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Workshop Build

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Blog series by ~Julie~ updated 10-05-2014 12:56 PM 29 parts 68295 reads 212 comments total

Part 1: Clearing the land

02-07-2010 09:42 PM by ~Julie~ | 9 comments »

This is a blog about the building of my workshop which has been ongoing now for almost 3 years. My husband wanted a garage for car storage and working on cars and I wanted a workshop for woodworking. We decided on a 40’ x 40’ building with one half for him and one half for me. It was my job to sketch up a rough version of what the building would look like. The plans were drawn by both of us and an architect was needed, according to the by-laws in our township, to design the fl...

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Part 2: Preparing the foundation

02-08-2010 04:32 PM by ~Julie~ | 11 comments »

In May 2008, after a long winter and very wet early spring which delayed construction, we dug the trenches for the forms and the footings: Forms being built, leveled and straightened: Styrospan had to be laid under the cement foundation: We decided to heat the whole garage and shop floor with in floor heating which would be heated with the use of an outdoor wood stove. Since our home was already using hot water heating, the house was piped and ready to be switched over from ...

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Part 3: Laying infloor piping

02-10-2010 04:29 PM by ~Julie~ | 6 comments »

In June 2008 it was time to start getting the in-floor piping and the electricity hook-ups into the foundation before the cement could be poured. The wood stove that will heat the new workshop as well as our house will be placed in between the two buildings. It will sit at the side of the driveway approximately 50 feet north of the house and 75 feet south of the workshop. Since our hookups will need to be at the farthest side of the house, a trench needs to be dug about 75-100 feet each ...

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Part 4: The pour

02-16-2010 04:47 PM by ~Julie~ | 13 comments »

My husband and I did almost all the work in building the new shop but we did hire a group of men to pour and smooth the new floor. Here’s the pump truck starting the pour in the north east corner: Pouring in the north west corner: Close up: Finishing up: All done: And the pad for the wood stove to sit on: ...to be continued…

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Part 5: Blocks and insulation

02-22-2010 04:53 PM by ~Julie~ | 2 comments »

It was July 2008 and since our foundation was all in, we were on to the blocks and then the framing. Our plans called for one row of blocks sitting on the foundation. Blocks were not put at the doorways at the front and side of the building and also where the large garage door would be.This shows the front workshop door area: 2” thick styrofoam had to be placed vertically around the whole perimeter of the building. We have cold winters and this is to hopefully keep the heat ...

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Part 6: Framing

02-24-2010 05:05 PM by ~Julie~ | 5 comments »

Finally time to frame the walls! We used 2×6 lumber and 8’ foot lengths for the studs that are 16” OC. These are placed on a 2×6 plate and with two 2×6’s for the top plate. Of course this sits on top of the blocks and so it makes the wall height about 9’. We put the walls up in sections and used the top 2×6 to run across sections to hold them together. We did have anchor bolts that came up from the foundation, through the holes in the blocks an...

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Part 7: Floor/Ceiling Joists

02-27-2010 10:53 PM by ~Julie~ | 4 comments »

In order to be able to have a 40’ building without interior walls other than one right down the middle, we needed to have joists that would carry across the width of the building and give us room above for storage. Regular trusses don’t allow for much empty space for storage, so we had joists designed with our particular needs taken into account. The joists are I beam style, 40’ long and sixteen inches deep. They needed to be placed 16” OC, so that meant an order ...

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Part 8: Covering the outside

03-01-2010 04:33 PM by ~Julie~ | 5 comments »

It was still August 2008 and since we had rented the backhoe to help moving the joists around, we also made use of it to place our outdoor wood furnace, that will heat both the workshop and house, into position on the pad: The backhoe was then used to lift plywood up on top of the joists: This was used as a floor for the upstairs loft area: It was time for aspenite to go on the outside of all the framing. It ran from about half of the blocks to the top of the ceiling/floor joists.Here...

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Part 9: The attic

03-06-2010 06:21 PM by ~Julie~ | 4 comments »

Now where were we?Oh yes… we have to start the upper floor, I am going to call it the attic. Let me remind you that my husband did all of this part completely on his own. I was recovering from carpal tunnel surgery and unable to carry anything or hammer or do much at all other than supervise! There were no stairs yet, so all the pieces had to be pulled up from the front or brought up on a ladder. It was a lot of heavy work for one person and a heck of a lot of pieces. He started by ...

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Part 10: The roof

03-12-2010 04:52 PM by ~Julie~ | 3 comments »

It was Sept. 2008 at this point and the next step was putting plywood on the roof. Of course all of this plywood (to cover a garage of 40’ x 40’) had to be lifted up through the attic and most of it was nailed from the inside and reaching out. We put up the garage door and got a truck load of fine gravel to keep the front area smooth and neat for the upcoming winter season. Because I thought it was dangerous for my husband to do and we were running out of time befo...

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Part 11: Insulation and wall covering

03-16-2010 01:47 AM by ~Julie~ | 1 comment »

At this point, the building was up, it was winter (Nov. 2008) and time to insulate. Batts were placed in the attic walls between the studs at the end walls. Also we placed insulation between the ceiling joists, leaving an airspace at the top. Over Christmas there was a big wind storm that knocked down some trees. This one was beside the new garage and fell away from it, most likely because some of the roots were cut while clearing the space for the foundation:Here’s a view of the east side...

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Part 12: Starting to paint, the woodsheds built, soffit and fascia

03-27-2010 02:52 AM by ~Julie~ | 3 comments »

In June of 2009, I got started on the painting on the garage side before all the OSB was up on my workshop side. I used Kilz Original and put on two coats. This was hard to do because you really have to push hard on the roller to get it in all the recesses in the OSB and my hand pain problem was not compatible with all that roller work. Anyway, I did do it, here is the back wall of the garage and the dividing wall with one coat: I started moving my tools into the shop so I could wor...

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Part 13: Front Room Painting and Casings

04-16-2010 04:59 PM by ~Julie~ | 9 comments »

This spring I was finally getting the workshop painted and ready to use! My shop is divided into a front room that will be used for assembly and finishing and the larger workshop part at the back. Here’s a rough sketch of the layout: The OSB walls have all been painted with 2 coats of Kilz original primer, here’s the east side wall of the shop part before the paint: and with the Kilz primer: The front room with insulation only: with the OSB: and with...

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Part 14: The "Man Cave"

04-19-2010 07:02 PM by ~Julie~ | 8 comments »

I have been focusing on the workshop in our build, since this IS a woodworking site. But the other half of the building is for my “other half” and is his garage… also known as the “Man Cave.” I thought some of you might like a glimpse of that as well. We painted the floor with Behr 2-part epoxy, and painted the walls, the door and windows still need trim. (The right corner houses my Clear Vue Cyclone, which is not fully hooked up yet.) ...to b...

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Part 15: Making an interior window

04-22-2010 03:40 PM by ~Julie~ | 2 comments »

As said in the previous post, my shop has a front room that is divided from the shop with a wall and doorway. I decided I would like an interior window between the shop and door so that I could see into the front room while in the shop, plus to allow me more natural light. While framing the wall, we used 16” OC studs but left a wider opening between the 2”x6”s where I wanted the window to be ( I believe it was about 24”). OSB was put over the wall on the shop sid...

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Part 16: The Lumber Rack

05-05-2010 04:34 PM by ~Julie~ | 27 comments »

Planks on the Floor, Planks on the Floor,Lookin’ Like a Fool with yourPlanks on the Floor… Sorry, just had to do that… My small collection of pine was sitting on the floor, waiting for somewhere nice to go: This wall was the decided place, it allows me to enter the open garage door on the garage side of the workshop with a load of wood and then bring it through the middle door that divides the garage from the workshop: I decided to use 2×4 uprights screwed t...

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Part 17: Cleats - Getting things on the wall

05-15-2010 08:06 PM by ~Julie~ | 7 comments »

Time to get supplies, especially clamps arranged and off the floor. I got my ideas from a few woodworking magazines that I have. Here’s the wall where the racks will go, in my front assembly room: I am using the French Cleat system and will have two rows of cleats on three walls of the shop. They are attached with screws every 16”, where the studs are under the OSB. My cleats are painted white, the same colour as the shop walls, that way they don’t stand out: ...

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Part 18: Cupboards on cleats (part 1 of 3)

06-05-2010 03:35 AM by ~Julie~ | 7 comments »

It’s time to post my cupboards I made to put books and magazines in, that will hang on the cleats in my shop.(see Workshop Build #17: Cleats- Getting things on the wall) For inspiration I used a cupboard in a magazine article, but changed the plans slightly. I wanted to have two cupboards to hold my woodworking related books and magazines. The article I saw had a moveable shelf, but I figured a fixed center shelf would be more solid and hold the heavy books better. Of course, it&#...

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Part 19: Cupboards on cleats (part 2 of 3)

06-07-2010 02:47 PM by ~Julie~ | 6 comments »

To continue the cupboard building, the 7 parts of the sides are glued together: Here are all four sides, for the two cupboards, propped up against the workshop wall: To accept the back piece, a 1/4” rabbet is run down the back of the stile: The top and bottom are to be 1/2” plywood, so a 1/4” wide dado is cut 1/4” down from the top and bottom of each side piece: A 14” wide dado is also cut in the center of the middle rail to accept the center fixe...

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Part 20: Cupboards on cleats (part 3 of 3)

06-10-2010 01:17 AM by ~Julie~ | 8 comments »

Time to finish off this cupboard blog. Here is the cupboard with a few coats of wipe-on poly on it: Here is the top joint, a dado-rabbet. It’s kind of rough looking, but will be covered with the piano hinge so I wasn’t as fussy as I normally would be. This shows the back rabbet that will hold the piece of 1/4” plywood. I put the poly on the piece before I put the back on. That way I could poly the big flat piece of plywood without shelf interference, as well a...

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Part 21: Strapping the outside

06-25-2010 06:46 PM by ~Julie~ | 8 comments »

Time to think about putting up the siding on the garage/workshop. First we need to strap it.The siding will be horizontal so we used vertical 1×3’s screwed into the OSB every 16” OC. Around the windows and across the bottom we used 1×4s. The back is a straight 40’ width which is taking a lot of pieces! Before we can do the front, we need to build up a bit of the front small roof and deck posts. We haven’t quite figured out if the strapp...

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Part 22: Tools on cleats

07-08-2010 02:15 AM by ~Julie~ | 6 comments »

I need to make some tool holders to get my tools a place of there own, where I know they are when I need them. I am going to make them so that they are able to hang on cleats, which I already have in part of my shop. I found a picture in Woodsmith magazine showing a way to hold tools. There were no plans, but it looked easy enough to make my own without how-to instructions. I wanted to hold three tools for now, my battery powered drill, my electric drill and my jigsaw. To figure out ...

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Part 23: The Front Porch

08-11-2010 05:42 AM by ~Julie~ | 8 comments »

Here is a sketch I made a few years ago before the building of our workshop/garage: Now, how to get that front porch on there? We had two large cement post holders put 13 feet apart when we did the garage pour. These have saddles set into them to hold 6” x 6” posts. We wanted the porch roof to have the same slope as the whole roof, so we had to figure out the length the posts would need to be to make the roof come at the right location above the door and light. We...

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Part 24: Wall - Mounted Bins

08-18-2010 04:44 PM by ~Julie~ | 11 comments »

I posted a question in the forum section here two months ago asking what others did for organizing all their screws, hooks, etc. in their shops. Some people suggested buying plastic bins, others said use jars or bags. I had a plan in a magazine full of shop storage and tool cabinets put out by the Woodsmith/Shop Notes people and so I decided to make my own. Unfortunately I felt like one of Santa’s elves with the assembly line of parts. It seemed to take forever to make all the b...

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Part 25: Starting the Siding

09-08-2010 07:22 PM by ~Julie~ | 4 comments »

Finally the siding is going to be put on the workshop. We decided on vinyl so that there wouldn’t be a need for continuous upkeep such as painting or staining. The colour is called Weathered Wood and looked greyish with some green in it, in the store sample, but appears more grey/blue in reality. The first step is to put the corner pieces on (ours are white), and J trim around the doors: Then the bottom strips go on: The siding hooks to the bottom strips and fits between...

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Part 26: Finishing the Siding

10-12-2010 07:53 PM by ~Julie~ | 9 comments »

Why do things always take longer to do than we think they will? The siding is on the workshop, so the outside is mostly complete. I just need to make a small front deck that will sit on the ground in front of my door. The sides were done (see previous blog post) but we had to do the back of the shop, which is a huge wall, 40’ long. The good thing is there are no windows there, so the bottom part went on quickly. We rented scaffolding from the Home Depot in order to be able...

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Part 27: Trimming the workshop windows

02-28-2012 06:13 PM by ~Julie~ | 7 comments »

I haven’t posted here in a long time, and finally I’m getting around to finishing my interior windows. On and off over the past few months I’ve been working on them. The front room windows had already been done by me a couple years ago. This is the south side, and where I enter my shop. I chose pine to trim the windows with because it’s my favourite and the shop cupboards and router table I made are pine.The vinyl clad windows were inserted from the outside and nai...

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Part 28: Trimming the workshop windows part 2

03-01-2012 05:17 PM by ~Julie~ | 5 comments »

The jambs are attached first, this shows the bottom sill and the side jamb: When the jambs are nailed in, they have to have shims put in between them and the framing, to keep everything level and perpendicular. I also had to add some insulation in the space. Next I put on the 3 1/4” wide side casings, all are 1/2” thick. Note that casings sit back from the jambs about 1/8” – 1/4”, something I didn’t know until I researched how to trim windows...

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Part 29: Leaving my fabulous shop!

10-05-2014 12:56 PM by ~Julie~ | 14 comments »

After building this beautiful shop, we are moving. Something I never anticipated when we built. But things happen and change is good. My shop is a shop to-die-for… I just LOVE it and I know I will never have another one this fabulous. I’ve written a bit about the building of my workshop, but really haven’t shown any inside photos. My husband and I built a 40’ x 40’ garage for both of us. The whole building has in-floor heat which is wonderful to work in,...

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