Converting an old pig shed into something useable

[pauloliver]

Hopefully this will be interesting to some, it's not a full build but quite a lot of work all the same!

I've copied this from another forum i'm using but figured it would be of interest to the people of retrorides too

I have been longing to do something with my workshop for quite a few years now but not had the time or money to do anything about it as well as living 150miles away from it. I'm moving back to the farm where my parents live and therefore I can now get the workshop sorted the way I would like it.

Predominately I am into tinkering with cars but I also really like the wood side of things too. I'm fortunate enough that I can have 2 large seperate spaces in the same building for me to have 2 workshops in one.

This is the current space:



This is the area I will be extending into:





As you can see, a total tip, no proper storage solutions, poor lighting and no wall/floor coatings to reflect the light. The plan is to fit out the extension, then move everything out of the old workshop and refit that before deciding on the overall layout. I hope 5k will cover getting a basic shell ready, inc paint and electric. I need to find somewhere to chuck the camper, tractor and truck whilst I do all this! I am going to remove the support beams (new stronger ones will be put in beside the current ones) to allow for the ramps to be fitted and make use of the full height of the place, this will require some engineering to ensure it's strong enough, I am seeking advice on this.

I think splitting it into two sections, one for metal work and one for woodwork is the best way with this place, also an office and a kitchen/shower/toilet block if I want.





I have been collecting and making my own tools since I was young, so I already have quite a collection of kit. I am also making and buying bits and bobs so I will include my finds as I update the thread!

[pauloliver]

I also meant to mention I am a tightwad and like my bargains :oops:

My recent acquisitions for the workshop are:

Bandsaw and engine stand for £40



Makita 2704 for £10, just needs a motor rebuild (parts come to £140 so that's pretty good!), it's currently in pieces hence why it looks quite bare.



Plymovent duct for £13.50, I already have the extractor fans to suit



A budget rolling cabinet substitute, for £20 i'm not grumbling! A nice thick gauge steel, 75mm castors and ball bearing drawers. The fold up surface is kind of handy, but both bits of surface will be replaced with something fresh, along with a bit of paint on the cabinet and it should be good to go.





I also picked up this SIP trolley for £40, it was new but needed the draw fixing which took about 10mins. It probably wasn't really worth buying at that price but looked handy with the slimmer draws for smaller tools.





I got this red cabinet for a tenner, it has ball bearing runners which is a bonus. I will equip it with wheels and a quick coat of paint, I have a new sealey top box that fits nicely on it (not that knackered one as per the photo!)




The following I got for for free which I was really chuffed about:

Gabro Sheet metal folder



Floor standing polisher that I have converted to single phase

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Metal lathe that I have converted to single phase (just need to make a panel for the switch, came with loooooads of accessories)



Axminster mortiser

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Flat steel bender (can do up to 10mm)

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Record tube bender

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Axminster Roller/brake press



Theres more tools, as well as loads of hardwoods and steel. I got very lucky!

[pauloliver]

After a bit of a delayed start some progress is happening on my workshop. The 'new' section was a total tip and the original workshop wasn't much better!

Quick tidy up, so much stuff in there it is really hard to keep organised! I also need to finish collecting the rest of my stuff from the garage at my house as that's ram packed 





The rubbish tip needed sorting, several bucket loads of rubbish and rubble in the JCB and some floor was exposed









You will notice the roof has been chopped about and that the top is sagging, turns out those mahooosive railway sleepers are totally rotten at the bottom. I have lots of wood and stuff on order so progress should happen (and stop when harvest starts, joy). I managed to get a load of free fluorescent light fittings so once the beams go in I can get those up ready for wiring in. I can't wait to get studding the walls and get a sealed area sorted, the floor can wait til after that.

Bonus deathtrap branch cutter that I found in an old mans shed down the road whilst looking through his tools he was selling, a 9" grinder on a 6foot pole with a saw blade is just wonderful...

[pauloliver]

Today we were rained off from harvest so that meant I could crack on! The wood arrived which meant I could finally start constructing something. I have studded out the toilet/shower/kitchenette area and that felt pretty good as it looked like progress and the roof is finally supported properly in that area! The septic tank for the house isn't far away so next time we have a digger in i'll get that excavated and then I can plumb it all in (the building already has a water supply).

Firstly I cleared the rubbish from the right hand side, there's still stuff there but it is easy to move and at least it's things I want to keep.



I then got on with taking down the rotten beam and stud walling, a few knocks with a sledge hammer and it fell apart!



As you can see I took out the RSJ, this will be welded to another one I have to make a length to support the big doors, I hate to waste!



The left corner hasn't had the stud finished yet, I'm waiting on installing the new beam before I do so so it all ties in.





I got given a load of Celotex offcuts several years ago and always thought they would come in handy for something. They were all a bit wonky so it was a mission trying to get them to fit together nicely so I'll get some expanding foam in the gaps, although insulating this area isn't totally necessary I figured it would be a good way to use old stuff up. I have some larger sheets I will use on the roof although that isn't foil backed but every little helps.



Tomorrow I hope to rip out the stud work above the block wall and renew that, I won't be able to do loads to it as I am waiting for the new beams to arrive but at least I can make some progress. After that it's the same thing with the larger stud wall on the other side.

[pauloliver]

Air filtration has been one of my worries since thinking about the inside of the workshop area as I quite like having functioning lungs and dislike having to wear a mask all the time (I know I will need to when i'm making lots of mess), I was going to buy a small unit from Axminster but then found this Jet AFS 2000 which is far more suitable for £100!



It makes my little car look even smaller! Very chuffed.

Feather edge started going on the outside:



Two new beams went in too, that felt really good as I could start to see the space opening up

Loads of rubbish was cleared out and old support posts removed, hopefully next two beams will go in tomorrow and then I can finish studding the tall wall



Well progress hasn't been fast, so many little jobs that keep popping up as well as other distractions!









Supports are all out and new beams in, Window frames made and the short wall is now getting covered in featheredge. I have been trying to plan out the lighting, I think I'll have 3 rows of lights over head per bay and some smaller lights at the back of the benches that can be independently switched on if needed. I'll have 20 double sockets and 4 16A sockets in total in this section, which sounds like lots but it's better than having trailing leads everywhere as well as constantly unplugging things. I hope to concrete some of the floor near the entrance next week when the ballast arrives, then I can crack on with the doors and get it locked up!

[pauloliver]

Outside wall is now finished (well, until I attack the other half of the building!) it was a total pain as there are so many cuts to do.



One row of lights went up which felt like a mini achievement!



Two are florescent and two are LED, I can't tell much difference between them to be honest which I guess is good!

I'll get the JCB out and do the others on the tall bit tomorrow then hopefully finish the studding on the tall wall so that I can start routing the wire for the sockets. Wood arrives for the doors tomorrow so I can start those over the weekend!

I've been busy with the doors, built them in on piece and then cut in half afterwards. This was far easier than trying to build them on the floor and fit afterwards!







Doors covered and shower/toilet block nearly covered



The old floor was smashed out today (1-2" concrete on top of insulation) ready for a new floor to go in.



My Porsche has moved in as it was in the way elsewhere, gives a sense of scale of the place!



I boshed together a rough adaptor for my extractor vent for when I'm welding/grinding, it works fine and the position is about as good as it can be to allow for good reach, easy folding and access so I'll get building a neater sealed version when I have time and cut out a hole in the wall for the extractor then that section of the wall can be boarded up.

[pauloliver]

I have got the tall wall up and 2 lots of concrete in (4-5" thick). I have put some wire in the floor ready for an inbuilt light so that working on cars is a little easier and there won't be lights/wires to trip over! The floor isn't anywhere near as smooth as I would usually get it even though we have done loads of floors before this just wasn't smoothing nicely and floating it would have been hopeless as the sections were too wide to reach. I will be concrete planing it ready for epoxy anyway so it'll smooth out substantially I hope and then I will be able to get sorting the other half of the place!





In a few days time I can get the other concrete in and a ramp into the building then I can finish off the small wall and move the stuff out ready for the epoxy

[gazz81]

Looks great, can't beat a good sized workshop.

[igor]

I totally have shed envy brother. Love that 9" grinder pole saw conversion. Health & safety in the workplace guys would have several fits if they caught you using that thing here in New Zealand.

[countvauxalot]

Awesome!

[sciclone]

Excellent.

Hope I'm not teaching you to suck eggs, but it might be an idea to have a sliding door or movable partition between the wood shop and the car area. Good for dust control, and it means you're not going to throw sparks while grinding onto any bits of sawdust.

[pauloliver]

Cheers for the kind words fellas!

Scicione, there is already a dividing wall, the workshop has another half! If you look at the last photo you can see through into what will be the wood workshop. The wall will come out to be built properly and have new doors as the current ones are a bit shabby. I will be adding a fire escape too just to be safe.

[mikeyp247]

When I saw your plans I made a noise akin to a 16 year old school girl getting asked to go to prom with the football team captain.

Your photos of the place and progress are making me green. Epic space.

[pauloliver]

Ha ha, I get that feeling whenever I go in there!

I was busy today so only got a door made. I wanted to use T&G but it was expensive and not available locally in treated form so I went with 18mm marine ply and a 5x2 frame instead. The ply was glued to the frame and also nailed for extra security. I also routed a v groove into the ply to make it look like T&G which I think has worked out alright, far better than keeping it plain! I need to decide on locks next but at least it'll be pretty difficult to break.





The grooves had saw dust in after rounding the edge, but you get the idea

[melle]

You're doing a great job there.

[pauloliver]

Cheers Melle!

I spent quite a long time today getting the door frame finished, lots and lots of routing out to cover the door hinges as they are a difficult profile to match! I think it's turned out fine though, fits tight and flush although aesthetically I'm not won over by my solution for the angled bit above the door... perhaps a light up there will break up the weird chunky look! it functions fine and that's really all I should be worrying about.

The door frame has been reinforced with steel to make it that little bit harder to break into, I'm looking forward to fitting the locks and handle, it'll look more complete then.

[melle]

Have you considered extending the roof? This would give you some nice dry outdoor workspace.

[pauloliver]

It'll have about a 2-3ft overhang when I fit the replacement sheets, the roof did continue as far out as the toilet block bit but I removed that section of the building as it was beyond repair and because it made access far easier, I wouldn't have been able to get the JCB in otherwise and the doors would have got in the way. Fortunately we have plenty of other covered spaces to use if needs be.

[pauly22]

Total garage envy. Looks great. I'm hopefully getting a little single garage built.

[dubscum]

i'd move in there