Rebuilding My Shed, Pt. 3

November 21, 2012 | by Ethan (email) |

I haven’t been giving my shed rebuild too much coverage. If you didn’t know, we already have a very good series on sheds covering everything from building different foundations, to building the shed, adding shelves, building a ramp and more. Last time we left off I was framing the walls and having a “fun” time matching the angle of my deck stairs.

After getting that back wall framed, the front wall went much faster because it had a lot of similar cuts. I opted for a wider doorway and sacrificed a little height because I wanted it to be easy to maneuver a mower in and out. Unfortunately, I’ve already smacked my head a couple of times on that 2×4.

The main reason for the blocking was to maintain the spacing between studs because I couldn’t just mark that top plate in the usual fashion.

The two side walls were straight forward with the only exception being that I ripped the top plate to match the roof angle.

The siding is T1-11, and it’s the same stuff Steve Wartman and his crew used for that shed build. I cut it so that it overlapped the band board, adjacent wall framing and the roof framing.

I measured and cut the siding for the front wall, but did not attach it because I needed to be able to slide the roof into place first.

Fred and a couple of friends helped me frame out the main portion of the roof.

I decided to use corrugated metal for the roof instead of shingle.

We attached a ridge vent and corrugated metal to the framing out in the open.

The roofing is attached with screws that include rubber washers to seal out water. We then slide the roof in place, and I joined the framing with nails through the underside of the top plate.

I trimmed the entire roof and doorway with Azek.

The corners are another PVC trim product, and I used it because there was limited space between the shed and the pressure-treated ” retaining wall”.

For the door I used scrap pieces of flooring and the T1-11 I cut out for the doorway, and I’m really happy with how it turned out.

I still have a few things to caulk, and I want to reuse the old pavers in front of the doorway. I think it looks really good, and the next big rainstorm will tell me if it’s watertight.

I sealed the joint between the corrugated metal and the PVC with silicone.

The door trim, jambs and door stop are all Azek PVC, and no that is not blood in the corner.

Here’s a look at the OSB, T1-11, PVC sandwich door.

Inside the shed I’ve already started storing a few items, and you can see the sweet Gladiator Geartrack compliments of Ace Hardware. It’s heavy-duty enough that I can hang just about anything. So far I only have rakes and some lawn and garden tools.

The hooks can be positioned along the entire length of the track.

Ace also sent me this Porch Light, and it’s a terrific addition to the shed. It’s a motion-activated, LED light that only comes on at night (or when the shed door is closed). It’s perfect for illuminating the shed when I need it, and I highly recommend this light for anyone else in a similar situation.

The tools need to make their way back to the OPC shop before I can get the mower (and anything else) squared away.

I was able to branch the electric going to a rear flood light and setup an outlet in the shed for charging batteries. However, I’m keeping the batteries inside for the winter.

I’m pretty stoked about my shed, and I’m proud to have built it myself. I’ll be even happier when I know for sure it’s watertight. The next big rainstorm here in Maryland will find me huddled in the shed staring at the roof.

29 Responses
  1. Eek565 says:

    Nice looking shed Ethan. Now it just needs a heater, mini fridge and an old t.v. 🙂
    My Dad’s shed has a corrugated roof and it has issues from time to time with leaking through the roofing nails (granted it’s old). He did it the old way with caulk so I’m curious how the ones with gaskets hold up.

    • Ethan says:

      Thanks! I joked that it could be our in-law suite. We used a drill/driver with a low gear to put in those screws because it’s important to create a watertight seal without damaging the gasket. From what I’ve read, they should be good to go for a long time.

  2. Rodney Hytonen says:

    What’s that silver colored machine being used on 2×4’s, on the ground, in pic #4; and shown stored on the right rear looking inside the shed? Some sort of contractor’s jointer/planer?

    • Ethan says:

      Hey Rodney,

      I don’t recall seeing you comment before so I wanted to say welcome, and I hope to see you around OPC again.

      That’s actually a Bosch job site table saw (#1031). I’ve talked to a lot of contractors about their table saws, and DeWalt is by far the most popular. I’ve had a great experience with the Bosch, and I’d recommend it to anyone.

  3. trebor says:

    Looks great Ethan! I think it turned out well.

    What did you use to cut the roofing?

    • Ethan says:

      It’s pretty thin metal so I think a regular circ saw would work. I used a twin-blade circ saw from Ridgid that’s designed for metal (and other materials), and it cut like butter.

      • Joe says:

        tin snips would probably work just fine as well.

        • Fred says:

          Potentially so. I always find that with snips I have a tough time keeping everything even. With the ridges, snapping a chalk line ends up only hitting the ridges and not the valleys…. So if you are snipping I think it might be hard to make work. This is one of the few projects that we really found the Ridgid twin blade circ. saw to be really good because it eliminates kick back. Unfortunately, I think Ridgid is discontinuing the saw due to lack of interest. It’s one big problem is that it can’t cut a full 1.5 inches deep, so you can saw through 2x material.

  4. paintergal says:

    The shed looks great! That Gladiator Geartrack system is sweet. I’d not heard of that before.

  5. bigredmachine says:

    Thats what I call making the most use of dead space I have ever seen, another great job……..

  6. poiboybf says:

    Looks awesome. Killer porch light too. Did you make the door yourself or use some sort of squat-sized prefab?

  7. Reuben says:

    The shed looks great, but how did you make that excellent wreath on the door?

  8. Jake says:

    Looks great. Love the way the door is built…..I need to rebuild mine (currently made out of plywood sandwiched between an interior and exterior 2×4 frame….talk about heavy)….wonder if that way would work for a set of double doors that are about 4×8 each. would have to be lighter at the least lol.

  9. Icarus says:

    Like the porch light and pretty cool how you branched the electric, did you need a permit for that?

  10. Ethan, that’s a great use of an underutilized space under the stairs. Thanks for taking the time to really explain how you built it.

  11. This looks really great and is a smart use of space. My father did something similar with T1-11 on his garage, but to mimic siding.

  12. I wouldn’t be worried about it leaking. We use those fasteners all the time on commercial metal buildings. The only thing that may leak is if you didn’t put closure strips at the ridge cap and edges but the rain would have to blow sideways.

    • Fred says:

      Any idea how long the gaskets last out in the weather. I figured no leaks for 5 years easy… but seems like with repeated heat/cool and dry/wet cycles that they might break down after 10 years or so….

      • Dr_No says:

        Corrugated iron is a pretty common roofing material here in Australia and the screws are always put through the raised part (ridges) of the corrugations, not in the valley. This way the water runs away from the screw holes so it doesn’t leak. Just don’t put the screws in too tight or it can flatten out the corrugations.

      • We regularly get 20+ years before replacing the roof but one of our shop buildings has the original fasteners and it has been up for 30+ years (in MN weather).

  13. Mickey says:

    I’m a little late to see this post, but just wanted to add my compliments. It looks great! Very good use of space too.

  14. Looks brilliant Ethan! Love the corrugated roof and the light. Well done!

  15. Paul&Aundrea says:

    Love the shed. I hadn’t seen the geartrack either. I think I just found my father-in-laws Christmas Present! The light looks like the perfect solution for us as renters as well. We really need a light for the back yard, but didn’t want to go through the expense and time of adding another corner light. Do you have a riding or push mower?

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