Converting a cattle barn to a shop

[fflintstone]

After plowing the white fluffy stuff that fell overnight, I was able to go out to the shop and get something done. I now have OSB on the lower portion of the west wall. Soon there will be a 32’ long 4’ wide shelf 8+’ off the floor. (Just above the windows) the other day I put more backer board on the north wall behind where my bench grinders will be.
I want to get one row of foam board on the ceiling adjacent to the west wall. I will actually have to put more up above where my gorilla shelve will go.

South end of the west wall.

North end of the west wall.

North wall grinder area.
You can see the high mounted windo for venting the welding area in the corner.

 

[sids04]

Looking good.

 

[fflintstone]

looking good.

thanks!
Merry christmas all!!!

 

[JC23]

Keep it up, man. You're gaining on 'em!

 

[fflintstone]

Keep it up, man. You're gaining on 'em!

Yeah, I try to get between 2 and 5 hours a day out there but I have days I can’t get out there. Sometime today a mobile glass company is coming to put a windshield in my car. I will be out there working while they do that. After that thought I wont be out there till Monday.

MERRY CHRISTMAS ALL!

 

[JC23]

fflintstone.

In your early posts, I thought I saw a bit of light up on the top plates where they meet the roof rafters. What are you doing to fix that? And I'm curious how you'll be doing the ceiling in there - both in where you'll put it and how you'll insulate it.

 

[fflintstone]

fflintstone.

In your early posts, I thought I saw a bit of light up on the top plates where they meet the roof rafters. What are you doing to fix that? And I'm curious how you'll be doing the ceiling in there - both in where you'll put it and how you'll insulate it.

If you look at the latest west wall pictures you will see OSB above the 2” x 10”s that the trusses rest on. Before, the soffit area was wide open and the breeze would just flow thru (it acted as a carburetor venturi) the OSB is ½ - 1” below the roof tin allowing some soffit ventilation, but buffering gale force winds.
For now the ceiling will be just 1” ridged foam board. When money makes itself available I will add white roof tin as a ceiling. Until that time I cant add anything else. My trusses are on 4’ centers, and the foam board will barely support itself.
After I have roof tin up then I will add some loose fill stuff. I wont be going with a huge R-value though.

If I were still employed in the automotive engineering field I would have put pex in the floor and insulation over it. Due to the untimely occurrence of the global economy, I have to scale back future plans. I take pride however on scrounging bargains.

 

[JC23]

So you'll end up with a flat ceiling, then? Good. That will help retain your heat.

I dig the idea of using roof tin or even that plastic stuff that looks like it on the ceiling. I wanna do that on my next one.

Keep diggin' man. You're doing great on both the execution and documentation of your build.

 

[yamaharacing21]

lookin good man!! keep it up!!! i can't wait to see it with all the tools

 

[fflintstone]

lookin good man!! keep it up!!! i can't wait to see it with all the tools

Yeah me too! The tools that is, most of them will go against the west wall. That is why I want that wall done, the large storage shelf on the wall, and at least a few feet of foam board up on the ceiling. My wife moved the gorilla shelves in. she is tired of my Stuff in the house. I wanted to keep the stuff out till I am done. It is easier to move tha scaffolding around with less ****.
I am really tired of not having the right tools available. My impact is buried somewhere and I hate changing tires the old fashioned way. I bought my IR thundergun to use it!

 

[fiveohpatrol]

Good looking project you've got going. You may have already mentioned it, but how are you attaching the OSB on the walls? Looks like it's sandwiched between the posts, and not on the face of them. Just toe-nailing them?

 

[fflintstone]

Good looking project you've got going. You may have already mentioned it, but how are you attaching the OSB on the walls? Looks like it's sandwiched between the posts, and not on the face of them. Just toe-nailing them?

No toenailing. The OSB is screwed to the horizontal girts that hold the outer siding up. I had to find 3 ½ screws to go thru the 2” of foam board. You can see the horizontal girts in the early photos. I also have to screw the second layer of foam board down. I have learned that I was putting way more nails in the first layer than I needed to.

 

[fflintstone]

Did you ever have one of them days when despite your best intentions nothing you wanted done got done? I had every intention of starting on the shop well before noon and working till 6:00. Well I did get out before noon, but the wife has been pretty pissy about not having the winter tires on the van yet. I can’t blame her; we are supposed to have rain on top of the packed snow. Tires should be no big deal but the winter tires are on a rack way out back under a tarp and my impact is still buried on my trailer. So I plowed a path out back. Took off the plow, put on the bucket. Loaded up the tires brought them up to the shop. Drove to the neighbors to borrow an impact. Changed his standard fitting to my industrial size fitting. Put the impact on and no dice, definitely not my IR thundergun! So I had to hand crack all the lugnuts before using the impact. As you can see a simple project is not so simple.
After fishing that up and breaking for a late lunch, I had to put the plow back on the tractor in case of snow (not in the forecast, but pushing snow with a bucket *****) I tried to make some jamb extensions for the south wall windows. All the rough sawn wood I had was frozen together. After busting it all apart and putting it somewhere the sun can help thaw it, I decided to run the torpedo heater on the wood while I made a shopping list for lowes/HD. At 5:00 I cut my losses with nothing really done.
I promise to get some jamb extensions, insulation and OSB up tomorrow.

 

[jktruck150]

Thats ok, we all have them. Been there done that, funny how the "Honey do's" take priority! Keep up the good work!

 

[fflintstone]

As promised, jamb extensions, 2 layers of foam board and some more OSB up.

 

[sids04]

Wow it sure is coming together nicely. I imagine it's starting to get more comfortable temp wise as you get more osb up.

 

[V-10 Killer]

Coming right along, looking good man

 

[fflintstone]

Wow it sure is coming together nicely. I imagine it's starting to get more comfortable temp wise as you get more osb up.

I think once I get some of the foam on the ceiling it will definitely warm up in there. It was nice yesterday when doing the wife’s van because the sun was out, and all the south and west facing windows. Today it was a little cooler and no sun.
I need to find or make a wood burner though. I can’t really make one till I have 240V power out there. I picked up some stainless stovepipe off CL, but until I have a wood burner it makes no sense to cut a hole in the roof. I think I will pay my carpenter friend to do it actually, I don’t like being on steel roofing with my weight.

 

[fflintstone]

Coming right along, looking good man

Thanks! come up and check it out sometime. I am only 16 miles from Midland.

 

[willy3486]

Is that fence on the Ridgid tablesaw factory or is it aftermarket? I have a powermatic tablesaw I woulld like to have a new fence for it. The one that came on it has round tubes and is a piece of junk. That one you have looks great,if its aftermarket is it a mulecab brand? I looked at one of those a few years ago and liked it.

 

[fflintstone]

Is that fence on the Ridgid tablesaw factory or is it aftermarket? I have a powermatic tablesaw I woulld like to have a new fence for it. The one that came on it has round tubes and is a piece of junk. That one you have looks great,if its aftermarket is it a mulecab brand? I looked at one of those a few years ago and liked it.

It is an INCRA fence “system” mine was the 52” set up with optional router table and all the stuff to do dovetail joints. It was ungodly expensive at the time, but before 911 I had money shooting out of my A$$ so cool tools were bought a lot.

http://www.incra.com/product_tsf_lsts.htm

(About midway down the page)

The fence with all the extras was more expensive than the saw.

I will say that it is an awesome fence, and I do enjoy using it.

The adjustable infeed and outfeed rollers are something I made myself. If I was going to do allot of woodworking I would make in and outfeed tables though.

I am going to set up the saw for 240V. I specifically ran a 20A 240V line to run it and one of my drill presses.

The factory fence that came on my Ridged saw was actually pretty good. I think I got $50 for it on CL. I know the saw is cheaper now than when I bought mine and it may come with a cheesier fence.

 

[TheNerd]

Place is coming along great, keep us posted on the progress.

 

[fflintstone]

Place is coming along great, keep us posted on the progress.

Thanks! I picked up paint for the OSB today but I am too lazy to paint today. It is supposed to be warm tomorrow so I will try to hit it early.
The warm temps and the rain are making the show go away so I am hoping to “find” some stuff to bring into the shop.

 

[fflintstone]

The temps were over 40 yesterday so I painted 2 gallons worth of OSB and cement board. I am quite certain the OSB will look like ****. As I was finishing up, the early stuff was drying and looked real blotchy. I knew it would take more than one coat but I didn’t think it would be that bad. At any rate I am hoping it will be a lot more light reflective in there. I will try to post a picture after church today.

 

[TheNerd]

OSB will take a few coats of paint. I used some cheap Menards White latex paint, after 4 coats I could still see through it. After some swearing, I switched over to some Killz primer I had, worked great, but I still did two coats.

 

[fflintstone]

I love killz paint for problem stains and what not. I used a cheap oil based barn paint and hope for good two coat coverage.
There is real something wrong with our society when states are banning oil-based paint. There is a sticker on the lid that says not for sale or use in these states and lists about 15 states.

 

[Bevis]

what are you securing the rigid board to the walls with ?

 

[V-10 Killer]

How's the project coming along, any pics after the paintjob?

 

[fflintstone]

what are you securing the rigid board to the walls with ?

The first layer (1") of foam board is nailed with 1 1/2" cap nails. The second layer of foam is put up with 2 1/2" drywall screws that I have to add caps to by hand (pain in the a$$) then the OSB is held on with 3 1/2" drywall screws.

After I started putting up the OSB I figured out I was using way too many nails on the first layer. I really just need to hold the foam in place till the OSB is up.

 

[fflintstone]

How's the project coming along, any pics after the paintjob?

We had lost the charger to the camera batteries, but just found it yesterday. I am not pleased with how splotchy the first coat of paint is. However it does reflect more light. I don’t think it will be warm enough for a second coat till spring. If I find a wood burner for cheap, then I could heat it up to paint a second coat. I have been real lazy and have had motivational problems. As a result I have not been out there since I unloaded supplies from the trailer Sunday. I have to find my rotary laser, the next project is the 32’ long shelf and I wont do that without the laser. I have to crosscut some ¾” plywood and have to schedule with the wife to do that.
I have pretty much shamed myself to get out there early Thursday to get stuff done.
BTW your cabinets look great in the grey.

 

[fflintstone]

AAAAAAAAARRRRRRRRRRGGGGGGGGGGHHHHHHHHHHHHH!!!!

I got out to he shop early (for me at these temps) and with much “concerned high volume conversation” about saw safety from my wife, we managed to get the ¾” plywood cut.
Had some errands to run with the family and wanted to get out there at dusk to use the rotary laser to set my shelf height. I have been looking the last 3 hours for my @#$%^&^*& rotary laser and can not find it! I last used it to set up the layout for my cement pour in October. I took it to church when I was hanging some pictures, but I never used it there. I have not seen it since November and I am getting frustrated!
I am so sick of all my tools being under a tarp, or scattered here or there when I need them.

 

[V-10 Killer]

AAAAAAAAARRRRRRRRRRGGGGGGGGGGHHHHHHHHHHHHH!!!!

I got out to he shop early (for me at these temps) and with much “concerned high volume conversation” about saw safety from my wife, we managed to get the ¾” plywood cut.
Had some errands to run with the family and wanted to get out there at dusk to use the rotary laser to set my shelf height. I have been looking the last 3 hours for my @#$%^&^*& rotary laser and can not find it! I last used it to set up the layout for my cement pour in October. I took it to church when I was hanging some pictures, but I never used it there. I have not seen it since November and I am getting frustrated!
I am so sick of all my tools being under a tarp, or scattered here or there when I need them.

Aah I hear ya man,
The only thing more frustrating than that is going out afterwards and buying a replacement ....... and finding the original 5 minutes into the job. I did that about 4 times this spring remodeling my house
You'll get it how you want it, just a little more time.

 

[fflintstone]

AAAAAAAAARRRRRRRRGGGGGHHHHH 2! Well I gave up and let my wife look for it. And after about 15 minutes, she found where she put it. I had about an hour before “big bang theory” comes on so I thought I could sneak out and put some layout lines up. The laser is not a high end model and I get better results using it at night. I pulled it out of the case and tested it, as the last time I used it I could tell the batteries were going. No joy again! The unit takes 2 D batteries, and I found one loose battery in the junk drawer.
I can go a mile and a half to the corner store and pay $6 for two batteries(that have been sitting on a shelf for a couple years), or I can drive 15 miles (and back) to HD and buy 4 of them for $4. argh!
I did forget to mention I did pick up an unopened 5 gallon container of white oil based primer from the restore for $50. The cheap farm and fleet stuff I was using was $14 a gal or $65 for a 5 gal tub.

 

[fflintstone]

Ok I got my batteries and headed out around dusk, set up the rotary laser and marked my layout line for my 32’ long storage shelf. Snapped some picks of the paint on the OSB. The fiberboard did better with just one coat. As I posted before, I picked up 5 gallons of white oil based primer for the next go round but I don’t think temps will come my way till March.

Southwest corner

Northwest corner

 

[fflintstone]

Well I finally got off my dead **** today and went out into the shop. I made these jumbo shelf brackets for my big 4’ x 32’ storage shelf. I also cut the 16+’ oak fascia board for the front of it. I thought about routering the name of the shop into the fascia before I put it up, but that may slow my progress down. We will see how I feel about it tomorrow. One of them snowball things. If I router the name then I should really plane the roughsawn wood first; but the planer is under the tarp and 16’ long wood is a pain to work with.
Anyways here are my JUMBO shelf brackets.

FYI the plan is to put all the **** we have condensing 2 houses into one: into totes and put them up there. Then I put 2 of my drill presses and all of my woodworking tools under the shelf along that wall. I hope to get a mobile base for the joiner

 

[OBNXIOUS]

Those are pretty neat shelf brackets! Your build has been good to watch... and I can appreciate the budget consciousness! Keep up the good work!

 

[fflintstone]

Those are pretty neat shelf brackets! Your build has been good to watch... and I can appreciate the budget consciousness! Keep up the good work!

Yeah they are some big a$$ shelf brackets. Most people have no idea what the shear strength of ¾” plywood is. I want it beefy enough that I don’t have to worry what is up there.
The budget thing has really hit home. Property tax is due in less than a month and I have a killer CC bill from Christmas and getting all the little things. That being said I need to spend another $60 on four sheets of subflooring for the shelf. $60 here $90 there, all ads up when you are trying to get by on unemployment.

 

[SK Guy]

Good Luck with the project. Those barns are drafty, hope you can get it all sealed.

 

[2ndgenguy]

I enjoyed reading through your thread. Great job on the conversion so far, and sharp looking Jeep. I noticed you have EOD on your bumper, are you an EOD tech?

 

[Mikea57]

Love the shop, love the jeep man!! I've got a question for you about your board insulation. What R value would you guess you've got in there now? Did you do 1 or 2 layers of 1 inch, (I've forgotten now)?

I've got a 24' X 26' detached garage I'd like to insulate on the cheap and that looks like that might work!!

Oh yeah, and we went to Dallas over the XMAS to New Year's week and while there I took my boys to the Malibu Speed Zone that they have there. They have chromed 12" adjustable wrenches on the doors to use as handles there. That was the first time I'd seen that, and then a couple of weeks later I see the same idea on your build!!

Keep on plugging and good luck finding a job!