Above 1200 Sq/FT The Shiloh Shop Project.......................

[bimmer1980]

June of 2011.

I started the work on the Arch Dormer of the garage....

This was a long planning and required a modification to the garage plans prior to ordering the trusses. I wanted to maximize room in the attic area of the garage. While a traditional dormer may have been sufficient, I became fascinated with the arch or barrel dormers on some older houses. I wanted to give this a shot and I thought it would look pretty neat when it was complete.

The Dormer width is 72" between the three ply trusses.

Much design work was done in a 3D CAD program to make this all work....

 

[bimmer1980]

Arch dormer framing continued.....

One end had a large window in it and the other was framed for a smaller glass block window...

 

[bimmer1980]

Continued work on the Arch Dormer in June of 2011.

Once the gable wall of the dormer was assembled, I removed the window panes and used some horizontal boards to provide a lift point for the forklift.

Then it was a matter of lifting and maneuvering into place.....

 

[bimmer1980]

During this time frame, my father-in-law passed away in a tragic car accident. Due to all the complications and family distress, there was no garage work done for awhile.

This whole ordeal was a shock. The accident happened on Father's Day (June 2011) and then he spent a week in the hospital for about a week before he died. He was unresponsive that week.

It is sobering to look back upon that time.

 

[kent_323is]

Good pics of all the framing work!

Hard to believe it's been that long since your F-n-L (Dale) passed away. He was a good guy.

Did you make all of those steel plate assemblies that tie the trusses to the rafters, shown towards the end of page 4?

 

[Growlertdi]

This is a fascinating process and well documented. Thank you for sharing, I look forward to seeing more.

So sorry to hear about your F-n-L. I also had a great F-n-L and miss him daily.

 

[bimmer1980]

Thanks guys!

Yes, I made the large steel bracket pieces for the LVL's to connect to the trusses. Probably a bit overkill with the 3/16" steel plate and 3x3 angle, but you never know if a hoist might need to be connected to them some day......

 

[bimmer1980]

August 6-2011.

I was finally ready to get back to doing some work on the garage.

The rear wall of the Arch Dormer was a little bit different than the front wall due to the shape and size of the window. This made it easier to frame, but required a tight fit with the forklift forks.

Once the wall was up in the air, I had to rotate it on the forks to align it with the wall.

Probably not exactly OSHA approved work surfaces...

Then the wall was braced and ready for some walls.

 

[bimmer1980]

As noted previously, I had cut out all the curved rafters in anticipation of the arch dormer framing....

I also build up the wall frames and hoisted them into position to test fit.

 

[bimmer1980]

Had some other travel things happen in August, so it was slow going on the garage.

Finally in Mid September of 2011 I had some more progress.

The walls and sheathed and wrapped. Then hoisted into position and fastened.

 

[bimmer1980]

In the mid September 2011 time frame I was also finally able to start setting the curved rafters after setting the LVL beams into the pockets.

It was quite satisfying for me to set the curved rafters. They were the culmination of lots of planning and preparation work.

 

[bimmer1980]

At the beginning of October, 2011, I was working on the myriad of details associated with the arch dormers.

--Eave boards
--Transition framing from peaked roof to the arch shape.
--Additional blocking on ridge beam for additional nailing of the sheathing...

 

[bimmer1980]

Here are some additional pictures that show the various blocking and framing for the arch dormer.

I also made up some special stands and planks so that I could more easily work on the arch dormer.

The vertical boards on the skid steer bucket helped me move the planks from one side of the garage to the other dormer.

It's hard to see in these pictures, but the sheathing is on in the last couple of pictures. I used two layers of 3/8" 3-ply CDX that is glued and nailed. It was a little interesting to get it to roll over the arch dormer, but it went fairly well... Of course, the more challenging part was to cut the transition area to fit well.....

 

[bimmer1980]

Mid October of 2011.

Here are some additional shots that show some better details of the process of the sheathing....

As it was getting dark as we were finishing up, the one picture got a little blurry.

There's my B-in-L Cory standing on the dormer and admiring our hard work.

I'm loading up the glue gun.... I have used a lot of glue on this garage!!

 

[bimmer1980]

It might be worth a post showing how I moved the planks around.....

 

[jeffcoll]

Very Nice! The details make this build pop!

 

[DarrenF]

awesome job man

 

[kent_323is]

Looking good! It's good to see these pics again of the build process.

 

[54earl]

That is a lot of work for a guy and his friends/family.

 

[bimmer1980]

Yup, It was a lot of work.......

Skipping ahead thru some details.... Thanksgiving of 2011. 11/25..

I wanted a 2" layer of roof deck insulation, but was required to have purlins for the standing seam roofing to screw onto.... Hence, 2' of foam and purlins...

This was a fair bit of work, but made for a solid roof assembly.

 

[bimmer1980]

The purlins and a variety of other work on the garage took awhile. I was also lining up the order for the standing seam steel roofing material.

The curved SSR material was a challenge to get... had I known that, I might have just gone with regular SSR..... oh well... live and learn.

Mid April of 2012 I was working on the box returns for the gable and soffits...

 

[bimmer1980]

April 19 thru 21 of 2012. I was moving around the garage to finish the gable sub framing and box returns.

I also made some fork extensions to allow me to move a tower of scaffold. That helped the productivity..... It beats tearing the scaffolding down for each relocation...

 

[bimmer1980]

May 4th of 2012.

The Standing Seam Steel arrived. I had also drawn up and ordered some custom steel trim. Of course, the metal fab shop couldn't follow the drawing, so that had to be remade. That was a pain in the rear....







They were able to remake it in about a week and deliver it.

 

[bimmer1980]

Finally in Mid May, the 12th, of 2012, I was able to get started on the trim work.... I wanted to do this before the roofing material to lap all of the weatherproofing materials in a precise manner.....

If I were to do this again, I would proceed with the roof and detail it out slightly differently.... Regardless, here's how I works....

The trim is designed to have minimal exposed fasteners.. The J-channel provides the bottom attachment and room for soffit at a later time.

 

[bimmer1980]

May 17, 18, and 19 of 2012. I was able to start installing the SSR on the west dormer of the garage.

Notice the detailing of the peel and stick underlayment and the synthetic underlayment for the rest of the roof. This stuff is designed for underneath SSR.

You can also see the layer of 2" polyiso insulation.

 

[bimmer1980]

End of May in thru June of 2012 I was focused on the roof and the myriad of details required to get that done.....

 

[bimmer1980]

Continuing the roof the weekend of 6/25 and 26 of 2012....

An older gentleman by the name of Albert was helping on the roof as well. He was a treat to work with. He has since passed away due to cancer, but I greatly enjoyed the time he was helping me!

The valleys were a bit of a challenge to hem. I ended up making a longer hemming tool to do the bend in one shot. The hemming tool I had originally purchased was only good for a straight hem.

 

[bimmer1980]

Into Mid July of 2012. Making some more progress on the roof.

The valley pieces are challenging......

I also was painting the cut edges of each panel.....

The trim brake was handy throughout this roofing project....

Also notice the 6' x 8' window that I found on craigslist for $100. It provides a lot of light into the garage....

 

[wasfast]

That was quite a bit of work for the SSR. Should last forever though.

 

[WhoWhatNow]

Wow, this was so much work. Great job.

Unrelated question, what kind of hitch do you have on your E30? I just picked up a 91 coupe and want to add a hitch for my small 4 X 6 trailer.

 

[bimmer1980]

Thanks guys.

I don't have a picture handy of the BMW E30 hitch. I ended up selling the car after some issues with passing PA inspections.... The hitch had two bolts that attached it to the aluminum bumper and a pad that attached to the bottom of the wheel well. It was on the car when I bought it used. Due to some cracking on the aluminum bumper, I took the steel hitch mount off, then used the aluminum MIG welder to add a doubler plate around the bolt area. I did that work in SD before I moved to PA.

Thanks for looking at the project!

 

[kent_323is]

Looking good!

 

[bimmer1980]

Early August of 2011, I was working on installing the ridge cap. That was the worst part of the whole job.

From doing the first part of the garage roof, I figured out that the current "Chicken-Hooks" for the ladder did not allow for ease of working on the ridge.

In Early September of 2011, I worked on fabricating some new chicken hooks that give clearance for the ridge cap.

 

[bimmer1980]

I knew that I wanted a curved window for the front of the garage. In searching craiglist, I eventually found the right size for $40. Then I could work on framing in the opening and installing the window.

September 30, 2012.

Arch window framing.

I also pushed the window frame out a few inches to allow it to coincide with the future brickwork.

 

[bimmer1980]

Next up is the preparation of the work on the Arch dormer..... I need to organize some of my pictures... then I will start posting on that work......

 

[yeldogt]

Great job .. so am I reading correctly ..7 years?

 

[bimmer1980]

Great job .. so am I reading correctly ..7 years?

Thanks for checking it out! Yep.... and then some. Definitely not the quickest project on here.....

 

[1Garageman]

Any more updates?

 

[bimmer1980]

Thanks for checking in... I haven't posted in this thread for awhile... I need to get back to digging through my photos and posting.

Currently the Heat is "On" (it's a balmy 62 degrees inside) and I'm working on framing out my bathroom....

 

[zanyad]

Impressive build. you left off in 2012 when you were working on the roof. Any updates to share?