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72-year-old couple building a barn (garage/workshop)

NASMAN

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Dec 18, 2007
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295
Location
Hills of Arkansas
Thought that some of the DIY people might like to see what a couple of old enthusiast, with no regard to those that say you can't, are in fact doing.
As the title of this thread says we both turned 70 just a few months ago, we were 69 when we started this. This project is located in Arkansas, where we moved to in 2007. Bought this nice little cabin cause my wife just plain loves it. My problem with it was it had no garage, workshop or any space for extra storage. She said "well than build something"
Most garage workshop buidings in this area are metal buildings on a poured slab, I didn't think that was much of a challenge nor would it go with the house or the property very well.
Original idea was to build a pole barn and pour the floor last. This got altered because of the rock ledge under the only useable area. So I had to build the site up put down the floor and build up from that. Also wanted to do a bit of post and beam type of construction and have in fact incorperated that into the framing.
Arkansas has not been the best place to atempt this. 2009 has been the wettest year since they have been keeping records. (1882) Also when it is hot it is very humid as well. But it is what it is and we are working thru it.
Other than having to have some help to bring in the 13 loads of sb2 fill and level it and to get three real nice locals to actually do the cement pour. (didn't feel I could handle that much cement by myself) All of the rest has been done by us. When I had to do a heavy lift or some other task I would build a device to help us do it. Linda can not lift much and doesn't do well with high places. It takes a lot longer but it is ours and we enjoy it.
I will try to add some pictures, this is my first time on here. We also have over 700 pictures of the project on our website, but not sure we are allowed to link that.
windowsno111609_30.gif

Above; This is a shot of how the interior will look.
windowsno111609_46.gif

Above; This picture shows the project as it sits as of today. (Dec.2009) To see how we got to this point continue to scroll thru the pictures. I have put up a lot of pictures but not all that will take you to where we are now. Not sure how many I can post in one sitting. If this works I will add the rest either as a edit to this or as a new post. Thanks for looking and hope we are able to pass along some ideas.
sb2pad_03.gif

Above; It will take 13 of these to level it out and base for driveway.
sb2pad_05.gif

Above; Drains for gutters were laid under driveway area.
sb2pad_30.gif

Above;Fill done and leveled and trimed.
diggingthefootings_01.gif

Above; Starting to dig the footings for the monolithic pour. We let the fill sit for two months and some heavy rain. Boy that stuff gets hard. All hand dug.
diggingthefootings-2_10.gif

Above; That was hard digging and it was hot too. Note; Water level in the center of pad.
formsbugsbolts_09.gif

Above; Forms done and sprayed with release oil.
formsbugsbolts_12.gif

Above; Had it sprayed for termites etc. a must in this area.
doingthecement_08.gif

Above; Plastic, rebar and wire screen. Ready for cement.
doingthecement_26.gif

Above; Setting post and sill plate anchor bolts.
doingthecement_35.gif

Above; Finnally something to build on.
foundationdone_04.gif

Above; Tarred below ground level.
foundationdone2_03.gif

Above; Now it is ready.
stagingfirsthalf_14.gif

Above; This is what I am building to be able to lift the posts and beams into place, so that we can do it by ourselves.
stagingfirsthalf_16.gif

Above; You can do a lot with a good wife and some c-clamps.
stagingfirsthalf_22.gif

Above; Will be going up on this a lot so put in a stairway.
stagingfirsthalf_24.gif

Above; Base is done, next will add second story and the hoist.
stagingsndhalf_11.gif

Above; Adding top A section. Bottom attached with some gate hinges we had.
stagingsndhalf_13.gif

Above; Using a com-a-long to pull top A up.
stagingsndhalf_20.gif

Above; Two inch sch.80 pipe thru the A's.
stagingsndhalf_29.gif

Above; Hoist lifted and put into place with com-a-long.
stagingsndhalf_33.gif

Above; Ready to do some work. Lin has named it Derrick!!
centerrafters_05.gif

Above; Layout for center section rafters.
centerrafters_06.gif

Above; Making a template for center rafter gussets.
centerrafters_11.gif

Above; Rafter gussets precut from template. Short ones on top are for gable ends.
centerrafters_18.gif

Above; Doing the cut for the birdmouth. Using a real true 2 x 4 as a guide.
centerrafters_23.gif

Above; Rafters cut and ready to assemble.
centerrafters_26.gif

Above; Love my nail gun. Also laid down a line of construction glue before nailing.
centerrafters_27.gif

Above; These 12 ready to use, but will be put in a storage bay until we need them. 5 more to make that will be the top of the cants. Check out Lin sweeping up. Every step is cleaned up, she just plain makes it all work.
centerrafters_33.gif

Above; This one is for the front gable end and has a support to hold a decorative beam.
routerjigs_08.gif

Above; Built these router jigs to notch out the main posts. Made out of an old table leaf that was left from previous owner of house, and some scrap pieces.
postprep_01.gif

Above; 17 douglas fir posts that were in Texas and shipped up here. 16 footers. Best 10 will be the main posts in the center, 5 will be cut in have for outside posts, 2 will be cut into brace pieces. All were real nice but a bit expensive.
postprep_10.gif

Above; Posts graded and marked as to which will be used for and where.
postprep_12.gif

Above; Braces being cut from the two selected posts.I use a DeWalt compund mitre saw that I alltred to get more depth of cut.
postprep_13.gif

Above; Saw guide to make cuts on ends so that will fit into notches in posts. These are cut with a Milwaukee framing saw.
postprep_14.gif

Above; This is how these will fit.
postprep_17.gif

Above; Using the previous shown jigs with a router to notch the post. Douglas fir machines real nice, throws out a lot of chips.
postprep_20.gif

Above; Post with first notch ready to be fitted with brace.
postprep_23.gif

Above; Only nine more to go.
To continue to see the project go to page two of this thread and we will be posting as many as we can. The program has a cutoff of text at 10,000 so it seems that the way I am doing it I can only put apx. 40 pics in one post. Or as always you can view the whole project at www.ninetyninesigns.com . Enjoy.
 
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OccupantRJ

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Re: 70 Yr old couple building a barn (garage/workshop)

Sir, I commend your perseverance, imagination, and determination! My kind of man. Never give up.
 

GeorgiaHybrid

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Sep 9, 2008
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Location
Extreme NW Georgia
Re: 70 Yr old couple building a barn (garage/workshop)

Let me one of the first to welcome you and to say "WOW". That is a beautiful post and beam frame and a neat adaptation of a barn style frame for a garage. You can link to your site from here or pick the pics you wish us to see and post the links as above.

Keep us in the loop as the shop progesses. This is looking to be one of my favorites on this site.
 

inliner1940

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Feb 12, 2008
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Location
Texas
Re: 70 Yr old couple building a barn (garage/workshop)

Welcome to the site.
I also commend you on your journey and destination. It is looking good.
Yes, we have to engineer things to help us when we do not have help. Been there, doing that too.

Good luck, hope to see more of your progress.

Walt
 

HotRodKush

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Dec 12, 2009
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Re: 70 Yr old couple building a barn (garage/workshop)

Subscribing, this is awesome.
 

colt zantop

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Apr 20, 2006
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michigan
Re: 70 Yr old couple building a barn (garage/workshop)

wow...we have had some incredible builds (1930's auto shop) and now this one posted just in the last week!!!! a couple of my favorites already! I cant wait to see it finished!

AWESOME WORK!
 

Bull

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Dec 12, 2005
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MA
Re: 70 Yr old couple building a barn (garage/workshop)

This is indeed a good week here at the GJ...another awesome new build for us!

I love barns, a lot, so of course I love your building. Is that called a "monitor" style, because of the way the second story is?

Your ingenuity that is allowing you to raise the posts and beams yourself is impressive...I don't have the mind for it, no way!

Welcome, and post as many additional pics in this thread as you can!
 

Cryptic1911

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May 24, 2008
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Willimantic, CT
Re: 70 Yr old couple building a barn (garage/workshop)

Wow, nothing like a couple oldtimers showing us youngins how its done! Great job! looks beautiful so far.
 

Mickey O

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Oct 25, 2009
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Chicago, IL
Re: 70 Yr old couple building a barn (garage/workshop)

So this is what you kids do when left to your own devices, absolutely fantastic.
 

Fueler

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Jun 22, 2006
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Location
Urbana, IL
Re: 70 Yr old couple building a barn (garage/workshop)

I appreciate the Egyptian style engineering in your Derrick. That's a compliment by the way.

I do think we are going to have to call you Wilson (tool time Tim's neighbor) since that hat always seems to be in the way. :bounce:
 

WhatThaFrig

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Dec 7, 2006
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Re: 70 Yr old couple building a barn (garage/workshop)

All I can say is.........WOW!!! Great work!
 

bobadame

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Dec 26, 2007
Messages
1,124
Re: 70 Yr old couple building a barn (garage/workshop)

Really inspiring project there. I'm also building a monitor style barn but I'm only 61 years old. That is a beautiful building for sure.
 
OP
N

NASMAN

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Dec 18, 2007
Messages
295
Location
Hills of Arkansas
Re: 70 Yr old couple building a barn (garage/workshop)

Took the liberty of figuring out the link the project:
http://www.ninetyninesigns.com/barnproject/h2ome33.html

I wondered if someone might not do that. You are correct and thanks all for the kind words.
If I close this down and get some z's, I will post more pics tomorrow adding to the original post.
Actually the web site URL is one of three that we had before we moved here. We used to sell reproduction signs on the net. (among other things) I kept this one just in case I needed it for something like this. It's cheap, hosted by Go Daddy. www.ninetyninesigns.com also will get you on the full site.
Thanks Lin and Dave
 
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NASMAN

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Joined
Dec 18, 2007
Messages
295
Location
Hills of Arkansas
Re: 70 Yr old couple building a barn (garage/workshop)

This is indeed a good week here at the GJ...another awesome new build for us!

I love barns, a lot, so of course I love your building. Is that called a "monitor" style, because of the way the second story is?

Welcome, and post as many additional pics in this thread as you can!

Yes you are quite right, It is called a Monitor Barn. Also known as an RCA (for raised center aisle) Barn.
 

OldtruckDude

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Sep 5, 2009
Messages
327
Re: 70 Yr old couple building a barn (garage/workshop)

Great Barn! I am inspired by you and your wife. Thanks for taking the time to post and Welcome to the Board!:beer:

john
 

c5golfguy

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Aug 29, 2006
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323
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Dallas, Jawja
Re: 70 Yr old couple building a barn (garage/workshop)

Just got into Las Cruces, NM on my way back to Atlanta from the holidays and had to log into GJ. My wife and I are exactly half your age and we had to pick our jaws up from the floor b/c we are just in awe of you and your wife's dedication, expertise, and creativity. Thank you for posting this and sharing your gorgeous barn with us. I'm subscribing, you got me hooked!
 

Mr Mushman

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Jul 7, 2009
Messages
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Re: 70 Yr old couple building a barn (garage/workshop)

You guys are definitely an inspiration, and by inviting us into your journey, you have definitely "taken away our rights to complain" about anything we could be going through during our own projects. This is such a huge undertaking to say the least ... Even though Christmas has just passed, the presents keep on coming. I commend you and your wife for all your amazing work and energy, thank you for being an inspiration to me and I am sure to many of us here at GJ. Pretty much anything is possible at any age ... When there is a will, there is a way and you guys are the living proof ...
 

Daniel Dudley

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Re: 70 Yr old couple building a barn (garage/workshop)

Of course we can't wait to see what you did next...

Nice Project.
 
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ZRX61

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Solar Blight Valley, SoCal
Re: 70 Yr old couple building a barn (garage/workshop)

When you get done I think the lefting device (Derrick) could very easily be converted into a Trebuchet.... which is what I thought it actually was when I saw the first pic of it :)
 
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NASMAN

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Hills of Arkansas
Re: 70 Yr old couple building a barn (garage/workshop)

When you get done I think the lefting device (Derrick) could very easily be converted into a Trebuchet.... which is what I thought it actually was when I saw the first pic of it :)

We are in a tourist (summer) area because of the lake. Many would stop and make comments as to what Derrick actually was suposed to be. Some did say catapult (trebuchet), nobody used that version. Guillotine was a favorite along with many others.
As I get time to post more pics, or if you go on the web site, you will see that Derrick will change his size and shape as the construction is needed. So alas he will not be able to hurl watermelons at the guys down the road.
 

Jack Olsen

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Re: 70 Yr old couple building a barn (garage/workshop)

This shop makes me optimistic about what I can do in my next three decades.

And Lin and Dave, I suspect you'll still be coming up with new projects three decades from now. You're an inspiration.

Thank you for the post.
 

rustyproject

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Jackson Ms
Re: 70 Yr old couple building a barn (garage/workshop)

I used to go to Mountain View Ark for work. I think Ark is under appreciated for it beauty. I made some lifelong friends that live in that area. Funny thing is none from the area but all have similar love of quality work(woodworking and pretty much anything mechanical). I'll tell them about your build. I'm sure they will be as excited as I am to see how you progress.
 

bazzateer

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Watford, Great Britain
Re: 70 Yr old couple building a barn (garage/workshop)

WOW!

If I can have a third of your drive and energy when I'm just 50 I'll be so very happy. You are an inspiration, and to have both of you equally passionate about this project is a real blessing. Subscribed.
 

E30bimmer

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Dec 1, 2009
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Chicago
Re: 70 Yr old couple building a barn (garage/workshop)

Well, I just turned 49 last month so I've got 20 years to get caught up with you. Excellent craftsmanship on those exposed beams--can't wait to see how this turns out.
 
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NASMAN

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Hills of Arkansas
Re: 70 Yr old couple building a barn (garage/workshop)

I added more pictures to the original post at the start of this thread. The idea was to try to keep it in a continuous format in one place. The first add on went ok, but than as I was afraid of, the program rejected my next atempt at adding even more. Stating it had a text issue of over 10,000.
So I am open to suggestions on how the correct way to do this is. In the meantime and in case this is the only alternative, I will add the next set of pics in the order here.

postprep_26.gif

Above; Shows the notches made and a sample brace for the longitude bracing.
centerpartone_01.gif

Above; Will need to have these support anchors ready to hold up the first and added bents.
centerpartone_06.gif

Above; Temporary spacers were straped to post while we premade each bent.
centerpartone_10.gif

Above; Don't have a portable drill press so made a guide to keep the big drill straight.
centerpartone_12.gif

Above; Second floor joist prebolted to post.
centerpartone_14.gif

Above; First bent all prebolted together. Checked for square and match marked.
centerpartone_17.gif

Above; Raising the first post.
centerpartone_19.gif

Above; Yep it's up.
centerpartone_23.gif

Above; Lifting the rafter section with the help of the cross piece that is temporary bolted to the rafter section. Also shows that posts are braced with 4 side and end braces.
centerpartone_28.gif

Above; Besides being bolted, each joint is nailed using special hardened pole nails. Three to four at each joint.
centerpartone_29.gif

Above; First of five standing on it's own.
centerpartone_31.gif

Above; Drilling cement for post locator. We use a 5/8 cement lag.
centerpartone_35.gif

Above; Stud has to be cut off flush with top of nut to clear the Simpson post pad.
centerpartone_38.gif

Above; Temporary braced to first set.
centerpartone_44.gif

Above; Basically now it is just repeat, except for number five which needs to be done after we turn Derrick around.
centerparttwo_06.gif

Above; Threading up a couple lags in our little fake beam.
centerparttwo_09.gif

Above; Trial fit.
centerparttwo_10.gif

Above; Lin shows how it will look.
centerparttwo_20.gif

Above; Derrick gets a little tight as all the post get in place. But it worked on paper and yep, it did work.
centerparttwo_26.gif

Above; Good view showing the rafter headers and some of the east west corner bracing.
centerparttwo_28.gif

Above; Taking the top off of Derrick.
centerparttwo_30.gif

Above; Let the A down using the electric hoist.
centerparttwo_31.gif

Above; The other side was let down with a com-a-long. Let the pipe come down with it. That pipe was heavy for an old dude balancing on a step ladder.
centerparttwo_34.gif

Above; Christmas time 2008.
centerparttwo_35.gif

Above; Main frame up.
centerparttwo_36.gif

Above; Next step will be to put the 12 rafters on those headers.
centerparttwo_37.gif

Above; Weather has been our biggest problem. 33 degrees when I took this picture. But rain has been the hardest to cope with. It doesn’t help the wood either.
This is as many as I can put into this post. Also am worked out for today, if we are to make it to see the new year come in at midnight I need to take a break.
HAPPY NEW YEAR TO ALL. ENJOY.
More pictures have been added 4 posts down.
 
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gonzoengineer

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Nov 29, 2009
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Location
Groveland, FL
Re: 70 Yr old couple building a barn (garage/workshop)

That's a barn raising...
461px-Amish_On_the_way_to_school_by_Gadjoboy2.preview.jpg


:D

Fantastic work so far. I admire your ingenuity to overcome limited tooling access. Your solutions are quite elegant in function. Gotta love a wife that is so gun-hoe to jump into the work with you!
 

autoist

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Re: 70 Yr old couple building a barn (garage/workshop)

So far, I've spent hours on your site & still haven't looked at everything! Amazing!
 

thammel

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Oct 3, 2005
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Maryland
Re: 70 Yr old couple building a barn (garage/workshop)

I am really enjoying these posts! All you guys who are still young - don't stop doing things and also don't think you won't be able to do things as you age. I turned 60 2 weeks ago and am still going strong. I'm in the middle of a tile job for the new mudroom floor that attaches the new garage to the house. I think there are a couple of keys to staying able to do these things; 1) don't stop doing them, 2) eat healthfully and 3) don't gain weight (very important!). Also, 4) keep exercising - I don't mean working around the yard - I mean by doing specific exercises and running, swimming or bicycling. After my back started bugging me at 36 because of too much basketball, I switched to bicycling. I still ride over 1000 miles a year and since 1992 have ridden over 25000 miles. Yes, you read that right. At my peak I was doing 3300 miles per year. Jack Lalane is my idol!! If you don't know who he is, google him. You'll be amazed at his feats!

Keep on building!!

(By the way, tile floor jobs are a pain!! It's not the tile that's the pain, but the cement board required before that!!)

Tom
 
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NASMAN

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Dec 18, 2007
Messages
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Location
Hills of Arkansas
Re: 70 Yr old couple building a barn (garage/workshop)

Adding more pictures.
craftersp1_04.gif

Above; Hand carry the center rafter up the stairway.
craftersp1_06.gif

Above; Push one end of upside down rafter over the top of the header.
craftersp1_08.gif

Above; Put other end up on header and leave rafter hanging upside down and bring up two more for this section.
craftersp1_09.gif

Above; Pick one up from the middle and roll it up. Set it against one of the ones that are attached to the poles. After I had three standing up I slid them in place on the headers and tacked a temporary stick to hold in place.
craftersp1_13.gif

Above; Note, working off a stepladder on top of Derrick.
craftersp1_15.gif

Above; First three done. Jan. 2009 and then weather turned to winter.
craftersp1_22.gif

Above; Needed to get the other posts out of the way , so decided to cut them in half now and take them to storage.
craftersp1_24.gif

Above; Lin showing where these half long posts will go when we get done with the top of the center section.
craftersp1_25.gif

Above; Took this picture from up on top with the sun at my back. Thought the shadow shot was interesting.
craftersp1_26.gif

Above; Center rafters in place, from second floor.
craftersp1_35.gif

Above; Simpson ties at the bottom of the rafter.
craftersp1_34.gif

Above; Using 1 x4 yellow pine for purlins. Not concerned with snow load etc. here in AR.
craftersp1_36.gif

Above; Looks like a barn.
cpurlins31109_03.gif

Above; Finished late this night. Check out the full moon.
cpurlins31109_06.gif

Above; Covering with plastic to protect from weather.
cpurlins31109_12.gif

Above; Setting Core-a-vent strips on prestained cedar face boards.
cpurlins31109_16.gif

Above; Bottom purlin and face board both done with western red cedar. Center section is now ready for tin.
tinroofno41809_02.gif

Above; Cutting pieces of foil bubble foil to be used under tin.
tinroofno41809_04.gif

Above; Built this walk board to go up and stand on while installing roof. Pitch is 8/12 and will not be able to stand on the foil. Bottom has a rug remnant glued to it. Hooks are made from a couple of leftovers pieces of rebar.Note, every other rafter blocked in for foil bubble foil seam.
tinroofno41809_06.gif

Above; First piece of foil. Four foot wide, very light. Hard to handle by yourself if there is any wind.
tinroofno41809_08.gif

Above; Staple top and bottom but not pulled tight.
tinroofno41809_11.gif

Above; Bottom closure and condensation weep strip.
tinroofno41809_14.gif

Above; Predrilled the tin, makes putting in the screws much easier. And uniform too.
tinroofno41809_17.gif

Above; It got a little breezy and Lin wanted to help hold down the bottom of the foil. She was nervous about the height so I tied her to the header.
tinroofno41809_22.gif

Above; Last piece on North side. Note, temporary cap to keep rain out of getting in between tin and foil.
tinroofso62709_01.gif

Above; South side pretty much a repeat of North. With different temporary cap.
tinroofso62709_12.gif

Above; The seams of all the joints of the bubble foil were taped using aluminum foil tape.
tinroofso62709_17.gif

Above; Last temp. cap ready to fall into place.
tinroofso62709_19.gif

Above; Pulled rope and block and cap fell into place. All this just to keep the rain out until I can get a few days of good weather to put up the top vent and permanent cap.
ventsystem62709_02.gif

Above; Had to build another style walk board cause could not use hooks at top. This will push against Derrick at bottom.
ventsystem62709_10.gif

Above; View of temp. caps from the top.
ventsystem62709_08.gif

Above; The safety rope that is tied to my climbing harness. Also check out the supervisor safely on the lawn.
ventsystem62709_09.gif

Above; Unique view of our house.
ventsystem62709_06.gif

Above; Double row of top closures. Flat stock as you can kinda see on north side screws down over these. Than the Core-a-vent top vent and than the metal cap.
ventsystem62709_17.gif

Above; This is the top vent with the screw system I came up with and stainless washers.
ventsystem62709_25.gif

Above; Center section roof done. 356 screws just for the cap section alone.

Thanks for all the kind words, enjoy showing it to you.
 
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LeadDoggy

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Joined
Jun 13, 2007
Messages
61
Location
Thousand Oaks, CA
Re: 70 Yr old couple building a barn (garage/workshop)

I have learned alot from this build and it's not done yet!

SubScribed to this one
 

Keep

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Jan 1, 2009
Messages
1,398
Location
Oshawa, Ontario
Re: 70 Yr old couple building a barn (garage/workshop)

That is one classy looking shop. Cannot wait for the updates.

It's always nice to see experience put into action. Thanks for posting.
 

greg

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Dec 12, 2006
Messages
201
Location
Eden NC
Re: 70 Yr old couple building a barn (garage/workshop)

Beautiful work on your monitor , I am amazed at your ingenuity . I get out to Fayetteville AR twice and year and that is some pretty country .
 

NUTTSGT

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Re: 70 Yr old couple building a barn (garage/workshop)

Wow, nothing like a couple oldtimers showing us youngins how its done! Great job! looks beautiful so far.

No kidding. I never really thought about cutting those bird mouths all at once.

I hope to have the same get up and go when I'm you're age, 30 years from now. :beer:
 
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