Above 1200 Sq/FT The Ole Barn Workshop by BigNuge

[quietsailor]

I've seen 10' X 6' sheets of timber/chipboard - do you think you'd be doing large scale woodwork in the future, it would be handy to have a bench capable of taking large sheets.

Another idea is to have different sides for different jobs - one side for woodworking, another for tearing down engines. There's a thread on here for building welding benches but a lot of the ideas on that could apply to your bench
- adding in hitch receiver tubes under the bench so you can swop vices, grinders in and out.
- having power and air points scattered along the periphery.

Just to add to this idea, a friend of mine made a bench in the past out of a 10X6 sheet (might have been 2 4X8's)- he had a shelf sticking up in the middle to hold the tools/parts he used daily but the shelf was easily removable if he needed the full area.

He was a kitchen maker and seemed to make a lot of tall presses to this design might have suited him more than others - it'll depend on what you're making on the your bench every day

I think he had it divided in half in the long way ie instead of 10X6 he had 4'6" X 6 twice over

 

[BigNuge]

Can't wait for the pics - you going with shingles or a metal roof?



I would not go any bigger than 4 feet for an island type bench. We had a island that was 6 x 6 at one of the shops I worked at in the past. It was way too big. It was an absolute bear to walk around if you needed to get to the other side (you wouldn't think it's a big deal, but it gets old). Also, if there's something on the edge of one side of the bench, you cant reach it from the other side, and are forced to walk around. Unless you do a lot of work with big assemblies....less can be more.

Went with 40 year Tuff Rib metal. Got 75% of it up today, finishing up tomorrow. It's been hot as hell here, not great for handling these things....oh and working on the roof in the blazing sun alone sucked....lol.

But, I'm happy with how it's coming out!

A sample of the next update post....





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[xtremek]

The roof looks nice. What are you going to do for venting? Someone looks comfy in that chair.

 

[Mr. Roboto]

That looks great! The roof and a fresh coat of paint are sure going to brighten up the barns exterior big time. You ever think about throwing a cupola up on top?

 

[BigNuge]

The roof looks nice. What are you going to do for venting? Someone looks comfy in that chair.

Lol, yeah...we were all burnt out by the end of this roof job. The weather was beautiful for cold beer drinking, roofing....not so much. We rotated guys on the roof, and most just grabbed a bottle of water and sat in the shade for a bit to cool off.

As far as venting, there is none currently and I am not adding any. The barn is completely open on the second floor, all the way to the roof sheathing. There are windows up high that I plan on opening & installing screens once I have the barn buttoned up a bit more, but that's about it.



Now for the bad news, which pi$$ed me off something serious. Turns out the order was one full panel short. I have a hard time understanding how they did it, but when I give the roof dimensions to the roofing manufacturer I would expect them to send me enough panels to allow for trimming. On the other hand, the barn roof is 7" out of square on the North end, and 3" on the South end. We have very little waste (less than 2') from the custom starter cuts, so I still don't understand why I ended up a full panel (3') short.

In the end, I will be calling the folks I got the roofing from this morning to get the panel coming ASAP. I have a 3'+ section of roof that is open to the strapping...and the rainiest week in months coming this week.

All in all I'm happy with how it came out. A couple hours worth of work will wrap it up after the panel gets here. Other than that, I think it improves the appearance of the barn tenfold. And the parts that are under the new roof are nice and dry (it's raining like crazy this AM).

Full update post to follow....gotta load all the pictures to my computer.


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[BigNuge]

Howdy folks. I apologize for the delay in any updates, it has been a tough couple of weeks for me. I just lost one of my brothers to drug addiction. He had been struggling for some years with it, and fell to it 2 weeks ago....it has been difficult for me.

That said, I took some time off of work to support my mom (who has been taking it very hard) and other brother.

After a couple of REALLY long days sitting inside I had to get out and keep myself busy or I'd go nuts. I got out to the barn and continued chipping away at it. Picked up 13 fluorescent light fixtures (2' x 4' - 4 bulb) off of CL for $10 each. Hung 7 of them in the workshop space & equipment storage area. Built the main bench, ended up building it 4' x 10' and am very happy with it. Got the drill press and grinder in place. Got 2 quad outlet boxes in as a start. Officially disconnected all of the old electrical & lighting in the barn, running the whole place on new electrical.

This brings us to a question for you guys. I started framing out the compressor closet, which is going under the stairs just as I had drawn it up. I did the hockey puck under the feet trick for vibration isolation. I also want to use a braided flexible line at the air connection to isolate vibration there too. The question I have is related to insulating for noise. I am not worried about thermal insulation, only noise. Seeing as the compressor closet is in one of the outside corners, two of the walls are outside walls, and two are inside walls (including the closet door). I was looking at 1" or 2" foam board insulation, but was wondering if that would give me enough sound deadening.

So, to summarize....for those of you with compressors inside the building, in a closet (I can't put mine in a closet outside where it gets well below zero outside in the winter), what have you done to get it quiet as possible?




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[upndown]

I just want to send my Condolences to you as well as your family! Be strong for your Mom, she's gonna need it.

My kids almost lost their dad to Alcoholism, now I'm very thankful to be around to say that!

Your barn is going to be great! And as always I'll be tagging along.

 

[sublime68charger]

Sorry for your loss,

Keep up the great work on that barn.!!!

 

[xtremek]

Sorry for your loss. Your family has my prayers. As for the compressor closet, my closet is up on the wall so I could have more floor space. I used what I had on hand, and that's regular fiberglass insulation for the walls. I put "peel-n-seal" on the floor and still plan on using pucks. Then I'll put fiberglass insulation and finally drywall on the bottom. Back to the walls, I might put 1/4" luann and then cover that with more "peel-n-seal" and finally some drywall. There's a build thread here where someone did some sound deadening on the walls of his living or theater room so the noise wouldn't transmit to the rest of the house. It looked like a top notch job.

 

[BigNuge]

Thank you for the thoughts guys.

As far as the compressor closet, I think I'm going to use egg crate foam inside of the 2x4 petition studs. Not looking for silence, just manageable noise while working in the shop.

Any other ideas??


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[Jjbates]

BigNuge, was curious, what color is your roof metal? It looks black.

 

[BigNuge]

BigNuge, was curious, what color is your roof metal? It looks black.

Yep, black. The whole property is going to be a white/black scheme. Black shutters and select trim pieces, white siding.


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[Jjbates]

Yep, black. The whole property is going to be a white/black scheme. Black shutters and select trim pieces, white siding.


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I've put metal on several buildings and my last two houses. I want to put metal and the house we just bought but the only color that seems to go with the blue/gray of the house is black. Let us know how it holds up. My concerns were fading and heat with black. Thanks

 

[BigNuge]

I've put metal on several buildings and my last two houses. I want to put metal and the house we just bought but the only color that seems to go with the blue/gray of the house is black. Let us know how it holds up. My concerns were fading and heat with black. Thanks

Yeah, I have no expectation of eternal color...and I certainly wouldn't with asphalt or any other color metal. They all fade.


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[BigNuge]

OK, so time for an official update post. A ton has been done since my last official update.

First post, the roof has been done. I don't have a picture of it completed, but here are a bunch taken during the work....and man was it a lot of work.















Learned a lot, and I'm happy with how it came out.

 

[BigNuge]

Next, a bunch of work inside.

Now that the barn is nice and dry, its time to get things going on the inside.

I got the last new post up, cut all of the remaining old posts & beams out (the ones that I replaced with new ones...lol), so now the "vehicle/lift bay" is at its final dimension. Hauled 2,700# worth of old painted wood to the dump.

I got the entire workbench area cleaned out, all new beams and supports in, got the bench built (4' x 10', top is nice and tall @ 42"), got the lighting in and operating, shelf for the tunes, and beer fridge in and operational.

Also, started on the compressor closet. I have to wait to complete the door side of the closet because the east wall is getting re-framed & new sheathing.






Lastly, I had a thought...what if I built a nice low "desk height" drop leaf type thing at one end of the bench....you know, for sitting down nice and comfortable and doing a small job like electrical soldering, carb rebuild...you name it.




Soooo, what do you guys think??

 

[colt zantop]

First off, so sorry for your loss....hang in there.


Secondly....this is going to be an awesome place when done. Looks way better already! Keep us updated.

 

[xtremek]

I like the desk height part. I have a standing order in for a bar stool to use at my bench. I love the look of what you've done so far. If I were in your shoes, I'd make my closet big enough to put a 2stage 80gal. compressor in it.

 

[BigNuge]

If I were in your shoes, I'd make my closet big enough to put a 2stage 80gal. compressor in it.

That's exactly what's in there!!

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[BigNuge]

Got the drop table finished up. The supports I got are really nice, and are a perfect fit for the job. Great work surface, can't wait to use it!








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[BigNuge]

Hey guys, thought I would check in. It's been a busy Summer, but I picked off a few things in the barn project.

I got the compressor wired & fired. It is so much quieter than my noisemaker oiless rig. Now I have to plumb the air throughout the workshop. I'm going to use black pipe. I was thinking of using 1/2" pipe, but wanted to know if you guys thought that would be large enough. If not, I could do 3/4". Also, I scored 2 100' Legacy air hose reels from a shop that was renovated. I ordered $67 worth of parts to repair the reels. I plan on hanging both reels on the ceiling of the vehicle bay (on either side of the bay), with the hose stops positioned to keep the hoses 3' off the floor when retracted. I also plan on air line taps in select locations where I might use it, as well as a couple spots over the bench. I have several air regulators that I'll be using so I can knock the pressure down at the bench depending on what port I connect to....oh, and shutoffs everywhere so I can isolate whenever needed.

In unrelated news, I used the barn to secure a couple of 4Wheelers that were in the bed of my truck while I was away for a couple days. Love having the barn as a usable space!!








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[bulletpruf]

Looking very good! Now you have a nice place to work on the Cougar...any updates there?

 

[xtremek]

I see you have necessary snacks for the supervisor.

 

[BigNuge]

Lol, the supervisor needs his snacks for sure.

No update on the Cougar. Still finishing the barn, and the Cougar needs a good chunk of $$ to get launched. I suspect it'll be a couple years before I dive into that....unless I hit the lotto...lol

Any thoughts on the size of air line I should run around the shop? It would be used for air tools, and a possible sand blasting cabinet that I'd put close to the compressor closet. Like I mentioned above, I'd like to run 1/2" black pipe, but would run 3/4" if it was needed.

Thanks for the input guys!


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[BigNuge]

Well hello everybody. It's been far too long....

I've been working on the barn pretty steadily as time and funds allow. A lot has happened since my last update

So, to kick this update off I wanted to mention that I got my first floor unit of my house rented. It's been a huge weight off of my shoulders having this occupied. One of the extra bonuses of the new tenant is that he owns several pieces of equipment (skid steers/small loader etc.), as well as a nice dually dump truck....all of which has come in handy several times already!! A big part of the exterior/landscape portion of the project got done way ahead of schedule....what a great bonus!!!




With all that said, I got a lot of other things done as well. The lift is in, and has already come in handy. I absolutely love having a lift of my own!!




The new garage door is on, and man it is such an improvement from the old sliding doors.....



So...I knew I had some wall issues on the east wall, towards the bottom. Well, it was worse than I thought...



I tore the lower 6' of the entire east wall down...all rotted. Also, 4 of the 5 main posts on the east side were rotted, some worse than others. Got the barn on temporary post jacks and replaced all 4 rotted posts. Had to dig new footings for 2 of the 4 posts. The other 2 had the original granite footings to sit on.




Now, that left me with a 6' x 50' wide open wall.....got that closed up just recently, with a brand new entry door. The barn has never been so secure!




I'm working on framing & sheeting in the lift bay this weekend....I'll update with pics when I'm finished.

Thanks for looking!




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[MarkG]

I got a kick out of your 4 x 8 table-----I built mine the same way about 20 years ago using almost IDENTICAL construction, down to the way the 2 x 4's lap on the bottom shelf! I left an overhang on the top though, to allow for clamping stuff down at the table edges when needed. I also have a lot more clutter on mine than yours! :S (Big shelves seem to collect stuff in my shop!)

 

[BigNuge]

I got a kick out of your 4 x 8 table-----I built mine the same way about 20 years ago using almost IDENTICAL construction, down to the way the 2 x 4's lap on the bottom shelf! I left an overhang on the top though, to allow for clamping stuff down at the table edges when needed. I also have a lot more clutter on mine than yours! :S (Big shelves seem to collect stuff in my shop!)

Nice!

Mine is actually a 4' x 10', with a 28" x 48" drop leaf type desk at one end. Also, now it has a 36" x 48" 3/16 plate steel topper on the other end. One heavy mofo!!!



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[BUGTHUG]

Enjoyed the barn rebuild, nice old barn good bones. Love your Toyota, I have a 2008 crew cab, it only has 32k miles on it.
I have a IR, identical to yours also. I would use some 2" styro foam and enclose the closet. Also on your airline I'm using the blue pex line that Northern tool sells, can't think of the name for some reason. But its the stuff you just cut and slide into T pieces. I went with the 3/4 alum coated, comes in a kit and easy to put up, so I guess. I still haven't got mine up yet. I'll think of the name or some smart people know what I'm talking about.

 

[BigNuge]

Enjoyed the barn rebuild, nice old barn good bones. Love your Toyota, I have a 2008 crew cab, it only has 32k miles on it.

I have a IR, identical to yours also. I would use some 2" styro foam and enclose the closet. Also on your airline I'm using the blue pex line that Northern tool sells, can't think of the name for some reason. But its the stuff you just cut and slide into T pieces. I went with the 3/4 alum coated, comes in a kit and easy to put up, so I guess. I still haven't got mine up yet. I'll think of the name or some smart people know what I'm talking about.

Thanks!

Love my Tundra...I've driven them all for work/personal. The Tundra is the best towing 1/2 ton package out there. I also have an 03 4Runner Sport with the 4.7 V8.... Sweet machine, and it's killer off road!

Yeah, I have already piped the entire place in 1/2" black iron. Came our great, and works great. I'm definitely going to be insulating the compressor closet once I can finish the compressor closet...which I couldn't finish until just 3 days ago (east wall was wide open). Now I can finally add the door and insulate.


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[Mr. Roboto]

Great to see an update from you! The place is looking awesome, you've certainly been busy. The wall repair looks awesome, and I am super jealous of that lift. It looks right at home in there!

 

[MacTexas]

Nice looking place.

 

[BigNuge]

Got the lift bay closed in, lift bay lights up and wired.

Had junior this afternoon/evening, so he was daddy's helper wiring the lights.

And the result:

Now to work on the furnace....


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[crkleve]

Great plan and project! I always enjoy seeing an old barn 'made new' and used again. Love the updates and photos!! GOD Bless!

 

[bulletpruf]

Looks like a great work space -- love the lift and the lighting -- and can't beat the character of an old barn. Color me green with envy!

 

[BigNuge]

Thanks guys, it's been a long road...but I really like how it's turning out! It is coming together very close to the original plan!


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[xtremek]

Putting the lights up was a big mistake. Now you can't use the excuse that you couldn't see what you were doing.

 

[lowbucktruck]

It's looking good in there, BigNuge! That's becoming a nice work space. Thanks for sharing your progress on the barn. I'm sure that Junior will have fond memories later in life of helping Dad in the barn.

 

[STINEY]

Very nice!

What thickness OSB did you use?

How did you put it up?

Any insulation behind it, and if so, what did you use?

Where did you get the lights? Reasonable price?


This is the next step on my shop barn project, closing in the inside so it can be heated. I was leaning towards sheeting it with the thinner steel siding made for inner walls, with a layer of R20 foam board behind. Interested to see what you planned.

 

[BigNuge]

Thanks for all the compliments guys! I am excited to do all sorts of projects will my boy in the shop!

Very nice!



What thickness OSB did you use?



How did you put it up?



Any insulation behind it, and if so, what did you use?



Where did you get the lights? Reasonable price?





This is the next step on my shop barn project, closing in the inside so it can be heated. I was leaning towards sheeting it with the thinner steel siding made for inner walls, with a layer of R20 foam board behind. Interested to see what you planned.

OSB is 1/2"

Petition walls are wood stud framed, OSB is screwed to the studs.

No insulation at this time, but definitely part of the future plan.

I got the lights on CL. A local business upgraded his whole building to new LED lighting. I got those lights for $10 each...he even threw in 2 extras for no charge in case there was an issue with one. I now have 11 of them up and working, one needs a ballast...I still think it was a good deal though!

That is exactly why I'm putting up the petitions, so I can heat it reasonably well. The furnace install is my next step. I already have it, just need to vent it, wire it, and fire it up!




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[BUGTHUG]

When I first started reading this, I pictured the location of the barn being way out , by itself. Neighbors not so close. But at least you are next to a asphalt road, so that makes it easier to get to.
Lift looks great, could use a little more height but should work fine. That's my next big investment I think.