Shipping Container Workshop (aka The Bunker)
- Thread starter TheWalrus
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Lou's Garage
Well-known member
Looking Good! Keep us updated as you progress.
Lou Manglass
Lou Manglass
toyotadriver
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- Joined
- Dec 30, 2010
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Looks good. Did you paint them? If so, what type/brand of paint did you go with?
Is there an access inside between them? How did you handle the roof?
Is there an access inside between them? How did you handle the roof?
They were originally one 40' hi-cube container; cut in half, ends welded up, personal door fitted in the original end opposite the main doors. Painted by the co that supplied them (RAL Bottle Green).
The plan is to join them together internally by cutting out part of the dividing walls, insulate & board them out, install power and use as a workshop to restore my 4x4 van - which is currently in a rented unit about 30 miles away. Where they are is about 5 miles up the road.
I've got to be a little bit careful with the planning permissions for the site; they have to stay transportable and stay classified as 'temporary' buildings, so any work I do can't be too permanant or the classification changes and I'll need planning permission. So all the conversion work means they have to stay easily seperatable (if thats a word).
First job I'm going to do is bolt them together. Next will be to cut out the access, then I'll be using foam/mastic/flashing to 'seal' the gap between them. Insulation is going to be the foil type stuff - gravotherm (spray on foam insulation) would have been my preference but it's beyond my budget. Next frame it internally, then another layer of foil, then board the frame over. There's a power pole right next to it - I'll talk to an electrochicken when I'm nearer ready for that part as to the best way to get power connected.
The access won't be to the full interior height of the container so I'll see if I can get away with just bolts to hold it together, rather than having to weld in a couple of support beams. Nothing will be going on the roof (except me to fill the gap/waterproof it).
At the moment its essentially a big sealed box with no windows (only the tiny original container vents), so I need to think about proper ventalation as I intend to do some welding in there, plus emergency lights as it's very dark with the doors closed for if/when I trip the power - I don't want to put windows in it. The double doors will be locked/bolted on the inside so the main access will be the personal door (it's got a decent 10 point locking system). I'm also going to use it for some domestic storage so may build a small internal room to try and keep stuff clean in there while I make a mess in the rest.
I did a bit of preliminary work last weekend and soon realised I'll need ear defenders as a big metal box doesn't half rattle when you drill/cut it! Proper work will start this coming weekend.
hardtop5000
Well-known member
The Bunker definitely has that military look.
In the UK, do you have what we call whirlybirds in Australia? It's a rooftop, wind-driven, rainproof extractor fan, mainly used for ventilating roof spaces. For this application you'd need one small intake vent on a wall. Then the whirlybird would draw air from The Bunker at a low rate.
In the UK, do you have what we call whirlybirds in Australia? It's a rooftop, wind-driven, rainproof extractor fan, mainly used for ventilating roof spaces. For this application you'd need one small intake vent on a wall. Then the whirlybird would draw air from The Bunker at a low rate.
They exist, but mostly we see them on vans, as they can get hot enough to justify them. Otherwise it's generally not hot enough to warrent their use.
I don't really want to go cutting a hole in the roof, but I might in the back as the back is flat steel so easier to cut & cover (rather than working round the corrugations of the roof & sides). Good idea in the right place tho.
Terrick down Under
Well-known member
try putting a couple of ACRO props along the cut area to hold the roof up and release the downwards pressure.
The sections you cut out will make great awnings at the front or side.
The sections you cut out will make great awnings at the front or side.
Its been a few weeks, but got the 2nd lot cut out of panels today. The reason it was a few weeks was the weight of the first set of panels was a *lot* heavier than I thought - I could barely move the following day. I pulled my sacroiliac ligaments at the base of my back and I've been laid up for weeks!
So the current set can stay where they are - a body-builder freind has offered to come and help me lift them out of the way.
Next major job will be weather dependant - sealing the gap between the containers. A typical british summer means rain, so I need a break in the weather for a couple of days to get foam and a roof seal in. In the meantime I can tidy up the rough edges of the cuts and start work on the interior.
So the current set can stay where they are - a body-builder freind has offered to come and help me lift them out of the way.
Next major job will be weather dependant - sealing the gap between the containers. A typical british summer means rain, so I need a break in the weather for a couple of days to get foam and a roof seal in. In the meantime I can tidy up the rough edges of the cuts and start work on the interior.
Krokodil
Well-known member
Looking forward to your progress. Good job thus far.
This weekend has mostly been about waterproofing. I jammed a 'noodle' (25mm diamater foam rod) between the containers to act as a backstop, so when I filled it with foam I wouldn't be filling an enourmous void, just a few centimeters up to the surface. Then filled the gap with expanding foam. let it dry, then applied some flashing primer paint, let that dry then apply the flashing. It's bitumen-based, so should allow a little flexibility for metal expansion/contraction. Still a bit more to do, but I'd say it's 90% waterproof - will tell you when it rains!
I got a bit carried away at the front though, so may have to chisel some of this out if I can't open the door properly!
I got a bit carried away at the front though, so may have to chisel some of this out if I can't open the door properly!
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Started grinding down the floor between the containers - seems to be taking ages!
I'm going to overclad the existing floor; it's quite damaged near the original door, but still solid. I don't need to get the metal absolutely flush, just enough so it won't stick out over the height of the OSB I'm going to put in - I'll work out what exactly will go in the space between later (might fill it with concrete/epoxy, might pack it and put a slightly thinner OSB board as a filler).
I'm going to overclad the existing floor; it's quite damaged near the original door, but still solid. I don't need to get the metal absolutely flush, just enough so it won't stick out over the height of the OSB I'm going to put in - I'll work out what exactly will go in the space between later (might fill it with concrete/epoxy, might pack it and put a slightly thinner OSB board as a filler).
Floor gap ground down to a few mm:
And support added for interior frame:
Just some fettling left to do; now need to order wood for the frame itself. I've been holding out as long as I can as timber prices are silly ATM, but I can't really wait any longer. I've worked out a way for it to be 'self supporting', in that it won't need securing to the interior of the container - no drilling holes thru the walls/roof, just fixed to itself. More pics to come.
And support added for interior frame:
Just some fettling left to do; now need to order wood for the frame itself. I've been holding out as long as I can as timber prices are silly ATM, but I can't really wait any longer. I've worked out a way for it to be 'self supporting', in that it won't need securing to the interior of the container - no drilling holes thru the walls/roof, just fixed to itself. More pics to come.
Timber has arrived so started insulating & framing the inside:
Also put some flashing over the ends of the roof; I think it looks fairly neat so I will add a thinner strip down the gap betweeen the containers over the foam filler too:
Also put some flashing over the ends of the roof; I think it looks fairly neat so I will add a thinner strip down the gap betweeen the containers over the foam filler too:
First layer of insulation & framing out the inside continues...
I'll tidy up the first layer of insulation then put a second layer over the top. Nothing is screwed to the container walls or roof - the frame is only fixed to itself.
Did notice some serious condensation on the inside this morning, which reminded me I need to install ventilation....!
I'll tidy up the first layer of insulation then put a second layer over the top. Nothing is screwed to the container walls or roof - the frame is only fixed to itself.
Did notice some serious condensation on the inside this morning, which reminded me I need to install ventilation....!
Terrick down Under
Well-known member
if you get a computer cooling fan and fix it to the inside of the top vent, and connect to a 5w solar panel that should take care of your required air flow to keep the moisture levels down.
Ceilings going in. Foil insulation stapled to the boards:
I'm doing this single handed, so I'm using this method; three large screws partially inserted in one side, lift the board up so it's sitting on my platform and just touching the screws. Prop the board against the screws:
Lift up the other side, keeping the board above the screws and put in a tempoary screw to hold the other side - rest the board on the screws:
Use a little wedge to lift the board to it's final position, then screw the board to the rafters above it:
Et voila!
Walls next.
I'm doing this single handed, so I'm using this method; three large screws partially inserted in one side, lift the board up so it's sitting on my platform and just touching the screws. Prop the board against the screws:
Lift up the other side, keeping the board above the screws and put in a tempoary screw to hold the other side - rest the board on the screws:
Use a little wedge to lift the board to it's final position, then screw the board to the rafters above it:
Et voila!
Walls next.
First side boarded out.
Wall boards lifted up with bodgit(™) lift:
Mistakes were made though... I'll need a get a case of arcylic filler to fill all the gaps! I can't cut straight for toffee, even with a circular saw...
I also plan to paint it all in fire-retardant white paint.
Interior room next, so we can start using it to store stuff & I can tidy the other side up, ready for framing and boarding. Should be easier/quicker, as the first side has been a good learning experience.
Also awaiting quotes for wiring. I'll do first fix (cabling), but I need a proper electrician to connect everything (according to UK Part P regulations).
Unfortunately my roof seal is leaking (got 10cm in a bucket after 2 weeks of rain). I'm going to re-seal it, but will have to wait for a spell of dry weather to do it.
Getting there though!
Wall boards lifted up with bodgit(™) lift:
Mistakes were made though... I'll need a get a case of arcylic filler to fill all the gaps! I can't cut straight for toffee, even with a circular saw...
I also plan to paint it all in fire-retardant white paint.
Interior room next, so we can start using it to store stuff & I can tidy the other side up, ready for framing and boarding. Should be easier/quicker, as the first side has been a good learning experience.
Also awaiting quotes for wiring. I'll do first fix (cabling), but I need a proper electrician to connect everything (according to UK Part P regulations).
Unfortunately my roof seal is leaking (got 10cm in a bucket after 2 weeks of rain). I'm going to re-seal it, but will have to wait for a spell of dry weather to do it.
Getting there though!
nadogail
Well-known member
May you get many years of service and enjoyment from your "Iron Clad" shop, as you also enjoy Good Health!
67CarGuy
Well-known member
Cool build! Did you get your condensation issues straightened out?
Been a while since the last update.. All boarding out finished today.
Dodgy panoramic view...
Also roof leaks fixed - love this stuff:
Still got half a tin left.
No condensation now, in fact it's quite warm (once you get moving!) so I don't think I'll bother with any heating, except maybe some frost protection in the storage room.
Still lots to do: got a few sheets of the ply left over so going to make a workbench out of some of it (done it before, works well for me and easy to replace when I damage it beyond repair). Put up more shelves. Put a door on the storage cupboard. Fit lights & power. Tidy up the gap between the units - going to cover with anti-rodent mesh, as if it does leak again I'd like to be aware of it, rather than finding out when a build up of water breaks thru the ceiling! Gap filling (I really can't cut a straight line) - oh, and move my van in!
I've also got a plan for making a ceiling-hoist, using the attachment points on the container interior to make use of the height. I'm not going to put much weight on them as they are not officially load-bearing but they should be ok for a platform to expand the storage:
Dodgy panoramic view...
Also roof leaks fixed - love this stuff:
Still got half a tin left.
No condensation now, in fact it's quite warm (once you get moving!) so I don't think I'll bother with any heating, except maybe some frost protection in the storage room.
Still lots to do: got a few sheets of the ply left over so going to make a workbench out of some of it (done it before, works well for me and easy to replace when I damage it beyond repair). Put up more shelves. Put a door on the storage cupboard. Fit lights & power. Tidy up the gap between the units - going to cover with anti-rodent mesh, as if it does leak again I'd like to be aware of it, rather than finding out when a build up of water breaks thru the ceiling! Gap filling (I really can't cut a straight line) - oh, and move my van in!
I've also got a plan for making a ceiling-hoist, using the attachment points on the container interior to make use of the height. I'm not going to put much weight on them as they are not officially load-bearing but they should be ok for a platform to expand the storage:
Mostly moved in - and I have lights!
Down the center of the workshop, with a little light over the high shelf
...and down either side of the place where my van will go. You can also see my hoist experiments; this was just with paracord, but proper hardware is on order.
Down the center of the workshop, with a little light over the high shelf
...and down either side of the place where my van will go. You can also see my hoist experiments; this was just with paracord, but proper hardware is on order.
Transport day is here!
Hoist works as intended...
...and Beaker is in!
Had to lift the roof a little more on the hoist to get him under; I'm going to cut off the pillars on the replacement roof as I don't need them, then I should be able to lower it back so it all fits nicely.
Now the 'real work' begins...
Hoist works as intended...
...and Beaker is in!
Had to lift the roof a little more on the hoist to get him under; I'm going to cut off the pillars on the replacement roof as I don't need them, then I should be able to lower it back so it all fits nicely.
Now the 'real work' begins...
