Above 1200 Sq/FT Barn Workshop build
- Thread starter ururk
- Start date
Wokspaces above 1200 squarefeet.
Friday, Oct 18: Well, I pushed myself, but didn't have any help to measure these panels so I called it a night. I had a tough time going around this window - messed up a panel, cut it an inch too short, among other annoyances. Still not sure how that happened.
I have to pick up some lumber tomorrow morning, then will finish this side. I've been pretty good about justifying tools on this project, but one tool I refused to buy was an electric metal shear. That was the stupidest decision I ever made. I ordered a drill-attachment from Amazon... it has already saved me several hours worth of time.
I have to pick up some lumber tomorrow morning, then will finish this side. I've been pretty good about justifying tools on this project, but one tool I refused to buy was an electric metal shear. That was the stupidest decision I ever made. I ordered a drill-attachment from Amazon... it has already saved me several hours worth of time.
mike93lx
ALLIANCE MEMBER
Oh man, a project like that without a nibble or electric shear? Well, you certainly learned from that!
Tell me about it! It would not have helped much with the roof. Since I didn't feel like I needed one for the roof, why would I need one for the siding?
Oh, there are at least 108 feet of reasons, and those are just the corners. That's assuming one hand cut per corner, but inevitably I had to make at least two cuts to remove the lock or batten, then a final finish hand cut. I still have three end panels to do (and two long cuts), so this cutter will get some use.
Saturday, Oct 19: I finished the side, but again it gave me a lot of difficulty. The last piece took me FOREVER. I was ready to give up and screw it in, but after unfolding and refolding it, I got it to snap in.
Spent about an hour or two cleaning things up outside (lots of cardboard to break up). Then got the first panel up on the front! That electric shear - honestly - that should have been my first purchase. 16 feet of a siding board, cut in less than 4 minutes.
Sunday is supposed to be even nicer/warmer than today.
With rain forecast for Monday, I'll be taking a look at some reclaimed barnwood for the door surround.
Spent about an hour or two cleaning things up outside (lots of cardboard to break up). Then got the first panel up on the front! That electric shear - honestly - that should have been my first purchase. 16 feet of a siding board, cut in less than 4 minutes.
Sunday is supposed to be even nicer/warmer than today.
With rain forecast for Monday, I'll be taking a look at some reclaimed barnwood for the door surround.
Blackhawks63
Well-known member
The finish of the exterior is in sight. Congratulations.
Sunday, Oct 20: 9 panels on today, 18 panels left to install! It's a mix of 16' and 20' panels. I got an estimate for 18' panels to reduce waste, but it turns out at the longer lenghts, the $/linear foot is cheaper, and the 20' panels cost less (I needed six 20 footers).
Did I mention my phone camera is awesome? The sun had essentially set, and the sky looks like it is still light out.
Here's my running list of things to get done:
1) Finish siding (duh)
2) Foam side door and make/install inside trim
3) Install outside trim in both "doorways"
4) Put on rear roof (removing the temporary roof is going to be a PITA)
5) Install wood surround around doorway
And that's it. I'm a bit concerned that the inspector will want the extrior foam covered... I think I missed my window for that, though, as the temperature is getting below 40 every night, and the instructions for the various coatings all want it to be over 40 for 24 hours. Not sure if I should ask the township or not.
Did I mention my phone camera is awesome? The sun had essentially set, and the sky looks like it is still light out.
Here's my running list of things to get done:
1) Finish siding (duh)
2) Foam side door and make/install inside trim
3) Install outside trim in both "doorways"
4) Put on rear roof (removing the temporary roof is going to be a PITA)
5) Install wood surround around doorway
And that's it. I'm a bit concerned that the inspector will want the extrior foam covered... I think I missed my window for that, though, as the temperature is getting below 40 every night, and the instructions for the various coatings all want it to be over 40 for 24 hours. Not sure if I should ask the township or not.
Once the barn is approved, I may post to this thread a bit as I finish up some things (but won't post daily):
1) Interior paneling
2) Electrical Install
3) Grading / landscaping (general plan is to bring grade up to the floor - minus 2", concrete pad for the side door, some form of hard pack gravel in front of the big door, and 2' of rock around the permimeter)
I'm really bummed about some of the electrical quotes I got, I really wanted to get it electrified this year.
1) Interior paneling
2) Electrical Install
3) Grading / landscaping (general plan is to bring grade up to the floor - minus 2", concrete pad for the side door, some form of hard pack gravel in front of the big door, and 2' of rock around the permimeter)
I'm really bummed about some of the electrical quotes I got, I really wanted to get it electrified this year.
FTWingRiders
Well-known member
Seriously looking fantastic! This is one thread I've followed since you started, and tho you got a lot of flak for being so particular, I think the final results speak for themselves! Please keep updating as often as you can.. We really want to see the whole project thru to the end!
Congrats on such a great barn.
Congrats on such a great barn.
Sorta update. Inspector will be coming by next week some time... will know exactly by Monday.
Picked up some reclaimed barn wood for the door surround. I'm going with horizontal lap siding, wrapping the entrance. Not sure if I'm going to put any wood preservative on it.
Taking the next two days off, temp should be in the mid 50's (perfect temp) and dry.
Picked up some reclaimed barn wood for the door surround. I'm going with horizontal lap siding, wrapping the entrance. Not sure if I'm going to put any wood preservative on it.
Taking the next two days off, temp should be in the mid 50's (perfect temp) and dry.
mike93lx
ALLIANCE MEMBER
Blackhawks63
Well-known member
Pay someone to do bare minimum electric, then get approved by inspector. Then do the rest yourself, which honestly will be pretty straightforward.
Electrical work: Run to barn, meter enclosure outside, electrical panel inside.
I know enough about electricity to be safe, enough to research proper wiring, but am concerned I won't be able to complete the outdoor work before snow, based on my current track record. I'm certain interior electrical work would go quickly (bare minimum for inspection).
I know enough about electricity to be safe, enough to research proper wiring, but am concerned I won't be able to complete the outdoor work before snow, based on my current track record. I'm certain interior electrical work would go quickly (bare minimum for inspection).
BoilermakerFan
Well-known member
Why do you need a meter panel on the outside? Why not just run a feed from the house panel to a subpanel in the barn? That would be cheaper.
The house has a 200A service (main breaker, the actual service may be capable of higher load, but the panel is protected by a 200A breaker). I do not need three-phase, and am unsure if I need anything more than a 100A "service" to the barn.
I could put a subpanel in the barn, but all the appliances in the house are electric: dryer, range, stove, A/C. I haven't done a proper load calculation, so the "least planning effort" way to go about it was to do another service drop from the pole. Everything around here is underground... so a lot of trenching. I don't plan on putting A/C in the barn, though may regret that decision one day.
The main problem, I guess, I don't have anyone to discuss this with.
mike93lx
ALLIANCE MEMBER
Make a post in the electrical section. You'll get plenty of support
BoilermakerFan
Well-known member
You don't need a separate service...
I rewired my entire house in 2000. I don't think the NEC has changed that much in 19 years, but your local inspector would be able to help you.
I have a 200A service main panel. I put in a 90A sub-panel for the kitchen, a 60A lighting sub-panel, and a 60A sub-panel in the garage. Every room in my house has dedicated 20A circuit for receptacles and a dedicated 15A circuit for lighting. This far exceeds the NEC's minimum requirements. At the time, we had an old Jenn-Air range which required a 60A circuit by itself. My A/C is older and on a 40A circuit. Everything else is pretty standard.
I've never come close to tripping the main breaker.
Wednesday, Oct 23: FINISHED THE METAL SIDING!
So what's left?
Pre-inspection:
1) Trim/wood around doors
2) Install rear roof
3) Remove pump jacks
4) install soffit facia on front
Post-inspection:
1) Coat foundation foam
2) Foam doors/windows
3) Trim/casing around doors/windows
Much later:
1) Electrical
2) Grading
3) ???
The order of some of this might change, and I have a very short time to do the first four. I'm going to find out if the foam needs to be covered before it is approved. If it needs to be covered I'm kinda screwed, since the temps are just hovering above 40, and the coatings need to be applied when the temp is over 40 for 24 hours. Plus, I don't have time to do the foundation coating before final inspection. Sigh.
So what's left?
Pre-inspection:
1) Trim/wood around doors
2) Install rear roof
3) Remove pump jacks
4) install soffit facia on front
Post-inspection:
1) Coat foundation foam
2) Foam doors/windows
3) Trim/casing around doors/windows
Much later:
1) Electrical
2) Grading
3) ???
The order of some of this might change, and I have a very short time to do the first four. I'm going to find out if the foam needs to be covered before it is approved. If it needs to be covered I'm kinda screwed, since the temps are just hovering above 40, and the coatings need to be applied when the temp is over 40 for 24 hours. Plus, I don't have time to do the foundation coating before final inspection. Sigh.
I've posted here in the electrical forum:
https://www.garagejournal.com/forum/showthread.php?p=8141007
https://www.garagejournal.com/forum/showthread.php?p=8141007
smschriefer
Well-known member
Congratulations on completing the siding! I'm sure your fingers are happy - no more cuts! I can't wait to see you working inside instead of out.
fourbyford
Well-known member
Looks GREAT! Congrats on this accomplishment and may the force be with you during the inspection...
...D
...D
Thursday, Oct 24: Took a half day to work on the rear roof. At some point in the past I realized I needed a walkable surface to put the siding on, so put on a "temporary" roof - thin plywood and leftover Ice+Water shield. Removing that was mildly annoying - though the membrane was rated for "60 days exposure" it was still stuck on very well, and waterproof, and significantly greater than 60 days. I didn't find any damage below the decking, though the edge of the plywood absorbed a ton of water and about 4" of memberane was unstuck.
I then had to add a few additional furring strips - they were slightly thicker than the original strips - maybe 1/16 to 1/8. I should have planed these down a bit, but didn't. So, there is a slight - impossible to see from the ground - warp in the roof.
I'm not terribly happy about this, but, meh it will be fine. Well, I could always cut off the portion that is exposed and plane it down tomorrow... sigh.
I'm confident I'll finish the roof tomorrow, hopefully get the pump jacks down as well. Less confident about getting the facia on, but we'll see.
I then had to add a few additional furring strips - they were slightly thicker than the original strips - maybe 1/16 to 1/8. I should have planed these down a bit, but didn't. So, there is a slight - impossible to see from the ground - warp in the roof.
I'm not terribly happy about this, but, meh it will be fine. Well, I could always cut off the portion that is exposed and plane it down tomorrow... sigh.
I'm confident I'll finish the roof tomorrow, hopefully get the pump jacks down as well. Less confident about getting the facia on, but we'll see.
Your barn is amazing. The post and beam looks beautiful, and you have done an excellent job with the siding and roof.
But please dont go back and undo this roof that no one can see. Yes, you are a perfectionist but sometimes you just have to let a couple little ones by for the sake of getting things done. 1/16" to 1/8" sould be well within reasonable standards.
Keep up the good work. I am going to enjoy watching your progress no matter what you do.
But please dont go back and undo this roof that no one can see. Yes, you are a perfectionist but sometimes you just have to let a couple little ones by for the sake of getting things done. 1/16" to 1/8" sould be well within reasonable standards.
Keep up the good work. I am going to enjoy watching your progress no matter what you do.
Blackhawks63
Well-known member
Good luck on the inspection. Be prepared for the inspector to have a couple issues that will have to be fixed. It happens. They have to earn their salary.
Friday, Oct 25: Rear roof is 99% complete - I need my roofing supplier to bend the last piece for me, then I can install it.
Stuff left to do:
1) Trim/wood around doors
2) Hem ends of roof (front and sides)
3) Remove pump jacks
4) Install soffit facia on front
I was going to work late tonight (weekend will rain) but rather am going to get up early tomorrow.
Stuff left to do:
1) Trim/wood around doors
2) Hem ends of roof (front and sides)
3) Remove pump jacks
4) Install soffit facia on front
I was going to work late tonight (weekend will rain) but rather am going to get up early tomorrow.
mike93lx
ALLIANCE MEMBER
looks awesome. lets get some pics from a little back. that one above is great.
if you haven't stepped back in a bit to admire your work, please do. it's so easy to get buried in the details that it's sometimes hard to appreciate the whole thing
if you haven't stepped back in a bit to admire your work, please do. it's so easy to get buried in the details that it's sometimes hard to appreciate the whole thing
Jayman17
Well-known member
What a journey, and mostly done by yourself! Very nice building you have here. You should be proud. 
I like the siding, what brand/company is it?
I'm looking forward to seeing how the inside is finished. I know you said pallet wood so I think that will be interesting.
Jay
I like the siding, what brand/company is it?I'm looking forward to seeing how the inside is finished. I know you said pallet wood so I think that will be interesting.
Jay
Thanks!What a journey, and mostly done by yourself! Very nice building you have here. You should be proud.
I'm looking forward to seeing how the inside is finished. I know you said pallet wood so I think that will be interesting.
Jay
Siding (and soffit) is by Quality Edge - their "TruCedar", 10" board and batten. I was kind of frustrated as I had an impossible time finding a competitive brand with the same style of install and look. Overall I was pleased with it - but I'm trying to get six 10' boards replaced due to scratches that were on the boards. The distributor hasn't heard back from them, so I might give them a call directly.
As for the interior... that has changed slightly. I have a stack of pallet wood about 4' x 4' x 3'. I did not comprehend how much work it takes to rip pallets apart when I started. So, when I decided to do metal siding, I also decided to use the original siding boards for the interior. They currently take up half of the barn's interior
I figure I'll mix in the pallet wood where it makes sense, if it does. I'm right now angsting over whether I go horizontal or vertical with the boards... leaning towards vertical.
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Saturday, Oct 26: A waste of a day. I had one minor/major thing to do with that rear roof - snap on the last panel. But first I had to bring it to the guy who made my panels. Did I mention he totally screwed up the measurements? I needed a 1" wide pan for my last pan, yet the other side has an 7" pan. The starter should have been narrower. I blame myself as well for not checking his work, but c'mon. Sorry for the rant. Plus, a 1" pan is more of less impossible to snap on and hem closed.
Anyhow, he folded it (and scratched up more on the metal brake, yea), I spent several hours getting it snapped and hemmed on.
I had to make a special clamping tool because my metal folder didn't have enough purchase, and I was only able to bend a few inches by hand before my hands couldn't bend anymore.
Also did a bit of cleanup outside, broke down the 1/4" ply sheets I used for the temporary roof, it proceeded to rain, so I went inside and began the long task of breaking up the larger pieces of metal for the scap place (too long for my trailer), cleaned up the loft, and made another trip to Menards for some trim boards for the garage door.
Hopefully this post doesn't sound too negative I'm a bit bitter about the weather, but it could be worse - it could be snowing. It's supposed to be a balmy 58 tomorrow, dry, so I should get everything done. And if not, Monday is going to be even nicer - 62 - who needs to go to work anyways? I still have 21 days of vacation left
Anyhow, he folded it (and scratched up more on the metal brake, yea), I spent several hours getting it snapped and hemmed on.
I had to make a special clamping tool because my metal folder didn't have enough purchase, and I was only able to bend a few inches by hand before my hands couldn't bend anymore.
Also did a bit of cleanup outside, broke down the 1/4" ply sheets I used for the temporary roof, it proceeded to rain, so I went inside and began the long task of breaking up the larger pieces of metal for the scap place (too long for my trailer), cleaned up the loft, and made another trip to Menards for some trim boards for the garage door.
Hopefully this post doesn't sound too negative
I'm a bit bitter about the weather, but it could be worse - it could be snowing. It's supposed to be a balmy 58 tomorrow, dry, so I should get everything done. And if not, Monday is going to be even nicer - 62 - who needs to go to work anyways? I still have 21 days of vacation left Sunday, Oct 27: A much better day than yesterday, morning was rainy and windy, so I spent time cleaning the interior a bit. Then spent the rest of the day on the trim around both doors.
I took care of some long-standing things that needed to be done - added some flashing on the bottom sides of both doors, and removed the excess plywood around the side entrance.
Installed some custom flashing on the top inside to cover any exposed wood, installed trim at the top of the garage door, and made a bracket of sorts for the side trim:
It'll be pretty clear what I'm doing tomorrow.
Also started installing the strapping on this entrance:
Tomorrow, well, I pretty much have to finish everything.
I took care of some long-standing things that needed to be done - added some flashing on the bottom sides of both doors, and removed the excess plywood around the side entrance.
Installed some custom flashing on the top inside to cover any exposed wood, installed trim at the top of the garage door, and made a bracket of sorts for the side trim:
It'll be pretty clear what I'm doing tomorrow.
Also started installing the strapping on this entrance:
Tomorrow, well, I pretty much have to finish everything.
Monday, Oct 28: Progress!
Hemmed the roof caps:
Finished the garage door trim (need to remove the peel and stick, concerned it will remove the paint from the door):
Half-finished the side entrance surround:
Also, no pictures but:
1) Installed 2 of 6 pieces of soffit facia
2) Replaced a damaged piece of soffit I hit with the pump jack pick today
3) Removed the pump jacks!!!!
As to item #3 - removing the pump jacks really improves its appearance - proportionally, they made it look narrow and tall. Removing them made it look signifincantly squattier.
So... probably wondering, what's left:
1) Finish side entrance (main priority)
2) Install four pieces of soffit
3) If time, caulk then recoat the garage door trim
I figure, if I get flagged on the soffit I'll gladly pay the $35 for a second inspection. Plus, I'm concerned he'll want the exterior foam covered. But the entrance really should be finished. I worked till 9:00 tonight.
Hemmed the roof caps:
Finished the garage door trim (need to remove the peel and stick, concerned it will remove the paint from the door):
Half-finished the side entrance surround:
Also, no pictures but:
1) Installed 2 of 6 pieces of soffit facia
2) Replaced a damaged piece of soffit I hit with the pump jack pick today
3) Removed the pump jacks!!!!
As to item #3 - removing the pump jacks really improves its appearance - proportionally, they made it look narrow and tall. Removing them made it look signifincantly squattier.
So... probably wondering, what's left:
1) Finish side entrance (main priority)
2) Install four pieces of soffit
3) If time, caulk then recoat the garage door trim
I figure, if I get flagged on the soffit I'll gladly pay the $35 for a second inspection. Plus, I'm concerned he'll want the exterior foam covered. But the entrance really should be finished. I worked till 9:00 tonight.