The Evolution of A Stable - PIC HEAVY

[Sonseeahray's_girl]

Well, two weeks ago we finally started working on our stable and to say that I'm excited is understating it

Since I'm documenting the whole project, I thought I'd share the pics and progress on here, since very few other people will appreciate it

A little background info and details:

The foundation for the stable is an existing 25-30 yr old tennis court which was laid so well all those years ago, that there has been no heaving and very little cracking of the asphalt, so obviously a terrific base, and very convenient, since it's already there! The dimensions of our stable are 60'x32', with 8 - 10x12 stalls (5 on one side, 3 on the other), an insulated and heated 10x12 tack room and an insulated and heated 8x10 water/feed/storage room. The walls are 8' high on the outside, sloping up to a 14' peak in the middle of the roof. There is a man-door on the south east end of the barn, in between the two insulated rooms, and a set of double doors for the horses on the north side. Also on the north side will be a 12' overhang, where we will have an outdoor wash bay later on (next year).

Note: most of the pics are facing north, towards the end where the double doors will be. You'll see a screen of 20' tall chain link fencing that's mostly covered in trees and vines. This will stay intact as it provides an excellent barrier against blowing snow and wind in the winter

To get started, we had to power wash the construction area, and eliminate the weeds/dirt/moss that was on some of it.

August 29/09


Then we started laying the sills. For the sills, we obtained 1" rubber belting, and cut strips of it to fit the 2x6 lumber that we were bolting into the asphalt. Hubby got this idea as it will enable the bottom sill-plate to stay drier. We also inserted three pieces of rubber tubing in each stall, under the sill plate, for water flow out of the stalls.

August 30 - Sept 3/09


After the sills were laid



Then we had to get the asphalt guys to come and resurface, and create a slight slope to the outside walls inside the stalls. So the centre aisle was built up 2", and the stalls were built up 2" on the stall front side, gradually sloping down to the outside walls. Again, this was for drainage (to work along with the pieces of rubber hose that were inserted under the sills). So I can go in every spring and hose out the stalls completely, and all the water will just run right out!

Sept 4/09


And 11 tonnes of asphalt later, the base is ready and waiting!

Sept 8/09


On the right hand side of the above picture, you can see the two rooms that were not built up with asphalt..the one on the left of the dark passageway is the water/feed room, the one on the right (north) of the dark passageway is the tack room.

View from the north to south, standing where the double doors will be:


The posts you see are the beginning of the first wall, which we've since competed as of today, but I don't have the pics downloaded yet, so stay tuned!

I'll keep updating this thread as we go so you all can see our progress. If you have any questions, feel free to ask.

[redboy]

Very cool!! Congrats on getting started on your barn!

[Horselady44]

How exciting!!!! I bet your totally stoked! I am 4 you!!!! My dream is to have one of my own someday...so I can def understand your excitement! CONGRATS

[merleliz]

Woo Hoo! Looks like a great beginning! I am pea green with envy...I'm nagging Paul for another run in shelter with not much response...what a good hubby you have!

[Sonseeahray's_girl]

Okay I uploaded three more pics of the first wall built and ready to be stood up:







Each stall will have a 3'x3' dutch window.

I forgot to mention, we're doing all the work by ourselves, with the exception of the asphalt of course.

Merleliz, you're right, my hubby is a wonderful man. He hasn't had one fishing or hunting day in over 4 years, and all because he's working so hard for our family and farm. I cannot stress enough what that man has done for me!

[corporate cowgirl]

Wow--your stable will be amazing! Interesting that it's built on an old tennis court--and so neat that you can recycle it.

[Mav2007]

This will be fun to watch unfold. As it moves forward could you also specify what materials you are using. I think I could gain some valuable information for in the future. Thanks!

[Deanna]

I built mine last year. Had to though as my other barn was floating in the air like Dorthys house in the wizard of OZ It was completely destroyed by a microburst that lifted it up off the ground while two of my horses were in it. No injuries except for cars where it landed. Mostly superficial damage it was quite scary. I like watching the begining to end posts of barn building.

[Terry]

Thank you for letting us watch as the work progresses on your new barn. It sounds like it will be amazing when it's done! I love that you will be able to hose out the stalls and the water will just run out the tubing. Very good idea! I also love the fact that you are doing this on an old tennis court - no dirt floors to make things all dusty! I'm really excited for you, and excited to watch the progress (and get some ideas in case I ever need to build another barn)!

[Sonseeahray's_girl]

Originally Posted by Mav2007

This will be fun to watch unfold. As it moves forward could you also specify what materials you are using. I think I could gain some valuable information for in the future. Thanks!

How specific would you like me to be?

For the sill plates 2"x6" I cannot remember the name of the wood as we intended to use hemlock but couldn't get our hands on any at the time and needed it right away.

For the 6"x6" square posts we are using red and white pine

For the 4"x4" square posts we are using cedar

For the 2"x4" studs we are using spruce

We bolted in the sill plates directly into the asphalt using lag bolts. We tried a different kind of bolt that comes in a sleeve and is supposed to fan out after screwing it in so as to lock the bolt, but they were crap and didn't work. The lag bolts worked beautifully.

We're using a framing nailer to tack everything in place, and then following up with 4" galvanized spiral nails.

The 6x6 posts are hand-notched at the top so that we can create a three piece laminated beam of 2x6 boards.

The centre walls (stall front walls) are 12' 6x6 posts which are notched at the top again, also will be hand notched in order to connect them at 8' high, running across the fronts of the stalls.

We also have some California Cedar beams which we're adding 4 of them for decorative purposes running across the hall way near the top of the peak.

The stall fronts and interior walls of the entire barn will be done in White Ash, and the bars on the stalls will be green but unfortunately we cannot afford a green roof too, so that will have to stay the regular silver colour.

I'll keep adding to my materials list as we go along, and I remember things.

[Red Gate Farm]

What a great project! It's going to be beautiful. I love the step by step journal with pictures you're doing here. I'll be following this thread

[libbytn]

Great looking beginning and even better hubby!! Look forward to seeing the end result.

[BBT2T5]

Very nice, congrats! The old tennis court has me mildly amused.

[Sonseeahray's_girl]

I know, it's so weird to have one out in the country like that, but hey, whatever floats your boat! They really put a lot of thought into it, the location in relation to the house is perfect, and there's a second driveway that runs directly past it, in between it and the backyard/house area, going to the back barn.

We haven't made much progress this week so far...we were busily routering out our notches for the posts for wall #2 when the router bit snapped in half and of course it was after all the stores were closed. Went to get a new bit the next day, found out that there were NONE the right size to be found in the entire city (what are the odds of THAT?) and also learned that we most likely would just end up snapping the next one anyways. So, we ended up buying another bigger router, which is really more appropriate for the job we're doing anyways (1/2" shaft, as opposed to 1/4") but then hubby got called out of town on business for two days so that set us back again. But we'll be working on it again tonight, so I should have pics of the first two walls up by this weekend! Can't wait...stay tuned!

[Sirita_88]

It looks great! I can't wait to see the progression into a nice barn!!

[Sonseeahray's_girl]

Okay, so a lot of time has passed since my last update, but here goes!

September was not as productive a month as we'd hoped. Between lousy weather, unexpected business trips, 25th wedding anniversaries to celebrate, company from out of town, equipment malfunctions, etc etc....

BUT we kept on plugging, and I'm happy to report that there are now TWO walls standing! The raising of these walls was so nerve-wracking that I thought I was going to throw up, but dear husband came through and did a perfect job.

Here are both walls waiting for standup yesterday October 2:



And UP we go!






It was at this point that the rain started coming down pretty heavy, so I had to put the camera away, but we braced the wall in 6 spots, and then stopped for the day.

Today, I left for the grocery store and came home to this





To give you an idea of the size of the windows:

More progress has been made today, I just haven't been outside to see it yet. Hubby's friend is over helping, bless his heart, so I've been taking a much-needed rest day. More pics to follow!

[Horsie Michelle]

So cool! It sounds like yuo guys really thought things out and it's really neat to watch it all unfold.

I can't wait to see more pics and pics when it's all done. I'm sure it's going to be awesome...I'm envious.

[snwflk]

VERY NICE! It will be awesome if you can get it finished before winter..?

BUT either way.. that will be awesome when its finished..

very jealous..

[Sonseeahray's_girl]

Thanks guys.

We're working hard to get it completely closed in by the end of November. That means roof on, siding on, doors on. The stalls won't take long to build, so we're hoping to move the horses in by the end of December.

The tack room will obviously not be done by then, but the main goal is to have the horses in before the January nasty weather comes.

[snwflk]

Even if you can get the main frame/roof done. then its like a nice neat lil shelter and you can work on the innerds later?

BUT SO COOL.. Plus the journaling of it is neat for us to watch.. GIVIN me idears for when I finally move my sorry touckas out to the country!