Wednesday, December 31, 2008

Garage work: Insulation, drywall, cabinets, attic, lighting

Insulation, Drywall, and Cabinets
Over the past few months (November & December), we have been working on the inside of the garage. We started in the far left corner where the workbench will be.



The garage was pretty much just a structure with very little wiring and plumbing completed. This allowed Zac to put wiring and utilities where he wanted. First, all the wiring and outlets went in place along the wall where the workbench will be.

Along with the wiring, the plumbing for compressed (shop) air was installed. Currently there is no place to connect the shop air up to, as the compressed air tank will be housed in a new West Wing of the garage (to be built later). For now, all the air is getting routed and will be connected when that wing is built.

The shop air lines are being routed overhead, and there will be several drops throughout the garage.

The old electrical panel was removed because it only had 6 breaker slots. It was replaced with a new panel that has 12 breaker slots.


Once the wiring and air lines were installed, insulation could go up.

On this wall will be two air conditioning units, one above the workbench and one above another work area further down the wall. Zac started by framing where the AC unit would be and routing the electrical for the unit.


Four holes were drilled in each corner so that the frame could be located on the outside wall. Zac then cut the hole in the stucco.















With the outside stucco removed, the wood was cut and removed so that the through-wall AC unit could be installed.






Next, drywall was installed, taped, and mudded. Once the wall was dry, cabinets were installed. These cabinets were from the kitchen. Some were in too poor of shape to even be used in the garage, so we only used the good cabinets. Zac built wood frames around each cabinet to support the workbench. This way, the workbench load would be supported on the frame and not the cabinets.

Originally, Zac was planning on running base cabinets all the way to the wall. I suggested leaving a gap as a workspace so that one can work seated at the bench with their legs under the bench. This is also the area where the bar chairs can be stored.
After framing, Zac closed in the area to give it a more finished look. A shop air drop is located on the left.


The three beams nailed across the top of the frames are to give the workbench structural rigidity. We tend to work on heavy things on the bench such as motorcycle engines, and this will prevent the benchtop from flexing and breaking.


After the frame was complete, the benchtop was installed. This was a pre-fabbed counter top from Home Depot. The entire workbench is 14 feet long.


With the workbench in place, this gave Zac a higher area to set his ladder for installing the upper pieces of drywall.

2 x 4 wood beams were lag bolted to the studs in the wall, and the upper cabinets were screwed into those. Most likely the cabinets will fall apart before falling down.


Cabinet doors were installed. This is almost a complete kitchen's worth of cabinets. There are still a few base cabinets left over that will be used as individual work stands for tools such as the drill press, chop saw, etc.

This is the reason we need so many cabinets. We have our old 3-car garage worth of stuff all over the floor of the new 6-car garage while the storage areas are getting built.

The walls were primed and painted with a standard white garage paint. We have a lot of surface area to cover in the 6-car garage, so we chose white as it comes cheap in 5 gallon containers.



A close-up of the AC unit, an 18,000 BTU unit. The second will be the same unit purchased later to go in the spot further down the wall. The gap in cabinets above the workbench will also work well for working on tall items that don't fit under the cabinets, such as truing bicycle wheels.


Attic
There was no attic, only exposed beams. So with the clearance and amount of room up in the ceiling, Zac decided to floor in a section to use as storage space for items that don't get used often, but take up a lot of room (motorcycle fairings, bike flight cases, etc). From the floor to the ceiling in the attic is 6 feet, so one can walk around up there comfortably.


The start of the floor:

A view of where the floor will be extended to.


Another view of the start of the floor. Once completed, there will be 800 square feet of storage space in the garage attic. We also purchased a drop-down attic ladder kit, which will be installed soon (and documented in a future post).


Lighting
The existing garage lighting is severely limited. There are two 8 foot fluorescent lights that are on the left side of the garage. The bulbs are a pain to change, store, and transport because they are so long. Zac decided to install 2 rows of 6 lights that are each 4 feet long (and contain 2 bulbs). This will put out a total of 816 watts, for 0.6 watts per square foot. Task lighting will also be installed under the upper workbench cabinets for detailed work, such as working on engines.

A view of the first row of 6 lights installed, with the new lights off and the old lights on.

Old lights off and new lights on. The second row of 6 lights will be placed parallel to this row and just in front of the garage door opener lights.

A few months ago, we had also installed lights on the outside of the garage. There are 4 lights, one between each garage door and one on the very end of the garage.

The lights are controlled by a photo cell that turns the lights on when the sun goes down. (The area around the cell will be painted to match the rest of the garage).

Laundry room sink installed

The old laundry room showing the original sink in the counter top (and the old finish on the cabinets):


The old laundry room sink was too small and nasty to re-use. We decided to go with the largest sink we could fit, which was a Kohler kitchen sink turned sideways, since the limiting dimension was the depth of the counter top.

The sink is cast iron, so Zac had to re-inforce the counter top to support the weight of the sink before it could be installed. This shows the finished re-inforcement. We also installed a new Pegasus faucet in oil-rubbed bronze.
This was the old plastic plumbing that was under the sink:

It was removed and replaced with chrome-plated brass:

We also added a trash can that mounts to the cabinet door.
Here is the new sink installed. The drain is also oil-rubbed bronze. The black finish matches the kitchen sink.The new sink compared to the old sink.

And this is the sink and counter in the completed laundry area. Above the sink will be a bar for hanging clothes that require hang drying.

New hallway dome light fixture

The old fixture:

Zac was waiting for all of the bulbs of the old light fixture to blow out before he changed the fixture. I don't know why. Anyways, here is the new fixture. Since it is in the center dome of the house, it casts really cool shadows on the walls.


Friday, November 28, 2008

Laundry room cabinet re-finishing

Wow...it's been awhile since I've updated the blog. I'll try to catch up.

Sometime last year I completed the re-finishing of the base cabinet for the laundry room. I decided I need to get the collection of cabinets out of the upstairs bedroom, as they are taking up too much room. The laundry room has 2 upper cabinets, while the craft/hobby room has 3 upper cabinets and 2 base cabinets. I decided to finish off the laundry room.

The cabinets are in decent shape for use in the laundry and craft rooms. I wanted to stain and re-finish them because the oak was stained with a reddish dye. This made each room look dated. Not that the '80s weren't a totally righteous decade, but they just don't fit my taste.

Re-finishing cabinets isn't the funnest thing in the world, which is why it takes me forever. I start by sanding off the old finish, which takes about 3 hours per cabinet (the trim work on the front of the cabinets takes forever to sand). Then each cabinet and door gets a coat of wood conditioner, followed by 3 coats of tint. The tint needs to be wiped off after 20 minutes. After the tint cures, each cabinet and door sides get 3 coats of sealer, which requires sanding with 200 grit sandpaper between each coat. See why it takes me so long?

The upper cabinets required additional work. The original cabinets had messy undersides, which will be seen when they are on the wall. So 3 sides had to be cut down flush with the bottom so that a thin piece of oak could be attached and stained the same color.

Here's how the short upper cabinet started out:The center cabinet had the same unfinished bottom:

The cabinets got hauled outside where Zac and I did all the cutting on sawhorses to avoid any damage to other surfaces. A thin piece of oak was trimmed, glued, and nailed to the bottom and sides. The sides had fake veneer that couldn't be stained, so I roughed that surface with the sander and glued the real wood to it, followed by nails. Oh, and I found that vacuuming the cabinets with the soft brush attachment (for curtains) works well for getting the majority of the sawdust off of the surfaces. After vacuuming I followed up with a tack cloth.

The upper cabinet with the new sides and bottom attached:

The room that will be my future craft/hobby/sewing room is currently my cabinet re-finishing room. This keeps everything clean while the various coats are drying. The old laundry room counter top is what is resting on top of the sawhorses, and makes a perfect wood-staining worksurface.

The yellow Post-Its are status notes for each door and cabinet so that I can keep track of where each one is at in the process.

Here is the completed and stained center upper cabinet. In the photo below it is upside down, so the top is the finished bottom.

Here's a comparison of before and after. The "before" is one of the craft room cabinets yet to be done. *sigh*


Zac finished hanging the cabinets. The scene before this one was me sitting on the washer with the short cabinet on my head while he put the supporting screws in place.
The cabinets are in! And no one was killed or seriously injured in the process.
Now the upper cabinets match the base cabinet that was finished, oh, forever ago.
The next step was to install hardware. I found some drawer pulls in oil rubbed bronze at Home Depot that matched the new doorknobs well. And it was the 10 pack, so I saved a ton. Do you know how expensive some drawer knobs can be? Yeah, look them up sometime. I've found some that are $50 EACH! I have 18 knobs to put on between the two rooms, so that's not happening.


Upper cabinets with pulls installed:
And the base cabinet completed. The left and center top "drawer" blocks are fixed in place as that's where the laundry room sink will go (right where the mysterious glob is in the photo). The left upper drawer is still functional as a drawer.
Now it's time to order the laundry room sink and faucet. The sink will be a black top-mount sink and the faucet will be something in oil rubbed bronze to match all of the hardware. We are also going to attach a bar to the side of the upper center cabinet and attach it to the wall to hang clothes on for drying. Then we can stop using our canopy bed as a clothes line.
In other laundry room news...
Opposite of the base cabinet is the door to the water heater closet. We needed a home for the iron and an ironing board, so Zac found a cool in-door kit and installed it in this door. From the front you can't really tell what magic lies inside:


Open the door and there's a cool little cubby where a fold-out ironing board and the iron live.


There's a little lamp (because ironing in the dark can only lead to disaster) and a plug for the iron. The plug operates on a timer.

And when you open the door you can see how compact the iron and ironing board storage area is.