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Between 265 & 485 SQ/FT The 12-Gauge Garage

Workspaces sized between 265 and 485 squarefeet.

Bob Heine

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Jack,
You mentioned low-voltage lighting so why not put the lights on the aircraft cable? You can put the cable at almost any height and tension the arch as much as needed. Might be easier than stringing the lights all the way to the top of the arch.
 
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Jack Olsen

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I got a lot of small pieces done on the deck and pergola today -- and at the end of the day I got to put up the tower, which was definitely the most physically difficult (and dangerous, honestly) part of the job so far. The idea is to pull the whole steel structure straight up 84", hold it there, and then weld in the 20 upright pillars that will support it. The wooden structure that's shaped like a ladder is there to cradle the thing as it goes up.

I probably won't get to do the actual lifting until Monday. But if there's time weekend, and I can get the rest of the thing set up, I might try raising it just as a test.

tower02.jpg


tower01.jpg
 

Dan in Pasadena

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Jack, What's the weight of the whole lift? It looks like you're using a boat trailer crank to raise it(?)

Just make sure when you start cranking your head is not under anything that can brain you if it fails. In my business we "hope for the best, but plan for the worst".

Let me know if I can be of some help over the weekend. - Dan
 
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Jack Olsen

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The roof structure weighs less than 400 pounds. That's too heavy for me to just grab and lift up, but I don't think it will be a problem for the tool I'm using to lift it. That said, no one should try this at home. I'm using a winch, not a hoist -- which is not the correct tool for the job. But the issue with the thing I'm lifting is size more than weight.

But once it goes up, I'll be wearing a hard hat. I don't worry about the whole thing coming down and hitting me. The shape of it means it could fall and still not be able to hit me, so long as I'm under it. But there's a legitimate concern with it coming apart and a piece cracking me on the head. I don't think it will happen, but it would be foolish to believe I know every possible thing that could happen. Even if you consider that I'm raising a piece that's inside a box (formed by the walls around it) that prevent it from moving laterally, I'll be much more relaxed once all 20 pillars are welded in place.

I've gone over it again and again in my head. I will say that I THINK I've found a way to raise this thing up with stuff I had on hand and some 2x4s. I made the pulley out of one of the pipe dies and the shaft from my roll bender.

If my math is right, it should be exactly tall enough. I'm glad I didn't make it too tall, since it is very heavy and was an unwieldy nightmare to thread through the structure in order to get it from horizontal to vertical. At one point, I was pretty sure that the little consumer-grade step ladder I was using was going to collapse under me as I lifted it. I switched to a better stepladder, and it inspired a lot more confidence. Still, it was like I was raising a mast on a ship all by myself -- through a metal cage.
 

tc-cad

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Mequon, WI
That looks great Jack.
Where do you get the covering material?

Did you ever hang that Porsche Sign I made for you?

TC-CAD
 

51rider

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Jut caught up on all posts since 4th March had to post on what a great read it was.

Loved the video & am intrigued by the pergola project. Looking forward to watching it develop.:beer:
 
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Jack Olsen

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Thanks!

tc-cad, the cover is going to be Coolaroo shade fabric. I haven't put up the Porsche lettering yet, but it's in the pipeline, as they say.

Today I wore my hardhat...

hardhat.jpg


Because while the kids napped, the pergola roof went up, up, up.

58455846.jpg


ceiling.jpg
 
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Jack Olsen

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And with that clueless look in the picture, you can bet he's 'Master of None.' :)

But I'm not easily intimidated by new projects.

(And I'm glad nothing fell down on top of me.)
 
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Jack Olsen

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The whole thing came crashing down the first time I lifted it. The three 1" lag bolts that were holding the winch to the boom pulled right out of the wood. It was pretty scary, and it made me reconsider the way I was doing things. The problem was that there was no redundancy in the design. If the point where the chain was fixed below the steel lifting assembly failed, the whole thing would come down. If the mounts for pulley up on top failed, the whole thing would come down. If the central crossmember that was taking most of the load for the ladder-shaped component failed, then I'm pretty sure the whole thing would come down.

You get the idea.

So good sense prevailed at that point and I added the two vertical pieces on either end of the ladder/cradle thing. At that point, I would raise it a foot and then re-fasten the pair of 2x4s on either end so that if the crane gave out, it would only come down that short distance. Stopping every 12" also let me readjust the fore-aft and left-right balance of the thing so it stayed level and wasn't encouraging the boom to lean in any one direction.

Now that I think about it, 'good sense' might not be the term to describe it, really. Maybe 'less stupidity' is more accurate. But the good news is that after I replaced those lag bolts (with 3"-ers), the thing didn't come down. And I knew that if it did crash down, there wasn't much danger of it injuring me, since the spider-like shape of the whole thing put the impact points along the perimeter of the deck. If the crane failed, I knew the steel would do some damage to the fence and walls. But that's better than doing damage to the builder.

I should be clear about my methods on this project. OSHA would tear me new one for doing it the way I did. And I'd encourage anyone reading this to not try it the same way. There are hoists out there with remote controls. You should never be raising something heavy while you're standing beneath it.

But thanks for the kind words. I'm still not really sure what the finished project is going to look like. But I'm only about ten days from seeing it.

dozerbuilder01, the dies are from Swag Offroad. They have a whole set of products to turn the $111 Harbor Freight roll bender into a motorized powerhouse. The dies were $150, I think -- which isn't bad at all for what they are. They also make an improved drive shaft for the bender, as well as wings that improve the structural strength of the thing, and a kit to add a bottle jack and a pipe threader to power the thing. I've been really pleased with everything I've bought from them. So here's a link.

www.swagoffroad.com

I didn't take any pictures today, but I disassembled the ladder-shaped cradle and the boom/mast where they stood. Because I've added aircraft cable to support the arches, it was easier to just disassemble the pieces up in the air than it would have been to thread everything back down past all the obstacles. I won't have the paint to finish the job until this coming Thursday, but I want to finish up everything but the paint before then. After that, I oil the deck itself, install the fireplace and put in the furniture.
 
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1Garageman

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That is an amazing structure that you are building! I can't believe you are finding a way to make this big heavy structure all by yourself!
GOOD LUCK!
 

Matthewjb

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The vertical pieces at either end seem a good idea. But what was stopping the whole structure falling sideways? Was it just held up by the walls of the house and garage?

I won't have the paint to finish the job until this coming Thursday

Are you painting the frame now it's in the air? That should interesting.

How about suspending a small child from the boom armed with a paintbrush? Nothing could possibly go wrong.
 
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Jack Olsen

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Thanks.

Matthew, the whole thing is symmetrical, so it was pretty stable once I found the center point to lift from. I also worked out the best width for the ladder/cradle thing so that the 'feet' of each arch wouldn't sprawl out when it lifted up. Instead, they came in about six inches so the whole thing went up without touching any of the walls.

One trick was getting past that wall unit air conditioner. I thought it would slide out easily, but it was stuck. So I cut a little of the top spine and two of the legs off so that I'd be able to lift the roof straight up. That was fortunate, since the single arch made it pretty simple to determine the ideal width for the ladder/cradle when it came to how much the legs would sprawl/contract. It also moved the center lifting point over slightly, which meant the boom of the crane wasn't going to get pinched into the center junction point where the spine met with two of the diagonal arches.

Here's the cut. You can see where the paint ran out and there's only primer.

thecut.jpg


The only part I didn't have paint for was the section I knew I was going to have to cut off and weld back on. I got impatient and reattached it yesterday, so I actually will have to do a small amount of painting at the 16' height. But it's adjacent to my garage roof, so I should be able to stand on the roof for the painting part, and not balance on a ladder.
 

Matthewjb

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the whole thing is symmetrical, so it was pretty stable once I found the center point to lift from

I suspect that says a lot about how well you put it together.

I'm disappointed there is no photo of you up in the air welding the end back on. That is how you did it?

I assume building a elegant new unit for the a/c outlet will be the next project.
 
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Jack Olsen

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That was a little scary, since I had to stand on the very top of the tallest step ladder. But I was able to hold onto the frame itself. I used my little HF inverter stick welder ($89!) and it worked great. It's only about four pounds and it's the size of a lunch box.

Today, I cleaned everything out, and hosed the deck off. There's still a lot to do, but it feels a little like a significant piece is now done. (Forgive the white primer all over the place.)

wetterc.jpg


wetftp.jpg
 

markviii

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east central IL
Very fine work! I find it easier to do something "on the edge", or more than I should be doing alone, while I'm alone (like moving a rolled up 9' x 12' rug up to the third floor of our house). Dumb, but no witnesses.

Chris
 
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Jsf721

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Jack,

Sorry if I missed it but WOW, Just WOW. THat is some project to tackle by yourself.

Do you need any permits for this type of work? Where I live in NY I would have had the puliding department after I erected the lift! LOL.

After we had the flood from Hurricane Sandy I was rippping out Sheetrock and carpeting with my boys and the guys from the building inspectors department were walking house to house telling us we all need to get permits. He was sure to tell us that the permit fee's were being waived since there was a natural disaster but I needed to open a permit and submit proof of insurnace / license # for any and all contractors. If I was doing the work myself I needed to sign an waiver form.

Good Luck with the project and I am just wondering how you will get a tan after the fabric is installed??? I am thinking you are most likely butting a scisor lift under the lounge chairs? I am thinking a 4 post lift might be safer?
 
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Jack Olsen

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Thanks!

It's a miracle that I haven't hurt myself, frankly. (I'm going to knock on wood, too, since I'm a long way from finished.) Especially on the ladder work, it's constantly running through my head how quickly an ordinary day could turn into a real headache, with a lifetime of pain/limping/whatever just a slip away. But so far, so good.

Jsf721, I believe I've done this correctly in terms of permitting. Here are the pertinent sections of the LA code.

The following items do not require a Building Permit and are not within the scope of the Building Code (Section 91.0101.5):

Pergolas and lath houses, both of which shall be outside of any fire district, not over 400 square feet in area, and not supported by or attached to any portion of any building.

A building permit is not required for the following (however, please be advised that all work must still comply with the requirements of the City of Los Angeles Zoning Code):

Platforms, walks and driveways not more than 30 inches above grade and not over any basement or story below.

Additionally, a platform that is lower than 12" above grade is exempt from setback requirements, which means I can build it right to the property line.

All that said, an annoyed neighbor can wreak havoc with any project. So I'm trying to be polite and open to any input my neighbors might have.

This morning I got the long cedar planter boxes put in along the sides of the deck.

plantboxes.jpg


Later today I'm doing some work on the fence adjacent to my neighbor on the south side. Tomorrow, I hope to paint the primered steel.

Then I want to fill the holes that need plugging, sand and oil the deck itself.

As soon as my UV-safe thread arrives in the mail, I hope to get busy with my sewing machine and the shade fabric for the top.
 

firecracker

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Wonderful "JackO" just wonderful i've not bin here long but yours is one of the most interesting builds ive looked at, spent hours looking back at your garage/car/house, got to get stuck into mine soon.:bowdown::bowdown:
 

Dan in Pasadena

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Jack,
That's just OUTSTANDING!

Now, speaking as a knucklehead myself let me just chastize you on lifting that whole thing yourself when you could have gotten help.

Yes, I DID IT TOO and for the same reason and almost hurt myself - this was lifting a giant I-beam into position on (overloaded and yes, top step used) ladders in my garage. But you've got little ones that need you Dad!

Ok, that said. Just a fantastic design, vision, and execution. I'd love to come see it sometime!
 
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Jack Olsen

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Thanks.

I got the UV thread for the shade fabric today. But I also got the rest of the paint -- so now the primer is covered up.

onecolor.jpg


Slowly but surely.
 
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Jack Olsen

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I've got to get that camera back on the balloon. :)

This morning, I painted a corner where I extended the fence up (gray), the window frame (gray), and the window AC unit (to match the wall -- or rather, to make it as unnoticeable as possible). I'm also testing out the heights for the 'temp' lights.

You can see what the corner used to look like in this 'men working' shot.

notcleanangleonnewcorne.jpg


Here it is today.

angleonnewcorner.jpg


Closer and closer.
lampheight.jpg
 
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Jack Olsen

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Three lights up, tonight:

secondnightshot.jpg


The wide-angle lens makes it look like you could hold a barn dance in the place. In reality, it's only 19'x20'. But there's plenty of room for my wife and I to dance, should the need arise. :)

The key is to look at it and try to imagine the cover reflecting light down, with some more lights. And furniture and a fireplace. And of course plants -- my wife will go to town with landscaping it.

I think it's going to look pretty nice.
 

Huxley

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We need a shot of the dirty garage after this project.

Anyone else dying to build a replica of this pergola?

You made the wife wait a while for this but she has to be blown away now, correct?
 

Bob Heine

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When my wife asks for a pergola, an image forms in my mind. When Jack's wife asks for a pergola, he channels Christopher Wren and builds a little backyard cathedral. My image is the little one...
74031e44-628e-4d56-8d49-05fa03d694d9_zps5300412c.jpg


Jack, thanks for another inspiration. It really is an outstanding example of your creativity. Sadly my wife will never see it. I already get enough "why can't you do that."
 
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Jack Olsen

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We need a shot of the dirty garage after this project.

Anyone else dying to build a replica of this pergola?

You made the wife wait a while for this but she has to be blown away now, correct?

I'll never claim to be a neat worker. This was the center bench early on in the process. It's only gotten worse.

messl.jpg


But it should clean up in about an hour, I'd guess. We'll see.

My wife was very patient. I mader her wait years for this, and the back yard became a repository of junk (and poor man's paint booth) for a LONG time. There was no way to cut the grass anymore, and the weeds grew to shoulder height. Maybe because of all that, she's very happy about where things are going. :)

Jack, a projector through the window onto the back wall would make a nice use of the space on a saturday night.

That's part of the plan. Movie night for the kids.

When my wife asks for a pergola, an image forms in my mind. When Jack's wife asks for a pergola, he channels Christopher Wren and builds a little backyard cathedral. My image is the little one...
74031e44-628e-4d56-8d49-05fa03d694d9_zps5300412c.jpg


Jack, thanks for another inspiration. It really is an outstanding example of your creativity. Sadly my wife will never see it. I already get enough "why can't you do that."

Thanks. And that's just it -- they always have such flat roofs. I always thought it felt like the opposite of what it should feel like when you're outdoors. Even if it's high up, a flat roof feels like it's coming down on you. Snow and wind loads notwithstanding, I thought the gothic arch would make a great shape for this sort of thing.

Now, my original idea was to follow the actual cathedral arch dimensions, which would have made the roof about twice as high as it is now. My neighbors would have surrounded the place with torches if I stuck with that plan, I think. And I couldn't blame them. It would be the tallest thing in the neighborhood. So the shape of the arch isn't as pretty as it might have been, but I still like it. We'll see if the neighbors do, too.

Jack,

I might have missed it, but what type of decking did you use? Whatever it is, it's beautiful. Did you stain/seal it?

It's the one big expense for this project -- fully half of the total cost (with the total including all the other materials and a fireplace and furniture). It's Cumaru, which is a Brazilian hardwood (Ipe is probably the best known, but it's more expensive.) Cumaru is a very dense, very hard wood. It sinks in water and will dull your saw blades in a hurry. But it's rot and insect resistant and should last for a half a century at least. I used 5/4x6 pieces and I am going to seal it with the Penofin oil product later today. What you see right now is just the naked wood.

I used a system where the screws go in from the sides to hold it down, so the fasteners are less apparent. So far, the method seems to have worked well.
 
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