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Project by tyvekboy posted 08-02-2020 06:10 PM 1385 views 0 times favorited 24 comments Add to Favorites Watch
SHOP and SUNROOM ADDITION • No picture No picture No picture No picture No picture
Zoom Pictures

August 02, 2020

Hi Everyone! I hope everyone is staying well and safe during the pandemic.

I know I’ve been absent from LJ for just over 3 years. However, I have not been idle. This is the first of many posts to catch you up on what I’ve been up to.

I’ll make every attempt to make this as short as possible in documenting this project.

============== START OF PROJECT ==============

My shop space had reached a critical point and I could no longer move in my shop. My options was to move to a house with a bigger basement or expand the basement area of my house. Thirty-eight years of accumulation would take me years to move so my most economical option was to add more basement space.

This is the before and after photos of this daunting project. I decided to be the general contractor of this project which is the largest project I’ve ever undertaken.

I spent a year using Sketch Up designing the addition.

July 2018 was when I started this project by removing the brick veneer from the outside walls of the existing basement that would be the inside walls of the expanded workshop.

After the brick veneer was removed, the existing deck was demolished.

A hole was cut into the existing wall that would serve as a passage way from the old shop to the new shop addition. This was necessary at this point so that when the foundation was poured it would be level with the existing shop.

The finished passage way was designed to be about 46 inches wide to allow me to move the biggest piece of machinery (my delta cabinet saw) from my old to new shop. This width also allows me to move furniture around and out of my shop.

Then the foundation was poured along with a 10 ft x 50 ft patio. This patio has proven to be very useful in moving materials into my shop.

After the foundation had cured I proceeded to frame the passage way opening.

Since this side of the shop addition would be partially under grade I decided to build a 4 ft high cinder block wall on this end of the shop addition.

Then the basement framing got started with the help of a carpenter friend. That wide opening in the basement wall framing is for a 6 ft wide steel roll-up door that I included in the design of the addition. This along with the 4 ft wide passageway between the old and new shop would allow me to comfortably move large projects in and out of the shop.

The sunroom walls and roof were then framed to keep the rain out of the shop. All the walls and the roof was sheathed. The walls were wrapped with Tyvek and the roof sheathing was covered with a waterproofing material. The windows and doors were also installed in the framed openings.

The sunroom windows consist of a 4 ft x 6 ft picture window flanked by 2 double awning windows for ventilation on the long side. The short sunroom wall has 2 joined double sash windows also for ventilation. The basement addition has 2 small windows (32 in X 16 in Vinly Hopper Windows) on the long wall and 2 more on the other wall. All hopper windows can be opened for ventilation if required

The steel roll-up door was then installed to completely close in the structure.

I then hired a mason to install brick veneer around the shop addition so the addition would have the same architectural look of the existing house.

After the electrical was roughed in and the insulation was installed the paneling for the sunroom ceiling was installed. As shown in the picture four non-structural beams were incorporated in the sunroom design. Their purpose was to provide a place to hang a ceiling fan and lights since the sunroom had a vaulted ceiling.

Installation and finishing of the sheetrock was the next task completed. This photo shows the size of the closet in the sunroom.

The last task that my carpenter friend helped me with was cutting and installing the stair stringers.

The last task completed in 2018 was to have hardi plank siding installed.

January 2019 started with finishing the sunroom beams by covering them with pine boards that were pre-stained.

Custom corbels were cut from glued up 2X8’s and were stained and installed. They are purely aesthetic and non functional.

Since the house was due for a new coat of paint and new gutters that was done next.

Finishing the sunroom started with trimming all doors and windows and installing crown molding around the vaulted ceiling and other places.

A metal roofing contractor was hired to install a standing seam metal roof.

The next task was to finish the french balcony decking and railing. All the decking and handrail parts were painted before installation. Round balusters were used. Now you must be wondering why we have a french balcony. There are two reasons. First reason was to have a place to put bird feeders since we have a nice big picture window to view our back yard. Secondly it makes it easier to clean the windows on this side of the sunroom.

Finishing the stairs and stair railing was completed next.

Since we’re getting older and I thought it would look nicer, I decided to install a 16 foot aluminum ADA compliant handrail which I bought on-line. It came in two 8 ft pieces with a splice and mounting brackets. It was very easy to install.

The trick was to make a jig to join the two pieces of handrail after they were cut to length for the stairs. I took a scrap piece of 2×8 and drill a hole approximately the side of the handrail. I then cut it in half and clamped it around each half of the handrails about 12 inches from the splice. Then using a band clamp I squeezed both pieces of the handrail together around the splice.

One of the most appreciated feature of our sunroom is the 9 ft long X 3 ft deep closet. Two 4 ft bi-fold doors were painted and installed.

The last task that would complete the sunroom was the installation of vinyl click-n-lock floating floors and the shoe molding. On April 5, 2019 I received my certificate of occupancy after my final inspection.

Prior to starting this project I had a 5 barrel rail water collection system that sat underneath the deck. This system was re-installed outside of the shop addition. The system is fed from the gutter off the edge of the metal roof.

This story can’t be complete without showing you the status of my new shop addition. Studs and insulation were added where needed.

Electrical was then roughed in for quad electrical outlets 42 inches above the floor spaced about 5-6 feet apart. Outlets over the cinderblock wall were located a little higher. Two circuit breakers supply power to every other quad outlet.

Then 5/8 inch plywood sheathing walls were added to form the walls of the shop. While installing the plywood, a 1 inch hole is drilled and the romex is pulled through the hole before the plywood is screwed down.

NOTE: As with my old shop, the plywood sheets were installed vertically after they were cut into 3 pieces — 3 ft, 1 ft, and 4 ft sections. They were installed with sheetrock screws. The reason why this method is used is to allow me to relocate the quad outlet if the need arises in the future by only removing a 1 ft section of the wall.

After the walls are installed and painted, the metal quad outlet boxes are screwed to the wall and the outlets and covers are installed to complete the electrical outlets.

Nine 4 ft LED shop lights were hung from the open joists.

This 2 year project was considered complete after I built a short wall to help me level the ground about 5 ft away from the edge of the patio. As you can see here that my wife is enjoying this area for a little vegetable garden.

============ END OF PROJECT ==============

I hope you enjoyed the story of my shop expansion and sunroom addition.

Comments and favorites are welcomed and appreciated.

Thanks for looking.

Stay safe and well.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

24 comments so far

View Madmark2's profile


3055 posts in 1801 days

#1 posted 08-02-2020 06:42 PM

Well done.

-- The hump with the stump and the pump!

View LakesideWoodworker's profile


24 posts in 1283 days

#2 posted 08-02-2020 06:54 PM

Looks great. Very nice design and well finished. I am glad you finished it. I started building my shop 15 years ago and still have some insulation and sheet rocking to do. Have been able to use it, but it would be nice if the finishing touches were done like yours.

-- Lakeside Woodworker

View John Stegall's profile

John Stegall

556 posts in 4729 days

#3 posted 08-02-2020 06:55 PM

Lots of really hard work went into the design, preparation, and execution. Great job.

-- jstegall

View Jim Jakosh's profile

Jim Jakosh

26643 posts in 4318 days

#4 posted 08-02-2020 07:08 PM

WOW….......That is a great addition to the shop and the house upstairs! Very nice design and finishing. I can see why you have been off the computer for a while!!

Nice work, Alex…...........Cheers, Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Lenny's profile


1720 posts in 4739 days

#5 posted 08-02-2020 07:13 PM

Huge undertaking, well executed!

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View  woodshaver Tony C   's profile

woodshaver Tony C

8185 posts in 4565 days

#6 posted 08-02-2020 07:14 PM

A huge undertaking and it look like a huge success too! Great to see so many build photos it really show all the hard work that went into your project. Congratulations on a fantastic job!

-- St Augustine FL, Experience is the sum of our mistakes!

View sawdustjeff's profile


30 posts in 2753 days

#7 posted 08-02-2020 07:19 PM

Great Project, good design and execution. I’m envious!

View DocSavage45's profile


9068 posts in 4055 days

#8 posted 08-02-2020 10:05 PM

Congratulations on a job well done. Good you subcontracted the metal roof.

-- Cau Haus Designs, Thomas J. Tieffenbacher

View JCamp's profile


1413 posts in 1763 days

#9 posted 08-02-2020 10:07 PM

Great project. Really adds to the place, it actually totally transforms it.

-- Whatsoever thy hand findeth to do, do it with all thy might

View sras's profile


6319 posts in 4342 days

#10 posted 08-02-2020 10:16 PM

That’s quite the upgrade!

-- Steve - Impatience is Expensive

View luv2learn's profile


3137 posts in 3515 days

#11 posted 08-02-2020 10:23 PM

Now that is a massive project and well done as well.

-- Lee - Northern idaho~"If the women don't find you handsome, at least they ought to find you handy"~ Red Green

View clieb91's profile


4264 posts in 5147 days

#12 posted 08-02-2020 11:09 PM

Nicely Done. More Shop Space is always needed.

and welcome back.


-- Chris L. "Don't Dream it, Be it."- (Purveyors of Portable Fun and Fidgets)

View dukeofburl's profile


13 posts in 3147 days

#13 posted 08-02-2020 11:18 PM

Really nice job! I’ll bet you already have the new shop space filled up.

-- dukeofburl

View LittleBlackDuck's profile


7884 posts in 2033 days

#14 posted 08-02-2020 11:20 PM

Been a bizzi ’boy... Great enhancement… Now all you need is more clamps… you can never have enough clamps, especially when you have the storage room.

Love your still, but how do you keep the bloody neighbors away from it,

Now that’s what I call a good back up.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View BurlyBob's profile


9293 posts in 3478 days

#15 posted 08-03-2020 12:58 AM

Wow, that is one incredible addition.

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