On Friday afternoon, after FB arrived, we managed to finish placing the remaining two corner posts (using the manual post hole digger thank you very much). Then on Saturday morning we started to build the first level walls of the shed. I used a method based on a site I found online since these were the most detailed instructions I could find. http://www.oklahomahistory.net/palletshed.html
We started by attaching three pallets together using long bolts and washers. Pallets are made of varied types of wood but the "skids" (the three solid pieces you see running length wise) are always made of oak. This is where you want to drill holes and attach the bolts. You need a real drill for this, not a cordless (laughably wimpy against oak) so if you didn't inherit an industrial one from your Grandpa be prepared to buy or borrow one. Drilling the holes, believe it or not, is the hardest part. Oak is like a rock.
We started by attaching three pallets together using long bolts and washers. Pallets are made of varied types of wood but the "skids" (the three solid pieces you see running length wise) are always made of oak. This is where you want to drill holes and attach the bolts. You need a real drill for this, not a cordless (laughably wimpy against oak) so if you didn't inherit an industrial one from your Grandpa be prepared to buy or borrow one. Drilling the holes, believe it or not, is the hardest part. Oak is like a rock.
Then you lift the entire "wall" and mount it to your corner posts (we used pressure treated 4X4's). The site I used as a reference doesn't use corner posts, he anchored his to the ground using rebar but the corner posts make the walls more solid and a lot easier to attach.
It took us most of the day on Saturday to get the first level walls built and attached to the frame. By then we were all burned out (literally) and decided to finish the next day since the heat was taking a toll. The first level is where you learn the most - meaning you make the most mistakes - so it takes a bit longer.
On Sunday we attached the second level. Bro and I debated whether or not to attach one pallet at a time or follow the instructions and attempt to connect as one wall unit. For the record, these suckers are heavy! I've got ample girl power going on but lifting this whole wall above my head was testing my confidence a little. We finally devised a plan to use the truck as a scaffolding, lift the wall onto the back of the truck, stand inside the truck bed and lift it the rest of the way. It worked like a charm. By the time we were attaching the last wall, it started to pour down rain. We decided to break for lunch at this point.
Then the rain stopped and we hurried to complete the frame for the roof. This also required standing on top of the truck because the highest slope of the roof is 10 feet high and using a drill on a ladder - eh, not so easy. By the end of Sunday, the entire frame was complete. We have a two foot pitch from front to back to allow water and snow run off.
Then it was time for Fearless Bro to return home. He left us with his trusty cordless drill since the hardest part requiring "manly" strength is done. We still need to complete the roof, the siding and build a door frame. Then we plan to build customized tool shelves using the leftover pallets. So we still have a ways to go before completion but I'm pretty pleased with the structure we have so far.
Stay tuned!
Stay tuned!