At this point in the project, I am finding it difficult to keep up with the progress. Every day it seems there are 3-4 crews working on different things at the same time. And most mornings, the really cool stuff is happening just as I’m sitting down to give Mateo his breakfast. But I’m doing my best to capture as much as I can in photos as well as video for release later. Since I tend to get the same questions repeatedly, I’ll try to answer the most common questions below. Let’s get it on!
Windows and Doors
We had three large windows installed as well as one small window in the bathroom. The door was put in on the same day and it was quite a treat. Something about windows and doors really makes the structure feel like a real building. Maybe it’s corny but I think it’s one of those little milestones that gives you the warm and fuzzies.
Why so few windows? Because like most night-walkers, I hate the daylight! Actually, it has everything to do with filming. Remember, the only reason you are reading this is because I am not just a woodworker, but also a podcaster. Of course from a woodworking perspective, I’ll take all the natural light I can get. But natural light causes me major headaches when it comes to video production. Another thing to keep in mind is that while windows are beautiful, they consume valuable wall space. So even if filming wasn’t a concern, I would still practice some restraint when it comes to windows. Anyway, I decided on three as my absolute maximum, keeping in mind that the front door will let in a lot of light too.
Why not go with light tubes? I think light tubes are a very compelling option. Unfortunately, things moved so fast and the budget was so tight that I didn’t have a chance to do my research on these. From what I understand, they are fairly easy to install even post-construction, so it might be something for the future if needed.
Why no garage door? Primarily because garage doors suck for anything other than vehicles, in my opinion. Reasons include high cost, their general lack of energy efficiency, their tendency to let dirt and bugs in, and the fact that they consume a significant amount of interior ceiling and wall space. Every shop I’ve had to date has had garage doors, so I am ecstatic to see them go. I decided that a good quality double door was the best route for me. At a full opening size of 6′ Wide x 8′ High, I can’t think of anything I won’t be able to fit in there.
Insulation
The insulation crew showed up and finished their work quickly. We had R-38 put in the ceiling and R-19 in the walls.
Once the insulation was in place, the room took on an oddly uncomfortable deadened feel. Anyone who has been inside a building during this phase of construction knows exactly what I’m talking about. Having absolutely no reverberation in a room is a little unsettling. Anyway, while it was great to see progress, I couldn’t wait to get onto the next phase: the drywall.
Why didn’t you go for spray foam? Primarily because of cost. This project is already stretching our budget well beyond our comfort zone, so at some point we just had to pinch it off. This is the same type of insulation used in our home so I’m pretty confident that it will be adequate for my shop space.
Drywall
It was pretty exciting when the “drywall dropper-offer” showed up. That’s the official term by the way, just look it up! I am sure these delivery vehicles are old news to many of you, but for me it was pretty awesome to see as the arm hoisted the 12′ long sheets up and over my house and down to the shop door. The following day, the drywall crew showed up and made quick work of the task. Before the end of the day, the entire shop as well as the patio ceilings were completely covered. The speed at which these guys work has to be seen to be completely appreciated. And yes I did get a good amount of video! With the drywall in place, this shop is really starting to look like something!
Why not use plywood for the walls? I actually prefer the look of painted drywall. As you may recall in my old shops, I like to install tongue and groove boards on walls where the utility and look of a wood wall is preferred. I should also mention that I’m not entirely sure about the code restrictions on something like this. But it wasn’t really of interest to me so I didn’t research it or ask my builder about it.
Stucco
As many times as I’ve seen the process of applying stucco to an Arizona home, I never seem to get used to it. Being raised on the East Coast, the whole concept is still foreign to me. As we know already, the framing is covered with OSB (oriented strand board). As a weather barrier, asphalt-saturated paper was applied everywhere, including around the support poles on the patio. The next step wass to apply styrofoam panels and then a wire mesh. This week, they will apply the actual stucco product known as Western 1-Kote. While it is called “1-kote”, it will actually be applied in three total coats: a scratch coat, a brown coat, and then a finish coat with the final texture. You can read a little more about this stuff here.
In the last picture in the series below, you can see a spot where a patch is being made, giving you a good look at the stucco layer before and after. The reason for the patch (and a few others) is that the patio lights for the shop and the house patio extension are all being tied into the existing switch in our kitchen. When we turn the lights on, the entire patio lights up in one shot. Sweet!
Are you sure they aren’t applying EIFS (Exterior Insulation Finishing System)? Yes. Western 1-Kote is a very common stucco application used here in the Phoenix area (and many other places). I never even heard of EIFS until a recent Twitter conversation with Dyami and Vic. But to answer the question, Western 1-Kote is a real stucco application and not something synthetic like EIFS.
Air Conditioning
The original shop plans called for a standard ducted heat pump system. I wasn’t confident in this choice by any means and after numerous discussions with my buddy Vic Hubbard (a woodworker and energy efficiency consultant), it was clear that a ductless mini split was the way I needed to go. There are two primary reasons: efficiency and noise. Just think about what a ducted system has to do here in Arizona. The air travels through ductwork that resides in an attic where temperatures routinely reach 130-140F! The ductwork then punches through the inner envelope to deliver the cold air. This is very inefficient setup and unfortunately, running the HVAC ductwork inside the shop just isn’t in the cards.
Concerning noise, a traditional system includes a very noisy air handler. Additionally, the sound of the air coming through the vents is quite loud. I am sure you never noticed, but in the old shop, I actually had to turn the A/C off during filming sessions. This meant I was making repeated trips to the thermostat to start and stop the system. This is a ridiculous process for someone who films nearly every day during the Arizona summer.
Thankfully, a ductless mini-split addresses both concerns about efficiency and noise. The units themselves are incredibly efficient and they require absolutely no ductwork. And the noise level is so low that I will have no problem filming with the units set on a slow fan speed.
Now I don’t know if this is the case everywhere, but whenever I ask a local HVAC guy about mini-splits, I get funny looks. It seems most of these guys just don’t like them. I don’t know if it’s a technology thing or a job security thing or what. But with some companies, it’s like pulling teeth just to get a quote. Fortunately, the company my builder uses didn’t flinch at the request and designed a system he feels will cool the space adequately. Vic and I have our suspicions that it might be a little bit overkill, but that’s OK with ductless mini-splits. These systems adjust on the fly and thanks to this “inverter” technology, you don’t get penalized for oversizing. The final configuration is two outdoor compressors (one double stack that you see below and one single stack in the back) and three indoor units. Between the AC and the three ceiling fans, I should have no trouble keeping the shop at a reasonable working temperature.
I am a commercial construction project manager and we have used the mini splits on several projects. The biggest problem we have seen is that they are not well suited for dusty or dirty environments. The filter media is inadequate and when the coil gets too dirty the unit freezes up. I have seen folks install an shop made filter box on the return side to allow for installation of pleated filters.
Also for anyone concerned with losing valuable wall space, Mitsubishi makes a system that is similar to the mini split but has a cassette that is mounted in the ceiling instead of on the wall.
I just wanted to see how things are going.
its been 20 days or so…. so that should be plenty of time for the exterior to dry and to see some improvement….
Bump?
“Drywall dropper offer” thats a new one. I always thought it was “that truck thingy with the arm and the forks that makes my job of lifting stuff way easier”
Marc,
The shop is coming together well! I’m in AZ too, looked at the split systems, and wanted to go that way. Unfortunately, my budget was not up to the task. I ended up using a vented free standing 13000 btu Ac unit.
While it is a bit noisier, it does the job, and keeps me in the shop even on the hottest days. My favorite feature of this unit is it’s dehumidify setting. We get a strong monsoon season here ( Sierra Vista) and the humidity control is needed.
Looking forward to seeing you working in the new shop!
Gerry
Marc,
It’s great to see how well your own shop is getting along. I planned to build my own shop this summer but that got delayed so maybe next summer. I have only started woodworking recently (I am only 14) and I am slowly adding tools to my collection. I have found your videos and articles very helpful. I will certainly be joining the guild when my shop is built.
Marc-
That is a really sweet set up. Looks like you have all your bases covered very well thought out. Enjoy your new space and be creative in it.
Marc,
The shop looks awesome… Can’t wait to see the finished article
James
I used to have a 1700 sq ft shop before i moved to Arizona, now i just have my garage, I have lost some enthusiasm to tackle woodworking projects but i am learning to cope with my new space and adapt my woodworking projects to fit my garage. I cant wait to see what guild builds come out of this shop and how your projects will adapt with the new space. Very jealous :-)
Exciting – lots of progress!
I agree with you on just how fast these guys move. We’re in the middle of an extensive home renovation – reconfiguring lots of existing space and lots of new space – and it’s been bang-bang all the way through. We are also at the drywall phase – it showed up on-site this past Friday so these guys will probably knock it off today and part of tomorrow. It’d take me a year of Sundays to knock off what they do in a day or two.
I know that stucco and adobe construction are very popular out west and there sure is a lot of stucco here in the southeast. As I prepare to paint the house I must once again scream from the top of the step ladder, STUCCO S___S!!! I have not completed all of the scraping and already I have bloody knuckles, found some rotten wood and this evenings surprise was a carpenter ant colony! This area is where they used a spray on stucco directly onto the wood rafters etc on the carport. So far it looks like I will not have to touch or even explore the tar paper, wire mesh, troweled on stucco areas of the house. This stuff can look great but I sure am not a fan of it applied over wood. It just hides way too many things especially here in the humid southeast.
Sorry for the personal hijack Marc, but I just had to vent before I took a sledge hammer to the carport. :>)
Marc, I recently built my own home and went the mini split route and we absolutely love it. Our house has a pretty open layout which makes it work well. We, too, got of quizitive looks as people had no clue what we were talking about. Not one local heat & air installers in the area had ever installed one and we finally found one taker to do it…. but we had to find a unit ourselves. They made sure to lay on a thick layer of pessimism. But we had done our research and were confident it was the solution for us. I can’t tell you how happy we have been with it; it’s quiet, effictive and efficient. And no ducting to clean…. ever.
We actually had one person admit why installers steer everyone toward’s ducting:- labor$$$.
Anyway, I think you made a wise choice that you’ll be happy with.
Terrific progress, and only a couple of weeks left. The follow thru and not settling for something else will pay big dividends in the long run!
Good call on the heat pump, I have that for my home. Fewer windows are good too, all that sunlight will produce too much heat specially in AZ. But “At a full opening size of 6′ Wide x 8′ High, I can’t think of anything I won’t be able to fit in there. ” will come back to bite you, please let us know when it does (like when you want to put in that new multi machine in there on a forklift or that 25′ long cherry table for the conference room at the big corp.) A man always needs more room and more power.:-)
Hey Marc,
Place is really coming together. I noticed that no vapor barrier was installed in the ceiling. Do you know why? What kind of insulation are you using?
Standard practice around here. I guess there isn’t much “vapor” in the desert. :)
Marc the shop is coming along nicely…… won’t be long now! I too questioned the absence of the vapour barrier. It has to be a regional thing. I know it’s code up here in the great white north. I really suffering from size envy, I could put about 2 1/2 of my shop in yours. Enjoy.
Marc, What a great feeling it is to have your shop space coming together. The decisions to make, the spacing of the windows, where to put the doors etc. etc. When I built my shop, and looked at it without tools and woodworking stuff, I thought to myself, “I’ll never fill this big space up”. Wrong! A shop is never big enough!! But it’s my space and I love it. like I said, what a great feeling it is.
Thanks Blair. I sometimes go in there and try to visualize the space and you’re right. It doesn’t take long to fill it up!
In the Weekly Wrap-Up you said something about getting curtains . . .
http://www.blindschalet.com/ta.....apery.html
:)
Also, I’m going to be taking a look at the mini-split as I’ve just moved into a 2 car garage. I can live with the heat given sufficient ventilation, but ventilation isn’t going to help warm it up this winter.
I was actually joking about drapes. I plan on getting the same type of shutter blinds we have in the house. But the ones you linked to are pretty sweet!
Oh, I knew you were joking – that’s part of the fun is finding stuff that people didn’t have in mind when they make comments.
Some of the stuff that’s out there that you wouldn’t think is out there is pretty remarkable.
You could use this TV for doing your editing – just have to give up a wood rack or two in order to find room for it :)
Just a point of clarification. While the variable feed drive on the mini-split does allow for oversizing the equipment, there is a point of diminishing return. If oversized by more than about 1.5 times the heating and/or cooling load, you start paying for a unit that is just idling. My concerns of oversizing were calmed when I found your HVAC guy was using two outside units. This will allow you to really dial in what you need. If, as I suspect, the entire system is oversized too much, you can simply run the compressor with the two interior heads or the other with the single head. My suspicion is the single head unit wont get much on time.
As far as air barriers, yes it depends on the climate.
How did your old plan with the mini split work out? I know you were planning on moving it over to the shop once you got it built, but it looks like a bigger unit than I remember.
I get jealous every time you update… Im getting ready to move into my best shop yet. A two car garage with 2 outlets on the wall, 3 if you count the one for the garage door opener. my current shop only has one outlet (that is not currently working) so Im always moving plugs around. Im excited for you!
Great looking progress :)
I’m a HVAC guy. Started out life in bulding services consulting, and you’ve hit the nail on the head regarding the attitude to split units.
My old boss used to lament them because they took the engineering out of big sites traditionally needing central chillers/ calorifiers, etc, and any old technician could install the split units with not too much thought. So was seen as a kind of shortcut, and not ‘real’ engineering.
However in your application, splits are exactly what you need :)
I reckon that insulation should cover your pretty well in all fairness. It isn’t the absolute optimal solution but it’s a lot better than not having any at all!
I don’t understand the wall setup. OSB is a moisture barrier. But the moisture
comes from the inner side of the shop. The drywall is moisture open. So all
moisture will come into the inner side of your wall. Here in Germany a standard
construction is to have a moisture barrier on the inner side of the wall right
behind the drywall. And from in to out the wall becomes more open. Maybe it makes
a difference between the climate and the use of air conditions. Can you explain?
I actually cant explain as I am not a builder. But I imagine climate has everything to do with it.
My understanding is that it is a combination of differences.
I am not a builder either, but I did have similar questions when we were remodeling. The “moisture” barrier goes on the outside of the building. OSB alone isn’t a good enough moisture barrier for most US building codes, since wood will slow water, but not stop it. When you add the tar paper, it is then up to snuff for keeping weather out. The second barrier you are speaking of is on the inside. This is the “vapor” barrier, which serves to keep inside climate inside, and outside climate, well…outside. The vapor barrier is intended to reduce the condensation in the walls that leads to black mold, and has the added benefit of being “effecient”.
Regardless of climate, a modern building should probably have both. (at least according to building codes in WI)
It just isn’t required here in Phoenix. It isn’t a short cut, it’s just not needed I guess.
The difference is that heating is rarely needed in this particular climate. Normally, a vapor barrier is supposed to keep moisture from migrating into the the wall cavity, where it makes its way through the insulation to the inner surface of the exterior wall sheathing. In a heating climate, this sheathing will be so cold that moisture may condense on it, causing all sorts of problems. In Arizona, the sheathing will rarely get that cold, and if it does, it won’t stay that way that long, and the moisture will quickly evaporate.
lol! Oh man, I just pictured you running out the window, but taking time to give your hey ladies look and finger point to the camera on your way.
That really is the only way to escape a fire in style I think. :)
I am enjoying all the progress reports on the new shop. My one concern is that you only have one door. No safety exit…..or do you plan to use the windows on the patio for that?
As for the mini-split, my AC guy suggested it last year when we were discussing a separate unit for the garage/shop area. It is unbelievably quiet. Work nice too.
Honestly, if there’s any emergency requiring me to exit the building, my ass is going out that window, lol.
Incredible space!!!! Bet you can’t wait to make some sawdust!!!
Any plans for the soon to be empty garage besides putting a car in there?
Car and much needed storage space. We are those weird neighbors who go all out every year at Christmas time so we need a place to store the seasonal decorations :).
The funny looks are because of the lower install cost on the split units. I’ve asked a few contractors here in Arkansas about them and I’ve been told that most HVAC guys don’t like them because a good portion of heating and air install cost is running the duct work. Split systems take that part of the job out of the equation and no labor means no paycheck. I’ve thought above adding one to my future shop.
These mini splits are very intriguing. I’m interested to know what you think of them after a summer.
We need that crew in NY – they are making so much progress – how much time between starting the insulation and the Sheetrock being finished?
You will be in before you know it!!
Did your drywall-dropper-offer-guy have a nifty remote control for the crane? I had mine delivered (game room, not shop) yesterday and I thought it was cool when he strapped on the remote and went upstairs to guide the load to the window.
If they had a remote, they didn’t use it. The dude was manning the crane from the vehicle itself.
Looking great, Marc. It has really progressed quickly. You’ll be moving your equipment back in no time!
Did you think about packaged thermal air conditioners? No ducts, but probably more noise.
What’s a packaged thermal air conditioner?? Come here Google!
http://www.mitsubishielectric......index.html
cooling and heating in the same unit.
I installed one Mr. Slim unit this summer. Will be able to try the heating function in a couples of weeks.
The cooling works great, very quiet inside. It makes far less noise than a home fan.
If google failed you or gave up…I am an HVAC designer, I’ll try to give a brief description.
A packaged terminal air conditioner (PTAC) is an “all in one” unit. Most commonly used in hotel rooms. They get installed in the wall so that half of it sticks into the room and the other half is outside. The “inside” part has the controls and heating parts. (hot water or electric coils) Then the back side would have the louver for fresh air and the coil and compressor for the air conditioning. As you know, they are rather noisy, and really not that efficient. Especially when you compare them to the ductless type system you went with. I totally agree with Vic. The ductless type system is the way to go for you. (We are actually using that type of system in a library renovation project. It a registered historical site, very few options to run ductwork. So ductless system to the rescue.
I guessing things should be rapping up very soon now. It’s looking great. And I’m sure you are giddy like a school girl. Congrats. Can’t wait to see the next progress posting.
Ahh, back in Jersey we used to call those…..Air Conditioners. :) Honestly I grew up thinking central air was for really rich people. My mom used to make us all sleep in the living room so we’d only have to run one AC unit. And she would only turn it on when it was absolutely unbearably hot. But I am all too familiar with those units. Definitely too loud for video production.
Drywall on the wall. That means that the end is coming. What’s left to do inside ? plaster, flooring, electricity and plumbing finishing….. and finally moving in…
Thanks a lot for the update!
Marc, when do you expect the shop to be finished and set up? It looks great so far.. Looking forward to see the finished product.
With a couple weeks. We are pretty darn close!
Awesome progress! What are the four circles in the ceiling?
Nevermind! They’re for your ceiling fans.
Nope. There are three ceiling fans. The big holes are for speakers. :)
Marc,
Shop is starting to take form and looks great. I bet you can not wait to start making some wood chips in it.
Andy
When my old garage door buckled I had to replace it. After doing some research I went with an insulated garage door with R-19 rating because while putting in a wall with conventional doors would have been preferred from a shop standpoint, it wouldn’t fly without involving the HOA architectural committee or a much more expensive permit and plans review process with the city. As an insulated garage, I’m required to do none of these. I’m sure that it will not be as efficient, but I’ve also preserved the garage to be used as a garage by a future homeowner when it comes time to sell it, and I didn’t want to lose that flexibility. As it is, at this point everything that I put into the shop, including the mini split I’m going to install, will be able to be removed except for the walls, wiring and door.
Looks fantastic Marc!! Great progress and very exciting to see it getting close to finishing. Going to be an amazing shop, the very best of luck with it!!!
Lookin good, lookin good…
I’m with you on the garage door. I would LOVE to yank mine out and wall that puppy in. But where the shop truly is a converted garage, it’s just not an option. I’ll just have to keep my broom handy for the sand that blows in and my boots on to stomp the nasties that crawl through in the night.
I can’t wait to hear the final thoughts on the mini splits. I’m considering one for the shop, but not convinced I’m ready to incur the cost yet for a shop I hope to one day soon be moving out of.
Matthew, the nice thing about a mini split for people in our situation is we can take it with us when we move, and all that has to be repaired is a single 3″ hole in the wall.
Those drywall crews are amazing.
In my old townhouse I removed a medicine cabinet that was partially sunk in the wall, so I had to buy a small sheetrock panel and some tape/mud to patch up the hole. The hole was the size of a medicine cabinet, so it was probably 2′x3′ or so and it took me the better part of a day to get that hole patched up and it looked like crap. Contrast that to when they built our current house and they sheetrocked the entire 4k square foot house in half a day and then the mudding guys came in and knocked out that just as fast with no sanding required and it looked fantastic.
I am going to finish my basement myself, but when it comes to the sheetrock part we are definitely contracting that piece out.
This is so exciting.
I didn’t build my dream building for my workshop, but I am finishing it on the inside to fulfill the dream.
It is exciting to see this all to come to fruition considering how long it has taken to get to this point.
Congrats for you and your business.
Those Mini-Splits are the way to go. My parents have a large, VERY old house (1917). It is by no means well insulated or energy efficient. they installed 8 of them (almost every room in the house) their energy bill went from $460/ month to less than half that!! and talk about quiet! best investment they ever made.
General shop design question: Are you planning on keeping static and noisy machines like dust collectors and air compressors outside of the shop(enclosed), in the shop but enclosed, or just hanging out in the shop – noise be damned? Sorry if this is covered already and I missed it