Above 1200 Sq/FT Cleaning Up My Shop

[RickP]

Great progress photos on the construction!
You did a bit of work building this house.
I imagine you slept well every night the last couple of years.

The garage is the hill on the left. You can see the bond beam is being filled and rebar is ready for another level.

That should be a very strong wall. Our mason just used wire mesh for the horizontal reinforcement. I like your way better.

And the custom L blocks you made for the garage slab were a great idea -- I wish I'd done that in a couple spots...

I also placed sheetrock nailers on top of the wall spaced 1-5/8" apart. You can see the gaps on top of the wall above. I measured and put them in place at my leisure to get them accurately placed.

Another great idea! I'll bet the guys working at your site appreciated your labor and time saving tricks like this one. (not to mention the built-in QC check from having all the truss spacing pre-measured)

Here's the box in place on the near side.

I'm going to use this one next time I need it!

Your house (and your view) look absolutely amazing!
Nice work.

 

[RickP]

But I do have to take issue with one of your posts:

I must admit I'm surprised I didn't give up.

"We do this not because it is easy, but because we thought it would be easy"

I have to ask: when's the last time you gave up on anything?

For a project that's this big, your stubborn streak serves you well!

 

[oldironfarmer]

Lot's of blank space on this wall, but she didn't want any windows there.

Tothe left of the wide opening (kitchen window) is a pantry and the laundry room left of that.



I put a window in the crawl space.

She asked why?

Because I wanted to, natural light, and it makes it look like a room.

Oh.

The other side would be hard to scaffold. The forklift is just the ticket here.



We've had rain and the river is up. This is Lake Keystone backwaters when the lake is full.



The locals call the woods between the waters an island. 50 years ago it was an island, the slough was connected on both ends except during very low water. Now it's connected by silting except during very high water. The vegetation accelerates the silt laydown, of course.

An old friend stopped by. Darrell was a telephone man, farmer, and great friend.



Time to do something about the slope downhill of the garage door.



You can see where the form got away during the garage slab pour.

 

[OnWildcatMountain]

I hand built trusses for the cupola. They can just be handed up.



At this stage we had a wind storm.



Just before dark the wind was 30 mph out of the south and the cupola was leaning. I shouted at Shane and scrambled up with a ratchet strap and got it stabilized. He arrived soon after and we got the one he brought up. with two straps on it we were able to jack it back plumb. In retrospect it was a risk not worth taking but we got lucky. No more wind forecast but we got sheathing on it in a few days.

The kind lady threw a fit when I started to put roofing steel on. I hired a local guy and his dad and they got started.



She was being unreasonable, the purlins make a ladder but I compromised. I carried the metal and stacked it on the scaffold for them.



It was good to see steel going up. Purlins kept magically appearing on the roof.



I decided against sheathing the roof because the material was high. 2x4x16 was much cheaper and makes a solid roof. I used to build pole barns so I was comfortable with this design. We had decided to use spray foam and it will stick nicely to the underside of the sheet metal.

I doubt the lady was being unreasonable. She just couldn’t have you hurt since the plans were all in your head!

 

[oldironfarmer]

Great progress photos on the construction!
You did a bit of work building this house.
I imagine you slept well every night the last couple of years.



That should be a very strong wall. Our mason just used wire mesh for the horizontal reinforcement. I like your way better.

And the custom L blocks you made for the garage slab were a great idea -- I wish I'd done that in a couple spots...



Another great idea! I'll bet the guys working at your site appreciated your labor and time saving tricks like this one. (not to mention the built-in QC check from having all the truss spacing pre-measured)



I'm going to use this one next time I need it!

Your house (and your view) look absolutely amazing!
Nice work.

Thanks for the kind words. Since I'm not an experienced builder I'm free to dream up stuff.

Although I slept pretty well, I would wake up in the middle of the night worrying about how I was going to do the next step, and was there anything else that needed to be done first. I got lucky and didn't have to undo much of anything.

Some guys really don't appreciate being asked to use a new method. I usually give in because the cat will still get skinned.

The lady and I did most of the work and no complaints from her. Shane would come by after work and on Saturdays and help. We tried to have stuff ready for his strong back.

The mason wanted to help fill blocks (he was working by the block so filling was on his time) but his helper didn't want to rod the cavities and much as I did so I did that myself for the most part. If you can get the wet concrete to settle more by rodding then it wasn't full and I wanted no gaps in the fill.

The metal guys were all a lot better than I was so I really appreciated them.

My buddy Mark is an old refinery construction hand and very savvy. We worked together well when he could be here.

But I do have to take issue with one of your posts:

I have to ask: when's the last time you gave up on anything?

For a project that's this big, your stubborn streak serves you well!

Ha! I'm a quitter. I give up on stuff all the time. Right now I'm fixing a stubborn fuel leak on the filler to my purple 35 Chevy. The radiator hose that was installed years ago is very hard. I thought about putting sealant between it and the tube but instead I just gave up on it and am fixing it right.

I gave up on working a full time job. It just takes too much time.

The list is endless, I just gave up on trying to add to it.

 

[oldironfarmer]

I doubt the lady was being unreasonable. She just couldn’t have you hurt since the plans were all in your head!

Good point! My ace in the hole was to not make written plans someone else could follow so she had to put up with me or not get her house finished.

Say, what does the sign say on your avatar? I can't quite make it out.

 

[oldironfarmer]

Here's a good friend that stopped by. Todd and I worked together in Houston from 13 to 15. Knows his chit.

I bought Bob from his dad. He's laughing because the lady and I had no adult supervision on the house design.



He also doesn't approve of my scaffolding. Notice he wears fire retardant clothing for leisure wear.

The only place you can see the hatch on the cupola roof is from the ground is from this angle.



Such a nice place for a steel platform, what a view it would have...

We decided to put faux stone on the bottom three feet of the house.



It is not any cheaper but is quick and I can install it. It also does not require a foundation and some places it goes a long way from solid ground. It goes up in 8" by 36" manufactured panels.

Some panels are raw ends for straight runs and some have finished ends to go on corners.



It looks pretty good if you don't do a close inspection.

Sheet metal guys installed the stained glass window the lady had made for the stairway.

 

[RickP]

The vertical rebar and concrete will make your walls incredibly strong:

The mason wanted to help fill blocks (he was working by the block so filling was on his time) but his helper didn't want to rod the cavities and much as I did so I did that myself for the most part. If you can get the wet concrete to settle more by rodding then it wasn't full and I wanted no gaps in the fill.

And you definitely did it right!

Our porch has block supporting a slab, and it has horizontal cracks along the bottom of the slab. I should have done the reinforcement myself like you did...

The metal guys were all a lot better than I was so I really appreciated them.

You were smart to hire the masons, window, and metal guys. It looks they did a good job, quickly.

 

[oldironfarmer]

It was hard to get to the window on the end of the dormer.



Roof is about done.

I gave up on trying to make a simple roof line to save on installation so we've got lots of valleys.



Left a ten inch gap in the stone on the porch. My plan is to put half a cedar log on each end appearing to support the porch, then a full cedar log on each side of the steps.



The stone stops at the porch level.

I spied a 1930 Model A in the drive



I was in the cupola hiding out while the lady worked.

Darrell and his eldest son. That boy is about 6'-8" and a tight fit in a Model A.



Darrell was having severe health problems and passed away a few months later. He kindly sold me the Model A, knowing I liked cars but had trouble acquiring them.

 

[oldironfarmer]

The vertical rebar and concrete will make your walls incredibly strong:

And you definitely did it right!

Our porch has block supporting a slab, and it has horizontal cracks along the bottom of the slab. I should have done the reinforcement myself like you did...



You were smart to hire the masons, window, and metal guys. It looks they did a good job, quickly.

They are strong, solid walls. The bond beams add immensely too, with concrete encased horizontal rebar.

I really didn't want to hire help, but the lady kept saying she would like to see the house finished in her lifetime.

It was the smart move contrary to my desire.

I also have to say, she has never had a new house before and is very excited about this one. Her statement has been "if I don't live to see it finished, the excitement and enjoyment has been worth it". That idea humbles me greatly.

 

[oldironfarmer]

We took a day off and took the pontoon boat ten miles up the river from Lake Keystone and saw this new house being built.



Cool! Snooty rich people but I like the house.

Getting windows in!



Wish I'd hired a framer. They would have fit better...



Old saying: Powder and paint, makes a girl, what she aint"

Same can be said for trim and caulk.

Time to dig a ditch to get power and water to the house.

The power pole is on the property line but actually within the neighbor's yard.

Everyone gets along.

 

[patlun]

I really didn't want to hire help, but the lady kept saying she would like to see the house finished in her lifetime.

It was the smart move contrary to my desire.

I also have to say, she has never had a new house before and is very excited about this one. Her statement has been "if I don't live to see it finished, the excitement and enjoyment has been worth it". That idea humbles me greatly.

Interesting and impressing as usual. Sometimes we need help to make the best decisions, sometimes the best decision is to hire help

 

[Finallygotit]

Andy, just out of curiosity, about how many square feet of living area did the house end up being?

 

[jblnut]

I gave up on working a full time job. It just takes too much time.

The list is endless, I just gave up on trying to add to it.

Best thing I ever did was quit my full-time job! I used to work 45 to 50 hours a week and now I work 70+ and wouldn’t change a thing.

Well, not that I can really change it, but my new boss can be a bit stubborn and hard to deal with at times.

This morning the kids and I sat down and read through the updates on the new house, and Leo asked who Andy was. I told him Andy was the person that made Mom the trivet we use every day on the table. He immediately said, OK, I like Andy!

 

[Seagoon]

Ah! The innocence of youth

 

[oldironfarmer]

Interesting and impressing as usual. Sometimes we need help to make the best decisions, sometimes the best decision is to hire help

Yeah. I like hiring good help. The problem is I seem to just sit and watch them work. And run and get stuff so they can keep busy. I can't get much done when someone else is there.

Andy, just out of curiosity, about how many square feet of living area did the house end up being?

I think right at 3,000 sq ft plus 500 sq ft in the heated and air conditioned garage.

Best thing I ever did was quit my full-time job! I used to work 45 to 50 hours a week and now I work 70+ and wouldn’t change a thing.

Well, not that I can really change it, but my new boss can be a bit stubborn and hard to deal with at times.

This morning the kids and I sat down and read through the updates on the new house, and Leo asked who Andy was. I told him Andy was the person that made Mom the trivet we use every day on the table. He immediately said, OK, I like Andy!

Was that the job installing electronic systems in barns, etc,? Or are you still doing that? You certainly got me telephone service in my shop. Thank you again.

You can tell Leo I like him too. I'm glad he and his sister age getting to grow up on a farm regardless of the uncomfortable chores.

 

[oldironfarmer]

Started installing, from left to right, power to the pump, power to a future gate opener/utility outlet, water line in a yellow gas pipe used for a conduit, and power from the pole.



Power to the pump, water from the well, power to the opener.



Common ditch from this juncture to the house. I put the freeze proof spigot at the juncture in part to help find it later. The house is on a softener, the spigot is not.



Metal guys took their forklift home so I'm back to scaffolding.



It was really hot, they were really tired, and they got a job remodeling inside a giant warehouse so they walked. A local guy and I finished the soffits and other undone tasks. Gray metal below the red, gutters, downspouts.

Wayne came back and laid the stemwall for the front of the porch.



Bob obliged us by using his strong arms and back to move pallets of block close to the job.

Thanks, Bob.

 

[oldironfarmer]

I've been working on the wiring for some time. Just about finished.



The furnace for the great room goes in the attic space just between the steel beam and the flooring (upper left).

I broke down and rented a Home Depot 35 ft lift to get all the soffits done. It was expensive but really handy. Saved money since I was paying the guy to put up soffits.



The site is a little tight but Bob pushed it in and out with ease.



The stained glass window fits right in.



After getting prices for insulation I find an old acquaintance's cousin has a spray rig. he was less expensive and almost faminly.

His schedule was also better and I knew I'd get no hidden extras. Wiring in exterior walls had to be done before they showed up.

 

[oldironfarmer]

Insulation sure went fast. He had a big crew, 8 to ten day one and day two.

Where it grows past the surface of the wall they have to shave it back. Also lots of masking and lots of cleanup.



It was great fun to watch. I'm still cleaning off overspray.

The spray every other cavity then go back and do the infill after the first has cured.

I could still run some wiring which did not touch the outside wall/roof.



I managed to get the soffit lights in before they two blocked me.



All the while we're doing soffit and trim.



I spent off hours cleaning windows.

 

[oldironfarmer]

Decked the front porch on the new stemwall.



Got sheetrockers started.



Looking like a house





Started running ductwork for the HVAC central unit.

 

[jblnut]

Was that the job installing electronic systems in barns, etc,? Or are you still doing that? You certainly got me telephone service in my shop. Thank you again.

You can tell Leo I like him too. I'm glad he and his sister age getting to grow up on a farm regardless of the uncomfortable chores.

Yup. Worked off the farm doing mostly Lely milking robot installs and repairs. I enjoyed it quite a bit but don’t miss most of it.

Good to know the phone system is still working !!! You are welcome. Anytime !!

Words can’t express how much I appreciate the opportunities we’ve been given to live on a farm.

The kids just keep getting bigger !!

 

[Farmall450]

You seldom see engineers with a tool.

Hey now, I'd argue a keyboard is a tool with the right hands!

 

[Farmall450]

It was really hot, they were really tired, and they got a job remodeling inside a giant warehouse so they walked. A local guy and I finished the soffits and other undone tasks. Gray metal below the red, gutters, downspouts.

Did they ask/discuss it with you, or just quit? That's crazy to think a legitimate business would do that under any sort of typical arrangement unless you were paying day by day or whatever.

 

[oldironfarmer]

Did they ask/discuss it with you, or just quit? That's crazy to think a legitimate business would do that under any sort of typical arrangement unless you were paying day by day or whatever.

I was paying by the hour. It's one man and four or five semi-regular hands. Pretty good guys just trying to make a living.

No hard feelings on my part but I did only have that day for notice. They did say they'd be back when it cooled off but they were too busy then. I hadn't waited anyway.

 

[oldironfarmer]

Funny I had to design my own gutters. The local steel building material supplier didn't have a design for the pitches I needed. The salesman did give me some guidance but I had to provide them a sketch.



Sheetrock work is slow on a 20 ft ceiling.



I had set up a second rolling scaffold for wiring and the insulators, drywall, taping, and painting crews all used them.

Updraft furnace, I made the outlet plenum out of OSB lined with ductboard. Cheap and sturdy.



Four ten inch outlets going into the great room.



Coming into the great room.



The idea is to keep air rolling top to bottom and avoid stratification. 20 ft is a powerful driving force.

 

[oldironfarmer]

Trim and guttering in place, the odd roof line worked out ok.



Plumbers had their work cut out for them. Second floor bathroom had minimal fall through the floor of the attic trusses, the toilet and shower are on the far side and the tub joins close.



Then we modified plans and went with a dropped ceiling in the closet to get fall to the end of the closet toward the middle of the house running under the trusses. It is impermissible to drill holes in attic trusses like this. You can see in the previous picture electrical boxes for lights which will have to be relocated to the false ceiling.



I made a little box in the corner to accommodate a3" pipe going down a 2x4 wall (3-1/2" and 3-1/2") in lieu of building a 2x6 wall.

It's already fall 2022.



There's an aerobic system (big one) that's been sitting in the driveway for months needing to be moved down a steep hill, around a corner, and across the back to it's final installation spot.

Yes, his and hers FJ Cruisers.

 

[oldironfarmer]

The gentleman who brought the 25 ton rig over, and supplied the bulk of the washed rock used for fill around the block walls, has a big gin pole truck which had been down for years.

He had taken the radiator in to a shop in Tulsa. It was stolen while in their yard and they claimed they didn't have insurance. He bought a new radiator and installed it so he could do this job. It was the only way he or I could figure out to move the box. 6' by 6' by 14'.

I had thought to pick, boom out, set, walk the crane closer, repeat. He was sure there was not enough room to extend his outriggers and we would need a lot of cribbing on the hill.

First step was to notch the edge of the fill from the basement to make a place to set the tank. He brought a little track hoe.

He was sure he could negotiate the sharp turn with this long truck. He was really fighting the steering wheel.

Slow and easy and keep it low

It is steep and no room to maneuver.



The lady is his truck driver who has delivered most of our stone. She is savvy and runs gin pole trucks picking and hauling heavy oilfield loads. The other lady is the homeowner, keeping the neighbor's dog from getting under the truck.

She'll be coming 'round the mountain when she comes...



Once he made the corner it was easy.

I was glad to have it set.



And he charged surprisingly little.

 

[oldironfarmer]

We had some rain. I enjoyed watching the gutters work.

I found some leaks the metal crew had left. Dripping through the insulation.

Chief climbed out of the cupola, across the rood, and found where a kid on the crew putting ridge cap on had pulled screws back out to relocate the ridge cap he had put on crooked.



No choice but to inspect the entire ridge line for missing screws. Chief is part mountain goat.

Started filling around the septic. The sewer line will pretty much be on grade and we'll haul in dirt to cover it and make a yard.



Started building retaining walls to create flat places for the outdoor units.



A little crusher run and we'll have someplace to set them.



Bob likes hauling gravel.

Sheetrock is starting to define how the inside will look.



Yet to patch the clips which are 1/4" thinner than the drywall. I was going to use trim boards but ultimately just mudded them.

 

[oldironfarmer]

Leveled between the retaining walls and set the units. 5 ton for the big room and a four unit mini-split for the west wing. The east wing has one also.



Cleaning windows in the morning.



They don't seem to be getting clean.

Lights all work well. 15w led's at $6 each online.



Thin disk lights, dimmable. I was concerned with getting enough light down 20 ft so put in plenty, a constellation. They can be dimmed to get the light level desired.

Drove down to the causeway across the slough.



Handrail for the balcony. Decided to go with glass panels to retain the view and discourage toddlers from climbing over.




My great grandson was here so he volunteered to fab up the handrail.



Although he usually welds high pressure pipeline piping he did ok on the structural. I had to balk at putting on connections to pressure test it.

 

[oldironfarmer]

This is the hatch I fabricated for the cupola roof. It has tiedown lugs now, and was not welded yet in this picture.



I was looking for a stone to make a front step. My trim carpenter offered this out of his yard. It was an old foundation stone.



Initials and dated 1921 (upside down)



Time to start buying plywood for the cabinets. The best deal in Tulsa was Dakota Hardwoods.



And we ran a surface drain from the house outlet to the septic.



I use a shim under a level to get the fall right.

 

[oldironfarmer]

Parked the Lightning in the garage for one night.



The remote possibility of fire has kept me from doing that again.

Added remote control shades to the windows.



They are wired for recharging. I wasn't smart enough to think ahead and wire in the wall.



So I ran surface wiring.

Sample of cabinet construction.



Some in place.

 

[oldironfarmer]

A driving south rain led to some leaks. Dang!



Tracked the issue to where the sheet metal transitions to under the windows. Sealed all the windows again and had no further leaks.

Shower guys came and installed the shower glass and the balcony glass.



Built a lazy susan in the corner cabinet. I was able to get larger trays than if I'd bought package units.



Planted some pine trees to replace cedar trees that we removed.



And caught both my Ford trucks up at the house. 2015 F-350 SRW and 2023 F-150 Lightning.

 

[oldironfarmer]

Front view with the house closer to completion.



The trim guy is a neighbor's son but has some good experience. He suggested turning the window aprons with a miter instead of a 15 degree cut. I liked his sample.



Carpet guys showed up.



And the granite guys showed up.



I was still working on a roll around island.



Trash drawer on the right, spice storage on the left, storage behind.

 

[oldironfarmer]

Corner cabinet above, to the right of the sink would be an access issue so we designed some open shelves for display.



Fortunately for me Shaker is in vogue so the doors are simple and everything gets white paint.



We waited until after carpet to put down baseboards.



Here's the island with casters



Lots of doors to make.



And lots of drawer fronts.

 

[oldironfarmer]

Cabinets in place.



Of course we started using them as soon as they were set.

Refrigerator sets in front of an opening into the pantry so it can be pushed back as far as desired.



Put shelving in the closets (I still have some to go)



And shelving in the pantry. The refrigerator is behind the door.



And my man Shane put up subway tile.

 

[oldironfarmer]

I didn't do too good on grading plans prior to excavation so I've had to add two retaining walls to make a gently sloped back yard which goes up to the crawl space doors but leaves the basement walls exposed. I should have run the concrete blocks farther. But I didn't.



The sewer line exits the house right under the window above.



Bought the lady a gift to watch wildlife.



The view from the cupola is nice.

 

[Finallygotit]

Just amazing work Andy!

 

[Farmall450]

I was paying by the hour. It's one man and four or five semi-regular hands. Pretty good guys just trying to make a living.

No hard feelings on my part but I did only have that day for notice. They did say they'd be back when it cooled off but they were too busy then. I hadn't waited anyway.

All's well that ends well.

 

[oldironfarmer]

All's well that ends well.

And getting aggravated just ruins your day. Not theirs.

 

[oldironfarmer]

Just amazing work Andy!

Thanks, Dan!