The barn housing my mill, kiln and woodworking equipment is not climate controlled so working in the extremes of summer and winter can be challenging at best. Forget about doing any finish work except for a the rare days of decent temps and low humidity.
The pole barn that is heated in the winter houses my bio diesel processing, automotive and mechanical equipment. Sawdust, oil and vehicles do not play nice together.
So, it all started with a pile of logs from a clearing project:
(https://forestryforum.com/gallery/albums/userpics/10273/04172011_opt.JPG?easyrotate_cache=1310476693)
smiley_idea - I should build an addition to the saw barn that would be climate controlled and do double duty as my 'man cave'. I put pencil to paper and came up with my version of the dream shop to complement the saw barn and the woodworking equipment inside.
April 2012. I leveled the area to the west of the barn, dug footers, laid L block and filled it in with gravel.
(https://forestryforum.com/gallery/albums/userpics/10273/form_and_gravel_for_slab_040212.JPG?easyrotate_cache=1466848762)
Poured the slab, finishing it with a bull float.
I spent a good part of the summer of 2012 milling logs into 2x4, 2x6, 2x8, and 2x10 boards that were then kiln dried. The 2x6 studs were milled from big tooth aspen. Everything else came from the tulip poplar logs.
Setting the walls using my JMS log trailer:
(https://forestryforum.com/gallery/albums/userpics/10273/First_Walls_2.JPG?easyrotate_cache=1466848723)
(https://forestryforum.com/gallery/albums/userpics/10273/Four_Walls.JPG?easyrotate_cache=1466848828)
December 1, 2012 with the help of the lady across the street we began setting trusses. She loves to climb and is very nimble while I like to keep my feet on the ground or at worse on some scaffolding. Setting the trusses was a bit tricky because the first five were truncated to tie into the existing barn wall. We built the first three as a unit on the ground and hoisted them up with the JMS grapple. The rest were loaded over the south wall and pushed into position then nailed in place.
(https://forestryforum.com/gallery/albums/userpics/10273/Setting_trusses.JPG?easyrotate_cache=1466849296)
Working solo again I started installing the purlins and girts using the last of the tulip poplar.
(https://forestryforum.com/gallery/albums/userpics/10273/First_Purlin_and_Girt_2.JPG?easyrotate_cache=1466848692)
Once the purlins and girts were in place I enlisted the services of a couple carpenter friends to install the metal roof. I can climb up on the roof but getting back down never seems easy so I did all the ground work drilling holes and such. By December 15, 2012 it was under roof. Jette stopped by to give her approval.
(https://forestryforum.com/gallery/albums/userpics/10273/Roofing_complete_w_Jette.JPG?easyrotate_cache=1466849237)
I took January 2013 off to cut firewood and push snow around but by February 13, 2013 I had the doors and windows in and the addition wrapped.
(https://forestryforum.com/gallery/albums/userpics/10273/SB_Addition_001.JPG?easyrotate_cache=1466847973)
(https://forestryforum.com/gallery/albums/userpics/10273/SB_Addition_003.JPG?easyrotate_cache=1466847989)
(https://forestryforum.com/gallery/albums/userpics/10273/SB_Addition_004.JPG?easyrotate_cache=1466848002)
I spent March harvesting tulip poplar that was standing dead or stressed from the droughts of 2010 and 2012 and the tulip scale outbreak that followed. When I wasn't harvesting trees I worked on the large 10'x10' doors. I built the doors up using 2x4 aspen, 3/4" plywood and 2" rigid foam.
(https://forestryforum.com/gallery/albums/userpics/10273/Large_door_consruction_042413~0.JPG?easyrotate_cache=1466848888)
(https://forestryforum.com/gallery/albums/userpics/10273/Large_door_sheathing_042413~0.JPG?easyrotate_cache=1466848896)
(https://forestryforum.com/gallery/albums/userpics/10273/Big_doors_020614.JPG?easyrotate_cache=1466848404)
In May, 2013 a friend helped me install three 3'x6' glass panes in the south wall.
I spent the summer milling 1x6 tulip poplar, putting a ship lap edge on each side of the board. By August I had the addition sided.
(https://forestryforum.com/gallery/albums/userpics/10273/Siding_north_081213~0.JPG?easyrotate_cache=1466849328)
(https://forestryforum.com/gallery/albums/userpics/10273/Siding_west_and_south_081213.JPG?easyrotate_cache=1466849356)
(https://forestryforum.com/gallery/albums/userpics/10273/Siding_south_and_east_081213.JPG?easyrotate_cache=1466849344)
With the siding completed I went back to milling big tooth aspen and tulip poplar. This would be ceiling and wall material so it was kiln dried.
I was not able to turn my attention to the interior until February, 2014, building out the office, insulating the ceiling, installing the ceiling lights and wiring the outlets.
(https://forestryforum.com/gallery/albums/userpics/10273/wiring_east_wall_020114.JPG?easyrotate_cache=1466849525)
(https://forestryforum.com/gallery/albums/userpics/10273/wiring_office_2_020114.JPG?easyrotate_cache=1466849582)
(https://forestryforum.com/gallery/albums/userpics/10273/wiring_north_wall_020114.JPG?easyrotate_cache=1466849550)
After insulating the walls I turned my attention to finishing the lumber for the ceiling and walls. All the lumber was cut to rough length (approx. 75", 52" and 30"), jointed, planed ripped to 6" and then tongue and grooved. I initially attempted to do the t&g work on the Woodmaster 718 but I could not keep registration.
Planing:
(https://forestryforum.com/gallery/albums/userpics/10273/Planing_aspen_2_030314.JPG?easyrotate_cache=1466849158)
First attempt at t&g on Woodmaster:
(https://forestryforum.com/gallery/albums/userpics/10273/T_G_first_attempt_Woodmaster_053114.JPG?easyrotate_cache=1466849448)
Better solution - Jessem router table:
(https://forestryforum.com/gallery/albums/userpics/10273/T_G_tulip_060414.JPG?easyrotate_cache=1466849463)
(https://forestryforum.com/gallery/albums/userpics/10273/Router_table_t_g_022715.JPG?easyrotate_cache=1466849265)
By June 2015 I had enough boards to begin finishing. I did a lot of research on finishing paneled walls but could not find anything to suit me. I wanted to finish the boards front and back to minimize seasonal movement. I also did not want a gloss finish or something that would change the natural color of the wood. I came across a product by Target Coatings called EM6000. It is a water based acrylic and I could get it in a semi-gloss. This product is best sprayed so I set about cobbling together a spray booth and drying rack.
(https://forestryforum.com/gallery/albums/userpics/10273/Spray_booth_and_hanger_061014.JPG?easyrotate_cache=1466849432)
(https://forestryforum.com/gallery/albums/userpics/10273/Drying_rack_long_and_short_061014.JPG?easyrotate_cache=1466848541)
(https://forestryforum.com/gallery/albums/userpics/10273/Drying_rack_2_061314.JPG?easyrotate_cache=1466848525)
I did improve on the spray booth by replacing the plastic sheeting with and actual booth fabbed out of insulation board but apparently I never took a pic of it >:(\
The boards in the booth and the drying rack hung from box nails set in on end. I found out early on that I needed to enlarge the groove in the drying rack. The original groove did not totally encase the nail head and when I bumped the rack or dropped a board the resulting vibration set off a chain reaction that created an instant game of pick up sticks. :o
By December 2015 I had all the big tooth aspen finished and ready to install on the ceiling.
(https://forestryforum.com/gallery/albums/userpics/10273/sized_aspen_for_ceiling_101614.JPG?easyrotate_cache=1466849377)
The ceiling was completed July 2015. I used two 6' scaffolds to install the boards after I ran an air line from the barn to the addition.
(https://forestryforum.com/gallery/albums/userpics/10273/Ceiling_3.JPG?easyrotate_cache=1466849914)
(https://forestryforum.com/gallery/albums/userpics/10273/Ceiling_2.JPG?easyrotate_cache=1466850233)
(https://forestryforum.com/gallery/albums/userpics/10273/Ceiling_4.JPG?easyrotate_cache=1466850210)
(https://forestryforum.com/gallery/albums/userpics/10273/Ceiling_5.JPG?easyrotate_cache=1466850146)
It was back to milling, sizing, finishing and installing for the wall paneling. The wall paneling was up by June 2016.
(https://forestryforum.com/gallery/albums/userpics/10273/IMG_0888.JPG?easyrotate_cache=1466889128)
Feeling I was in the home stretch I bucked a number of 13' tulip poplar logs, milled, dried and sized the lumber. I used the Woodmaster 718 to make all the trim. Due to the length of the trim I could not use my spray booth or drying rack so I finished the trim using a brush. The coating went on well and dried nice and flat. Just like the ceiling and walls the trim got three coats on each side. One of the nice qualities of the EM6000 series of coatings is that it is ready to recoat in 30 minutes with 100% burn in of the additional coats.
Making crown moulding:
(https://forestryforum.com/gallery/albums/userpics/10273/IMG_0892.JPG?easyrotate_cache=1466889236)
Making rosettes on drill press:
(https://forestryforum.com/gallery/albums/userpics/10273/Rosette.JPG?easyrotate_cache=1466850022)
June 2016 it is done 8) 8) 8)
(https://forestryforum.com/gallery/albums/userpics/10273/Finished_east_wall_w_Millcat.JPG?easyrotate_cache=1466848570)
(https://forestryforum.com/gallery/albums/userpics/10273/Finished_north_wall_big_doors.JPG?easyrotate_cache=1466848603)
(https://forestryforum.com/gallery/albums/userpics/10273/Finished_walls_NW.JPG?easyrotate_cache=1466848640)
(https://forestryforum.com/gallery/albums/userpics/10273/Finished_large_windows.JPG?easyrotate_cache=1466848605)
(https://forestryforum.com/gallery/albums/userpics/10273/Loft.JPG?easyrotate_cache=1466848914)
(https://forestryforum.com/gallery/albums/userpics/10273/Office_North_wall.JPG?easyrotate_cache=1466849074)
(https://forestryforum.com/gallery/albums/userpics/10273/Office_NE_corner.JPG?easyrotate_cache=1466849046)
(https://forestryforum.com/gallery/albums/userpics/10273/Office_exterior_east_wall.JPG?easyrotate_cache=1466849076)
(https://forestryforum.com/gallery/albums/userpics/10273/Office_south_wall.JPG?easyrotate_cache=1466890743)
Finally it was time to get my remaining woodworking equipment that had been stored in the pole barn, getting covered in bio diesel mist, relocated to the new home.
Moving in:
(https://forestryforum.com/gallery/albums/userpics/10273/Office_ext_w_Jette.JPG?easyrotate_cache=1466849032)
(https://forestryforum.com/gallery/albums/userpics/10273/Moving_in.JPG?easyrotate_cache=1466849026)
(https://forestryforum.com/gallery/albums/userpics/10273/Moving_in_2.JPG?easyrotate_cache=1466849005)
(https://forestryforum.com/gallery/albums/userpics/10273/Moving_in_3.JPG?easyrotate_cache=1466848996)
(https://forestryforum.com/gallery/albums/userpics/10273/Microwave_on_top_of_range.JPG?easyrotate_cache=1466850082)
(https://forestryforum.com/gallery/albums/userpics/10273/Millcat_guards_the_door.JPG?easyrotate_cache=1466848962)
The workbench is actually where this all started. I began building the bench in 2011 and quickly realized I could not complete it in the pole barn. After I finish our basement in a similar fashion I will finish the workbench. All the wood is milled and finished for the basement so that should not take more than a month or two. (famous last words)
I repurposed the drying rack into a lumber storage/display rack inspired by a post from Al Smith.
(https://forestryforum.com/gallery/albums/userpics/10273/Lumber_rack.JPG?easyrotate_cache=1466848948)
(https://forestryforum.com/gallery/albums/userpics/10273/lumber_on_rack.JPG?easyrotate_cache=1466848922)
With the exception of setting trusses, installing the metal roof, and setting the windows the only other help I had was from Milcat. Here she is helping me measure :D
(https://forestryforum.com/gallery/albums/userpics/10273/Millcat_helps_measure.JPG?easyrotate_cache=1466848975)
Well it took about as long to post this as it did to build it. Thanks for reading and I hope you enjoyed the ride :)
8) smiley_clapping
Wow! Great build.
I've seen (no, lived in) houses that weren't as nice as your new shop.
Herb
Very nice build! ;) 8)
Well done. What a great presentation of that interior wood. Enjoyed your documentation pics, watching your plan turn into a very cool shop! Be proud of that effort as it is always a lot of work.....but REALLY a lot when you tackle most of it solo.
Man, that was/is awesome!!! 8) 8) Great Job.
Thanks for all the pictures too,
Terry
Goes to show what a man can do with some ambition doing all you can do and not have to hire it all out. My hat is off to you, sir,
Very nice job. smiley_clapping smiley_clapping
Great job, with real nice pics.
Robert, very inspiring. Now, I will never take another picture of my shop :).
Outstanding work!!!!!!
smiley_clapping smiley_clapping
Jus' one word.... unbelievable!!!
That is one nice shop, hope mine turns out half that nice. Well done
WOW! Awesome building! I know you are certainly proud of all the hard work that went into it.
I saw the concrete slab that you poured. Did you use any kind of sealant or anything on the floor of the building? In the last pictures (it was hard to tell) the floor looked like it has something on it.
Loved it. Thanks for taking the time to present your project.
Awesome work, OWW! It has to feel great to use that shop after all that work ;)
Really like what you have done. Excellent work. Just goes to show what one can accomplish when they set their mind to it. Impressive build.
What awesome man cave. Beautiful job you done good, your workmanship is outstanding. Thank you for sharing your journey
Wonderful workmanship! Outstanding job!!! smiley_thumbsup
Very nice.
A very nice story you have. And a very nice shop to work in. I hope to see some pictures of the things that you will build.
Great job. Thanks for sharing the pictures and taking us along on the ride. smiley_clapping smiley_clapping
It looks much different than it did when we were there. smiley_thumbsup Congrats on a fine job and also for the picture parade.
...almost unbelievable! But, you made your dream come true. You're an inspiration. All the best, Rob.
A remarkable combination of talent, patience and tenacity! Words escape me! 8)
Quote from: ncsawyer on June 25, 2016, 09:41:56 PM
WOW! Awesome building! I know you are certainly proud of all the hard work that went into it.
I saw the concrete slab that you poured. Did you use any kind of sealant or anything on the floor of the building? In the last pictures (it was hard to tell) the floor looked like it has something on it.
No. I opted to forgo the sealing. The slab in the barn was not sealed and has held up well. Hopefully I won't regret it.
smiley_clapping Absolutely FANTASTIC!!...What did you do?...hit to lotto?... I would never wanna leave the place...the ULTIMATE MAN CAVE. Very very well done Sir.
Robert, that is spectacular! A very nice testament to patience, planning and a joy for good craftsmanship.
As others have written; very inspiring! Thanks for taking us along on the journey.
(PS, I got a chuckle from the photo that showed a cat laying in a window!)
No need to play the lotto. The total cost was right at $20K. I have no intention of ever leaving. This is home.
Outstanding.
Rome was not built in a day. :D Enjoy the fruits of your labor, you earn it. ;D
You didn't post the size. So, how big? Anything you would change? Very nice shop.
WOW!!~
Nice work....and kudos on a well organized post as well ;D
Quote from: fishfighter on June 26, 2016, 12:05:40 PM
You didn't post the size. So, how big? Anything you would change? Very nice shop.
32'x40' with 12' ceilings. The office is 12'x12' with an 8' ceiling. The loft above the office will be used for lumber storage. So far the only thing I wish I had done differently is to have installed LED lighting instead of fluorescent.
Nice job, best project I've seen in a while. Looks more like a cabin than a workshop. It'll be pure pleasure working in there.
I am in awe :)
This is home,great job.Thanks for sharing.
Beautiful job! That is a one of a kind wood shop!
Wow! Fantastic! You did an amazing job. You are talented!
They now sell led bulbs that will fit in your fluorescent lights.
Very nice, an inspiration to some of us procrastinators.
Is that a mini-split for heating and cooling?
All the above x10. Great job. I'm real jealous. Beautiful work.
Quote from: Larry on June 26, 2016, 08:58:06 PM
Is that a mini-split for heating and cooling?
Yes. It is an LG unit mounted 10' above the floor. Fortunately it has a remote. ;)
I have been very pleased with it. I installed it Oct. 2015 and the climate control allowed me to finish boards throughout the winter months.
Impressive! Great job! smiley_thumbsup
That is one of those extremely projects you can talk about the rest of your life especialy.with the pictures that is a great job. I love that t&g on the inside We have a mill building that I built with my boys and it was a great experience that we talk about often.
That looks awesome!! 8)
After seeing all that hard work Robert, I'm exhausted! :)
You are a true craftsman.
Great job. When I get ready for mine I know who to call to build it.
That is awesome. I don't know how you have the time. Do you have any kids? Need one more?
How do you like your Woodmaster, I'm looking for a good planer.
Cool great job thanks for sharing
Great job on your project. Hopefully one day I'll accomplish the same.
Quote from: Waterford Woodworks on July 03, 2016, 07:20:26 PM
That is awesome. I don't know how you have the time. Do you have any kids? Need one more?
No kids at home and I don't need any at this time. :D I enjoy working with my hands and if I sit for more than a few minutes I fall asleep. So, I hardly watch any TV.
Quote from: dean herring on July 03, 2016, 09:41:30 PM
How do you like your Woodmaster, I'm looking for a good planer.
The Woodmaster is a decent planer and I have been happy with it. The fact that I can switch over to milling trim is a big plus. When I have a few hundred board feet to plane I wish I had a bigger dedicated unit.
Quote from: Kbeitz on June 26, 2016, 08:30:29 PM
They now sell led bulbs that will fit in your fluorescent lights.
I have looked but the longest LED tube I found was 4'. I need 8'.
What a shop! Job well done. Wish I had the space, time, money,....
Quote from: OneWithWood on July 05, 2016, 10:50:11 AM
Quote from: Kbeitz on June 26, 2016, 08:30:29 PM
They now sell led bulbs that will fit in your fluorescent lights.
I have looked but the longest LED tube I found was 4'. I need 8'.
They do make an 8' LED bulb to replace the 8' flourescent. They just changed them out at the auto parts here in town. I think he said they were around 35 a piece. Don't quote me on the price. They are bright.
Home Depot has them....
http://www.homedepot.com/p/Feit-Electric-8-ft-T8-T12-44-Watt-Cool-White-Linear-LED-Light-Bulb-8-Pack-T96-841-LED-8/206060373
Thanks for the link. Unfortunately my lights are high output, run in the cold, units and will not accept the single pin (have an oval push in connection). Hopefully some day there will be an LED replacement for them.
We are doing an LED retro in our district this summer. We are changing from a t-12. Everything goes into the current fixture. Take out ballast...snatch out the ends....stick in a driver and 2 LED strips and you're off to the next one. LED strips and the driver are magnetic. We started timing ourselves and one man can do the entire change in less than 3 minutes. There is a 9 month payback for us on energy savings and the the light produced in more than doubled...in some cases triple. I have yet to find a negative....except....I'm having a hard time finding a way to get rid of about 28,000 used T12 tubes!!!
Anybody burn T12's I can hook you up....by the truckload!!!
Quote from: hopm on July 06, 2016, 04:22:03 PM
We are doing an LED retro in our district this summer. We are changing from a t-12. Everything goes into the current fixture. Take out ballast...snatch out the ends....stick in a driver and 2 LED strips and you're off to the next one. LED strips and the driver are magnetic. We started timing ourselves and one man can do the entire change in less than 3 minutes. There is a 9 month payback for us on energy savings and the the light produced in more than doubled...in some cases triple. I have yet to find a negative....except....I'm having a hard time finding a way to get rid of about 28,000 used T12 tubes!!!
Anybody burn T12's I can hook you up....by the truckload!!!
Put them on the crageslist. They will sell
Been putting them on govdeal to give away....only had one taker
Quote from: hopm on July 06, 2016, 06:54:57 PM
Been putting them on govdeal to give away....only had one taker
Sure wish you was in my area... I have 54 lights in my shops that take that bulb.
Each light takes two bulbs.