[This is a work in progress and I will update this thread as I work on this. I just wanted to start it while taking a break from working in the heat]
So, I was looking at the thread for the least expensive, most bang for your buck DIY projects on the forums, and I ran across this one by @SavageEye:
I lost my job in late May, and I've started to get into the Halloween spirit, so I was looking for a cheap project to use up some materials I already had with minimal purchasing of new material. I decided to use the above as a template for mine. I also thought, depending on the cost, I might try and weatherproof it some, and when it is stored (out behind my main shed), it could be used as storage itself (instead of having to completely break it down and store it).
So, I first found some pallets to start with. I made sure they were all roughly the same size to make things easier. I then went to home depot and hit the "culled wood" section (70% off) and got away with $30 of wood for ~$10. Some of it I will use for this project, and some of it not. I will likely have to go back and get more. They seem to put it out on Mondays, so I'll just run out there first thing every Monday morning
I started by cutting some 2x4s in half and using them to join 2 sets of 2 pallets together making sure the slats were on the same side. The first thing I noticed is that the 2x4s were too big to go into some of the pallets. So I got out the table saw and narrowed them down a bit. I then screwed each section to the 2x4s. This way, they slide in easily, and when I dismantle it, I can just separate the walls into 2 sections for moving it to storage. Here is a picture of one of the sections. When I saw the picture in the thread above, I thought that it would be too short. I didn't realize that the 2 would be over 8' tall! Not that I mind, and if I want it shorter, I can always trim some off each side.
The next day, I finished the other side and added some 2x4s to the top of each section to connect the roof to. I used 2 2x4s along the top, then I took 2 more 2x4s cut to the width I wanted the finished product to be, and I joined the 2 pieces together. I did the same at the bottom temporarily. I won't have them joined at the bottom when I'm done so I don't have a tripping hazard. For now though, I wanted it supported until I could add some additional bracing to the top to keep it all together. I don't have a picture of the top at this point and to be honest, it's too hot to run out there and take a picture of it...LOL.
After that I cut a 2x4 in half and started to play with the angle of the roof. @SavageEye above used 2 extra pallets, but I wanted it to be a bit more structurally sound and a bit more weather proof. I know, the walls are not weather proof, and there are only 2 walls to boot, but I have some ideas on that later! For now, I think the pallets offer a great (free) base that is already weathered.
After I got the angle I wanted, I cut 2 8' 2x4s at the correct angle (4 rafters) and cut 2 2x4s and a 2x6 to the lenth I want the roof to be. The 2x6 will be the ridge beam and the 2x4s will be the wall caps. I am only using 2 sets of rafters on each side since I don't plan on walking on it. I figure a 40" span isn't so bad and if need be, I can add another later. I am also wanting to watch the weight to some degree. I attached the 2x4 rafters to the ridge beam and figured out the angle to notch the rafters for the wall caps. Basically, I put the wall cap under the rafters on each side, centered the roof on them, then used a scrap 2x4 to trace the angle. I then took each one off and cut the notch in them. I'm sure there is an easier way, but it worked and kept me busy
. Here is a picture of the roof on the bottom half of the prop. I have it laying down since it is more stable that way for now.
So, now we are at today. For the roof, I "was" going to cut up some fence pickets I had for making a fence picket coffin. I made 1 last year and never got to making the second, and figured for now, 1 coffin was enough. After researching doing a cedar shingle style roof, I figured it would be too heavy and too cumbersome by time I was done. If I was working, I likely would have actually purchased cedar shingles and done it with those since they are lighter and thinner. Ultimately, what I decided to do was just lay the pickets horizontally and over lap them (like a dog house). It is working out great. I'm not 100% sure they will stay waterproof, but for now its looking pretty good. I don't have any underlayment under the roof, and I'm not sure I will ever put any. I'll see how well it holds up. It is still rainy season here (raining every day) so It will get a good test. I did run out of the stuff I had just lying around, so I will have to run to home depot and get about 5-7 more to finish it and add a ridge cap. here is a picture of the 1 side almost complete covered. I got about half way up the other side as well.
Next I need to get more fence pickets for the roof. Once that is done, I will trim the roof to size with a circular saw. I figured it was going to be easier to do it that way then try and cut them all to length beforehand. I will also add fascia boards around it with some of the culled wood I bought.
For the main part, I plan to add some bracing to it to keep it fairly in square and to limit it's twisting in the wind. I am going to add as much bracing as I feel I need to keep it from falling over. I may even put posts in the ground to attach it to temporarily. Might be overkill, but I don't want to hurt any of my family of any TOTs due it falling over. I am contemplating actually putting on "siding" like is on the roof up the outsides. The reason for this is that I'm considering doing some stuff on the inside that I think will look cool. I feel like the pallets themselves look like plaster lathe. I figured i could use that to my advantage. You'll notice I have the walls backwards for this. I realized this AFTER I added the bracing to the top. It's not a huge deal to fix it, but i'm not gonna reverse it until I know for sure I'm gonna do it. Another idea I have is to put a picture hanging in there, with the eyes cut out and a phone behind it with one of those morph digital dudz videos playing. Just some ideas, not 100% sure what i"l do.
I'm not sure I will do the siding on the outside yet. cost is a main factor, and weight. I do want to use this to store stuff after I move it back to behind my shed, but I think that I could just buy a tarp and "wrap" it. I do plan on adding siding to the peaks of the roof, so that should keep most the water out and sun in combination with the tarp. I also like that I can likely just add a 3rd wall with siding (or a few more pallets stripped down) and put it somewhere else in my yard as a shed or out house. I have a feeling that it might have a different purpose each year.
I hope at least one person finds this useful. I am a programmer by trade, but I love to get out and build stuff. I don't care what it is. Some of this is overkill, but I like the challenge on figuring out how to do it (like making a proper roof, well, as proper as I needed it to be..LOL). I am open to any suggestions of any kind. I am also just open to any general conversation on the project. I am interviewing for jobs a few days a week, and have a 5wk old baby (and a 21 month old, and a 6y/o, and a 16y/o), so I am only getting to work on it when I can. I hope to have it finished and in place in the next week or 2.