Above 1200 Sq/FT Barn Workshop build

[ururk]

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.

Thanks!!! Sometimes I need a bit of encouragement to keep going, comments like these help!

As for matt_i - did not see his build! Thanks for pointing it out. I'm so deep into my project that I only come here to post, and spend most of my time worrying about the weather.

 

[ururk]

Thursday, May 18: Glued up the last of the window flanges:

I'm using biscuits to keep the two boards aligned. A thinner piece of plywood is then placed below this joint, creating a much stronger joint.

Frame ready to be weighted down:

It is impossible to see, but there are 3/8" strips of plywood below the top piece, (same width as the flange) coated with glue.

All weighted down:

My goal for Saturday is to get this installed, but not the window. It will likely rain Sunday, and I'm still waiting for parts from Marvin.

 

[ururk]

Saturday, May 20: I got a little bit done, but was rained out.

My goal was to install the window in the front, or at least get the opening ready. Unfortunately, I wasn't able to get any help in moving the pump jacks so moved them myself. It turns out the basic process was pretty "trivial". I unhooked it from the brackets, and slid it along the eaves, then picked it up and repositioned the bottom, moving slowly and deliberately . In truth, this was easier than in the past, so I might use the same technique to move them back to the side.

After getting the walk plank set up, I trimmed the window box (as I did with the other boxes), cut the 2x6 reinforcement, and it began to rain.

I'm still waiting on Marvin/Lumberyard for the missing foam corner gaskets. They were able to order a replacement crank handle... but evidently Marvin doesn't have a part number for the flange foam that they can order.

 

[ururk]

Saturday, May 27: It was a rainy week. Not steady - but enough to prevent me from doing anything outside. I finished the rough opening for the window, but still am waiting for replacement parts. I've been told they will arrive by the 31st.

I'm still trying to make a decision on the roofing material, but I think I've more or less made up my mind. I'm probably going to go with the local company downtown that rolls their own product. I was waiting for one more installation quote - it came in earlier in the week - clearly I cannot afford to have someone else do the work.

 

[ururk]

Figure I'd make a quick status update. I just picked up the replacement parts for the windows - I intend to install the window one day this week.

Additionally, I ordered a few things to make the siding process go quicker. A digital readout for my planer, and a Dust Deputy for chip collection. A future post will likely show my setup.

I got sidetracked a bit - not only is the barn going to get painted, but the house and shed as well. Unfortunately, the shed has suffered a bit of rot since the T1-11 siding was in contact with the ground, so I spent today trimming off the bottom 3.5", and replacing it with Boral trim (allows for ground contact, made form fly ash). I still have a bit of work to do on the shed, but will finish it tomorrow if it doesn't rain.

The "good" news is that I was able to choose a color.

 

[ururk]

Turned out nice today - again didn't get to the barn, but I nearly finished the shed rehab. I've sort of neglected things around the house while the workshop has been (and continues to be) under construction. Anyhow, this is sort of related tangentially so I'll explain...

We have a small 12'x16' garden shed, along with needing a coat of paint, the side trim boards were rotting from ground contact, as well as the bottom edge of the siding. We had brick pavers on the front, and a little deck on the back for garbage cans and such.

I'm using this opportunity to try out a rot-free trim option, Boral TrueExtrior. It's sort of like MDF, but made from fly ash so supposedly it is impervious to water. I'm trying it out to see if I like working with it enough to use it on the barn. Priced somewhere around the cost of Azek, it isn't cheap. I might just go with cedar or cheap pine.

The large blue splotch on the left is the chosen color. It is a bit on the green side. We picked one of the blues on the right from a swatch in the store. However, under certain lighting conditions, it veered towards the purple side.

Nearly done with the replacement trim. I'm not sure I like the stuff. The dust worries me (wear breathing protection, duh), and I'm not certain how long it will hold up. It seems fragile, though it hasn't cracked on me. No splits - I don't think it can split. It is trim - and not structural - so maybe I'm overthinking it.

Anyhow, I have to finish the trim this week, and will get to that window.

 

[ururk]

Tuesday, Jun 6: Finished the shed the other day. Not completely happy with the Boral. I know I dislike Azek, but honestly, I feel at least Azek won't crumble in your hands. I get the feeling from working with Boral that it needs to be handled carefully. I might end up using an PVC trim on the barn after all.

Anyhow, I didn't quite finish the window install today. I got the opening trimmed out as I've been doing:

Shimmed and done except the outside flashing:

It isn't going to rain tonight/tomorrow, should be OK.

 

[ururk]

Wednesday, June 7: "Finished" the window install:

I still have to spray foam around the frames, so technically the windows are not fully installed.

Next - order the metal roofing material and start processing some siding!

I haven't ordered the metal roof because I need to go in and talk through the install process to make sure I can do it. I'm still a bit afraid of the whole process - whether I can finish it in a reasonable amount of time, etc... but I have to start it soon, as that tarp probably has only two months of life left.

 

[Blackhawks63]

Hire someone to do the roof. They will bang it out in two days with the right equipment and know how. Not worth breaking your neck and given your way of doing things you might not get it done before the snow flies in December.

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[ururk]

Saturday, Jun 24: Had a bit of delay - was out of town for a week, and got food poisoning on the way home, that sure was "fun".

Anyhow, no pictures but I cleaned the barn, broke down a few pallets, and installed a digital readout on my planer. Over the next week I'm going to be planing my siding when I get home from work each night!

 

[Adkroot]

My timber frame build is a wrap and strap very similar to yours -xps sheathing as well. How do you like the performance of the 3m all weather flashing tape? I'd been considering siga wigluv having bought a roll, and it sticks very well to the xps, but costs quite a bit more than 3m.
Did you also find a caulking product that you found adhered well to the xps?

 

[Spareparts]

ururk, havent had a update for a while how is everything going. You didn't tackle that roof by yourself did you.

 

[smschriefer]

Yeah, ururk, we've been curious what you are up to. Hope all is well and the heat isn't unbearable.

 

[ururk]

My timber frame build is a wrap and strap very similar to yours -xps sheathing as well. How do you like the performance of the 3m all weather flashing tape? I'd been considering siga wigluv having bought a roll, and it sticks very well to the xps, but costs quite a bit more than 3m.
Did you also find a caulking product that you found adhered well to the xps?

I chose the 3M product because of that "real world test" of various flashing tapes - for my project it seemed good enough, and I couldn't afford the expense of wigluv. I have used some asphalt-based flashings for other parts of the project (Grace 12" flashing, as well as 6"), and cannot imagine installing that stuff all over the foam. I don't know how wigluv holds up horizontally, but I know other asphalt-based flashings will sag over time and need to be taped at the top. I'm sure a siga rep could address that concern.

I really like the 3M product, and am happy with my choice. Where I've had to remove the tape, it almost (but doesn't) pulls bits of foam with it. The only annoyance is the split liner - if you have to use that feature, it often tears in the middle. I wasted a ton of time trying to remove half the release liner, but thankfully that was only at penetrations (window openings). However, the ease of availability (Amazon Prime!), cost (check eBay prices too), and variety of widths made it a good choice for my project.

As for caulk, I haven't use any. There are a couple of areas (around windows) where I probably should have caulked, but again for my project I felt I probably didn't need to. I did use spray expanding foam in some areas. I messed up royally in this department - I should have bought a foam gun with refill cartridges - rather I bought individual spray foam cans.

Now... I will need to caulk above my windows when I get to the siding, but it will be inside a cut so probably won't be too critical. I will probably use an OSI product if they have something rated for foam.

 

[ururk]

ururk, havent had a update for a while how is everything going. You didn't tackle that roof by yourself did you.

Not yet.

Yeah, ururk, we've been curious what you are up to. Hope all is well and the heat isn't unbearable.

Sorry for the lack of updates. Not to make excuses... cue excuses: I've been helping prepare the house for a large get together, which has involved a lot of work I was not planning on. Painting, caulking, and so on.

The heat has been pretty bad, but thankfully it has decreased. Inside the barn it isn't all that bad - even with the high humidity outside, inside it feels comfortable. I don't yet have temp/humidity monitoring, but will once I get electric later this year.

In the interim I've been putting together a dust collection system for my planer, almost done, and have been trying to find a resource to guide me with the metal roof. For the former, I just didn't think the updates would be worth it.

As for the metal roof - yes, I still plan to tackle it. I think I've settled on a product - but am trying to find a lumberyard that sells it that can also help give me just a tiny bit of training on installing the product. I've watched numerous YouTube videos, but the product I'm looking at and the install instructions include additional steps that I don't quite understand from the line drawings. I talked with their technical support department, but they are geared to support Wholesalers so, the guy could only answer a few of my questions.

I really don't trust the company downtown which mfg's the panels in-house, although they did offer to give me an hours worth of training.

So... I'm really stuck in some respect. However, I'm going to plug away at my siding, and will settle on a product for the roof before the end of this month.

 

[Spareparts]

Thanks for the quick reply, all of us old coots worry about you youg guys tackling such a project, of course at your age we did the same thing, but we were bullet proof, LOL Just be safe when doing it so you can enjoy the shop when you are done, sorry we are never done with our shop's.

 

[ururk]

Wednesday, Jul 12: Finished my dust collection setup - only took three weeks to put together . Again, been busy on other areas of the property, and have (reluctantly) put the barn project on the side. My checklist has shortened considerably, so work can resume.

I've built a bunch of stuff specifically for this build, but this time I put together something I plan on using for a long time, though I will probably upgrade the vacuum one day. I bought a Dust Deputy - these things separate sawdust from the air using a spiral motion. In my limited testing tonight, it works as expected!


To start I cut out a lid for the garbage can on the CNC:

Added neoprene tape to the groove:

And bolted the dust deputy onto the wood lid:

The smallest dust deputy has 2" outlets, so I 3D printed two 2" to 2.5" hose adapters. I also had to buy a fitting for the planer to adapt that 4" outlet to 2.5". The vacuum (negative) pressure is sufficient to keep the lid on.

I was on the fence on this purchase - they make a bigger unit - but for what I expect to do long-term, this is the right size. Right now for planing the siding, it might be slightly undersized.

Expect over the course of the next week or two to see some siding planing updates, though I might not post pictures every single day, as the task is quite redundant.

 

[ururk]

Update: I found a local company that will manufacture my roofing. It took a while - and while it was a long wait it was worth it. The owner came recommended to me by way of a barn consultant I highly respect, and my concrete foundation contractor coincidentally was going to use him for his roof based on recommendations from other contractors.

Essentially, it will go up in two parts - he's making all of my trims first - ridge cap, channels to capture the pans, and any flashings. I'll install those, and then from measurements of those, he will cut the panels to length.

I hesitated in posting as there was a delay, and wasn't too sure if I was going to be able to use him for my project. The main reason I want to go with him, beside the recommendations (and reasonable cost) is his installation method. Most of the standing seam snap lock roofs use "barn trim" on the eaves, z-clips on the ridge caps (and any pitch transition), which result in perforations / rivets / screws all along the roof, not to mention the tricky detail of doing all of that while the pans are up. His system uses a sliding ridge cap, and two long pockets that hold the top of the panels to the roof. All of the trims go up first, then panels are hemmed and slid into the pockets while the snap lock is snapped in.

So... that's that. I've been busy doing other things, unfortunately, that took me away from the barn but those are almost done and out of the way.

 

[ururk]

Thursday, Sept 14: Took a little bit of back and forth, but I ordered the metal roof material!

I'll be getting the roof in two separate deliveries:

1) All trims (drip cap, ridge caps, etc...).

2) Pans

The first delivery should be ready in two weeks, at which point I'll install the trims. From there I'll measure between receivers to get measurements for the pans. Based on how this will be done, I should not have to cut any pans to length, just cut the 1" where it meets each drip edge.

 

[smschriefer]

I'm sure you're glad to get the roofing ordered. On a plus, it won't be as hot outside for the install. Looking forward to the install!

 

[Blackhawks63]

Any pics of the siding up? Hope you can get that roof done safely and before winter sets in. That roof of yours has already had a lot of time and exposure to the elements in it's unfinished condition. You don't won't to invite seepage, mold and rot. Godspeed to you on finishing it up safely and fast.

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[ururk]

I'm sure you're glad to get the roofing ordered. On a plus, it won't be as hot outside for the install. Looking forward to the install!

Same here!

 

[ururk]

Any pics of the siding up? Hope you can get that roof done safely and before winter sets in. That roof of yours has already had a lot of time and exposure to the elements in it's unfinished condition. You don't won't to invite seepage, mold and rot. Godspeed to you on finishing it up safely and fast.

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The tarps have held up extremely well - the foam itself is more or less impervious - though my concern lies with the tape, as it is not rated for as much exposure as it's gotten. But, with the tarps hopefully they block enough UV to keep the tape from getting ruined - the tape on the sides is still intact.

 

[ururk]

Saturday, Sept 16: Replaced the last piece of T1-11 on the house... oh wait wrong project. I've been repainting the house (while I waited for the roof to be ordered) and beside paint, I've replaced trim, sections of T1-11, re-caulked, fixed windows. Almost done.

Started planing siding:

Only 190 boards left.

 

[ururk]

FYI - township extended the permit for another year, but I really want to wrap this up this year.

Sunday, Sept 17: Got a bit more planing in today. I might not make a post for each time I work on the siding since I may only get a few boards done each day. I have a very bad feeling I should have started this part sooner, and I'm not certain my planer is up to the task, to be honest. This was one part of the project I just didn't think through carefully. I made some assumptions about rough sawn wood that I shouldn't have.

General procedure is as follows:

Plane to 7/8" thickness
Roll on wood preservative (all sides)
Prime (all sides)
Paint (one side)
Cut / preserver / prime / paint ends
Install with screws

I can't install the siding until I have the roof on, otherwise it will get rain behind it. While a little moisture won't hurt, I don't want massive amounts of rain to get behind it.

 

[ururk]

Provided the weather works out in my favor today (rains), I should get my first roofing delivery this week. That will give me at least the weekend to get it installed!

 

[Deezler]

Nice! Yeah get that roof on ASAP. I hope you'll feel a big sense of relief after that. With winter coming, I would do the siding on the north & west sides first, perhaps?

Glad your foam on the roof held up fine, I recall somebody issuing dire warnings earlier in the thread. I am always nervous about building projects until the roof is dryed in. Sometimes it takes a lot longer than you hoped.

keep trucking on it man!

 

[ururk]

Nice! Yeah get that roof on ASAP. I hope you'll feel a big sense of relief after that. With winter coming, I would do the siding on the north & west sides first, perhaps?

Yes - almost read my mind (is weather always worse on those sides?). I have to do the portion above the lean-to first as I don't want to walk over the pans. Then I'll do the lower side, then move onto the west side.

Glad your foam on the roof held up fine, I recall somebody issuing dire warnings earlier in the thread. I am always nervous about building projects until the roof is dryed in. Sometimes it takes a lot longer than you hoped.

keep trucking on it man!

Yes - I was concerned but more-so about the 2x4's. The ends exposed to sun have greyed a bit. Hopefully that doesn't impact their strength.

I planed a couple more boards yesterday and today. I realize I should have started on this sooner...

 

[Blackhawks63]

Roof first and foremost. It will be huge to get that done. Then you can do the siding at a pace that suits you. Bet you can find a good used planer on Craigslist. Set up an assembly line of sorts inside the barn to plane, prime and paint. Then once you have a decent stack done go outside ad put them up. Heck you could even put some up in the dead of winter. Do your caulking and trim work next spring when it warms back up.

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[ururk]

Roof first and foremost. It will be huge to get that done. Then you can do the siding at a pace that suits you. Bet you can find a good used planer on Craigslist. Set up an assembly line of sorts inside the barn to plane, prime and paint. Then once you have a decent stack done go outside ad put them up. Heck you could even put some up in the dead of winter. Do your caulking and trim work next spring when it warms back up.

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I’ve been looking, but so far nothing I can use. I think I need something that runs on 220 - 2-5hp range. I found one nearby but I don’t have power at the barn. I’d consider wiring up a temporary outlet at the house, but then I’d have to move all the siding twice yet again. The other option is run it off generator power - but that assumes my generator could handle the initial current spike (I don’t think it could), and I have unlimited funds for gas (I don’t).

I like my Dewalt - it just isn’t built for the board feet I’m running through it.

 

[ururk]

Update: first part of order should be delivered today. This is all of the receivers and drip edge. Once I install, I measure for the pans and he makes the pans to length + 1".

Also... I think I mentioned the siding that I have to plane to thickness. Well, the Dewalt was just not cutting it. I got through 35 boards in 2 weeks, which isn't fast enough with winter approaching. I found a great deal on a 220v, 3HP, 15" planer - $200 - and am picking it up today.

Finally, this report makes me happy:

https://weather.com/forecast/national/news/october-2017-temperature-forecast-the-weather-company

Above average temperatures, which means this should be a comfortable install, ignoring any rain/etc...

 

[ururk]

Saturday, Sept 30: Metal trim was not delivered - he evidently got a call from a builder and has to finish a job today for inspection on Monday, will be delivering the material tomorrow. Should I be worried? Hopefully not.

Picked up the planer - not sure whether I should run it up by the house or run a long 220 line down to the barn. I'd love to run a temporary 220 hookup to the barn, but it is a bit costly - I'd need about 120' in total of line. Machine has a 3HP motor - 20A - and I could locate it next to the garage and run a 20' pigtail off the electrical box temporarily while I work. Not sure what to do.

 

[mike93lx]

A 3hp 240v motor won't draw 20a unless it is locked up. Should be half that while running

 

[ururk]

I'm still rehabbing the planer (new belts, grease, etc...), but here's a picture of it in the Element:

 

[ururk]

Sunday, Oct 1: Drip edge and receivers were delivered. I set up the walk plank from the pump jacks for my work table. Probably the smartest thing I've done on this project

Removed the tarps from the roof, and the hanging pieces of house wrap:

Amazingly, the tarps were in perfect condition. They could have survived the winter! Anyhow, I felt a slight dampness as I took them off, so probably for the better. No mold/mildew/smell. Just a few abandoned hornets nests.

 

[ururk]

Monday, Oct 2: Got about 1/3 of the drip edge up.

 

[BoilermakerFan]

Holy cow man! I just read through the thread from the beginning. Subscribed!

 

[smschriefer]

Congrats on the progress! It is really looking good. On another note, if that is you in the last photo, you need new shoes. lol

 

[ururk]

Congrats on the progress! It is really looking good. On another note, if that is you in the last photo, you need new shoes. lol

LOL. Yeah, I've been chastised for about those shoes. I only wear them for special occasions . I didn't really pay that close of attention to the picture.

 

[ururk]

Tuesday, Oct 3: Finished the drip edge on the gambrel portion (missing two pieces) and installed the receiver for the ridge: