My 40x40 expandable metal build.

[Goose17]

First off, hello Garage Journal! Secondly, thank you for all the great information provided here. I have spent considerable time reading through threads here preparing for my garage.

I live in the greater DFW area and have a growing fleet of Mustangs. I have 2 in storage units, 3 at home and another one coming shortly. This is the reason I have been working on a garage.

My house is on a lake with the open area of the lot in the back yard. A big garage blocking the water view wasn't a good idea, so I was in search of land near my house. One section (a horse field) came up for sale and I had an unsigned contract to buy 1.5 acres. The seller backed out at the 11th hour and sold the lot to a developer. Needless to say, I wasn't too happy about it, but there wasn't much I could do about it.

Three doors down from me, my neighbor owns a big lot across the street. He has a small metal garage on it and there is an old dilapidated house that has been there forever. I approached him to buy the open area, but he wanted to keep that. He offered the small section with the old house on it and I took it.

First step was removing the old house:

After researching metal buildings, I went with Rhino. It wasn't the cheapest option, but it looked a little better built than some of the competitors. The guys at Rhino hooked me up with their best erector dude and he was fabulous, start-to-finish.

We added fill to raise the slab for water drainage:

Next was slab prep. I went with a 5.5" deep 40'x62' slab. The garage is initially 40'x40' with a basketball area planned for my 2 high school basketball playing sons. Once my sons move out/on, the remaining 40'x22' will "become" garage.

At this stage, I ran into a few week delay. The county came out and basically said I couldn't do what I was planning to do. Long story short (and many sleepless nights) the county relented and gave me the green light to proceed.

Next was a BUNCH-o-concrete:

Anchor bolts were put in place for the pour to anchor down the building:

The building finally arrived! Of course I am out of town with work and it was raining.

First beam getting erected:

 

[Goose17]

You can see the rear door that will access the back part of the "future garage," but it now goes out to the basketball area. We dropped the rear 40'x22' part of the slab down 1" so we wouldn't have water draining into the main garage area while that area is a basketball court. When the garage is expanded, the 1" drop will not be seen from the outside. It will look like one continuous building. The back wall will remain in place after the expansion and the people door will access the back area. I do plan to have a double car door and a side driveway added for the expansion.

Building complete minus the 2 12' high by 14' wide Raynor insulated doors.

An enclosed box!

Fill added for driveway:

Driveway forms in place and ready for more concrete!

The basketball area plan is to have one goal against the building with a 3-point shooting arc (this is why the back area is 22' deep) as well as 2 goals (one on each end) for play and dunking. I wanted the anchor holes, forms and anchor bolts done when the driveway concrete arrived since the trucks usually have extra concrete on them that goes to waste. My plan worked, but digging 2 monster holes in TX clay in July darn near killed me. Then I got to use a wheel barrow and haul concrete from the truck on the street to the back court. Needless to say, I am trying to flush those memories!

The monster basketball anchors (way overkill, but my 16 year old dunker bangs the goals hard!):

Driveway!

 

[Goose17]

If you only knew how many wheel barrows full of concrete were down in the hole! I actually lost count. It must have been the heat stroke!

Driveway curing with a summer retardant in the mix:

Awaiting for a couple basketball goals (one for each end). You can also see the weld-plates (far corner in pic) that have long anchor bolts that we put in the corners of the expandable area.

There was a delay at this point waiting on the utility company to connect power. My electricians hooked-up a meter base, but the power company took a couple weeks to connect. I had to pay to replace a transformer so the garage could get 200 amp service. The utility company then had to run power across the road and underground to my garage.

Here is a shot of the electricians SERIOUSLY SWEATING in my TX metal car oven:

I became a Sam's Club member and bought 30 Lights Of America 4' LED shop lights. I planned for 28 overhead and 2 for a workbench.

I was worried the lighting would be waaaay too bright, so I had the electricians separated the lights into 5 different switches. I actually got 26 lights up (due to garage door openers in the way) and with all the lights on, it is excellent light! I may try to get the missing 2 up somehow.

My industrial garage door openers don't have lights on them. I knew driving a car in there at night would be a challenge when getting out to find the light switches, so my solution was an LED motion sensor (with light sensor too):

I had my AC guy come and run 2 drains for HVAC so that when I get the walls spray-foamed, the lines would be buried. I plan on a 2 head mini split unit for AC and heat for the main area. More on the back area in a bit.

My 16 year old son was finishing the basketball goal install by attaching the net. The other 2 end goals will come in the near future.

So, a bit more info on my wiring and the back area... Since I will be having spray foam (more on that in a bit), I wanted the wires run now for the expandable back area. We ran a 220 circuit for another HVAC unit and 3 110 circuits (2 for plugs and 1 for lights). For the main garage, we also ran 2 220 circuits for future car lifts, 1 220 circuit for a compressor in a future loft (more on that in a bit) and 1 220 circuit for a future welder. There is a light switch for my future work bench that controls an outlet that is over the workbench area. I also have a light switch at the front door that controls a circuit for lights under the future loft. The "future loft" will be in one corner. I plan to build that out of wood. It will house an air compressor (with sound insulation) and a BUNCH of car parts. I plan to have a 2-post and a 4-post lift and might be able to use the 4-post lift as an elevator for the loft (an idea I got from this forum).

Another nice feature I got after talking with an electrician was the circuit layout... All of my outlets are quads and there are 2 different and independent circuits on each wall. Wall 1, the plug circuits go; A B A B. Wall two, they go: C D C D and so on around the building. There is also one quad in the middle of the workbench area that is on its own circuit. This layout should prevent too much load on any one circuit. Completing the electrical work is a dusk-to-dawn LED light at the front door, an outdoor waterproof outlet for my boys to play music while shooting hoops and a pair of LED floodlights on the basketball court controlled by switches inside the current garage as well as on the court.

Items remaining:

I am getting 2" spray foam insulation painted white on the 8th of August. Next will be HVAC to keep the space comfy. Other items are floor covering (probably epoxy), car lifts, loft, basketball goals, etc. etc. etc...

Well, that's my build thus far. Updates to follow.

 

[Catadj78]

Awesome build! Nice job on the lighting

 

[Savinyours]

What's the eve height? Very nice, mine is very similar, concrete should be poured this week.


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[ADSR]

cool build!

 

[Goose17]

What's the eve height? Very nice, mine is very similar, concrete should be poured this week.


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Walls are 14.5' to the ceiling with a 2:12 pitch roof.

Funny thing is it was much taller in person than I envisioned. I wanted high ceilings for car lifts, but I could have gone a little lower. In the end, I like the extra head room. I should have good space for storage in a loft.

 

[bluedog225]

Well done!

 

[930dreamer]

Very nice build.

 

[rslaback]

I can imagine why the city didn't want you to build it. The neighborhood looks to have nice expensive houses with manicured lawns and you just built a metal shed in the middle of it. It's a nice shop and all it just looks too industrial for a residential neighborhood like that in my opinion.

 

[Goose17]

I can imagine why the city didn't want you to build it. The neighborhood looks to have nice expensive houses with manicured lawns and you just built a metal shed in the middle of it. It's a nice shop and all it just looks too industrial for a residential neighborhood like that in my opinion.

There is no city. It's county. What you cannot see from the pictures is there are 2 other large metal garages near it and one small metal garage. Yes, the homes are nice (lake homes), but there are metal garages in the area.

The issue with the county was a street easement distance, but because of a paperwork issue on platting, I was grandfathered in.

 

[bullnerd]

TX metal car oven- lol!

 

[Goose17]

TX metal car oven- lol!

It's basically true. I checked the temp of my ceiling during the middle of the day... 142 degrees! The slab was 108 degrees (inside the garage)! Spray insulation is scheduled for the 8th and then it will be useable.

 

[matt_i]

Very good so far, I have a couple of questions, are you worried about errant basketballs denting the metal on the outside? Also I was looking at the formwork, usually a red iron building has massive boxed "holes" which become piers that support the columns, I didn't see those features jumping out. How did you get/make the foundation drawing?

Its probably not that big of a deal in your area but you could store boats in the winter for extra cash

 

[cajunfirehawk]

It's basically true. I checked the temp of my ceiling during the middle of the day... 142 degrees! The slab was 108 degrees (inside the garage)! Spray insulation is scheduled for the 8th and then it will be useable.

Congrats, closed cell or open? I live on the gulf cost and mine is an oven too!

 

[Goose17]

Very good so far, I have a couple of questions, are you worried about errant basketballs denting the metal on the outside? Also I was looking at the formwork, usually a red iron building has massive boxed "holes" which become piers that support the columns, I didn't see those features jumping out. How did you get/make the foundation drawing?

Its probably not that big of a deal in your area but you could store boats in the winter for extra cash

The spray foam will make the wall quite rigid, so I don't expect basketballs to dent the walls. Even without the foam, the walls are hard to dent. If I do get a basketball dent... Oh well.

Not sure what you mean by "boxed holes."

As for the foundation drawing. The building supplier provided an anchor bolt plan that the contractor used. The rest of the slab engineering was all done by the contractor that erected the building. He does these buildings all of the time and new what to do.

As for boat storage... I plan to fill the garage with cars! My boat gets drained and stays on the covered dock during the winter.

Congrats, closed cell or open? I live on the gulf cost and mine is an oven too!

For metal, closed-cell is needed. If you use open-cell, you'll trap moisture and get rust. Closed-cell also makes the walls rigid.

 

[bluedog225]

How do they form the step at the edge of your slab? Is that framed in or added when they are finishing? Thanks

 

[ScottsRX]

Great looking shed you've got there. Looking forward to seeing a few 'stangs in it.

 

[rieferman]

From one basketball dad to another... Nice work. Your boys will remember these good times forever.

 

[NUTTSGT]

Nice build and I have moved it to the Gallery Section. Keep taking plenty of pictures and make updates.


Did you ever consider putting the building up at the rear of the slab and put the basketball area out front ? When they're not playing ball, it could have been a parking area, car wash area or a place to set up for parties/get togethers.

 

[egnorant]

As a fellow Texan I love this build. I must say I was a bit concerned when I saw the metal going up with no insulation, but was relived when I saw the spray on solution.

Texas Metal Car Oven might be a brand name here in Texas!

Looking forward to seeing the Mustangs too! I currently have 3 project mustangs going right now. A couple are getting convertible tops (70 and a 91) and an abused 97 Cobra is getting all its boo boos fixed. 2 more are right behind these...69 convertible and an 84 GT Turbo convertible. If you run across a good Mustang II I have a silly project in mind!

Looks like your having fun.

Bruce

 

[Gator-J]

I am glad I found this one.

I just moved into a new house with a separate garage that looks to be the brand you purchased but in the 30'x40'x12' flavor.

I moved the shop in during 96 degree 110+ heat index weather over July 4th. I will concur with the car oven! Needs exhaust fans for sure.

Although mine is quite a few years old it is still the plain uninsulated steel walls. I have been contemplating what to do with interior walls.

What are you plans? Will you frame it out?

 

[bluedog225]

With regard to the heat, I put the Black Jack elastomeric white cool roof product on my shipping container. No vents. Checked my temp guage recently. Outside temp was 103F.; inside temp was just 105F. Much lower than I expected. The container gets full sun from about 11 am to 6 pm. Worth checking out. Water based and goes on easy.

 

[Faster346]

Looking great so far. I'm in the lighting stages of my building now, still not sure what route I'm going to go. Would you mind sharing what those lights ran you money wise? They look pretty nice!

 

[Goose17]

How do they form the step at the edge of your slab? Is that framed in or added when they are finishing? Thanks

That lip was created with wood when the slab was poured. This was the recommendation of my general contractor and prevents any water from entering your metal building.

From one basketball dad to another... Nice work. Your boys will remember these good times forever.

Thank you sir! I have a couple expensive end goals left to buy and I also have to paint lines on the court.

Nice build and I have moved it to the Gallery Section. Keep taking plenty of pictures and make updates.


Did you ever consider putting the building up at the rear of the slab and put the basketball area out front ? When they're not playing ball, it could have been a parking area, car wash area or a place to set up for parties/get togethers.

All good on moving it. I moderate a Mustang forum and understand the need to stay organized.

As for the basketball area... If I had it in front, when I expand the garage in the future, I'd have to buy 2 new big (and expensive) car doors. I didn't want garage doors between the sections, just a people door.

 

[Goose17]

I am glad I found this one.

I just moved into a new house with a separate garage that looks to be the brand you purchased but in the 30'x40'x12' flavor.

I moved the shop in during 96 degree 110+ heat index weather over July 4th. I will concur with the car oven! Needs exhaust fans for sure.

Although mine is quite a few years old it is still the plain uninsulated steel walls. I have been contemplating what to do with interior walls.

What are you plans? Will you frame it out?

I am having spray foam done on Aug 8th. They will also spray everything white. I think the white sprayed foam will be my inside walls with the exception of maybe some peg board at the workbench for tools.

Looking great so far. I'm in the lighting stages of my building now, still not sure what route I'm going to go. Would you mind sharing what those lights ran you money wise? They look pretty nice!

The lights (2-pack Lights Of America 4' LED strips) ran $65ish per box (per 2 lights). I think I spent a little over a grand for the lights, tax and shipping from Sam's Club.

 

[Goose17]

The Mustang fleet for those that were asking:

 

[AFBud78]

Do they put plastic up before the foam so you can replace a piece of metal down the road without messing up the insulation? With my luck the mower would throw a rock and dent or pierce the metal right after I foamed everything.

 

[heffneil]

If you use a closed cell you have to use a Thermal barrier I am told. I was quoted a price of about $4.50 a square foot for the closed cell with Thermal Barrier. Not sure why I keep uppercasing it. I am looking at a 40x 60 building and its very expensive with 16' high wall to insulate with foam.

 

[NUTTSGT]

Helluva collection you have. No four eyes ?

 

[LXCam]

Holy ****, you're serious about your stangs uh?

Congrats on putting together one very nice building. Is it strictly storage and lite duty wrenching or do you do more serious wrenching on the rides too?

 

[Goose17]

If you use a closed cell you have to use a Thermal barrier I am told. I was quoted a price of about $4.50 a square foot for the closed cell with Thermal Barrier. Not sure why I keep uppercasing it. I am looking at a 40x 60 building and its very expensive with 16' high wall to insulate with foam.

There is no "barrier." The foam is sprayed directly onto the metal.

Helluva collection you have. No four eyes ?

No "4-eyed Stangs" for me right now. My oldest is the 89 GT vert I bought in 91. I've been buying a ton of new parts to restore it factory new. I have another Stang coming in a couple weeks.

Do they put plastic up before the foam so you can replace a piece of metal down the road without messing up the insulation? With my luck the mower would throw a rock and dent or pierce the metal right after I foamed everything.

No plastic. Foam is applied to the metal and it makes the walls rigid. If you get a dent... Oh well. If you get a hole... Something serious had to hit it. I'd just patch the hole on the outside with a piece of the colored metal.

Holy ****, you're serious about your stangs uh?

Congrats on putting together one very nice building. Is it strictly storage and lite duty wrenching or do you do more serious wrenching on the rides too?

The building is a place for my Mustangs to live and get worked on. I've done all the work on the Shelby myself and enjoy tinkering with the cars. I haven't done any serious wrenching (like pulling motors/trannies), but may in the future.

 

[OHenry]

This is exactly what I was looking for. Very nice!

 

[Kevkx125]

Nice build on the shop and any mods on the 93 cobra?

 

[Goose17]

Nice build on the shop and any mods on the 93 cobra?

The 93 Cobra is original down to the tires and stereo and sporting 11,000 miles. It looks, drives and smells like a new car. It's a time-capsul. It only comes out a few times/year for a little exercise.

 

[Goose17]

After a long delay, the garage got prepped today for spray foam insulation. The sprayers will be back in the morning to insulate. I had a different spray foam contractor that turned out to be not so honest or good. He is gone and the new company looks promising.

 

[Seq]

Are you happy with the Rhino building? Getting ready to order mine from them this week.

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[Savinyours]

So what was the reason you went with garage doors instead of roll up's? I assume cost?


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[cajunfirehawk]

So what was the reason you went with garage doors instead of roll up's? I assume cost?

I did the same, two reasons; looks and I could get them insulated.YMMV

 

[Goose17]

Are you happy with the Rhino building? Getting ready to order mine from them this week.

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YES! I shopped around. Rhino looked to be the best built from what I saw. I have no complaints - all good.

So what was the reason you went with garage doors instead of roll up's? I assume cost?


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It wasn't cost. These doors were way more expensive. The doors I have are made by Raynor. I went with these due to their insulated R value. I plan to heat/cool the garage.

I did the same, two reasons; looks and I could get them insulated.YMMV

I agree they look better, but I simply went with them since they were the best insulated door the building company offered.