Above 1200 Sq/FT Barn Workshop build

[ururk]

Things look like they are still progressing well. I agree with not using a ladder - biased as I don't like being on ladders.

I hope the temps and weather in general work with you!

Thanks - the weather outlook is good, but can change as we all probably know.

I really would have loved to use ladders - cost savings is one of the reasons. However... the ground is uneven (I've considered leveling feet), I'm only one person who can actually climb the ladders (my family members can't, or shouldn't ), and it takes a lot of time to go up/down/move/etc... There are ladder jacks... but those are one trip away from the ER. I'd love to use the pump jacks, but I'm going to try and sell those soon and they won't work well with some of the areas I need to reach.

So, while it is very tantalizing to use the ladders, my sense is that if I don't rent this machine I'll be working on it through October and won't have a roof on. Even if I have to put siding on with a ladder, that I can do.

 

[ururk]

Friday, August 19: Finished perforating the flashing coil stock. 22 full jobs @45min and a final job at 30 minutes. Bending flashing tomorrow.

 

[ururk]

Saturday, August 20: Made the flashing! I've never done this before, but the process went pretty smoothly. Cut the roll to specific lengths, mark an offset, mount and roll cut, then mark where to bend and load and bend.

This is how it will be installed (viewing the bottom):

At first it seemed like the perforations were going to be a problem - I tried to bend the 1" first with the perforations on the *outside* of the clamp. They are not as structurally sound as solid flashing material. Ended up flipping all the pieces around and bending the 1" part first with the perforations under the clamp.

In addition to all of this, I stopped over at a paint store to look at stains. I have already made some general choices - semi-solid stain for the wood in a dark blue, chocolate brown trim (door, windows), and roof to match the house. However, I'm toying with the idea of a galvanized roof (clear) instead of a paint color. This picture shows the stain color I got as a sample, as well as the two roof samples. I think I'm going to need to go a shade darker for the blue:

Tomorrow I'm going to pick up plywood and rip it to 3" widths for the strapping, and install the flashing, and get the first one or two courses of peel and stick installed on the back wall.

 

[ururk]

Sunday, August 21: Bought some 3/4" 4x8 CDX - I'm making my furring strips out of this material.

Pretty straightforward process, just clamp and saw! Using my grandfathers Craftsman saw, better than the cordless for all of these cuts.

 

[1/2 Cup]

Awesome work, thank you for sharing..

 

[ururk]

Monday, August 22: Trying to do something - anything - each day. Hopefully frequent updates won't annoy anyone, it helps keep me motivated when I fall into despair or think, "I'll do it tomorrow".

Finished cutting the furring strips. I'll probably need four more sheets of plywood, but this will get me started.

Attached the flashing to the rear wall. Ran a bead of silicone caulk against the wood before putting it on:

Goal tomorrow is to get two side pieces of flashing installed and the first piece of peel and stick installed as well. It is going to rain Wednesday, so I should really get the ice and water over the flashing.

 

[ururk]

Tuesday, August 23: Got two more pieces of flashing on. I didn't get further because I had to replace a 6" x 27" piece of OSB that got wet from a plant leaf. Lesson learned.

One side, the other is a mirror image.

It's going to rain the next two days, so I might start marking out the window openings where I need to cut. Machine arrives Friday night or Saturday morning.

 

[matt_i]

Great work using CNC to make the punched coil stock! That is very unique and is going to look great.

I ended up buying a used Tapco trim brake for my build, it has been so helpful to have on-hand and I'm still thinking of ways to make it work for me. At first I planned to sell it off but I really like working with coil stock...so...it might find a home in the attic..

I also put in Andersen 400 series windows, not cheap but hopefully will pay off long-term, like 15 years from now. My free advice is to bend some more coil stock to make drip-caps for your windows. Imo that is the belt-and-suspenders approach.

The siding, trimming and finishing process takes a long time, admittedly, but I feel like paying attention to small details like laps, etc, is going to pay off down the road in less maintenance and a long-life building. Looks like you are going thru that phase also. I keep envisioning myself going out to work "in" the shop rather than "on" the shop. But its still enjoyable 95% of the time. Keep plugging away, interested to see more updates.

 

[ururk]

Great work using CNC to make the punched coil stock! That is very unique and is going to look great.

Thanks! It might be just a bit on the overkill end of things.

I ended up buying a used Tapco trim brake for my build, it has been so helpful to have on-hand and I'm still thinking of ways to make it work for me. At first I planned to sell it off but I really like working with coil stock...so...it might find a home in the attic..

Yeah - it was fun to work with the flashing. The best part is as long as I buy material from them, I can use their brake.

My free advice is to bend some more coil stock to make drip-caps for your windows. Imo that is the belt-and-suspenders approach.

Yep - I will be making some of that.

Keep plugging away, interested to see more updates.

Will do!

 

[ururk]

Thursday, August 25: Got 1/2 a roll up tonight! Only 8.5 rolls to go.

First, I applied a strip of flashing to the corner, as I was concerned the sharp ends of the OSB could rip the Perm-A-Barrier - after applying the barrier, I don't think the flashing was necessary. Then applied a layer of their recommended primer for OSB.

Had to wait for it to dry (1 hour) then put the first strip on:

And got the second strip on:

I'm not happy with the bottom - I wanted to overlap the flashing more than I did. I think it will be fine - but I will probably apply some flashing tape to the bottom for extra protection.

Ideally I'll be able to get a lot done over the next week. It only took 2.5 hours to do 1/2 a roll, so realistically I'm looking at 30 hours of work for the remaining pieces. That's assuming it doesn't get significantly harder as I move up, and I'm able to retain my helpers for that time

 

[ururk]

Saturday, August 27: One more row, was able to start a bit earlier.

 

[ururk]

Saturday, August 27: More peel and stick. I'm getting better at it, I think.

Primer:

Third row on:

--intermission (rain)--

Last row:

Finally put two pieces of flashing on:

Tomorrow I'm going to skip the primer on that first row where I added the flashing - I think the peel+stick will stay on the OSB. It is fairly "rough" and the OSB doesn't seem to have a waxy finish. Plus, provided I get the foam on in a reasonable amount of time, it won't have time to peel away as the foam will squish the Ice+Water.


Side note: I'm a perfectionist. This doesn't mean everything I do is perfect - look at those horrible wrinkles in the vapor barrier. That being said, as I work on this project my standards have fallen, or rather, what I will accept. In my mind everything is perfect and true down to 1/16". In reality I am elated when things are within 1/2". I started out measuring with a measuring tape, but now use the wildly imprecise markings on the side of the barrier to cut pieces to length. Maybe this is a good thing

 

[ururk]

Sunday, August 28: Bunch of updates:

Finished installing the flashing, primed one side of the barn, and installed more Perm-A-Barrier:

Cut down the door frame/box (was 1" too wide). Flashed against it. Installed the flashing and Perm-A-Barrier on the other side:

Started cutting the sidewall girts for the windows. Sigh, even with a laser level I still spent more time working on this than I ought to have:

This is one window box - basically it will stick out 5.125" from the external sheathing. I decided to call it quits for the day, next update should include the other window being installed and hopefully flashed:

 

[sean Buick 76]

Really nice work on this project I appreciate your attention to detail!

 

[ururk]

Monday-Tuesday, August 29-30: Haven't been able to do anything on the barn - been finishing up a project not barn related. I designed (based off a sketch of a running chicken) some race medals for a local run happening this Saturday. A local casting company created the molds and casted the medals in aluminum. Little did I know what I was getting myself into:

This is the finished product sans ribbon, looks better in person. The castings had gates that needed to be ground off (borrowed neighbors bench grinder). I used on old belt sander (mounted upside down to a sawhorse) to smooth the backs and edges. Then polished all the medals (40 in total) with a dremel and brass polishing wheel. Finally, a few dabs of sparkly green paint. And lastly a clear coat over the shamrock.

All in all a pretty cool experience, but just one side project which has pulled me away from the main project, the barn. Hopefully updates tomorrow!

 

[ururk]

Wednesday, August 31: Installed two window boxes. I finished the one I started a few days ago, and put a new one in:

Thursday I'm going to flash that side of the barn - took Friday off so I can (hopefully!) begin to put foam up.

These aren't completely finished - I have to put in a piece of wood on either side vertically (on the inside) to provide support for the box and allow me to eventually trim out the window. When this is done I don't want any OSB or plywood showing.

 

[ururk]

Thursday, September 1: Finished off the inside window boxes - these uprights are the same wood as the horizontal girts, but they don't have the same amount of sun exposure. Loctite construction adhesive, and screws through both the OSB and plywood frame hold them in place (and, conversely, the add some support to the window box).

Once the inside is finished (in about 10 years ), I will have trim covering up the plywood and gaps around the plywood.

Also - those knots look "terrible" but when I made my cuts, they only are through the top 1/4 of the board.

 

[ururk]

Friday, September 2: Progress! I actually think I can finish this project.

Two rows of peel+stick:

Then more:

I'm not happy how I flashed the tops of those window boxes, but they should be fine.

I also put another piece of the bottom flashing on, just one piece left to install.

Sunday and Monday my goal will be to put some peel+stick on the opposite side, and put the Ice+Water on the lean-to roof. Right now it has a combination of housewrap and temporary Ice+Water. Also start putting some foam sheets on the back end!

 

[ururk]

Sunday, September 4: I had ambitious plans, but a late start to the day and I only got a little bit done:

Ripped off the old Ice+Water shield. Though the tar held up (no leaks!), the top paper was starting to degrade in the sun:

One piece on - I also got the second course up.

Additionally - no pics - but I started marking out the second floor window opening.

 

[ururk]

Monday, September 5: Again, didn't get as much done today as planned, another late start beyond my control:

Marked and ready to cut:

This is how I cut the bottom sections - screw on an OSB guide:

Test fitting:

Installed:

In addition, I didn't take pictures because it was too dark, but I installed a row of Perm-A-Barrier. Goal tomorrow: beat the rain and install all of the membrane on that side. We'll see.

 

[ururk]

Here's how the inside of the window box was finished:

 

[ururk]

Tuesday, September 6: Finished putting up the membrane on the gable end:

Worked into the night:

 

[ururk]

Wednesday, September 7: Didn't have any help today, had to move all of the tools from the upper floor. By the time I moved everything, and got the next window box partially in, I had to stop due to how late it was:

I should be able to get the other two partially in tomorrow, and Friday fully install and start installing more membrane on the outside.

 

[ururk]

Thursday, September 8: One window box installed, two more to go:

 

[ururk]

Friday, September 9: One window box installed one more to go*:

It's been raining on and off, though it looks like a dry spell starting tomorrow for a whole week.


*Technically 1.5, since I never cut the hole for the middle window.

 

[ururk]

Saturday, September 10: Installed the upper window box:

 

[ururk]

Sunday, September 11: Finished installing the inner window box frames and more membrane:

I still have to screw in the upright pieces of wood, but I have to wait until I remove the housewrap. Any day now

Trying not to get discouraged. I keep thinking I can get more done in a day than what I end up doing. I'm taking Monday off.

 

[Modern Jess]

Trying not to get discouraged. I keep thinking I can get more done in a day than what I end up doing. I'm taking Monday off.

Hah! So true. I can't tell you how many times I have started out the weekend with big plans, only to get mired down in details and then wonder where all the time went.

Story of my life.

 

[ururk]

Monday, September 12: Got a ton done today - the weather was *perfect*. Temperature was constant through the day, slight breeze, no humidity.

Started priming the last long stretch:

Two rows on:

Found a little friend hiding under the housewrap:

And this frog was in a nook that I was getting ready to caulk:

At least these two were cuter than the hornets nest on the opposite side.

I removed the temporary OSB sides and replaced them with a correct thickness/depth 3/4" plywood frame:

Last corner of flashing:

Final shot of the night - worked till about 9. So, I was out for 12 hours, which is pretty good.

I am slightly - ok greatly - embarrassed about my job site neatness. I should figure out a way - large table, etc... to organize all of my tools and stuff while I'm working. Frankly, the area is somewhat secluded, can't see it from the road right now (trees) except from the private drive, so it's just me and any help that sees my lack of organizational skill.

 

[smschriefer]

You are getting close to having it all wrapped. Then comes the fun of siding. I do apologize in advance if you had stated your intentions, but what are the plans for siding? Board and batten, cedar clap, shingles?

 

[ururk]

You are getting close to having it all wrapped. Then comes the fun of siding. I do apologize in advance if you had stated your intentions, but what are the plans for siding? Board and batten, cedar clap, shingles?

4" of foam on the exterior (8" on roof) and then siding. So, a bit more to do

I'm following this type of technique:

See: https://buildingscience.com/documents/insights/bsi-056-leiningen-versus-the-ants-redux

 

[sean Buick 76]

WOW, I love it!

 

[bunks-tj]

great build i cannot wait to see it finished.

 

[ururk]

great build i cannot wait to see it finished.

Same here

 

[ururk]

Tuesday, September 13: One more row on!

One more 1/2 row, and one full row left. Depending on the rain, I might remove part of the tarp tomorrow when I get home and start the longer rows. I have a bit of wood I have to trim flush on both sides. Only 60 feet :O. Hopefully I can use my sawzall to do the trimming, otherwise it will take a long time.

 

[ururk]

Wednesday, September 14: Front is all done:

Priming:

Done!

Tomorrow the tarp is coming off and I will begin the roof membrane!

 

[ururk]

Thursday, September 15: Did I say the tarp was coming off? Sort of. One major step I had to take was to trim the edges of the 2x6 T&G roof decking. I wasn't too sure how to tackle it, as the angle was too steep for my corded circular saw, but it turned out that my cordless's angle was greater than 45 degrees.

This is what I had to trim - all 30 feet of it:

I ran the boards ragged originally, so each piece was a different length. I made up a guide from a scrap piece of plywood:

Prior to the guide I was trimming one board every 3' with an oscillating tool and running a pencil line - this guide sped up the time to trim and I got both sides done before the sun was fully down.

No peel and stick membrane today, unfortunately. I have to go to a wedding tomorrow, so I might not get any work done Add to this forecasts of scattered rain, and it might be a slow two days. However, I have some prep work I can start on, so it may not be all bad.

 

[y'sguy]

Just caught up with this awesome project. Love it!

 

[ururk]

Saturday, September 17: Sigh. Rained most of the day. I have two more rows to finish on the barn, finished one today - a total of 16' was applied.

 

[ururk]

Sunday, September 18: Beautiful day, I just need a few more of these and I'll be set.

Here's what I started with today:

Starting the last horizontal row:

Finishing the third roof row:

Tarps are mostly off at this point:

Last row - only need 9.5 more feet of the barrier, which I'm out of. I can use the roofing membrane, but am checking with MasonPro to see if they can get me a scrap piece.

It is such a relief to see the tarps off! No rain in the forecast. Hopefully the next update will include foam installation, but probably not since I need to get the roof boards covered.