Building A Garden Storage Shed

Project:
Building a garden storage shed to store all the pool stuff during the winter

Difficulty Level (Easy, Medium, Hard, Insane):
Medium

Process:
We bought a 9' x 17' x 5' pool but since our kids are still a bit too small, we decided not to put it up this year but instead use our cheapo 12' round (2' deep) walmart pool for one more year. Running out of place to store our stuff and considering how many parts came with the new pool I decided to build a 3' by 8' garden shed right beside the area we'll be setting up the pool.

The process was pretty simple:

1. Prepare the site by stripping the sod and putting a 4" layer of gravel
2. Build the base with pressure treated 2x4s and a 3/4" OSB floor
3. Build the walls with 2x2s and 1/2" OSB sheathing
4. Build the roof with 2x4s and 1/2" OSB sheathing
5. Installing the trim around the roof edge
6. Installing the drip edge around the roof edge
7. Installing the tar paper & roof shingles
8. Installing the siding
9. Fitting and installing the doors
10. Installing the door hardware
11. Build the shelves
12. Paint the exterior

Videos:

Pictures:

The lumber from home depot

Marking the site

Getting my boy to help me clean up the removed sod

Another view

Ready for the gravel

After the gravel base was laid

The base in its place

Framing the rear wall

Cutting up 2x2s

Sheathing the rear wall

Framing the side walls

Framing the front wall

Sheathing the front wall

Installing the roof

After the roof was sheathed

Installing Tyvek house wrap

The house wrap done

The tongue & groove boards used for siding

After the roof shingles were installed

Installing the wood siding

The siding almost done

Another view

The siding (minus the doors) done

Framing the doors

The siding and doors done

Close-up of the doors

After the shed was painted

Rear view of the shed before it was moved

Another view of the painted shed after it was moved against the fence

Both doors open

Another view

Close-up of the finished shed

From a bit further away

A view from the deck

Tools:
Table saw
Chop saw
Measuring tape & pencil
Framers square
Poly square
Level
Pickax
Garden rake
Shovel
Wheel barrow
Air compressor
Framing nail gun
Staple gun
Hand stapler
Knife
Crow bar
Hammer
Cordless drill
Extension chords
Saw horses
Pipe clamps
Roofing nail gun
Tin snips
Hand planer
Circular saw
Yard wagon
Ladder
HLVP paint gun

Materials:
7 - 4x8 - 1/2" OSB
2 - 4x8 - 1/2" OSB
2 - 2x4 - 8' PT
2 - 2x4 - 12' PT
10 - 2x4 - 8'
4 - 2x4 - 12'
Narrow crown staples 1-1/4"
3-1/4" galvanized framing nails
3-1/4" regular framing nails
2-3/8" galvanized framing nails
2-3/8" regular framing nails
1/2 roll of roofing nails
1 pack of shingles
80 - 1x6 - 8' tongue & groove boards for siding
4 hinges
2 door latches
1-1/4" deck screws
2" deck screws
3" deck screws
1 gal of deck stain

Cost:
$550.00

Time:
30 hrs

Savings:
$450.00

Conclusion:
Although it looks great and is very solid and quite a bit cheaper than a cheapo home depot or Canadian Tire garden shed, I'd probably buy the next one instead of making it as I don't really enjoy building these kinds of things anymore and it took a LOT longer than I anticipated.

Arbor for Burke #4 Horizontal Mill

Project:
Making a new arbor used on a #4 Burke horizontal mill

Difficulty Level (Easy, Medium, Hard, Insane):
Medium

Process:
I got a call from the same gentleman whom I made the Replacement Gear for 1974 Okuma Lathe for saying he had bought a #4 Burke horizontal mill but that the arbor was badly damaged and whether I could make him a new one.

The process was pretty simple:

1. Cut up a piece of 1.500" 4140 on my Metal Band Saw and chucked it up in my lathe
2. Center drilled both ends and mounted between centers
3. Turn shaft down to 1.250"
4. Turn 7.750" from the tail stock end down to 1.002" diameter and sand/polish down to 0.999"
5. Turn 2.375" from the tail stock end down to 5/8" and thread at 18TPI
6. Turn 1.750" from the tail stock down to 0.502" and sand/polish to 0.500"
7. Flip shaft around and put a B&S #9 taper (4.250" long, 0.800" on small end, 1.072" on large end" using the Digital Calipers Mounted on the Tail Stock
8. Sand/polish taper
9. Drill, bore and thread a 1/2" x 13 TPI internal thread for the draw bar
10. Mount arbor in milling vise and cut a 3/16" key way

I was glad to have the Cool Mist System for the heavier turning because 4140 work hardens pretty quickly so I was able to keep the temperature fairly cool. However, I did learn something the hard way. When using a slitting saw to cut a keyway on a shaft, cooling alone is not sufficient. I had the cool mist system spray (plain) water on the slitting saw and it worked great for about 60% of the length of the keyway but then something happened and it completely chewed up the teeth on my slitting saw. After spending a good hour sharpening the HSS slitting saw I decided to skip the cool mist but go back to the regular cutting oil and lo and behold, it worked like a charm. So, I will definitely go buy some water soluble cutting fluid designed for cutting to hopefully avoid that the next time.

Videos:

 
Pictures:

The old arbor

Close-up of the damaged arbor and thread

The B&S #9 taper with a 1/2" x 13TPI draw bar internal thread

Cutting off 13.250" of 4140 bar on my metal band saw

Doing some rough turning to get rid of the rust

Mounting between centers and turning the shaft to 1.250"

Using my mist coolant to keep the work piece cool

Another view of the mist coolant system (temporary setup)

The polished shaft

The shoulder which the cutter and/or spacers rest against

Getting ready to thread a 5/8" x 18 TPI

The threading setup

Chamfering the sharp edges

Cutting the taper end

The extension for my diy lathe dog

Another view of the lathe dog

The digital calipers mounted on the tail stock for easy resetting to zero

A different angle of when I was cutting the taper

The finished and sanded taper

Using the cool mist system for drilling the hole for the draw bar

Tapping the 1/2" x 13 TPI internal draw bar thread in the taper end

Another view

Close-up of the threaded hole

Dialing in the slitting saw

Dialing in the shaft

Another view

Cutting the 3/16" keyway

Another view

The old and new arbors side by side

Another view

Another view

Another view

The finished arbor

Another view

Close-up of the taper end

Close-up of the cutter end

Another view

Close-up of the keyway

Diagram with measurements

Tools:
Metal lathe & accessories
Metal Band Saw
Mist Coolant System
Digital Caliper Setup on tail stock
Emery cloth
Tap & die set

Materials:
13.250" of 1.500" diameter 4140

Time:
8 hrs

Conclusion:
Looks beautiful; I love my lathe!