2018 Garage addition

For many years I've pondered an addition to the 'big garage'...my 24x40 polebarn. Until a few years ago I had a 10x12 yard barn next to the garage, so my thoughts of a garage addition were mostly day dreaming. A few years ago one of the guys on the fire department posted on Facebook that he was looking for something to use as a chicken coop. I told him he could have the yard barn. Unfortunately, as he was preparing it for transport it collapsed. I guess it didn't want to leave. He salvaged most of the framing which he used in his coop, so part of the old yardbarn lives on.

With the yardbarn gone I now had an empty space that needed something on it. My Jeep CJ-7 and my Trans Am both need some mechanical repairs that will take some time to complete. I don't want them to clog up the big garage so I started thinking seriously about that garage addition. I also use the big garage to house our semi. It is also a work in progress.

Once I decided that a build was going to happen I went through several different floor plans. I was initially going to build a moderate 16x24 addition. I can only reasonably come out 16 feet from the back of the garage due to some large pine trees. The 24' was determined by using the existing polebarn posts. Then I decided to add a 16x16 addition onto the addition for small projects such as motorcycle and mower maintenance. This created an 'L' shaped addition. I planned to use a 16' overhead door and possibly an 8' door on the end of the addition for alternate access.

Once I started measuring it became clear I needed to make some changes. Some of the 16' overhead door wouldn't be useable due to a present structure so I changed to a 12' door. I also came to the realization that the 24' depth was too small to work on even the Jeep and Trans Am, not to mention my Superduty truck which is 23 1/2' from the grille guard to the bumper hitch. I decided to make the addition deeper by coming to the post that supports the big garage entry door. This gained me another 5 feet. I also added another 8 feet to the addition addition. You can't have too much space.

Here is the final plan. A 21x40 addition with a 16x8 lean-to to take advantage of the space at the end of the garage. A total of 968 square feet. This will double the size of the big garage. This way I can use one size of truss which should be manageable if I do it myself. I plan on three windows for cross ventilation. Insulating it is a possibility, as might be a mini-split. I decided to put the truss girts under the 10' girt on the existing garage. This should give me a 9 1/2' ceiling height when the concrete floor is taken into account, and allow for an 8' tall overhead door. If I put the truss girts OVER the 10' girt it would allow for a 9' tall door, but that would require taller posts. After some pondering I decided to go with the taller posts and the 9' door.

I'm a big DIY guy for two reasons...I'm cheap and it's horrible trying to hire work out. I planned for this to be a pole barn addition but one day the thought occurred to me that if I could find someone to pour a slab I could build a framed garage and when I was done building the addition it would be ready to use. I left a bunch of messages, emails, texts and only received one reply. I'd never heard of the company and they disappeared when I asked for references. So much for that.

My brother has an older Case 1537 skidsteer. Not the best machine for excavation but it is free and I could use it as long as I needed. He dropped it off one day and when I got home from work I hopped on to try it out. It was dead as a door nail. I jumped it with the Jeep Liberty and pulled it under the porch and put it on a battery charger. The next day I got two cranks before the battery was dead. An investigation revealed a bad battery and alternator. I replaced them. Cheap rental fee. Now it starts every time.

When I built another garage in 2006 one of the guys who helped was Dave Evans. He offered building advice and drilled some of my post holes with his tractor. He told me to call him if I ever needed any more holes dug. Over the years it was nice knowing that he was available. Sadly, Dave passed away last spring from cancer. Gone...and missed...but not forgotten.

August 2018

The excavation has started. The nearest silver line is the 40' mark. The pondering was over and it was time to get dirty.

Over the course of several weekends I excavated the site for the new addition. There is quite a bit of slope and I had to dig out almost two feet of dirt on the north end of the site. I used most of it to fill in some low spots and valleys on my property. Due to the proximetry of trees I had to deal with a bunch of roots. I finished the excavation over the Labor Day weekend.

One of the tools I wanted for this project was a decent laser level that would project 360 degrees. I looked on Craigslist and Facebook marketplace and found a nice Bosch unit in Madison, IN. As it happened, we were riding to Madison the next day. While we were down there we met up with the seller and I got a nearly new laser. Sweet. Included in the kit was a magnetic mount that I stuck to the side of the big garage. This laser level is not very bright in daylight so I usually waited until sun down to use it. It works well then. The first time I used the laser level I took measurements at various points around the excavation, then also made measurements with a water level I had. I was happy when they both matched. It gave me confidence in the laser level's accuracy. I've had some lasers that were junk.

September 14, 2018

I spent several hours building batter boards and using strings to lay out the garage. I took my time making sure the lines were square. When I took some measurements everything looked good. Then I marked the position of the posts. It was a hot and humid day and I was totally beat by the end of the day.

September 19, 2018

This morning I took Donna to Bloomington for her one month post-surgical review. Afterwards we ate at Olive Garden. We got home in plenty of time for my 2:30pm delivery of a skid steer with an 18" auger. I've rented the 'one-man' augers and skid steer augers and the skid steer auger is the way to go when digging a bunch of postholes. It chews through roots that will stop a smaller auger. I got it at Tri County Rental for ~$250 (delivered).

I dug thirteen holes. The first couple were pretty crooked. I might have to do some hand digging to properly set the posts, but I should be okay. On the third hole I finally got the hang of aiming the auger. Here is a nice, straight, 18" wide, 4 foot deep hole.

It is nice to get the postholes dug. Now the actual construction can begin. Friday Graber Post is bringing me a truck load of building supplies.

September 21, 2018

Grabers delivered the building materials today. They had to tilt the bed more than normal to get the bundles to slide off...and slide off they finally did with good velocity. They came back farther than expected and blocked my garage door. Also, the band on the leftmost bundle broke and some of the lumber spilled off the side of the truck. I spent a couple hours cleaning up the lumber and putting it under tarps. There is a chance of rain tomorrow. I also had to reseat a tire on the skid steer so I could move the bags of Sackrete.

September 22, 2018

This morning I was able to get the corner posts set before the rain came. I was glad to get this done as the other walls will be based off these. I spent a lot of time making sure they were square, plum, and the correct distances from the garage and each other. It took a lot of tweaking to get it perfect.

September 23, 2018

I hadn't planned to work on the garage today. After I finished my yard work and other chores there was still a lot of daylight left and it was a beautiful day. I cleaned out all the holes, added gravel, and set the posts in the holes. I also stacked the 2x12s that were on the trailer under an overhang. This emptied the trailer for an upcoming trip to Menards. Menards has their 11% off sale in progress so I ordered windows, doors, and some other supplies.

September 30, 2018

I spent two days getting all the side posts set. We had over four inches of rain one day last week so I got to scoop water out of the post holes one gallon at a time. What a pain. Otherwise, it was pretty straightforward. All the posts ended up within a 1/4" of where I planned them to be. I was happy with that. By the time I was done my body ached and I had no energy left. I only have the two end posts left then I can start framing.

October 4, 2018

I made a trip to Graber Post to pick up the trusses. I was going to do it after work but ended up doing it before due to an issue getting my trailer on base. I had forgotten to put the latest sticker on my trailer license plate so the cops wouldn't let me on base.

October 6, 2018

When I finished my weekend chores (haul trash, mow grass) I was able to get the last two posts set. It felt good to get that done. My parents got a new refrigerator today and I helped them unload it and load the old one. The sun was going down as I filled in the post holes.

October 14, 2018

Saturday I was able to get both 24' 2x12s up and one of the sixteen footers. Sunday morning brought rain and it drizzled most of the day. Despite that I was able to put up the girts on the west side.

I happened to measure my trusses today. My 21' trusses are actually 21' 1 3/4". I'm not sure what is up with that. I'll have to trim them down to 21'. Sigh...

October 21, 2018

I had a lot of stuff to do this weekend not related to the building project. Saturday I got the last outside truss girt up. Sunday I got the lean-to truss girt up and finished most of the other girts. I also framed the window in the lean-to.

I took a sample measurement across the truss girts. I was hoping for something close to 21'. I measured 21' 1/8". Nice! I have been happy with accuracy of the setting of my posts. I have rarely had to adjust the tops more than a 1/4". Not bad for a non-professional.

November 4, 2018

The past couple weekends I have been busy with other things but I was able to get some things done on the garage. I put 2x6 girts on the north end. I would have used 2x4s but Menards didn't have any long enough to span the whole side. My end posts aren't set at 8' increments so I wanted to span the whole side. Easier that way. I also framed the windows and door on the west side. I put on most of the treated 2x6 lower girts. I have to put in some drain Ts before I can finish the lower girts. I also installed all the inside truss girts. I had to put the last one up in a cold rain, but I got it done.

The weekend coming up is a 4-day weekend for me, and it isn't supposed to rain, so I hope to make more progress. I need to bolt the truss girts to the posts. I need to make the modifications to the current drain pipe to allow for the new perimeter drain. I need to build stubs to hold the trusses between the posts. The first truss I put up will be attached to the current garage so I need to remove some siding for that. Lots of little projects to do.

November 12, 2018

One of the things I needed to do was dig up parts of the existing drain system. I'm putting a perimeter drain around the new addition and connecting it to the existing drain. It was keeping me from finishing the installation of the treated bottom girts. Freezing weather is coming so I needed to get it done before the ground froze. I spent most of a day getting this done. Digging up pipe and adding adapters is a pain and I was glad to get it finished.

I also installed the floor drain plumbing. I used 4" schedule 40 to match the existing drain.

It took all day to drill and bolt the truss girts to the posts. I had to buy a new 1/2" bit. My others were so dull they would barely drill wood. I also trimmed one of the boards off of the post tops. The trusses will sit there.

I also extended the end posts to add more support for the end truss...

...and added some bracing. I plan to put a small pulley system here for lifting moderate objects. The rest of the weekend was spent at our fire department's chili supper.

November 25, 2018

I've been fighting a cold for a couple weeks and the weather has sucked so I haven't gotten a lot done. I put in the stubs for the trusses and installed some of the roof joists for the lean-to. The few warm days we've had have been ruined by rain.

December 16, 2018

This weekend I got six of the trusses in their saddles, although inverted. I tried to flip one over myself but it wasn't going to happen. They were too heavy and floppy.

December 24, 2018

This was a productive (long) Christmas weekend. I got the remaining three trusses in their saddles. I got the truss that will mount to the garage temporarily screwed in place. I will use it as a pattern to cut the metal siding. I also got the gable truss mounted upright by winching it up enough that I could hoist it into place.

On Christmas Eve morning the calvary (my dad and brother) came over and we flipped the nine inverted trusses. I spent the rest of the short winter day bolting the trusses to the saddles/posts and trimming the post tops. Next weekend I have four days off so I hope to get a lot of purlins installed.

January 7, 2019

I got some of the truss bracing in place and about a third of the purlins.

March 31, 2019

Much of January, February, and March was lost to crappy weather. I did little bits of the purlins here and there. Today I finished the purlins on the main building. While the weather was bad outside I replaced the floor in the garage bathroom. That ate up a couple weekends.

Part of setting the last truss against the main building involved cutting away some of the metal. As I was cutting the metal I was unpleasantly surprised by the flash and bang of cutting through a live wire I didn't know was there. This led to a couple discoveries. I have a circuit for the south & east wall plugins. Instead of running the wire from the breaker box about six feet to the nearest plugin they ran it up a post, across a truss, down the other side, then down the side of the building to start the run of plugins from the opposite end. They used about eighty feet of wire to start the circuit when they could have used six feet or so. Wire must have been cheap back in the early 90's.

In the midst of all this I also found this quality splice. No wire nuts, no box...just wrap some tape around it and hide it behind the wall. There was also a branch off of this circuit that went to the bathroom. I spent a couple weekends redoing and simplifying some of the garage wiring.

Because of these discoveries I had to remove more siding than I had planned. Whoever built the polebarn used nails so it was a chore. Hammer a prybar under the nail, then pop the nail. Repeat about 300 times. When I tried to remove the first piece of siding I found another surprise. For some reason they had placed one nail in the upper corner of each sheet which ended up being behind the gutter. I had to remove the gutter. More unplanned work. I carefully tried to remove the 40-foot gutter. However, one of the screws holding it up came out on its own and the whole mess came crashing down and bent it. Hopefully I can salvage parts of it.

April 7, 2019

I finished the purlins in the bumpout section and...

...installed all the nailers for the flashing. After seven months of construction it was nice to drive that last nail.

April 9, 2019

45 tons of gravel. Some of it is for the garage floor. Some is for the perimeter drain. Some will go on the driveway.

April 14, 2019

Gravel was the name of the game this weekend. Throughout the week I had worked on putting the drain pipe in place. Now that it was done I started putting gravel inside the garage and using the skidsteer as much as I could to dump it along the outside, too. There was still a bunch of shoveling, though. By the end of the weekend I was feeling it. I used my yard roller as much as I could to solidify the gravel.

April 22, 2019

Today I went to Menards after work and picked up the metal. I've been talking to a guy about pouring the floor. I can see the light at the end of the tunnel.

April 28, 2019

Saturday was a rainout. Sunday I got some of the roofing on after I finished my summer-time chores (mowing). I still haven't heard back from the guy about the concrete.

May 19, 2019

After a couple rainy weekends (notice a common pattern) I was able to get more roof panels installed, as well as the sidewall flashing. The next step after this will be to reattach the siding on the big garage.

May 20, 2019

Today is a monumental day. Today the garage is prepped for concrete. Stone City Excavating brought in additional stone, laser-leveled it, compacted it, then put down plastic and steel mesh.

May 21, 2019

Today is an exciting day. Concrete! After all the months of slogging through mud it was nice to see the concrete going down. It went down quickly.

There was off and on rain so they covered the open part of the roof. If I had been thinking I should have had them install the house wrap and saved me some work.

The truck barely fit. They even removed a couple girts so the boom could get to where it needed to be.

This was the first nine yards of concrete brought by the first truck.

The floor is poured. Now they had to wait for it to set up. At this point I went to work. I wish I could have stayed.

They worked all day. Here is the finished floor. The sealer really shines. It feels like a garage now. A couple days later we left for vacation. The floor can dry and I won't be tempted to walk on it.

June 8, 2019

After returning from vacation I wanted to get the metal put back on the side of the attached garage. The garage would get lots of water in it when it rained and made a huge mess. It was nice to get it closed in.

June 22, 2019

Due to copious amounts of rain it took a couple weekends to get the roof finished. It felt good to get it done. The garage is becoming closed in and I'm not a huge fan of walking around on slippery metal. One day my neighbor was grilling out and it smelled sooooo good.

June 29, 2019

I finished the siding on the east side. A side aggravation of all the rain was an abundance of mosquitos. I used a lot of mosquito spray.

July 7, 2019

The west side windows and doors were installed and trimmed. This allowed me to finish the siding on that side.

Now I can move on to Phase 2. I have decided to build a 12' lean-to on the north side of the garage. I will store the mower and yard tools there. It will have a 9 x 6.5' overhead door and a side entrance door. Speaking of overhead doors...

Hoosier Door in Oolitic supplied the doors for my other pole barn and the replacement 16' door for my small garage. In 2006 a 12 x 10 door was $870 installed. I need a 12 x 9' door for this garage. I drove over and got a price for the door. $1360!!!! Holy bat crap. I knew they would go up some, but damn...that's a 56% increase for a smaller door. I'll be saving big money at Menards for $686 and doing my own install. So much for supporting local business.

Late July, 2019

I cut the old guttering in half, knocked out the kinks, and painted it green to match the roofing. I positioned it to keep the rain from dripping on the doors.

Over the course of a couple weekends we made three trips to Menards to pick up supplies. Insulation, garage doors, entry doors, lumber for the lean-to, metal roofing & trim.

Our department recently bought a 2009 pumper/tanker that ate up a couple of my weekends. I installed the radio, portable radios, siren, and an auto-eject for power. The former owners had mis-wired the battery charger which had damaged it so we had to put in a new one as well as replace an air pump. I also did some re-wiring and simplified some stuff.

August 11, 2019

Earlier in the week I rented the skidsteer auger again and drilled the holes for the lean-to and set the posts. Today I put up the gerts, rafter header, and a few rafters. It will have a 9x6.5' overhead door and an entry door. I plan to store the lawnmower and yard tools here.

August 14, 2019

I had 3 tons of stone delivered and used the skidsteer to put it in the lean-to. I also cut the tops off the 6x6s, installed the rafter brackets, and finished nailing into the treated lumber. The next evening I installed the rafters.

August 18, 2019

Finished the gerts and purlins. Installed the roof. Framed in the garage door. Could have gotten a lot more done but spent Sunday working on fire trucks.

August 25, 2019

Filled in the last partial sections of roof metal. This was easier to do standing on the lean-to roof so I waited for it to be done. Installed the endwall trim and the gable metal. Finished screwing the lean-to roof (I had to get more screws). I put up one section of wall metal. The weather is supposed to be nice this long, upcoming Labor Day weekend so I hope to trim the doors and get some more wall metal on.

I'll be happy to get the overhead and entry doors installed. Our cats have taken to using the lean-to as a litter box.

September 1, 2019

Over the course of the week I installed the entry door and the trim for the overhead door and entry door. This allowed me to install the wall metal, which allowed me to install the corner and gable trims, which allowed me to put on the last piece of ridge cap. Sunday afternoon I put in the last screw.

I still have a list of things to do...overhead doors, wiring, insulation, lighting...but I'm considering the garage construction (and this page) finished.

I had planned to put plywood on the wall separating the lean-to and the garage. Then I started noticing all the scrap metal siding I had so I repurposed it. Some of it needs a good washing. Total cost...$0.

September 2019 - I had issues with both garage doors...

The Menards page for the smaller door said it needed ten inches of headroom (the room above the door). I designed the lean-to with eleven inches of headroom. When I assembled the door I raised it to install the springs. Thud. The door hit the rafters. What? Looking through the installation instructions (on the last page) it said the door needed twelve inches of headroom. Nice. I notched the rafters a trivial amount and the door worked fine, but it was aggravating the Menards page was wrong.

After I installed the smaller garage door I tackled the 12x9 door. I had the panels, both vertical tracks, and one of the horizontal tracks in place. I went to install the plate that holds the rod for the springs. Hmmmmmm...the trusses were in the way. I knew something wasn't right. The door required 14.5" of head room and I had 20". After looking at my other garage doors I figured out the problem. They had sent me the vertical tracks for a 10' door, not 9'. I contacted Ideal door and they sent me the correct tracks. It took a couple weeks to get them and I had to pick them up at Menards. Once again, more aggravation.

February 1, 2020

Today I finished the wiring and lighting and deemed the garage project officially finished.

I built storage shelves on both long walls. You never seem to have enough storage. I got the table from the fire station. It is very heavy duty. I put it on blocks to make it a good height. I used 15 four foot LED lights. They do a great job of lighting the garage. I think the white insulation helps.

I moved my 60-gallon air compressor from the other garage. I've had this compressor since 1987. Donna got me the tool chests for Christmas.

24,000 BTU mini-split. It does a good job of taking the chill off. It is a heat pump only (no electric coils). I expect it to do a better job as an air conditioner. It was easy to install.

Garage art.

The lean-to. It's a great place to store my yard stuff.

Update Fall 2020: The lean-to I had built on the old garage was handy, but once I built the new garage it was more in the way. I tore it down and built a breezeway in its place. The joists shown are the only new lumber I had to buy. I repurposed all the old material. Now we have an additional parking spot out of the weather.

Update June 2021: A windy storm brought down a large pine branch. The only damage done was a couple wrinkles in a couple pieces of gable trim where the pink arrows are.

Update May 2022: The evil hand of government has raised its head in the form of the tax assessor. This garage addition added 40% more floor space to my total garage area. However, the tax assesor felt it necessary to increase my assessment by 330%!! This is not mathematically justifiable but no one seems to care. I think they threw my official appeal in the trash. Apparently there is no oversight. Government sucks.

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