
5) Install the windows (finally!)
6) Metal roofing material should have arrived by now, so install that, peeling the tarp back like a banana
7) Install remainder of furring strips (every 2 feet)
8) Siding: Prep (sand/plane), Prime (oil), paint (latex) siding
I'm leaving out a lot of steps, but yeah, I'm getting close. I think.
So, next steps once the rear is finished:
1) Measure roof for metal and trim
2) Get quotes - two or three metal suppliers, two or three roofing contractors. However... the last ballpark construction quotes I got were too expensive, so I probably will do this myself
3) Put tarp on roof
4) Install trim (if I go with Azek / Hardie / Boral)
5) Install the windows (finally!)
6) Metal roofing material should have arrived by now, so install that, peeling the tarp back like a banana
7) Install remainder of furring strips (every 2 feet)
8) Siding: Prep (sand/plane), Prime (oil), paint (latex) siding
I'm leaving out a lot of steps, but yeah, I'm getting close. I think.
lieutenant
Well-known member
Way to keep at it. This is a slow build but you're making progress. Thanks for the detailed posts.
Yeah, sadly my pace is "glacial". I even annoyed one of my perfectionist friends who helped one day. I think his words were "it doesn't have to be perfect".
I have tried to break out of my pace, but it never lasts for more than a few hours. I'm quick when I write code, or do CAD work. But the actual process of doing... I measure ever so precisely. Then I step back, check the measurement again. Or I measure stuff I should just eyeball. I then precisely place the saw, etc... I think you get the picture. And I don't have a great system for planning for what is next. And if I have any doubts about something I research it till I'm blue in the face.
None of this means what I'm doing is correct, or that I did a good job - no matter how well I do something I'm usually off by 1/8" on the rough construction.
Bib Overalls
Well-known member
I thought I was about as OCD as a man can get. I was wrong..
Sunday, April 23: Finished the rear eaves, though I need to install some blocking in a few places. Will do later before the metal roofing arrives.
Added little pieces of wood to act as blocking:
Then the top piece:
All trimmed:
I then spent the rest of the day drawing diagrams and taking measurements for the metal roof.
I'm a bit, well, "worried" about my plans to roof this myself. I hadn't really reviewed the installation procedures for a metal roof, just the general steps and stopped into a metal roof mfg to understand what I needed to construct. The guy behind the counter made it sound trivial. There's a lot of caulking, riveting, and cutting/bending. I believe I can *do* it, but am concerned about how long it will take me.
Added little pieces of wood to act as blocking:
Then the top piece:
All trimmed:
I then spent the rest of the day drawing diagrams and taking measurements for the metal roof.
I'm a bit, well, "worried" about my plans to roof this myself. I hadn't really reviewed the installation procedures for a metal roof, just the general steps and stopped into a metal roof mfg to understand what I needed to construct. The guy behind the counter made it sound trivial. There's a lot of caulking, riveting, and cutting/bending. I believe I can *do* it, but am concerned about how long it will take me.
Madone_si
Well-known member
awesome work, man you set a high bar now for building a wood structured barn...
Friday, April 28: I have three quote requests out with two building supply companies and a mfg. I'm not sure when I'll get them back.
Moving onto windows while I wait for roof materials.
I kind of, sort of, ran into an issue with the window boxes I installed. The screw holes in the window flanges line up exactly with the outside of the box - this will cause structural problems with where the windows fasten into the flanges. So I need to remove 3/4" from the depth of the window boxes. I'll them make a simple flange... yeah not my greatest moment I made the boxes before the windows arrived. The alternative is to fasten the window into the box with a structural masonry bracket, but then I have to take off the window flange and I lose a nice way to flash the window.
Speaking of which I made some flashing today, here's a rendering of where it will go:
And the flashing:
The flashing will be inserted into a beveled cut into the foam - the term is a "reglet". You can probably find better pictures online. Then tape goes over the flashing at the top. This way, if water finds its way it should run over the foam, tape, then flashing.
And I tarped the roof:
It's going to be at least 3 weeks for me to get the material (I was told 1 week just to get a quote), and then additional time for me to install it. It has been rainy as of late, so I figured now would be a good time to put it on.
So, tomorrow I'll start working on the wooden window flanges - I'm going to do one window and see if I have to refine my technique.
Moving onto windows while I wait for roof materials.
I kind of, sort of, ran into an issue with the window boxes I installed. The screw holes in the window flanges line up exactly with the outside of the box - this will cause structural problems with where the windows fasten into the flanges. So I need to remove 3/4" from the depth of the window boxes. I'll them make a simple flange... yeah not my greatest moment
I made the boxes before the windows arrived. The alternative is to fasten the window into the box with a structural masonry bracket, but then I have to take off the window flange and I lose a nice way to flash the window.Speaking of which I made some flashing today, here's a rendering of where it will go:
And the flashing:
The flashing will be inserted into a beveled cut into the foam - the term is a "reglet". You can probably find better pictures online. Then tape goes over the flashing at the top. This way, if water finds its way it should run over the foam, tape, then flashing.
And I tarped the roof:
It's going to be at least 3 weeks for me to get the material (I was told 1 week just to get a quote), and then additional time for me to install it. It has been rainy as of late, so I figured now would be a good time to put it on.
So, tomorrow I'll start working on the wooden window flanges - I'm going to do one window and see if I have to refine my technique.
Saturday, April 29: Installed the first window flange. As with every steps in this project, the first of every new step takes a little longer. But, provided this works out the rest should go much smoother.
I don't have any in-progress pictures, unfortunately I didn't have anyone around today to take pictures
First steps was to get the corner-to-corner measurements from the installed box - I used a large piece of cardboard for this.
Afterwards I cut a frame out of two sheets of plywood
Trimmed the box flush with the foam
Then... installed the flange:
I screwed it in around the perimeter of the frame, as well as through the foam into the 2x6" girts. I hung from the whole assembly, no movement whatsoever.
And did a test fitting of the window:
I forgot to order 6" flashing tape, only have 3" on hand, so am waiting for Amazon to deliver (Monday). Most likely, will get this one installed this week, then if the weekend is nice get the other frames prepped.
I don't have any in-progress pictures, unfortunately I didn't have anyone around today to take pictures
First steps was to get the corner-to-corner measurements from the installed box - I used a large piece of cardboard for this.
Afterwards I cut a frame out of two sheets of plywood
Trimmed the box flush with the foam
Then... installed the flange:
I screwed it in around the perimeter of the frame, as well as through the foam into the 2x6" girts. I hung from the whole assembly, no movement whatsoever.
And did a test fitting of the window:
I forgot to order 6" flashing tape, only have 3" on hand, so am waiting for Amazon to deliver (Monday). Most likely, will get this one installed this week, then if the weekend is nice get the other frames prepped.
Some additional window comments...
I'll probably be trimming them out like this:
http://mattrisinger.com/exterior-rigid-foam-w-modern-hardie-plank-siding-details/
Depending on how the siding phase goes, this could change, but I like the clean look. However, it will have to look good with standard trim on the corners, so I may change my mind. Otherwise, I'll probably trim around with 3" trim board in a traditional way, with some sort of drip cap.
I'll probably be trimming them out like this:
http://mattrisinger.com/exterior-rigid-foam-w-modern-hardie-plank-siding-details/
Depending on how the siding phase goes, this could change, but I like the clean look. However, it will have to look good with standard trim on the corners, so I may change my mind. Otherwise, I'll probably trim around with 3" trim board in a traditional way, with some sort of drip cap.
Sunday, April 30: Since I'm waiting for the weather to clear to install the window, I didn't want to do too much today before I get it installed. Just in case something doesn't quite go as planned.
I spent today rebuilding the tops of the sawhorses and fixing them a bit, cutting the "blanks" for the window flanges, and putting in countersinks for the big screw heads. Other than that, didn't get much done - too rainy outside.
If this window install goes well, I'll switch into production mode and crank out the flanges and install them all in one day. Then I'll focus on getting the rest of the windows installed. Then the top window flanges, then the upper windows!
I spent today rebuilding the tops of the sawhorses and fixing them a bit, cutting the "blanks" for the window flanges, and putting in countersinks for the big screw heads. Other than that, didn't get much done - too rainy outside.
If this window install goes well, I'll switch into production mode and crank out the flanges and install them all in one day. Then I'll focus on getting the rest of the windows installed. Then the top window flanges, then the upper windows!
Saturday, May 6: After "enduring" nearly a week of rain, finally had a nice day to work. Got one window installed, and the other two window flanges up.
I ended up first putting a layer of housewrap over the window flange, and installed normally per 3M's flashing / Marvin's direction. A1 method:
I did not install the metal flashing above the housewrap - I'm probably going to make some additional flashing before I install that, to simplify the install.
I ended up first putting a layer of housewrap over the window flange, and installed normally per 3M's flashing / Marvin's direction. A1 method:
I did not install the metal flashing above the housewrap - I'm probably going to make some additional flashing before I install that, to simplify the install.
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Sunday, May 7: Finished installing three windows, and prepped another window flange.
This wide shot shows the way I added the housewrap:
When I install the siding I'll reduce a bit of the height to the housewrap, but will leave 1' on either side of the flange.
Installed (erm, sort of - this doesn't show the final state with vertical flashing strips on the sides and the top properly flashed with the WRB, I don't seem to have a final photo for some reason)!
I've never installed windows, but am VERY glad I got the window boxes level. I simply snapped all the shims to the same thickness, placed them where required, and once set I didn't have to do any moving around of the window.
I'm waiting for a foam gun (cheap unit from eBay, uses the screw-on type cans), but this is the window unit from inside:
I finished the flange on the other side, one of two smaller units I need to install:
Also... I know the hanging housewrap looks horrible, and I have housewrap laying around in the background. Once I get through the window installs, I'm going to do some cleanup. I'm meeting with a metal roof salesperson Wednesday (really dreading it), and from there will decided on the metal supplier for my roof... then order that. I'll have three whole weeks to work on other things while I wait for delivery.
This wide shot shows the way I added the housewrap:
When I install the siding I'll reduce a bit of the height to the housewrap, but will leave 1' on either side of the flange.
Installed (erm, sort of - this doesn't show the final state with vertical flashing strips on the sides and the top properly flashed with the WRB, I don't seem to have a final photo for some reason)!
I've never installed windows, but am VERY glad I got the window boxes level. I simply snapped all the shims to the same thickness, placed them where required, and once set I didn't have to do any moving around of the window.
I'm waiting for a foam gun (cheap unit from eBay, uses the screw-on type cans), but this is the window unit from inside:
I finished the flange on the other side, one of two smaller units I need to install:
Also... I know the hanging housewrap looks horrible, and I have housewrap laying around in the background. Once I get through the window installs, I'm going to do some cleanup. I'm meeting with a metal roof salesperson Wednesday (really dreading it), and from there will decided on the metal supplier for my roof... then order that. I'll have three whole weeks to work on other things while I wait for delivery.
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Blackhawks63
Well-known member
Making progress. I don't at all understand your window construction. Have you accounted for normal expansion and shrinkage of the wood around those windows? And how do those walls breathe? So much foam board and house wrap, but did you think of air pocket? I say this sit respect because it's your building and your sweat equity. But son, you need to stop overthinking.
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Sent from my QTAQZ3 using Tapatalk
1) The window boxes have the mfg's recommended 1/4" around all sides (the interioir picture didn't show this very well). Windows are all fiberglass and shouldn't expand/contract too much.
2) Walls don't - and shouldn't - exchange air with the outside. There is a peel and stick membrane on the outside of the OSB. Zip sheathing taped would probably have worked the same way, but at the time I didn't know about zip sheathing, unfortunately.
3) To make the building "breathe" - well, assuming there isn't enough air exchange - I'll probably install an HRV. But I'm not certain one will be needed.
4) Air pockets - the foam isn't yet fully fastened, but I don't expect air will get trapped between the foam layers causing pockets - every time I've screwed into the foam the foam has "compressed" to 4" thickness.
Overthinking? Unfortunately, I cannot help myself even though I know I need to stop overthinking.
Saturday, May 13: Built the first of two window flanges for the second floor:
To save a bit of money, I cut them in pieces from a full sheet of lumber:
I then biscuit jointed the places where they joined up, glued those together and glued a thinner sheet of plywood to the back (to bring the thickness in-line with the strapping. Lacking a sufficient quantity of clamps...
To save a bit of money, I cut them in pieces from a full sheet of lumber:
I then biscuit jointed the places where they joined up, glued those together and glued a thinner sheet of plywood to the back (to bring the thickness in-line with the strapping. Lacking a sufficient quantity of clamps...
Sunday, May 14: Installed the first of the two big windows.
Flange uncovered:
One of the online resources for this kind of construction says that, for windows wider than 3', a 2x6 should be placed under the window to help bear the load. I was on the fence whether or not to do that - the window boxes were pretty stiff already, etc... but decided, for peace of mind, to embed a 2x6 into the foam:
Flange installed:
Window nearly installed:
(I don't have a final installed picture)
Flange uncovered:
One of the online resources for this kind of construction says that, for windows wider than 3', a 2x6 should be placed under the window to help bear the load. I was on the fence whether or not to do that - the window boxes were pretty stiff already, etc... but decided, for peace of mind, to embed a 2x6 into the foam:
Flange installed:
Window nearly installed:
(I don't have a final installed picture)
So... what's left?
1) One more big window - will be installing this weekend if Marvin gets me a replacement part (missing piece for the installation)
2) Window flashing made up and installed
3) Strapping and siding - strapping needs to be constructed, and put up. I have most of the wood pieces already cut, but spacer material needs to be added.
4) Sliding door mount points and doors needs to be made
5) Metal roof install
6) Siding
7) Rest/sleep
8) Final grading
9) Clean up/out interior, sand, and do any trim
I can finally see the end of this project, but have some large tasks ahead. Sorry if some of these updates seem trite.
1) One more big window - will be installing this weekend if Marvin gets me a replacement part (missing piece for the installation)
2) Window flashing made up and installed
3) Strapping and siding - strapping needs to be constructed, and put up. I have most of the wood pieces already cut, but spacer material needs to be added.
4) Sliding door mount points and doors needs to be made
5) Metal roof install
6) Siding
7) Rest/sleep
8) Final grading
9) Clean up/out interior, sand, and do any trim
I can finally see the end of this project, but have some large tasks ahead. Sorry if some of these updates seem trite.
95riosnake
Well-known member
I don't know how I never saw this build until now but wow, what a project! I think the most impressive thing is it seems like once the timber structure went up, you've been doing the lion's share of work solo. I almost always find myself having to work alone, either due to lack of help or lack of patience to get others to understand my method. Cheers to you for having what seems to be an amazing amount of persistence and drive.
I thought to myself several times that you and your build really remind me of another build on here, matt_i and his "Tool Crib of the North" but I see he has already popped in here several times and I'm sure you're already aware of his project. You two are most definitely cut from the same cloth. Watching both of your builds is such a cathartic experience for someone like myself. Every time I am laboring over a minute detail, one which usually will never be seen or known by anyone but myself after completion, and my friends/family/wife are giving me **** for not being able to just go the quick and dirty route, it's nice to know there are others out there who share the same passion in what they put their time and effort into. I will definitely be following along, thanks for taking the time to document and share this with everyone.
I thought to myself several times that you and your build really remind me of another build on here, matt_i and his "Tool Crib of the North" but I see he has already popped in here several times and I'm sure you're already aware of his project. You two are most definitely cut from the same cloth. Watching both of your builds is such a cathartic experience for someone like myself. Every time I am laboring over a minute detail, one which usually will never be seen or known by anyone but myself after completion, and my friends/family/wife are giving me **** for not being able to just go the quick and dirty route, it's nice to know there are others out there who share the same passion in what they put their time and effort into. I will definitely be following along, thanks for taking the time to document and share this with everyone.