Ah, the hard work was done...  Or was it?  I got the roof framed, and it was time now to get it shingled.   Before I get to that, the last little bit of framing needed to happen - the cupola.  Here you can see the base I had constructed while framing up the roof:

You can also see the roofing materials nowhere near I wanted them to be - I wanted them on the roof, but there they are on the ground...  Of course, they are the heavy ones - architectural layered shingles, which basically means each bundle weighs twice as much as a regular bundle...  but I digress... 

Here's a rear view of the building, showing the cupola framing and the rear overhang I neglected to include in the last installment of this unending adventure:

It was much easier to frame up the cupola on the ground, as there were several angled cuts to make and it's easier to make any adjustments where the saw is closer than a run down the ladder...  besides, that 8/12 pitch is hard enough to stand on.  That - and I wanted to make sure I got the weather vane installed properly.  I purchased it from The Weathervane Factory located in Bar Harbor Maine.  I had considered something more whimsical, but in the end I am happy with this purchase - it fits the finished design of the building quite well.  Here is the framed cupola, complete with vane, on the floor of the shop:

And - of course - in it's final resting place on the top center of the shop:

The cupola is a functioning roof vent, along with gable vents at each end - there should be plenty of air traveling through the attic space with this setup.   I used pre-made louvers just to save on time and keep them a bit more maintenance free...   In retrospect, I think if I were to build it now, I would use a larger roof on it - something with a little Asian influence - but, I'm not going to tear the thing down for it!

Anyhow - I had the roof sheathed now, the cupola framed and in place, and all that was left was to heft all the shingles up onto the roof.  By my calculations, it was going to take about 18-1/2 square or so, or 56 bundles.  That's 56 trips up the ladder carrying some god-awful heavy material.  Of course - it was mid August, the hottest part of the year... You can't shingle a roof unless it either the hottest or coldest part of the year, you know.

I have mentioned that one of the reasons I was able to build my own shop was because I had become my dad's caregiver after mom passed away.   Dad had come to live with us right at  New Year's, and did quite well at first.  But it was about at this time that his condition (Alzheimer's) became quite severe.  It made working on the shop during the day difficult at best...  Dad had taken to wandering off on me, wouldn't come out to the shop to "help" me any longer, and I couldn't leave him by himself for more than about 10 to 15 minutes, even if he was sleeping.  Usually I would have to wait for my wife to get home from her work to "take over" for me so I could work on the roofing in the evening.  The nights were long, and the weather cooler in the evening, so it wasn't all bad, I guess...  

We took him in to see a doctor and she suggested we contact Hospice of North Idaho - that they might be able to help us out.  What a godsend those people were...  They came out three times a week, giving dad care and me some time to run errands and get some work done.  I cannot thank them enough for their exemplary service, they were truly wonderful.

As a result, I don't have any photos of progress on the roof so here it is magically complete, about a week after Labor Day:

It took me about a month to get it from the picture before to that one.  First to go up was the class A chimney for the wood stove, the mast for the electrical service, then the fascia board followed by the shingle underlayment   Here you can see the mast for the electrical service, and my temporary scaffolding re-erected after being torn down when the roof framing was completed:

It was no fun doing this side of the roof - an 8:12 pitch gets hard to stand on after a while, and I'm no fan of heights...  It took all of my courage at some points.  I did use roof jacks for this side, which made it easier. 

It ended up taking about 19 squares of shingles to complete, I used the heaviest kind (of course!), an architectural "layered" shingle that has a 35 year warranty.  What I really remember is how exhausted I was by this time...  When I did work on the shop, it was at a frantic pace.  The shingles were heavy, of course - and I can still feel the pain in my shoulder from lifting them into place.  I had to wear tape over my fingertips, as rubbing the stone on the shingles had worn my fingernails down to where they were bloody.  Worst of all was that Dad was a 24 hour a day job, as he had no sense of day or night anymore. 

Dad was rapidly getting worse, and I stopped work on the shop to spend time with him.  He passed away on the 21st of September.

The next month was spent bringing him back to his home to be buried next to mom, and to get together with family to decide what to do with their estate. 

Getting back, it was well into October.  Life was about to change for me - no longer tied to the house, I needed to get back out into the workforce.  My focus now was on updating my resume and on storing what I had received as an inheritance from the estate.  When I started the shop, we had no idea how long dad was going to be with us, and there was a finite amount of money to work with.  We had it worked out where once the shop was complete, dad and I could start working out of it, making money out of it, hopefully enough to allow me to remain as his caregiver.  It turned out that wasn't to be, the time with him was too short, and the shop was incomplete.  I wasn't far enough along with it for it to work for its income, so it would have to take the back burner while I once again joined the 9 to 5'ers.

When everything was settled, I did spend some time on the shop buttoning it up for the coming winter.  First was to put some siding on the cupola so the flashing would keep out the rains:

Next was to get the windows and doors installed so the building would be enclosed:

It was finally starting to look like a building!  The overhead door is a 10' x 10' "residential" door from Overhead Door... I'm quite disappointed in it, it's not a very tough door and the panel with the windows is too high to look out of - the only other option would have been to have them be too low... 

I also got the electrical panel hooked up so there was power, but that was about it for the winter.  The next thing I knew, I was reporting daily to a new job and my time for working on the shop was drastically cut back to a few hours a week.  With the cold weather and darkness of winter approaching, not much would happen until spring could shake off the icy grip of what seemed to be the longest, coldest winter...  But there were a few things I could do...

Coming up next - knee braces and some other miscellaneous structural work, and hooking up the electrical...

Part VI

With the foundation finally out of the way, it was time for my part to start - framing. I find framing fun, so long as it's not my regular job... and I have done it in the past, so I wasn't too nervous about doing it, except for one thing - the wall framing would be full of angles and small complications that would challenge my abilities... but then again, I like a challenge.

I started by putting together a list of materials I would need, and set out to visit suppliers to get some prices. I'm fortunate to have a large number of building supply outlets all within a close distance to where I live... I didn't get to a fraction of them and I visited two borg stores, a lumberyard associated with a nation-wide chain, 1 local franchise lumberyard (several different locations, but all of them are located within a 100 mile or so radius), and two locally owned lumberyards to get prices. The borg prices were not all that far out of line - but those places simply aren't set up well for putting together large loads and they were the furthest from my house, not to mention the service was basically non-existent from these two places in my experience, so I ruled them out almost immediately.

One of the two locally owned lumberyards' clerks told me that "their estimator is out on a job today - but I'll take your list and he'll get back to you first thing tomorrow"... I never heard from them again. Honestly - if they can't call me back on a larger purchase like this they either don't want or deserve my business. I did notice these guys were out of business/were bought out about a year later - I wonder why?

The national chain store lumberyard's prices were relatively high for my tastes. A friend who was also pricing out a shop told me they were by far the cheapest he had found - but he was buying a packaged garage design, vs. my "custom" order, so that may have had something to do with it.

That left two yards to visit, and these two yards became the final 'competitors' for my business - the local franchise and the other local lumberyard. The cheapest cost I found was at the local franchise store (who also happened to have the closest store), with two caveats - their lumber was of lower quality and their service wasn't all that stellar (not bad - just not stellar). The local yard was more expensive, but the quality of their material was much better... But something else happened while I was at the local yard that convinced me to go with them...

While getting a list of prices from one of the clerks, he asked the fellow behind him what the current price was on OSB, who looked at my list to see how much I was looking for. He said something like "well, for this much I think we could do $6.75" (which was 25 cents more than the other's price). He then looked over and started asking me about what I was building, and we struck up a conversation. Turns out he was the owner of the yard, and we both came from similar backgrounds... In the end, he won my business the old fashioned way. It did cost me a few hundred dollars more to do business with him, but I can say now that the price was well worth it - his little lumberyard gave me by far the best service of any I had dealt with up to then - or have since.

From there, i took my material list and divided that list up into the order needed, starting with the wall framing and roof framing, the roofing, and the trim, siding and interior work. This would allow me to pick up materials and not have to have them sit outside or be in the way while I was working on the building... Here's the very list I used:

I had decided to use 2x6 studs @ 16" O.C. (On Center) for a couple of reasons - first, for the insulation value. In the large scheme of things, they don't cost all that much more money over using 2x4's. Second, one of the main tenets of the gathering darkness that is the future is the cost of energy. It may or may not happen, but to me it's better to be over-insulated rather than under. Energy costs can become crippling - though they are "relatively" inexpensive now, that may not always be the case.

This is also the biggest reason I don't have a large amount of windows - though I may regret this decision the most of all Natural daylight is a huge bonus, but it does come at a price. There's not just the initial cost of the glazing, there's the added cost for heating to consider. I did end up bumping up the size of the windows to the next size, which I think was a good decision.

Another reason is so it holds what's nailed to it without "waves". Structurally, 2x4 studs at 24" o.c. are fine, and will easily hold up the building. You could probably get away with even less... But then any siding you nail to it, or drywall, or even plywood - will not be held straight and become wavy over time. It might not be right away - but it will happen.

Anyway, I now had the material, and it was time to start building. The very first walls I needed to build were the most complicated - the north and south ends, both having a gable; and since I was using rafters and not trusses for the roof, it meant the studs would have to be framed old-style.

I used to know how to use the a framing square, and all the functions that go with it like rafters and the like. But it's been too long, and not having used that knowledge it's long slipped from my grasp. Fortunately, I am an architect - and have access to computer drafting programs that allow me to size each stud *exactly* and help me layout their location on the top plate even though they are angled - here's the framing plan for the north wall:

You can easily see the benefit of knowing how to use a cad program here. I was able to size each individual member and provide for space for the lookouts all before lifting a nail. I printed out a copy of the above and framed up the main part of the wall (not including the lean-to part) exactly as shown on the floor of the shop, and did the same for the south end (which I will show further down). Then, it was time for an old fashioned "barn-raising" - I gathered a few friends and relatives to help me put the walls up:

Most of the time, you would build the wall so you could tip it up right where it wanted to live - but I could only get these guys together for the one day, so I built both the north and south walls to have them ready... There wasn't enough room on the slab to build them in place, so after we got the wall up we had to shimmy it down to it's final resting place and lift it up over the anchor bolts. I don't mind telling you - these walls were HEAVY! The more help the better.

A sill seal goes down first to fill small gaps between the bottom plate and the concrete foundation wall. The bottom plate is treated wood by code - this is done as it's the most likely location for water to puddle and over time rot the wood.

Once in place, the wall were roughly plumbed and then braced with 2x's tied to stakes driven in the ground or using a pair of 2x's to form a triangle on the inside. These were the only two sections of the wall I planned on tipping up like this - the rest would be built in place by myself.

Next up was the south wall:

The studs were all sized in that drawing, and I created a second drawing to help me lay out their location on the top plate:

Then it was on to putting up that wall:

After it was in place it was also roughly plumbed and bolted down to the anchor bolts in the foundation:

Once the walls were up and the help was gone, I went through and plumbed the two walls. To do this, I parked one vehicle on each side of the wall and tied a rope on each side of the wall, in a loop around the top of the stud and plate where the existing brace we had put up was located down to the bumper of the vehicle. I left a little slack in each line and using a stick, tightened the line like the cord on a bow-saw... Once the slack was all taken up, I removed the nails holding the brace and re-plumbed the wall, tightening the side it needed to go to by twisting the rope on that side more until the wall read plumb., then nailed the brace back into place. You can apply a great deal of pressure using this method, and I was able to plumb the walls around the entire building using this method.

Then it was on to the east wall (the top in the graphic below), which I framed in-place:

The headers over the windows and overhead door are triple 2x10 with a 1/2" plywood core, a diagram of which I will show in a minute... The .

This tied the north and south walls together on the east side, but I then figured should tie the west end of these sections together at the spot where the "main" roof butts into the "lean-to" portion of the roof - the spot labeled #7 in the graphic below:

This is to be the main beam for the roof at that spot, so it needed to be a pretty substantial - and straight - beam. I started by first setting up the two 6x6 columns at their planned locations that the beam would rest on (asking a beam to span 32'-0" is a bit much for traditional construction), as to split the span into thirds. A "U" shaped Simpson column base is bolted into the concrete and fastened to the column with nails and plumbed by forming a triangle with a pair of 2x4's nailed to the column to hold them in place - you can see them in the photo below (with the beam already in place):

The columns at each end are simply nailed together 2x6's that rest within the confines of the stud wall.

It was then time to construct the beam. The beam is made up in layers - first a 2x10, then a layer of 1/2" CDX plywood, then another 2x10, a second layer of CDX, and finally a third 2x10. It works out well with the layers of plywood, as then it ends up the same width as the 6x6 column it rests on:

It's great to have an air nailer for jobs like this - it would wear you out quickly nailing all of this by hand, there are a LOT of nails. Fortunately, I still had my old framing nailer from back in the day.

There was no way I was going to be able to construct the beam on the ground and lift it into place on my own, so I constructed it in place by placing the first 2x10 in place (crowned so the higher point is pointing up), holding it by nailing scraps of plywood to Then it was the next 2x10, and so on until the beam was complete:

A composite beam like this is stronger than a solid beam... the layers help guard against natural defects in the wood, and provide a more homogenous beam across it's length. It's still a bit of a stretch - and by code, these beams aren't heavy duty enough to span the entire distance - so I will add in some knee braces later in the construction process. For now, they will be enough.

To level the beam I used the old bucket of water with a clear hose trick, the same sort of one one documented here on the Taunton web site. I had tried a line level, which is what I used to determine the length of the columns, but ended up having cut the columns about 3/8" too short... Using the water level eliminates such inaccuracies - but I hadn't remembered the trick until after I had cut them. They can be a little difficult to use when you are by yourself and trying to measure a column that has nothing holding it up yet anyway, I guess... Anyway, the short columns were an easy fix with a "shim" of 3/8" plywood.

From here it was a matter of finishing up the rest of the walls and installing the sheathing, which ended up being 7/16" OSB:

There are some that don't like this product, and will only use plywood... Truth is, this material will work just fine for sheathing and is more environmentally friendly than plywood is. And - here's the real issue - it was cheaper.

For bracing, the sheathing on the four corners of the building were specially nailed to create what known as a "braced wall panel". This is done to stiffen the structure against it's natural tendency to lean. The special nailing basically means using ringshank nails 6" o.c. around the perimeter and down each stud line. Another good reason to have a nailer handy - that's a lot of nails.

One thing to remember here, which I nearly forgot:

You can't get into these corners after you've nailed the sheathing on - and if you don't, the corner will always feel cold in the winter and it will be a spot where heat can escape the envelope. Taking your time to insulate the building properly can make a HUGE difference in your heating bill, so if you are building a shop I would suggest you do this - even if you are not planning on insulating it. Someone may want to someday - and it's not much money to do now, but will cost you plenty later should you decide to heat the building.

That's probably enough for this installment. Up next - the roof!

This fall, our magazine is sponsoring the first-ever weekend conference devoted to hand tools and learning to use them.

We're calling it the Woodworking in America conference, and we'll be bringing together the country's best hand-tool woodworkers and manufacturers for a symposium in Berea, Ky., on Nov. 14-16.

There will be more than 40 short classes on tools and techniques during the long weekend, plus a marketplace where toolmakers can display (and sell) their wares, social events with the demonstrators and toolmakers and more.

So who is going to be there? Here's the list of people who have agreed to teach seminars during Woodworking in America as of this date (with more to come):

Roy Underhill: Known as "St. Roy" to the legion of fans who watch "The Woodwright's Shop" on PBS, Roy worked at Colonial Williamsburg and then launched his show about traditional hand tools.

Frank Klausz: One of the country's consummate craftsmen, Frank is a professional New Jersey cabinetmaker who trained in Hungary and has a lifetime of experience with the full range of handwork.

Michael Dunbar: Founder of The Windsor Institute, Michael has single handedly revived the craft of building Windsor chairs, has trained thousands of woodworkers and is a passionate student of the art and history of handcraft.

Adam Cherubini: The author of Popular Woodworking's popular "Arts & Mysteries" column, Adam is a devoted 18th-century woodworker who builds period pieces using period tools.

James Blauvelt: A Connecticut cabinetmaker, joiner and carpenter, James owns Bluefield Joiners and is a student and teacher of Japanese tools and traditions.

Robin Lee: The president of Lee Valley Tools in Ottawa, Ontario, Robin has been a driving force behind the expansion of the Veritas line of premium handplanes and a caretaker of the company's immense tool collection.

Thomas Lie-Nielsen: The founder of Lie-Nielsen Toolworks in Warren, Me., Thomas has been making and selling premium traditional hand tools for 27 years. Thomas's company was the trailblazer in reviving many traditional forms of tools that had been lost.

Larry Williams and Don McConnell: Two of the principals behind Clark & Williams in Eureka Springs, Ark., Larry and Don are bottomless wells of information about traditional tools and their workings. Both are accomplished woodworkers, planemakers and tool historians.

John Economaki: The founder of Bridge City Tool Works in Portland, Ore., John has long been a pioneer in developing new (and very beautiful) forms of hand tools for woodworkers.

Konrad Sauer: The owner of Sauer & Steiner Toolworks in Ontario, Konrad is one of the leading makers of custom infill handplanes.

Wayne Anderson:Wayne specializes in designing and building custom infill handplanes that are deeply rooted in the past but are each a completely original work of art.

Ron Hock: One of the earliest and most important players in the revival of handtools, Ron makes high-quality replacement plane irons, chipbreakers and marking knives in Ft. Bragg, Calif.

Mike Wenzloff: The founder of Wenzloff & Sons sawmakers in Forest Grove, Ore., Mike is a long-time woodworker and expert in saws and saw sharpening. His premium saw business has exploded in the last two years.

Joel Moskowitz: The founder of Tools for Working Wood and an expert on woodworking history, Joel has recently been making many traditional hand tools, as well as selling them through his catalog and web site.

Clarence Blanchard: The publisher of "The Fine Tool Journal" and the president of Brown Auction Services, Clarence sees more old tools in a week than most of us see in a lifetime.

Kevin Drake: After studying under James Krenov at the College of the Redwoods, Kevin founded Glen-Drake Toolworks, where he combines woodworking, toolmaking and education. His innovative tools have received numerous awards; we named his Tite-Mark one of the "Best 12 Tools Ever." 

If you are interested in attending, please visit the web site that is dedicated to this conference at WoodworkinginAmerica.com and sign up for the conference's newsletter (the sign-up box is on the top right of the page). You'll then be the first to be notified of when registration will open (it will be before July 1) and the pricing for this event.

Attendance will be limited to a few hundred people (we want to keep the event intimate and manageable), so be sure to register as soon as slots become available. We are expecting the conference to sell out.

There are more announcements and surprises ahead that I cannot share with you right now, so please stay tuned to the blog and the conference's newsletter.

— Christopher Schwarz

For me, finger joints have always been the nerdy, square cousin to the dovetail.

Finger joints are immensely strong when glued properly. But they are usually used by beginning woodworkers in places where a dovetail would be more appropriate, such as on a piece of 18th-century casework.

Add to that the fact that finger joints are tricky or dangerous to make on wide boards (without a commercial jig) plus the fact that gluing them with yellow glue is stressful, and it's a wonder that anyone uses them at all.

And so we decided to tackle finger joints for the Summer 2008 issue of Woodworking Magazine, which will be shipping to subscribers next month. It took us a few months to really pin them down (pun intended), but I think we nailed it (and no, cut nails are not involved).

Here's a small taste of some of the problems of the joint we solved after three months of testing in our shop:

Appearance: Finger joints are a product of the machine age. Using them in styles before circa 1900 is just wrong to the eye. So consider the joint for more contemporary pieces only.

Cutting them Accurately: Right now there are basically two different ways to cut the joint: A shop-made jig for the table saw for narrow boards, and using a router jig that costs several hundred dollars for wide boards. We set out to develop a simple and safe shop-made jig that could handle both wide and narrow boards. Senior Editor Robert W. Lang had a stroke of genius on this and solved the problem forever (in my opinion).

Gluing Them Easily: You can assemble small boxes with finger joints fairly easily when using yellow glue. But at a certain point, you hit the wall because the glue sets up before you can close all the joints. So the solution would seem to be a slow-setting glue. Well, that's one way to go about it. But we found an easier and faster way that is super-strong (see the photo of Managing Editor Megan Fitzpatrick's boot on a sample joint). In the end, it took an anvil to bust up our sample joints.

Also in the Summer 2008 Issue
The finger joint is just one of the major themes running through the issue. Here are some of the other stories you can look for in the coming issue:

Building a Better Chest: Most woodworkers build chests using the most convoluted and fussy assembly imaginable. After reviewing hundreds of historical models, we settle on a method for building a chest that looks more complex at first glance, but actually saves an immense amount of shop time, requires less fussing around and allows more design flexibility.

Crackle Finishing: Many woodworkers who try a crackle finish have inconsistent results. Sometimes it works; sometimes it doesn't. And predicting how much it's going to crackle is almost impossible. Senior Editor Glen D. Huey cracks the code of crackle finish and finds out that the easiest and most predictable way to do it is also the simplest.

Trimming End Grain: When you have to cut back some end grain so it's flush with some face grain, it's always an opportunity to mess up the project. We show you two (actually three) methods for doing it right every time with a block plane, sander and pencil eraser.

And one more thing about the Summer 2008 issue: This issue is going to be mailed out to subscribers in a protective plastic bag, which will reduce the chances that the postal service will mangle it. If the plastic bag works for you, let us know so we can encourage our manufacturing division to continue using it.

And if you're not a subscriber, you can easily remedy that here.

— Christopher Schwarz