Ash

How to Install an Exhaust Vent Fan in Your Workspace

January 11, 2017 by Ash 24 Comments

I’ve had garage ventilation on my mind for some time now. Between Eileen and I always doing projects in the garage, we produce a lot of fumes from painting and staining.

Cutting wood in there also throws a lot of sawdust into the air. Even when I work on the mower and other small engines in there, the smell of gasoline lingers.

On nice days when it’s not raining, we leave the garage door open and sometimes even put a fan to help exhaust the air.

However, this was not the ideal solution.

Many painting and staining projects would sit in the garage overnight filling the air with fumes, just to be aired out when the sun came up and when we can open the garage doors.

Aside from the noxious odors sitting in the garage the next morning, it would also delay the completion of these projects.

A better solution had to be devised for garage ventilation.

To add to the pressure, I recently acquired a snow blower for the upcoming winter snow storms, and that was bound to leave the garage filled with gasoline odors after usage. Even more reason to look into garage ventilation systems.

Garage Vent Fan

So I put my thinking cap on and wandered around the garage looking for ventilation ideas.

I knew I wanted to set up some type of fan that would exhaust the air, so I was looking for areas in the garage that would be an ideal location.

In my previous home, I used to run a lot of computer equipment in the garage that would produce a lot of heat. I had researched garage venting options back then and settled on a small fan and vent that could be installed directly in the garage door (via a small hole that you cut).

This solved my problem of exhausting the heat, but had an unfortunate side effect. During the winter, the garage door vent would let all the cold air in and drop the garage temperature below the freezing point, wreaking havoc on my paints and other liquids that were not meant to be frozen.

The garage door vents and exhaust option left a bad taste in my mouth ever since, and I was determined not to pursue that direction again. Also, to properly exhaust the size of my current garage, I would need a much larger fan and hole to make the job worthwhile.

Making a Plan for Ventilating the Garage

I finally settled on a way of venting the garage. I would find an ideal venting location in the garage, and cut a large square hole in the wall (roughly 14”x14” in between the wall studs).

Then I would install self-closing shutter vents on both the interior and exterior of the wall. Finally, on the inside, I would install a powerful exhaust fan to ventilate the garage. The double shutter vents were going to be key in helping to keep the cold air outside during the winter.

I did a lot of research on exhaust fans and decided on one with built-in shutters. I purchased a 14” diameter fan capable of 800 CFM.

No wiring was needed with this particular model because it just plugs into an outlet. I already had a wireless switch ready for it too, so I could activate it from the other side of the garage. For the exterior wall, I went a 14” aluminum shutter vent.

With the hardware identified, I looked for an ideal location for the vent. The best location would have been above one of the garage doors, but for aesthetics, I didn’t want the vent to be visible from the street.

So I went with a wall that faced the rear of the house. It would be practically invisible but still serve its purpose.

Here’s the location I chose inside for the garage exhaust fan:

Here’s where the vent would exhaust outside:

Preparing to Install the Garage Exhaust Vent

Above, you’ll see the first layer I went through was the drywall. Then I had 2 layers of insulating foam.

Next was the white vinyl siding. I left this intact for now while I awaited shipment of the exterior vent.

The cutout got a little rough at some of the edges, but it was not a big deal. The fan would cover all the edges, and hide any irregularities in my cut.

Next, I had to seal the top and bottom edges of the hole.

This was a necessary step to prevent the fan from venting air into the wall. I simply cut two pieces of 2x4s, inserted them in the top and bottom, and attached to the wall studs using some pocket hole screws (with the help of my Kreg Pocket Hole jig).

I put temporary hooks into the 2x4s to make it easier to maneuver them.

Here’s one of the 2x4s ready to be inserted:

Here’s a picture of the bottom of the hole, sealed in with the 2×4:

Next I inserted the exhaust fan to make sure it fit properly:

A few days later, the exterior shutter vent arrived and I resumed work on the project.

Constructing a J Channel Frame

Cutting a hole through the wall meant that I had to be careful to make the exterior side water proof. I couldn’t just cut a hole in the siding, insert the vent, and call it a day.

To keep water from penetrating the siding, I needed to use J channel. This would allow me to create a frame around the vent that would overlap the siding and shield the rough cut edges from water.

Here is a picture showing 4 pieces of J channel cut to make the vent frame:

This was actually my first time working with J channel, so I had to do some research online to see how to make the cuts on the ends (important to prevent water from seeping in).

I followed some great instructions on FamilyHandyMan.com (under the section “Install J-channel around the window”).

Here’s a picture showing the assembled J channel pieces wrapping around the vent:

Preparing the Siding for the Exhaust Fan

Now came the fun task of working with the siding.

To properly install the exterior vent, I needed access to the wall underneath the siding, which meant removing several pieces of siding. This was a learning process as I went along (I did all my research, so I was confident in the task at hand).

With the help of a siding removal tool, I was able to easily detach some siding, and pull it away from the wall.

With enough of the siding out of the way, I was able to continue work on the hole.

To help with the waterproofing, I used some flashing tape (left over from my shed project) to seal in the edges of the hole.

Here’s a picture showing the flashing tape in action:

In the event that water did make its way through the siding, the flashing tape would ensure that the water couldn’t seep behind the exposed edges of the foam insulation.

Installing the Garage Vent

Next, I inserted the shutter vent and nailed it in the wall studs. Here’s a picture showing some progress:

With the garage vent in place, I attached the J channel frame, overlapping the rough cut edges of the vinyl siding.

Here’s a close-up showing the finished outside wall with J channel:

Looks very professional, doesn’t it? It should be very water tight too.

Here’s a picture showing the vent from the inside:

Installing the Exhaust Fan

I was nearing the end of the project of putting vents in the garage. I inserted the exhaust fan in the hole and was getting ready to screw it into the studs.

Then, I decided to check the vents on the fan to make sure they opened and closed properly.

They opened fine. Unfortunately, they had trouble closing.

They would stick on the way down and not close all the way. This was bothersome because a partially open vent meant cold drafts coming in.

After some fiddling, I discovered that the hole I cut was too snug of a fit for the fan frame.

It was distorting the frame ever so slightly to cause the shutters to not close properly. If I pulled the fan about 2 inches out from the wall, the shutters worked fine.

So the solution was simple.

Making a Framed Wooden Spacer for the Garage Wall Exhaust Fan

I would built a 2×4 wooden frame between the wall and the fan, to give the exhaust fan enough distance from the hole for the shutters to operate properly.

I literally spent only 10 minutes on this task – I chopped some 2x4s to length with the miter saw.

Then I attached them to each other with pocket hole screws to form a frame.

Finally, I used some lag bolts (countersunk with a forstner bit) to attach the frame to the wall studs.

Here’s a picture of the garage wall exhaust fan frame (the pocket holes are hidden on the other side):

At last, the exhaust fan could be bolted to the wall.

I pressed the fan against the 2×4 frame and made sure the shutters opened and closed freely. Then I attached the fan to the 2x4s with some heavy duty screws.

My garage vent was now completed. I stood back, admired my handiwork and then fired up the exhaust fan with my wireless switch.

As the fan speed increased to full, both the inside and outside shutters opened to exhaust the garage. The fan was not that loud either (it was barely audible outside the garage).

Here’s a picture of the mounted garage wall exhaust fan (powered on) from the inside:

Here’s a picture of the outside of the garage wall exhaust fan, showing the vents open with the fan on:

I’m very excited about our new garage exhaust fan. I already used it this past weekend with great success.

We had a mild snow shower (about 4 inches), and so I broke out the snowblower to try it out.

As predicted, when I finished clearing out the snow from the driveway, and put away the snowblower in the garage, the still warm engine started to stink up the garage.

I engaged the new exhaust fan for a few hours, and the garage was back to normal.

I can’t wait to see what the fan does when the garage is full of sawdust in the air.

Total cost of putting the vent fan in the garage was around $150 and was collectively about a day’s worth of work.

If you are in need of exhaust fans in the garage, this tutorial will have your new garage wall exhaust fan up and running in no time!

Garage Vent Fan Update – Two Years Later

I was really pleased with the garage vent fan. It runs great and really airs the garage out nicely.

However, I did add on more thing to our garage vent fan.

I had been manually turning the fan on and off as needed. Sometimes I left it running longer than I anticipated.

So I wanted a better system of turning the fan off. I ended up purchasing an electronic timer switch and plugged the fan into it.

Now, I just press a button for how long I’d like the fan to run for and it runs for just that duration.

Learn how to properly ventilate your garage by installing a simple exhaust vent fan.

How to Fix Up Your Old Snowblower

December 17, 2016 by Ash 2 Comments

Having spent most of my life in warmer climates, I was 15 years old when I first saw snow.

I was captivated by it. I loved being out in the snow, playing snow sports, and even shoveling. To this day, I still love snow.

I’ve always wanted a snowblower, but we’ve never had a strong need.

After moving into our new house with a massive driveway, the snow last winter was too much. After a major storm, my neighbor lent me his snowblower, and I was enthralled.

It was so much fun to use, and even though I enjoy a good shoveling workout, it freed up a lot of time to play with my son in the snow.

So I was determined to get my own snowblower for next winter.

Purchasing an Old Snowblower

I started my snowblower search early fall. My goal was to find a good machine without spending a lot – even if it meant fixing an old snowblower.

I already had a lot of experience maintaining my mower – a 20-year old Craftsman riding lawn mower.

From simple engine oil changes to fuel pump replacements to carburetor rebuilds, I have the old riding lawn mower running like new.

So, I decided to look for a used snowblower.

Due to my experience with the Craftsman brand, I know that their replacement parts are plentiful and cheap online.

They also provide manuals and parts diagrams for almost every model equipment they make (just enter the model number on SearsPartsDirect.com).

I found an amazing deal – $125 for a Craftsman 5HP two stage snowblower with an electric start. Comparable ones were selling used for around $275.

For such a low price, I knew the old craftsman snowblower wasn’t going to be in perfect condition, so I kept my expectations low.

Inspecting the Used Snowblower

Upon my inspection, the snowblower was missing the pull cord for manual startup, and the carburetor would leak fuel every now and then.

It was also missing the control knob for the choke.

The guy selling it said the old craftsman snowblower would start making surging sounds after some time, until you fiddled with the carburetor fuel release screws.

He started it up though and it ran great.

I checked out all the forward/reverse gears. I inspected the impeller to make sure it was in good shape. The auger had no structural damage.

I was excited. For around $40 more in parts, I could get this old snowblower in top shape.

I happily accepted the offer of $125 and loaded the used craftsman into my SUV, with plans on fixing up the old snowblower.

I had brought along a pair of ramps I made a few weeks ago with two 2×8 wood planks and ramp supports.

This helped me load the used snowblower in the back of the car.

I did have to take out a few screws to fold the push handle in half to fit properly though.

I also wrapped the carburetor in a plastic bag to catch any fuel that was leaking (didn’t need the car smelling like gas for days).

Here’s a picture of my used snowblower before fixing it up:

Ordering Snowblower Replacement Parts

When I got home, I grabbed the snowblower model number off the back and went online to order some parts:

Based on my assessment of the machine, I put through an order for the following parts:

Carburetor
Pull starter rope and handle
Knob for choke
Spark plug

The price for the snowblower parts came up around $40 as I predicted. I considered rebuilding the carburetor (the leaking was probably from a deteriorated rubber seal), but new carburetors for this model were so cheap (around $15).

I actually just replaced my neighbor’s snowblower carburetor with the exact same one a few weeks ago too.

Fixing an Old Snow Blower

All my parts for the craftsman snowblower came about a week later and I went to work restoring the machine to tip-top shape. Below is a walk-through of what I did. Hopefully these craftsman snowblower maintenance tips can help you too.

Disconnecting the Craftsman Carburetor

I located the craftsman snowblower carburetor housing:

Then, I removed the housing to expose the snowblower carburetor:

I disconnected the yellow priming hose seen above (used to pump air from the priming bulb into the carburetor to force fuel out for a cold start), followed by the main fuel hose below:

It was important to clamp off the main fuel hose or fuel would immediately pour out once disconnected.

I used a vice grip, taking care not to squeeze so tightly that the hose would get damaged.

Fuel hoses are sometimes tough to disconnect, so I used special curved nose pliers to grip the hose and twist:

I had a plastic cup underneath the hose while disconnecting it, in case my vice grip clamp didn’t do a good job.

A word to the wise however – don’t use cheap plastic cups to hold gasoline. I didn’t think it was a big deal because I used a plastic cup the other day to catch some excess gas from my neighbor’s snowblower carburetor.

However, this time, a few minutes after collecting some gas, I noticed a small puddle on the garage floor.

Apparently the gasoline had eaten through my plastic cup!

I looked it up online, and discovered that some plastic cups are not friendly to gasoline. Most likely my plastic cup this time was made from a corn based product, which would be dissolved by the gasoline.

Next, I unhooked a metal link wire connecting the throttle control lever to the carburetor, and attempted to remove two bolts holding the carburetor to the engine block.

Removing the Snowblower Carburetor

The bolts were on extremely tight and I could not remove with a screw driver. The screw heads actually started stripping.

So, I brought out my impact drill and it did the job with ease:

Here’s a picture of the removed craftsman carburetor:

The removed piece actually consisted of more than just the core carburetor, so I had to strip it down to extract the carburetor (seen in the center of the picture below):

The piece on the right is called the intake pipe and connects the carburetor to the engine block.

Unfortunately, when I pulled it off the snowblower engine, a gasket in between the two ripped from old age.

My new carburetor didn’t come with this gasket (since it’s not technically part of the carburetor), so I had to order a replacement.

This meant I had to wait a few days to actually fire up the machine with the new carburetor. I could still proceed with the installation though, and just insert the gasket when it arrived.

Here’s a picture showing where the gasket would go on the snowblower:

To install the new carburetor, I just reversed the steps above with the new piece. I loosely connected it back to the engine block, awaiting the gasket for completion.

Spark Plug and Starter Cord

Next I replaced the snowblower spark plug:

After, I proceeded to fix the snowblower pull cord for starting it up. The original rope most likely broke from old age.

Here’s where the fix was to be done:

Here’s a picture showing the new pull starter rope and handle to be installed:

And, here’s the snowblower pull cord housing removed showing the old frayed rope:

I simply removed old pull cord and threaded in the new pull started cord, coiling it around the starter. Here’s a picture showing the repaired starter rope:

The snowblower pull cord remained secured to the starter and handle with knots on both ends.

To keep the knots from undoing, I used a lighter to melt the end of the polyester rope slightly (also a necessary step when cutting polyester rope to keep the ends from fraying):

When the intake pipe gasket arrived in the mail a few days later, I resumed work on the snow blower. I installed the gasket and secured the carburetor tightly to the engine block.

The craftsman snowblower was ready to be fired up. I rolled it outside and hooked up an extension cord for the electric start.The engine started up right away with the new carburetor and there were no more leaks. I also tested the snowblower’s pull starter with the new rope. The engine started up just as easily as the electric start.

Snowblower Engine Oil

Next I was going to change the snowblower engine oil. I let the engine run for a few minutes to warm up the engine oil (warm oil flows more freely when draining it).

Then I shut it off and proceeded with the oil change.

After remove the oil dip stick, I used a small funnel with a hose and an oil storage reservoir and drained the warm oil:

After all the snowblower’s engine oil was drained, I closed back the drain port and began filling 5W-30 motor oil into the dipstick hole:

While filling the engine oil, I took breaks regularly to check the level with the dipstick.

I learned the hard way that when you overfill the snowblower engine with oil that it’s going to come out of the engine one way or another, and not in a nice way.

Final Craftsman Snowblower Maintenance Tips

The craftsman snowblower revamp was nearly done. I replaced the missing choke knob. Also, the carburetor housing was vibrating excessively due so some missing screws, producing a lot of noise with the engine running. I dug through my garage screw collection until I found a fit.

Finally, as my final step in fixing up the old craftsman snow blower, I applied some non-stick ice and snow coating to the auger blades and impeller chute. This prepared the snow blower for the upcoming winter season.

This would greatly help prevent the snowblower chute from clogging up during use, and allow the augers to cut through the snow like butter.

Here’s the snowblower non stick spray:

In total, I spent around $165 on purchasing and fixing an old snow blower ($125 to purchase and $40 in parts) and put in less than 3 hours of work to get it in prime condition.

I’m eagerly looking forward to this upcoming winter and the next major snowstorm so I can use my new but used craftsman snowblower that’s running great.

Transforming a Kitchen Desk into Cabinet Space

November 30, 2016 by Ash 62 Comments

Over the course of living in our new home for a couple of years, we remedied our dated kitchen by refinishing our kitchen cabinets with gel stain, installing a natural stone backsplash, and purchasing stainless steel appliances (via some Black Friday discounts).

There still remained though, an odd looking corner next to the fridge. It was a desk area, with a floating cabinet drawer to allow space for a chair – and no cabinet storage underneath.

The previous owners of our house had used it as a kitchen desk with a chair.

Not only was it an inefficient use of space (the kitchen already had limited cabinet storage), but the protruding corner edge posed a risk to our young toddler, who was just about the same height.

Granted we could have put bumpers on it, but why not kill two birds with one stone and box in the empty space below the drawer, converting it into a normal cabinet for storage.

This would eliminate the dangerous corner edge and also turn the wasteful space into something usable.

It was settled – we would convert our awkward kitchen desk into cabinet space.

Here’s a picture taken from further away, showing the floating drawer to the right of the fridge. This picture was taken prior to the gel stain, backsplash, and new appliances.

Planning the New Cabinet

With our idea to convert the kitchen desk into cabinet space, I gathered the dimensions of the empty space and went to work in TinkerCad. Here is the design I came up with:

While playing around with the design, I originally omitted the toe kick (the recessed part at the front bottom). I didn’t think it was necessary and would have simplified the build a bit.

However, after Eileen and I discussed it more (and researched online about it), I decided to add it in. I never thought about it before, but that toe kick area is actually an ergonomic feature.

Without an area to insert your feet, getting up close to the cabinet (especially to reach the taller shelves) would put a lot of extra strain on your back to lean forward. The toe kick allows you to get up really close without leaning forward too much more.

Ordering & Preparing the Cabinet Doors

I planned on purchasing pre-made cabinet doors to match the rest of the kitchen. I lacked the tools necessary to create professionally routed cabinet doors from scratch, so ordering them online was the best option.

There were many styles available online, but they all seemed to fall into roughly the same categories across different vendors. The style that matched our other cabinet doors the most was a Cathedral style, with routed arch in the middle top of the door.

The doors were small (around 10” x 30”), so it was pretty cheap to order just two of them. I spent around $70 and they arrived in about 2 weeks (I got the best deal from Fast Cabinet Doors but there are lots of other sites to get custom doors from).

The doors came unfinished, so I had to stain and polyurethane them myself. I also got the same cabinet handles used in the rest of the kitchen for the new doors.

Here is a picture of the finished cabinet door with handle:

Constructing the Cabinet Box

The actual construction of the cabinet box was fairly straight forward. I just followed the design and measurements in the TinkerCAD drawing.

I used mostly ¾” sanded plywood for the surfaces. For the door openings, I used my compact circular saw with a clamped down piece of scrap wood for a guide. I used my jigsaw at the corners to make flush cuts.

The back left corner of the cabinet box has a piece of 4×4 serving as a leg to help support the bottom shelf.

I attached the plywood pieces to each other with small wood screws and construction adhesive. The outside facing screws were countersunk and were to be covered up with wood putty later and sanded to a smooth finish.

Finally, I used several small L brackets in strategic places to help provide additional structural support (like underneath the bottom shelf, and above the right door opening).

Once the cabinet box was complete, I placed it underneath the kitchen drawer for a fitting.

Staining the Cabinet Box to Match the Kitchen

After a successful trial fit, back into the garage it went for a final sanding before the stain went on. I used the General Finishes Gel Stain in Antique Walnut stain to match the rest of the kitchen cabinets.

We had recently just re-stained the whole kitchen, so had plenty left over to finish this new kitchen desk into cabinet project.

It took about 3 coats of the gel stain, and then 2 coats of polyurethane to get the box ready for the kitchen.

Eileen was worried about the color of this new cabinet matching the rest of the kitchen, as the gel stain was going directly on bare wood – versus the gel stain going on top of already stained wood.

The match was almost perfect.

If you look very closely, you will notice that the cabinet looks a little shinier than the rest of the kitchen; however, it’s an almost perfect match.

Attaching the New Kitchen Cabinet

Once ready, I put it back in place under the kitchen drawer and prepared the area for a permanent addition.

I first used my oscillating multi tool to remove a portion of the baseboard so the cabinet box could sit flush with the wall.

Then I attached two pieces of 2 x 4 to some wall studs directly beneath the kitchen drawer. I used these to secure the back right edge of the new cabinet box.

Using some L brackets, the front left edge of the cabinet box was screwed directly into an existing piece of wood (being used to help support the shelf).

The cabinet box was now firmly attached to the kitchen.

Final Touches

There were a few gaps and a slightly noticeable line where the new cabinet box met the existing kitchen drawer. So I sanded the wood down slightly at the gap (to remove the polyurethane) and filled with wood putty.

Once dried, I sanded down the putty to a smooth finish, stained it and re-applied the polyurethane. The line disappeared and the cabinet box transitioned into the drawer very nicely now

Here is a picture of the final product:

Additional Interior Shelving

After installation, I added a second shelf inside the cabinet to accommodate even more kitchen storage.

Here is what the inside of the kitchen cabinet looks like:

For under $100, this kitchen desk into cabinet project was well worth the effort. Although it take several days to complete due to the drying times for the stain and polyurethane, it was really only a few hours of work collectively.

The cabinet box blends in so well with the kitchen that we forgot it used to be a desk. The kitchen cabinet is huge and was such a great bonus in our small kitchen. We couldn’t be happier than we transformed that awkward kitchen desk into cabinet space.

How to Build Floor-To-Ceiling Bookshelves (With a Window Seat)

November 22, 2016 by Ash 78 Comments

How to Build Floor-To-Ceiling Bookshelves (With a Window Seat) Post Preview: Learn how to make built-in bookshelves with a window seat and cabinets below. The tutorial is simple-to-follow, and the bookshelves turn out beautiful.

Ever since building my first bookshelf in our first home, I’ve had a hankering ever since to do another one but on a much more grand scale.

My wish came true when Eileen came to me one day with some ideas for her office in our new home. An exciting project was brewing!

Since we didn’t have any large bookshelves in our present home, most of the books we packed up during our move were still in boxes. I’m talking cartons and cartons of books.

They were taking up a lot of valuable space in various locations around the house. So bookshelves were sorely needed.

Initially we were leaning towards a large L-shaped bookshelf in the office. Then Eileen had a great idea of placing the bookshelf against the window wall and incorporating a window seat.

The office window wall was very bland and not very exciting to look at. It was almost begging for a renovation.

Although it would provide a little less shelf storage than our initial L-shaped shelf idea, it would still be more than enough for all our books.

Also, the window seat would provide a little extra underneath cabinet storage, which is a pretty cool feature.

Planning the Built-In Bookshelves with a Window Seat

The project was essentially going to be two separate built-in bookshelves (on each side of the window) with a seat connecting the two in the middle. The seat would be sitting atop some wide kitchen cabinets for extra storage.

Above the window was just enough space for a single small shelf to store decorative items or horizontal books. Finally, some baseboard would run along the bottom, and some crown molding at the top.

Some designs I saw online used a standard shelf depth (around 12”) with the seat extending out further.

Eileen didn’t want a protruding edge, and she has the eye for design. So to prevent this, the depth of the seat had to be the same as the bookshelves.

Due to a closet opening on a perpendicular wall, I was restricted to a maximum depth of 15”. I was a little worried that this would not be enough depth to sit comfortably on, but a few trial sittings on 15” planks of wood proved to be acceptable.

This also meant deeper than normal shelves, but I wasn’t too concerned. I’m sure any extra space behind some books could be put to good use.

As with most of my projects, I started off in TinkerCad to sketch out a 3D design of what was floating around in my head. I came up with the following:

Determining Materials

With the design for built-in bookshelves flushed out, I was ready to begin.

I strongly considered using melamine covered particle board for the shelves, but instead opted for some good quality birch plywood.

Although the birch was a little more expensive, I wasn’t comfortable embarking on a project this size using melamine – a material I have never really worked with before.

Also I wanted to use a stronger material than melamine covered particleboard.

Next, I used a drawing program on my computer (Photoshop) to calculate the minimum number of 4 x 8 sheets of plywood needed to cut out all the required bookshelf pieces.

I then placed a Home Depot delivery order for all the bookshelf lumber (including some 2 x 4s and 2 x 6s for various segments in the design, baseboard, and crown molding for the trim and some miscellaneous hardware).

Here is the diagram I made in Photoshop to calculate the number of 4 x 8 plywood sheets needed:

Constructing the Built-In Bookshelves

When the bookshelf wood arrived, I quickly cut the plywood sheets into 15” wide strips using my circular saw and stored them for use shortly.

With all the materials on hand, I started the project.

Removing Carpeting

The first step was to remove the carpeting where the bookshelf would rest.

For a flat platform to build on, it needed to sit directly on the floor plywood sheathing. I accomplished this with the help of my utility knife and a metal ruler to help guide the cuts.

Then I removed some existing baseboard trim so the bookshelf could sit flush against the wall. The use of my oscillating multi tool helped out here to remove just enough baseboard, leaving the rest intact, so that the bookshelf would seamlessly blend in.

Here’s a picture showing me making progress on prepping the floor. I had to be extra careful removing the carpet tacking strips at the edges, as they were riddled with rusty looking nails:

Building the Foundation

Once all the bare plywood flooring was exposed and baseboard removed, I started work on the foundation for the two end bookshelf segments.

They would rest directly on the bare floor. I assembled the frames from 2 x 6 wood.

Here’s a picture of the completed frames:

While constructing the frames in the garage, the corners needed to be very square.

I didn’t have a 90 degree clamp at the time to assist, so using a scrap piece of 2 x 4 and two handy bar clamps, I got creative.

As seen in the picture below, I was able to lock in place two perpendicular pieces of wood allowing me to fasten them accurately with screws:

Here’s a picture of one of the frames in position resting on the bare floor (notice how I carved some grooves underneath to allow a coaxial cable to run through):

Relocating the Air Vent

I left the middle foundation frame (that the seat would rest on) for last as it would be a little trickier than the others.

There was a central air vent on the floor where this middle frame was going to sit, and so I had to redirect the airflow. After brainstorming various ideas on accomplishing this task,

I settled on a very simple yet effective method. I was just going to build a wooden duct into the foundation frame, and seal the inside edges with caulk to make it air tight.

Here is a picture of the end result (a louvred vent would be inserted into the front hole, which I cut out with my trusty jigsaw):

Here’s a picture after I caulked the wooden duct:

Securing the Foundation Frames to the Wall

Once the foundation frames were complete, I secured them in place. I used some lag bolts to attach the rear of the frames to some wall studs.

Then I used some L brackets to secure the front to the plywood flooring.

Here is a picture showing some L brackets in action:

You might have noticed a number of pocket holes in my construction. They are very convenient for attaching wood perpendicular to another one, especially in tight or not easily accessible areas.

With the help of a jig (I use the Kreg Pocket Hole Jig), they are very easy to make.

Here is a picture of one of the pocket holes up close:

Above the middle foundation frame, I also started building up the seat supports and cabinet housing, as seen in the picture below:

Helpful Tip: Here’s a useful trick I used while making the foundation frames. I had made a few alignment errors on the first frame, and so had to unscrew a few pieces and adjust.

Some wooden toothpicks came in very handy to plug the existing screw holes so that I could re-screw very near to those holes.

I simply stuck the toothpicks in the holes and broke off the protruding pieces. Here’s a picture of me ‘toothpicking’ the holes (all we had were party toothpicks, hence the bright colors):

Constructing the Shelves

With the foundation frames in place, I decided to start work on the shelves.

Making Dado Grooves

I was going to use the same technique as my first bookshelf I built in our old home – dado grooves to support the shelves, cut with a standard plunge router.

To start, I placed 2 of the bookshelf vertical end supports side by side, clamped them together tightly, and marked with a pencil where all the dados were to be cut.

Then using some scrap wood, I built a simple jig for my router to speed up the cutting and make all the dados identical.

Here are some pictures showing the the jig and the router in action.

With the help of the jig, cutting the dados was pretty effortless. Eileen even lent me a hand and cut some of them for me, while I did some other tasks.

Here are what the dados look like after routing:

Attaching the Individual Shelves

After the dados were all cut, I started attaching the individual shelves. To do this, I first applied some construction adhesive to the side of a shelf. Then I inserted it into one of the dado grooves.

Then while using some right angled clamps to hold the shelf in place (I decided to buy some to assist with this project), I fastened 3 deck screws from the other side to complete the task.

Here is a picture showing a shelf being attached:

Only the inner shelves used dado grooves. The top and bottom shelves were attached with just adhesive and screws.

Here is what it looked like with all the inner shelves attached:

Next, I applied more adhesive to the attached shelves, and dropped on the remaining dadoed vertical support.

Each shelf had to be adjusted so they fit perfectly into the dado grooves. Screws were also inserted to secure the connections.

Finally, I ran a 2×4 wood by the top shelf to serve as a mounting point for securing the bookshelf to the wall.

Priming and Painting the Bookshelves

To complete this bookshelf, I put on 2 coats of primer, and then 2 coats of a special urethane acrylic cabinet paint. I was worried about regular paint sticking to the books after sitting for some time, so I opted for this hard protective cabinet paint.

Then, with the help of Eileen, we carried the bookshelf upstairs and set it in place. Getting the shelf upstairs was no easy task, by the way.

I knew ahead of time that it was going to be a tight fit, but not impossible.

Here’s a picture of the shelf leaning, while we figured out just how to get it through the doorway.

The other bookshelf on the opposite side is actually slightly longer than this first one (due to the window not being perfectly centered on the wall). So we knew ahead of time that the second bookshelf would definitely not fit in our stairway and would have to be constructed upstairs in the bedroom.

Attaching the Shelf to the Foundation Frame

Using some deck screws, I attached the bottom shelf directly to the foundation frame. The left side of the shelf (touching the wall) was secured directly to some wall studs.

Finally, I secured the 2×4 cross piece at the top to some wall studs using some lag bolts.

Aside from the 2×4, I had used a countersinking drill bit to make the screw holes in the shelf. This made a clean hole for the screw to be countersunk without damaging the expensive birch plywood. I planned on filling in these holes with wood putty later to hide the screw head completely.

Here’s a picture showing the shelf secured in place:

Building the Second Bookshelf

Now it was time to start work on the second bookshelf that would sit on the right hand side.

As mentioned earlier, it was a few inches longer than the first one and would have to be constructed in the bedroom, rather than in the garage.

I did as much as I could in the garage though. First, I cut all the wood to the required sizes, and routed the dados using my jig. I also painted the individual pieces in the garage as well.

Also, I had to be careful not to get too close to the edges of the shelves with the paint though.

The edges would slide in the dado grooves, and any paint (particularly the urethane acrylic paint) would increase the thickness of the shelves and make this step difficult.

Working between the garage and the upstairs bedroom meant frequent trips up and down the stairs. Many times I would have a handful of tools to juggle.

Then during one of my frequent google search sessions for tool organizing ideas, I came across bucket organizers for tools. I didn’t even know they existed.

What a great way to repurpose the standard bucket. So I purchased one and made my garage/bedroom commute a lot easier.

Here’s a picture of mine:

Next, I transported all the individual shelf pieces upstairs, and started assembly with the help of some saw horses. It was a little more difficult to work in the bedroom due to the limited space, but it was manageable.

After the pieces were put together to assemble the bookshelf, I set it in place using the same steps I went through for the first bookshelf (securing to the wall and to the foundation frame).

Here is a picture of the right bookshelf partially assembled in the bedroom:

Here is a close-up showing the other vertical shelf support prepped with construction adhesive in the dados, ready to be attached to the rest of the shelf:

Both the left and right bookshelves were up at the point, and they were looking great.

Making the Window Seat

So next I started working on the middle portion – the seat and cabinets.

The cabinets were pre-fabricated ones I purchased online from Lowes. I got two of them to mount side-by-side. I just had to assemble them when they arrived.

Here is a picture of one of the cabinets after I assembled it:

To get the cabinets ready for installation, I built a framed housing for each. The I slid the cabinets into the housing, and screwed them in.

The top of the housing would also serve as the supports for the seat.

Here is a picture showing the cabinet housing completed:

Here is a picture showing the installed cabinets, as well as the seat attached with some countersunk screws:

Building the Top Shelf

With the seat and cabinets in place, it was time to install the final shelf above the window and get ready for the trim work.

To start, I ran three 2 x 4’s across the top of the bookshelves (in between the top front of the bookshelves and the ceiling).

Their primary purpose was to provide a nailing surface for the crown molding.

In addition, the middle 2 x 4 (that bridged the two bookshelves at the top) was going to help support the middle shelf that ran above the window.

I didn’t use dado grooves for this window shelf. I just used construction adhesive and screws to attach two plywood shelf pieces in between the two end bookshelves.

The top shelf piece also attached to the bridging 2 x 4 above. This window shelf was really long though (the same length as the seat), so to prevent it from drooping in the middle, I added a divider in the center to hold up the bottom shelf to the firmer top shelf.

Installing Crown Molding and Baseboard

Now it was time to install the crown molding and baseboard.

This was a relatively straight forward step. I had installed crown molding in the kitchen of our previous home, so was familiar with the procedure.

This time around though, I had a table saw, so the install went even easier.

For an easy crown molding install, having an angled surface to nail the trim into place is key.

So I measured the angle of the crown molding (the angle it would make with the wall), and ripped some 2 x 4s with my table saw to match this angle.

I attached them directly to the 2 x 4s already mounted on top of the bookshelves. Then, I used my finishing nail gun to attach the crown molding.

Here is a close-up of the crown molding:

The baseboard installed even easier. I just cut the pieces to length and secured them in with the nailgun.

The vent opening on the floor just needed a small top and bottom piece of the baseboard to blend in.

Here is what the baseboard looked like:

Attaching Trim

With the crown molding and baseboard installed, it was time to attach trim to cover the exposed edges of the plywood.

I couldn’t leave the bookshelves as they were because the plywood edges were very rough to the touch (easily leaving splinters) and were not very nice looking.

To save on costs, I decided to cut my own ¼” thick trim from 2 x 4s using my table saw.

I collected all the measurements I needed to cover all the exposed areas and got to work in the garage cutting the trim.

It worked out fairly well – although there were a number of knots in the wood causing several of the trim to break because they were so thin.

Also, other imperfections in the wood caused a few gouges in the cut trim.

So it definitely wasn’t perfect trim, but considering how cheap it was to make from 2 x 4s, it was worth it.

Besides, after the trim gets installed, I planned on patching up any flaws with wood putty. Then, once painted, the trim would look flawless.

Here is a picture showing the installed trim (I use construction adhesive and my finishing nailer to attach them):

Finishing Touches on Construction

Construction of the window bookshelf was pretty much complete at this point. I did attach some beadboard paneling above the seat with construction adhesive and the finishing nailer.

All that remained now was to fill all the countersunk holes with wood putty, patch and smooth any imperfections in the trim, caulk any small gaps (mostly with the crown molding and baseboard) and then apply paint where necessary.

Painting the Built-In Bookshelves & Wall

Eileen hopped in at this point to take over the painting. She painted all remaining wood – going over the edges, getting the trim, and touching up areas here and here.

She also painted the areas to the right and left of the window (which were currently still the color of the walls). That really made the bookshelf pop.

Here is Eileen hard at work finishing off the project:

Using our New Floor-To-Ceiling Bookshelf with a Window Seat

The project was now finished. Eileen immediately filled up the shelves with all the books we had, freeing up much needed space around the house. She even made a really nice cushion for the seat from scratch.

Here’s a picture of the cushion Eileen made for the window seat:

Here are a few more of the completed built-in bookshelves with a window seat.

The total cost of the built-in bookshelves project was around $600 and took me a few weeks to complete. It was a lot of fun to work on, and the payoff was huge.

It’s such a great addition to our home, and Eileen has a place that she loves for all of her books – it’s definitely her dream room now. Who wouldn’t want an entire wall of with floor-to-ceiling built-in bookshelves?!

To complete Eileen’s office, which is a sitting room off our bedroom, it needs some kind of doors. We are thinking about French doors or barn doors. What do you think?!

Make These Picture Ledges for Under $10

October 29, 2016 by Ash 59 Comments

Do you have a bunch of picture frames lying around and a couple hours of time on your hands? Make a DIY picture frame ledge. It’s simple to make, easy to arrange, and looks quite elegant.

Since our move, we still have boxes of pictures frames taking up way too much of our closet space. However, we are one ample box lighter, due to the awesome picture ledge that Ash made.

As I was digging through the box that held the white, cream, and grayish frames, I thought about a gallery. However, I already had one on a neighboring wall, so I wanted something different for this collection of pictures.

That being said, one of Ash’s least favorite chores is hanging pictures up on our walls. You should hear how he tries to procrastinate the task, let alone see his expression when he languidly follows me around the house with a hammer and nails.

And, he definitely does not enjoy when I ask him to hold the picture up to the wall, as I direct from across the room saying, “A little bit left, nope too much….” With my indecisiveness, that goes on for a little too long before I usually end up putting the picture somewhere else.

For these reasons, I knew Ash would love the idea of not having to hang any of the picture frames in this hefty box and instead have the pictures rest on a DIY picture frame ledge.

Would you know he had both photo ledges built in a couple hours?

He used all scrap wood, and then I painted with furniture paint for a nice finish.

The best part?

You can make them too for under $10!

How to Make DIY Picture Frame Ledges

Here are Ash’s instructions on how he built these simple photo ledges.

I came up with a very simple design for the DIY picture frame ledge. Here is an exploded 3D diagram that I created in TinkerCAD to show how the pieces came together:

I was able to use all scrap wood left over from previous projects. I cut the long pieces to the appropriate length. Eileen used the length of the love seat as a basis for how long she wanted the shelves.

Then, I formed the triangle support ends with my miter saw (this is one of my favorite tools – check out my other favorites).

After that, using some wood glue, clamps, and finishing nails, I attached the pieces to each other. Once the wood glue dried, I used the orbital sander to smooth down all the surfaces to make the different wood segments blend into each other seamlessly.

Since it was scrap wood, there were a few gouges here and there that I patched with wood filler and sanded down to a smooth surface.

Finally, my painter, aka Eileen, gave the shelves two coats of paint, and then it was ready to be mounted to the wall.

In mounting, I secured the shelves to the wall using two lag bolts, directly into two wall studs. The heads of the bolts stood out slightly, so to help blend them in, I covered them with some white paint to match the shelves.

Looking back, if I had some Forstner bits at the time, I would have countersunk the lag bolt heads to make them flush with the wood surface.

The cost of the project was free, as we had all of the material in our garage; however, I estimate the project costing $10 for the wood plus a quart of paint.

Our New DIY Picture Frame Ledge

I loved the way the picture shelves turned out. Ash built them so quickly, and without any trips to the store for additional materials, which is always a plus!

I think it took me longer to arrange the pictures than it did for Ash to construct them. (I’m super slow at arranging things…)

Everyone who visits has been commenting on how much they like them. A few people have said, “Have these always been here?” That is one of my favorite comments because it goes to show how great they look where they are.

Not to mention, Ash was so pleased that we didn’t have to hang all those frames. I haven’t told him we still have two more boxes of pictures in the closet. I’m not quite sure where they are going either. Maybe another picture ledge will be forthcoming.

Here’s another angle of our new DIY picture frame ledge. The more I look at it, the more I love it – and it was a lot easier than creating a gallery, and unlike the gallery, I can easily rearrange the picture frames too.

Shelving projects are one of my favorites – I just love different ways you can display pictures, books, and other items. I’m sure we will have more shelving projects coming soon.

Converting a CD Tower into a Pantry Shelf

October 15, 2016 by Ash 46 Comments

When we moved into our new home, we found an old, tall tower style CD holder shelf that the previous owners had left.

It was supposed to be screwed into the wall, but the screws were loose.

Seeing it as a hazard, Eileen wanted to remove it and toss it, but I had a feeling that we could repurpose it one day into something more useful.

So off it went into the corner of the garage where it sat for almost a year.

As the months went by, I was starting to regret my decision of keeping the tower because it was always getting in my way when working in the garage.

Then, one day as I was looking for some cashews in the pantry, I noticed something very interesting.

One side of the pantry had an extra thick wall. It was actually twice the thickness of a regular wall. How unusual, I thought.

My mind immediate jumped to storage.

If there was empty space in that wall, it could open up the doors for all sorts of pantry storage ideas.

Ever since I built a sliding spice shelf in our previous home (in between the fridge and the wall), I had been eager to come up with something similar for our new home.

The pantry was getting difficult to navigate with all our spices, and we could never find anything we needed. Unfortunately, there was no decent space to build the equivalent, so I needed other options for spice storage.

This thick wall was the perfect solution to our pantry storage shortage.

Planning for Extra Pantry Storage

First, I needed to assess the wall situation better.

I needed to know how much space was available inside this wall. For all I knew, it could have been thick to accommodate a central air duct.

I did some knocking on the wall and it sounded very hollow.

Still, I needed to know what was inside before unnecessarily ripping off a large chunk of drywall just to find the area impractical for use.

Using an Endoscope Camera

I took to the Internet and purchased a very cheap endoscope camera for my computer.

The endoscope would provide eyes into the wall and allow me peer around without causing too much damage.

When it arrived, I hooked it up to my laptop, tested it out a bit to get a feel for it.

Pictured below is the endoscope camera, which plugs into the computer via USB.

To give you an example of the detail it gives, I placed the camera inside my son’s fire engine, and displayed on the computer screen is a very detailed profile of the driver.

After testing it out, I then stuck it into a very small hole I drilled into the wall.

The camera had an adjustable light, so I could see inside the dark wall.

I looked up and down, and all around, and the endoscope revealed what I suspected all along – a lot of empty space!

Determining How to Use the Space

Now that I knew what type of space I was dealing with, I had to brainstorm the best way to make use of it.

It was a tall vertical space, so I was thinking along the lines of a vertical shelf to hold spices. That would certainly help with storage.

I went off into the garage to plan out designs for a custom-built shelf to fit the area.

In the garage, I saw some scrap wood resting in the corner that could be turned into shelf pieces, but once again, that tall tower style CD shelf was in the way.

The CD shelf was really starting to test my patience.

I was about to finally toss it out when I had a eureka moment. You know, that CD shelf looked very similar in size to the space that I discovered lurking in the pantry walls.

I anxiously took out my tape measure and did an exact comparison.

The shelf would indeed fit into the wall!

Good thing we did not throw out the CD shelf (more reason for Eileen to start accepting my hoard-ish ways).

It seemed like the perfect solution for spice storage.

It was not very deep, so it wouldn’t hold large cans or boxes, but would easily hold spices and baking materials, which was exactly what we needed.

Installing the CD Tower

Excited about repurposing the CD tower into a pantry shelf, I couldn’t wait to get started. I love being able to repurpose some of the junk I keep around. It’s my justification for keeping everything. And, we really needed the pantry storage. I was tired of rooting through baskets of spices.

Preparing the CD Tower

I could have used the shelf unaltered, but I decided to make it a little shorter for the pantry.

The full height would have sent it nearly to the ceiling, which would made it a little impractical for pantry storage that high.

Cutting into the Drywall

After the shelf was shortened, I needed to cut the hole in the drywall.

I first used a pencil and ruler to outline the exact cutout on the wall. Then I used a special drywall handsaw (commonly called a jab saw) to cut out the hole.

It was a little messy working with the drywall, so I kept my shop vac close by.

After the hole was made, I inserted the shelf into the wall to get a feel for how it would look.

It looked amazing! I couldn’t wait for Eileen to see.

Affixing the Shelf

Now I needed to permanently affix the shelf.

The shelf was not resting directly on the floor inside the wall (it was a few inches above the baseboard), so first I had to attach a 2 x 4 cross piece to rest the shelf on.

I used my Kreg pockethole jig and some pockethole screws to attach both ends of a short 2 x 4 to the wall studs.

I repeated the process to attach another cross piece above the shelf to secure the top.

Then I slid the shelf in between the upper and lower 2 x 4 supports and attached the shelf permanently using some screws.

Applying the Trim

All that was left now was to apply some trim.

I actually had a lot of extra trim left over from redoing some kitchen baseboard a few months prior.

The trim I had originally purchased was too tall for the kitchen, so I had cut it shorter using my table saw. Good thing I held onto the cutoffs.

They were the perfect size to use as trim for the new pantry shelf.

It was already painted too. I secured the trim directly to the shelf using some finishing nails.

Finishing Touches

I adjusted the heights of the individual shelves to accommodate a variety of spice configurations, and then the pantry shelf project was complete.

I loaded it up with all my spices and our baking materials, which freed up so much space in the pantry. It truly was such a perfect pantry storage solution.

This was one of the more simple projects I’ve done recently for such a big reward. I completed the project in a few hours, and best of all, it was free! If you are looking for pantry storage ideas, think outside of the box. You never know what you’ll come up with:)

I’m hoping to repurpose more of my stashed finds in the near future.

12 Must-Have Tools for Every DIYer

September 25, 2016 by Ash 3 Comments

I was sitting in my garage recently looking at my collection of tools on the pegboard, and was thinking how much I take them for granted a lot.

When working on projects, I don’t think twice about the tools. They are just sitting there waiting for use. I grab one as the task requires, and it gets the job done.

So an ode to my under-appreciated tools, I put together a list of the most used tools in my garage.

If you’re a budding DIY’er just getting your feet wet in the home improvement field, you should aim to acquire these tools as the need for them arises.

You could get them all at once, but that’s a pretty large investment, and a lot of the tools would probably just sit abandoned longing for usage.

Remember, as your skills improve, and projects under your belt accrue, so will your tool collection grow. Also, I didn’t include obvious ones like a hammer, screwdrivers or socket spanners.

So without further ado, here are 12 must-have tools for DIYers.

1. Cordless Drill

My drill is the most used tool in the garage. It’s such a versatile tool. It’s functionality goes far beyond just making holes with drill bits.

I use screwdriver bits to work with screws. I use a socket adapter to work with hex bolts.

When dealing with odd angles, I can use a right angle adapter to perform 90 degree drilling. With a paddle adapter, I can mix paint or grout.

Just recently, I discovered I can pump liquids with a drill pump adapter.

With so many different types of drill adapters out there, my personal collection is barely scratching the market, so I’m always on the lookout for cool ones.

My reliance on drill bit adapters encouraged me to even purchase a second drill.

It takes time to swap out drill bits or adapters, and it was starting to become an inconvenience when working with multiple ones at a time.

So tasks like drilling pilot holes for screws, and actually screwing in the screws was simplified to just a task of picking up the first drill, then picking up the second drill.

I even got extra batteries so that I could replace a dead one immediately.

These time-saving expenses improved my project efficiency tenfold.

So it’s a no-brainer why the handy drill is first on my list.

Some of the projects I used the cordless drill on are constructing the sliding garage shelves, creating a boxing speed bag station, and installing tile backsplash.

2. Miter saw

I originally purchased my miter saw for cutting the angles needed for a crown molding project I did a few years ago.

It turned out that this was just the tip of the iceberg of functionality that the miter saw could do for me.

Prior to the jawhorse, cutting wood meant breaking out the hand saw. I would rest the wood on whatever was nearby, and either stand on the wood or hold it firmly with the other hand.

If I had the Jawhorse setup, I would just clamp it down and make the cut.

Now I’m always up for a good workout, but making cuts by hand takes time. The cuts are also notorious for being inaccurate because it’s hard to cut perfectly vertical by hand.

The miter saw changed all that. I just put the wood in position, pull the trigger, press down the saw, and a perfect cut is made every time.

The miter saw also allowed me to do something I couldn’t do before – quickly prototype ideas.

A few of the projects I used the miter saw on are building the outdoor storage shed, the wagon for mower, and the water-saving rain barrel.

3. Wood clamps

For many years I got by without wood clamps. I did not know what I was missing out on.

Then one day I had to borrow a bar clamp from my neighbor to hold down some warped wood while I nailed it in place. I was hooked.

I could not have done that task without a clamp, and many projects since then have been aided dramatically with the use of wood clamps.

Clamps come in all types and sizes, from small C clamps to really long bar clamps, and everything in between.

I now have a variety of these clamps, including some specialty ones too – 90 degree clamps (when you need to hold two pieces of wood perpendicular to each other, like when building bookshelves) and face clamps (for holding two pieces of wood flush with each other for joining, like when using pocket holes).

Some of the projects I used wood clamps on are building my folding workbench, creating French cleat box shelves, and making an outdoor picnic table.

4. Table saw

The table saw has really brought by workmanship up a notch.

I bought mine out of necessity when I hit a snag building my storage shed.

I needed to make some long precise cuts that were too difficult to accomplish using my circular saw or by hand saw.

Being one of the more costly tools I own, I had delayed in getting a table saw for the longest time.

Now that I have one, I have never regretted the investment. I use it for everything from cutting T-11 siding to turning scrap plywood pieces into French cleat shelves.

It’s such a versatile and precise tool, even the neighbors (and the neighbors grown children) are coming to me for help!

As for accessories, I purchased an awesome featherboard to help guide my cuts (a lot of people usually build their own, but I needed one right away for a project and didn’t have the time to make one – plus the purchased one is much more flexible than one I could have built).

I also plan on getting some dado blades in the near future to quickly notch wood and cut grooves.

I used the table saw on many of projects including, the outdoor storage shed, the custom mailbox post, and the wagon for mower.

5. Random orbital sander

When you work with wood, you’ll come to appreciate a good sander.

There are lots of different types of sanders out there. Yet, for a DIYer, you can’t beat a random orbital sander. I purchased mine several years ago to help Eileen refinish an old wooden coffee table.

Prior to that, I had a little mouse sander, and that definitely wasn’t up to the task of stripping the whole table down to bare wood.

I was amazed at what a good job the orbital sander did. In no time at all, the wood was exposed.

I did have to use the mouse sander to get into the small, hard to reach areas, but that’s the purpose of a mouse sander.

These days I use the orbital sander for almost every sanding task at hand.

I just pick out the appropriate grit sandpaper for the job, fire up the orbital sander, and smooth wood is just moments away.

Some of the projects I used the random orbital sander on are the folding workbench, wagon for mower and outdoor storage shed.

6. Plunge Router

I purchased a plunge router a long time ago to help with cutting dado grooves for building a bookcase.

It did an excellent job.

Then it sat dormant for a long time until I started experimenting with bits other than straight cut bits. Now I find myself using the plunge router so much at the end of projects.

It really turns a good looking project into a WOW project.

Specifically, I’m using round-over bits to make nice beveled edges for my woodworking projects.

I built a picnic table the other day and didn’t want people getting splinters from the edges. So, I used the round-over bit to make a nice smooth profile.

Most recently, I made a very professional edge for my folding workbench with another version of the bit.

I’m excited to try out different types of routing bits in the near future and hone my routing skills.

I used the plunge router when I built a wall mounted bookcase and when I created my folding workbench.

7. Oscillating Multi-Tool

This is another recent addition to my tool collection.

I was working on a project the other day and needed to make sure really awkward cuts in a small space.

Realizing I didn’t have the tools to accomplish this easily, an opportunity arose to purchase an oscillating multi-tool.

I’ll admit that I didn’t know much about these tools at the time, but I was fairly sure it could accomplish the task at hand.

After some research, I bought a cordless version and it did exactly what I had expected it to do. I didn’t think I would be using it much more after that, but I was wrong.

I find myself grabbing this oscillating tool off the wall so many times to do cuts or to perform some sanding when I don’t feel the need to set up a larger tool.

It is sort of a hybrid between my compact circular saw and my electric sander.

A few projects I used the oscillating multi-tool on are the folding workbench, the sliding spice rack and an outdoor picnic table.

8. Wet/Dry Shop Vac

You would think that a shop vac was one of the first tools I got.

In actuality, I just purchased my first shop vac about a year ago. I can’t believe it took this long to appreciate the cleaning power of a good shop vac.

I had gotten used to saw dust being everywhere, and the floor of my garage looking like a mess.

With the shop vac, now everything is dust-free and my garage floor is always spotless.

After every wood cutting session, I start up the shop vac. In no time at all is the sawdust gone.

What I love most about the shop vac is that it picks up anything, including nails and screws. I didn’t know this before (any probably why I only just recently got a shop vac).

Now I don’t have to worry about parking the car in the garage and driving over sharp debris left over from past projects.

The shop vac makes certain that everything is removed from the floor.

9. Dremel

Every garage workshop owner should have a dremel and a host of accessory bits.

Not only is it great at precise woodworking cuts, but makes metalworking a feasible task for me.

I originally purchased a dremel to help me cut a hole in the side of my metal computer case. (I had bought an incredibly oversized processor cooler that was too large to fit inside the case. So, I need to punch a hole for it to stick out.)

I was a little nervous at first working with metal, and the sparks flying off the fiberglass reinforced cut-off wheels wasn’t helping, but it got the job done to a perfection.

In no time was a great looking square hole in this thick metal sheet, and my computer could now happily exhaust its heat.

Since then, I’ve never looked at metal as a barrier for me.

In fact, I recently bought some overhead garage shelving, and unfortunately, some of the assembly holes didn’t line up, so some bolts couldn’t fit all the way through. Without the dremel, I may have had to return it.

However, I used a tungsten carbide cutter bit and expanded the hole just enough to make it work. The dremel also works great for sharpening my mower blades too.

A couple of projects I used the dremel on when I was fixing up the mower and when I built my folding workbench.

10. Circular Saw (and compact version)

This is a staple tool of most garages.

I love waking up in the morning to neighbors whirring their circular saws as they are hard at work making sawdust. It’s one of the first power tools I purchased and has seen many hours in the field.

I use it for everything from ripping plywood sheets to cutting out lap joint grooves.

Most recently though, I acquired a compact circular saw and it’s a dream to use.

The downside of a regular circular saw is that it is heavy and bulky, and so hard to use in tight spaces or above your shoulders. They are also very tricky to do small precise cuts.

The compact version solves all of this.

It makes small cuts a breeze to handle, and can fit almost anywhere to perform the cuts. I originally purchased the compact circular saw to cut out window holes for my shed.

I tried using a regular circular saw, but quickly gave up because it felt really dangerous holding the behemoth over my head.

Now I use the compact one almost anytime I need to cut wood.

I love the convenience and precision it gives me.

It does have a very limited cutting depth though (little over an inch), and is not as powerful as a regular circular saw. So I still rely on the regular one for certain jobs.

I used the circular saw on many of my projects, including the outdoor storage shed and a custom mailbox post.

11. Power planer

These were introduced to me a few years back, and what an amazing tool they are.

I didn’t know they existed, as I had a regular hand planer, but it didn’t get much use. I was never really good at the technique and could not seem to get the blade sharp enough to be useful.

Then my neighbor lent me his power planer one day to help me shave down the tops of my closet doors so they would close properly.

In a few quick swipes, I trimmed a small layer off the tops of my doors. After that, they no longer jammed.

For years these doors never closed properly, and now they were fixed in minutes.

So I ended up buying my own power planer later on.

Not only do all the doors in my home close properly now, but I’ve used it in so many projects where I needed to level wood that wasn’t lining up right.

12. Finishing nail gun

My finishing nail gun was the most recent tool I acquired for my collection.

It was up there price wise along with the table saw, so it was an investment. However, it’s the crowning jewel of my collection.

You know you’re an accomplished DIYer the day you buy your first finishing nail gun.

I don’t use it as much as the drill, per say, but when I do use it, it’s such a convenient and efficient tool. It makes you want to keep going and going and get your project done.

I did a lot of research prior to purchasing the nail gun, and eventually settled on a 16-gauge version.

This thickness nail would be applicable to a much larger range of projects than other gauge nail guns could do. I originally purchased it to help install some crown molding.

Since then, I have used it for help in so many projects.

In just one weeknight, I built a variety of box shelves for the garage using the nail gun (with the help of construction adhesive and scrap plywood).

It would have taken me much longer using regular finishing nails and a hammer.

Just the other day too, I was erecting a 6×6 wooden post in concrete. I used the nail gun to temporarily attach some wooden supports to keep the post level.

I look forward to any opportunity I get to use to my finishing nail gun.

Also, I used the finishing nail gun on a couple of projects lately, including the French cleat box shelves and a shade sail.

Final Notes

I have plenty other tools (like my framing nail gun and jigsaw). However, this list of tools shines a light on what your average DIYer should aim to eventually have in their garage – the must-have tools for DIYers.

However, I do have a wishlist of tools that I would love to add to my collection. Things like a reciprocating saw, drill press, and sliding compound saw.

I’ll get those eventually as the need arises for them, and maybe they will have an impact on my list of most used tools.

Used tools?

On a final note about purchasing tools, there is nothing wrong with getting them used.

A little cosmetic damage is not a big deal, just make sure the tool still functions properly. Also, sometimes you’ll have to do a little bit of cleaning to restore used tools to optimal functionality.

A year ago, I had purchased a used Paslode framing nail gun on eBay for around $100. It retails new for more than double that.

The nails started to jam after a few days of usage. So, I bought a cheap cleaning kit. I took apart the tool and cleaned it internally with a special spray from the kit. It now fires nails like a brand new gun.

Anyway, all this tool talk has certainly gotten me in the mood to make some sawdust, so off I go into the garage.

Creative Garage DIYs to Increase Storage Space

September 6, 2016 by Ash 82 Comments

With our garage being my workshop and our primary storage area, it was filled to the brim with tools of all sizes, boxes and boxes of holiday decorations, yard tools and toys, and so much more.

We already did a lot of DIY projects that saved space and created more garage storage. I constructed a folding workbench, which was such an efficient workstation.

In a corner that formerly was a dumping ground of yard tools, I built a sliding shelf tower, which housed all of our holiday decorations. I also had a lot of creative shelves scattered around.

With so many things in our garage, any empty area was prime real estate, no matter how small.

A Hidden Gem

The other day, some wall space caught my eye – the gap between the two garage doors.

Right away I thought that it would be an excellent place for some narrow shelves. Strange that it took me a year to spot the little gem between my garage doors that could provide more garage storage.

Coincidentally, the project I was working on at the time (the built-in bookcase with window seat) produced a lot of scrap birch plywood.

This was expensive stuff – 4×8 sheets sell for $50 at Home Depot. So I wasn’t wasting any cut offs (I was quite inventive in the different ways I reused those scraps).

My shelving idea between the garage doors would be a perfect little project for some of the plywood scraps to get more garage storage.

Planning the Garage Storage Boxes

Simple flat shelves wouldn’t suffice though. With so little space, the shelves would be small, and things could fall off easily.

So instead of shelves, I started visualizing little boxes on the wall. How nice would it be to walk in wearing yard gloves, and have a box to toss them into as soon as I enter the garage?

I took the box idea a step further and considered using French cleats for them.

This would allow each box shelf to be removed by simply lifting it. It would lead to a very modular design where the boxes could be swapped with other ones on the fly.

Rather than digging through a box on the wall to find what I need, or make repeated trips to the wall, why not just take the box shelf with me? Not only would it create more garage storage – but it also would be very efficient.

Now that’s some clever thinking, if I do say so myself.

I came up with this simple box design below:

Here’s another view of the box design, resting on the wall via the French cleats:

Building the French Cleat Storage Boxes

I was excited to get more garage storage from this wasted space – I couldn’t wait to start building. Here’s a TinkerCAD exploded diagram showing in detail how it was constructed:

Constructing the First Garage Storage Box

In the diagram above, the orange piece on the far right is mounted to the wall (to allow the box shelf to drop into and secure to the wall). The rest of the pieces form the box itself.

The wall mounted piece and the other angled cut directly above it (attached to the box) form the French cleat system. I used scrap ¾” birch plywood for the box and French cleats.

For the floor of the box, I used ⅛” thick scrap plywood. I cut all the pieces to size quickly using my table saw, and then miter cut the side pieces for that nice angled profile.

For the French cleat 45 degree lengthwise cuts, I used the table saw again.

Then I used construction adhesive, some bar clamps and my 16 gauge finishing nail gun to assemble the wood pieces into a functional French cleat box shelf.

Technically, I built the first shelf without the nail gun. I just used regular finishing nails and a hammer.

Finishing Nail Gun for the Win

With these types of shelves, the strength comes mostly from the construction adhesive (that stuff is really strong when completely dry). The nails really just hold the pieces in place for the glue to set. So that’s why I used finishing nails.

Also, I didn’t want to risk splitting the plywood scraps, so finishing nails were a good choice due to their thin profile.

As I mentioned earlier, I was in the middle of a bookcase/window seat project at the time. Part of this project involved installing crown molding and baseboard.

I remembered installing crown molding in my previous home, and having an incredibly hard time doing it with finishing nails and a hammer. So, I ended up borrowing my neighbor’s cordless finishing nail gun, and the installation was such a breeze. I just held the crown molding in place, then tap tap tap, and the nails (technically brads) were countersunk, securing the molding to the wall.

So purchasing my own finishing nail gun had long been on my wish list.

I finally bit the bullet and purchased one for my birthday to use on the bookcase project. I also got some angled finishing nails to go along with it.

They arrived in the middle of these French cleat shelves. So the shelves were the perfect opportunity to hone my skills with the gun.

Here’s a picture of me using the finishing nail gun for one of the box shelves:

I originally purchased an 18-gauge finishing nail gun (keep reading to see why I returned it).

Sidenote on Nail Guns

For those not familiar with finishing nail gun terminology, the gauge represents the thickness of the nail. I’m using the word ‘nail’ loosely because these nail guns actually fire brads, which are strips of thick wire with a very fine head.

They are great for finishing applications (like securing trim) because the heads make a very small hole and require little work to conceal. The thinness of the brads also reduce the likelihood of splitting the wood when they are driven in.

Finishing nail guns are not to be confused with framing nail guns, which fire actual nails and use substantially more power to drive them (hence also more dangerous). I used a gas powered framing nail gun in my shed project if you are interested.

Anyway, I was saying earlier how I purchased an 18-gauge finishing nail gun. Unfortunately, I was not having a good experience using it with the birch plywood. Most of the nails would fire in straight, but then bend half way and stick out the side of the wood. It was very annoying.

I did some research online and found out that 18-gauge nails don’t work well in hardwoods (like birch) and will do exactly what they were doing with me (changing direction as they are driven into the hardwood).

So I decided to return the nail gun and get a 16-gauge version instead.

The new nails were noticeablely thicker and worked perfectly for me. The gun is now a permanent addition to my top 12 list of must-have tools.

What’s the best nail gun for a DIYer?

Depending on the type of woodworking project you’re doing, sometimes you’ll need a thinner nail (higher gauge) and sometimes you’ll need a thicker nail (lower gauge).

Unfortunately finishing nail guns can only fire a single gauge, so you’d need multiple guns to accommodate different nail gauges. This is obviously very expensive, and may not make financial sense for you unless you’re a dedicated contractor.

So, 16-gauge is a good compromise because a majority of the projects a typical DIYer works on can be satisfied with that sized nail gauge.

This has held true for me ever since purchasing the nail gun too. I’ve used it for everything from crown molding to shelves to quickly tacking on temporary supports for concreting wooden posts. It’s also my favorite tool, and well-worth the investment.

Finishing Up the Boxes

With the finishing nail gun, construction of 5 box shelves went by very quickly. I only made 5 because I ran out of scrap wood large enough for box shelves. The remaining smaller scraps had another destiny.

Five French cleat boxes were perfectly adequate for the space allocated though and would definitely create more garage storage and organization.

Here’s a picture of the completed French cleat boxes resting on the wall (they are empty below, but filled today will all sorts of goodies):

After this was completed, some of the remaining birch plywood scraps got used for another project.

Get More Garage Storage with These Ideas

I was going finishing nail gun crazy and just wanted to keep tap-tap-tapping brads. So, I ended up making an incredibly useful battery charging station for my cordless tool batteries.

The garage storage station consisted of four L shaped shelves fixed to the wall, with two triangular supports each.

Here’s a picture of the empty shelves on the walls so you can get an idea of the design:

Here’s what the shelves look like actually being used. This little nook helped get more garage storage and organization.

The shelves created more garage storage – enough space for 4+ battery chargers, extra batteries and a host of accessories.

I got creative and tacked on an empty plastic nail box to store stationary-like pencils, markers and scissors.

I’m most proud of my measuring tape holder though. I was always looking for my measuring tape and needed a dedicated location for it, so I mounted a metal strip to one of the shelves, and the measuring tape just clips onto it.

It’s in the perfect location too. Whenever I need a measuring tape, I just open the garage door and grab the tape off the holder. When done, I just snap it back on the holder and it’s there for future use.

Here’s a picture showing my measuring tape holder:

A Lot of Storage for a Little Effort

So that’s it for this round of more garage storage shelving. I constructed five French cleat boxes in the lost space between the double garage doors and added some bonus shelving too. Not only did I create more garage storage but this storage added another level of efficiency to our garage.

I completed everything on a Saturday with no additional cost to me because I used all scrap wood. Although I benefited a great deal from the finishing nail gun I purchased around the same time, it could have been done with just regular finishing nails and a hammer.

Stay tuned for future shelving ideas as inspiration strikes. I hope this article brought you some inspiration to get more garage storage too.

Make an DIY Photo Booth with Four Things

August 30, 2016 by Ash 26 Comments

For our son’s birthday last year, we had a small party with just our immediate families. We had just moved to a new house and barely had anything done.

Even though we were just having close family, Eileen, of course, went all out with zoo animal theme. She always does all of the planning – but asked me to help her create a DIY photo booth.

She created a bunch of photo props, while I looked for free photo booth software. To my dismay, I could not find any simple to use programs out there.

Most of them you had to pay for, and the free ones were terrible. What seemed like a simple task was turning out to be quite problematic.

So I decided to just write my own photo booth software.

By the end of the day, I churned out an app I dubbed Easy Photo Booth. Eileen was totally impressed, and we’ve been using the app at parties ever since.

To create your own a DIY photo booth, you need four simple things:

- Backdrop
- Props
- Easy Photo Booth software – free download, see below
- PC with a webcam

1. Photo Booth Backdrop

This can be as simple as a blanket or a large piece of felt. It shouldn’t be too complicated of a design because your party guests will be sitting in front of it.

At the zoo animals party, we used a lime green blanket as the backdrop and that worked out great.

At the Sesame party, Eileen created a nice Sesame Street scene.

She got a large piece of blue felt from a craft store, and then hot glued on white felt in the shape of clouds.

For the classic Sesame Street lamp post, she used dark green and white felt, and printed the Sesame Street sign on the printer.

Here is the background in the making:

Here’s a picture of the backdrop set up on our deck:

2. DIY Photo Booth Props

Props are pretty much anything glued to a thick popsicle stick.

Choose props that have to do with the theme of your party. Cute signs like “I came for the cake” are always a nice touch too.

If you do make signs, make them very large and easy to read. On the first go around, some of our signs were too small or written too thin to be able to read.

For the zoo animals party, we used these props (pic below). Eileen made the faces from foam, and the signs from card stock.

3. Easy Photo Booth App

I previously had trouble finding a photo booth app that was simple and free. Therefore, I made my version as simple and straightforward as they come.

This simple program is available at no cost to our readers. You can download it using the form above,

It’s an easy-to-use program that runs just like a digital photo booth. For more details on exactly how it works, keep reading 🙂

4. Laptop (with a web cam)

The last item you will need for the DIY photo booth is a laptop with a web camera.

In front of the backdrop and props, I placed a laptop (with a web camera) on a small table.

The guests would then see themselves on the laptop screen. Easy instructions on how to proceed popped up.

I even setup the software to save the film strip images to DropBox.

This allowed me to run a slideshow on the large family room TV of a live photo stream from the photo booth (via a second laptop I had plugged into the TV).

This way, other guests not taking pictures got to partake in the DIY photo booth fun.

Using the Photo Booth App

My photo booth software was a huge hit. It’s now a staple event at our parties, and even our friends/families use it at their events. So I wanted to make the software easily available for everyone for free.

Simply, join our mailing list to access our library with the PC version of Easy Photo booth. I’m sorry, I don’t have a MacOS version of it, but I can port it over to Mac if I get a lot of requests for it.Here’s a screenshot of the program in action:

Easy Photo Booth also offers an advanced mode if you want to fine tune the functionality:

Here’s what the software shows the guests after taking their pictures:

Film strip images like the picture above are generated from the software. It also saves the images individually in case you wanted to use a snapshot outside of the film strip.

I also added an “overlay” feature, which superimposes foregrounds onto your images. Check it out in action below (I’m hiding behind some tree coverage):

So if you’re looking for free and easy-to-use photo booth software for your party, you should definitely check out Easy Photo Booth.

You can host an awesome DIY photo booth with just four things – a backdrop, props, a laptop, and our photo booth software.

It’s fun, free and who doesn’t love a photo booth?!

Installing a Shade Sail for the Patio

August 27, 2016 by Ash 97 Comments

See how to install a sun shade sail in your yard, including how to erect the shade sail posts with this easy tutorial.

When the sun goes down, we love to sit out on our back patio.

Yet, we could never use the patio on hot summer days because the sun beating down made it unbearable.

My wife was somewhat keen on the idea of a retractable awning. With our son’s birthday party coming up, we had a lot of guests coming over, so our quest for shade on the patio became more of a priority.

However, as the party crept up, I began to veer from the retractable awning idea.

Our budget was under $300 for patio shade, and I could not find any decent awning within that price range.

I was looking for something that was around 16’ x 16’ and the prices went over $1000, far exceeding our budget.

Also with the party nearby, I wasn’t comfortable rushing a project like this by making a quick decision.

I started researching alternative ways of throwing some shade on the patio.

Something that really stood out were sun shade sails. These are large fabric canopies that are suspended in the air for shade.

I’ve actually seen shade sails at commercial establishments, but never knew they had an actual name. They are known for bright colors in fancy arrangements.

After a little research, DIY shade sail installation seemed completely doable.

Planning the Sun Shade Sail

I presented the shade sail idea to Eileen, and she was into it. The savings was huge, and a sun shade sail was the perfect, quick solution to blocking the hot summer sun.

For our DIY shade sail installation, I planned on attaching one side of the sun shade sail to the house, and the other side of the shade sail to two wooden poles.

DIY Shade Sail Installation Materials and Cost

The best part of my sun shade sail plan was the cost. I could get a 16’ x 16’ shade setup for under $150. Compared to an awning, installing a shade sail was a savings of over $800!

The bulk of the price of the shade sail was the actual 16′ by 16′ fabric sail.

The rest of the cost would go towards two 6 x 6 x 10 pressure-treated wooden posts, 4 bags of concrete (80 lbs each), 1 bag of paver base, and some shade sail hanging hardware.

My only concern was transporting the wooden poles for the sun shade sail from Home Depot.

I knew from past experience that 8’ was the max length lumber my car could carry with the rear door closed. These 6 x 6 posts were 10’ long.

After some logistical thinking (including looking at strapping them to my roof rack), the solution was very simple – just place them at an angle, with the excess hanging out the window.

Here’s a picture of car loaded up with the 6 x 6 shade sail posts, concrete and paver base. I was ready to install the shade sail.

Preparing the Shade Sail Materials

The first step in this shade sail installation project was figuring out where everything would go.

I spread out the sun shade sail on the backyard lawn to double check the measurements (the packaging said 16.5’ but I wanted to see what this equated to fully spread out).

The mounting fixtures for the shade sail needed to be larger than the 16.5’ square to allow the fabric to be tensioned properly.

Research online suggested a distance for the fixtures to be 10% larger than the sun shade sail itself. So this meant approximately 18’ for me.

Determining the Location for the Shade Sail

Now I had to locate an area on the porch where this 18’ shade sail square could fit.

The mounts on the house needed to be installed into wall studs for strength, so this meant every 16” (standard stud spacing) on the house could be a starting point for the 18’ square.

In addition to this, I had to contend with obstacles on the post side, like a wooden walkway I built last year.

I also wanted to leave an unsheltered part of the patio for the BBQ grill. It’s not safe to cook directly under shade sails because the heat could damage the fabric.

Taking all these issues into consideration, I eventually settled on an ideal location for our shade sail.

An Uphill Battle with a Rock

Unfortunately, my ideal location for the shade sail had a little snag. There was a giant landscaping rock right in the middle of where I wanted to install one of the wooden posts for the sun shade sail.

At first, I wasn’t worried, but when it actually came time to move it, I started scratching my head. I actually scratched my head for days, trying feebly to move this rock.

I estimated the rock to weigh around 500 lbs.

Additionally, I tried all sorts of techniques, including tying a chain around the rock and pulling with my riding mower. That didn’t work as the mower’s engine struggled under the load.

Then I experimented with a hydraulic trolley floor car jack. The rock started moving!

The movement was not enough to relocate the rock by itself, but it was a nudge (pun intended) in the right direction of getting back on track for the sun shade sail installation.

To complete the task, I determined that I needed a scissor car jack, and also a long heavy duty crow bar.

The additional car jack might have been unnecessary if I had a non-hydraulic jack.

Unfortunately something in my jack wouldn’t let it operate unless it was fairly level to the ground (I guess some fluid was not able to enter the correct passageway if the jack wasn’t level). I needed to use the jacks sideways sometimes to push the rock out of position.

So hence the need for an additional jack.

I decided to get a scissor type jack, as it was purely mechanical and could be used at any angle. Also, I wanted to get a long heavy duty crow bar.

I realized I was having some success prying the rock using my shovel, but the rock would have soon broken the wooden shovel handle.

Getting Closer…

The crow bar was amazing. It’s what helped me the most with moving the rock out of the way of where I wanted the shade sail poles to go.

It was 20 lbs of solid steel, 5’ long providing all the leverage I needed.

The tip was also shaped like a wedge, so it was easy to get it under the rock.

So using a combination of two car jacks (resting on pieces of scrap wood for support) and a crow bar, I was able to move the 500 lb rock far enough to continue my shade sail project.

Here’s a picture showing the results of my hard work. I now had the area clear for the sun shade sail post installation.

Installing the Sun Shade Sail Posts

With the location on the patio determined for our DIY shade sail, the rock moved, and the materials ready to go, I was finally able to start the process of installing the summer shade sail.

Digging the Shade Sail Post Holes

First, I started digging the support post holes.

I had a post hole digger already, but it was a little small for digging holes for a 6 x 6 post. It was really meant for 4×4 posts.

So I made it work by digging 4 holes adjacent to each other to make one larger hole for the sun shade sail posts.

For each post, I made a hole roughly 3’ deep by 1’ wide.

To help track my hole depth, I used a permanent marker and put depth measurements on the digger at 1 foot intervals (I don’t know why you would pay extra for a hole digger that came with depth measurements when you could just do it yourself).

It took a few hours and a lot of labor to dig both holes for the shade sail support posts, but I got it done.

The crow bar I used to move the rock helped out too. It was perfect for breaking any rocks or roots that I encountered.

Rain, Rain Go Away

With the holes dug, I thought it was time to start the concrete for the sun shade sail posts.

I actually had to wait a few days to start this task.

Rain was predicted for the next couple days, and I wanted at least a few days of hot sun to allow the concrete to dry properly.

So when the weather finally cleared up, I went outside to continue the sun shade sail project.

Unfortunately I forgot to cover one of the holes to keep rain water out, and so it was partially filled from a recent shower. It was not draining anywhere, so I had to pump it out.

I didn’t feel like wheeling out my large wet/dry shop vac for this. Then I went to the local habitat for humanity store to pick up something a gallon of paint Eileen saw earlier in the week, and I stumbled across a hand drill pump for $1.

I never knew about these pumps before. You hook it up to your cordless drill and it will suck liquids for you into one tube and out the other.

So I hooked up my pump to my drill and in a few minutes, the hole was emptied of water.

It was so cool!

Preparing for the Concrete for the Shade Sail Posts

Next, I screwed in several galvanized lag bolts into the bottom of the posts to serve as anchors into the concrete.

Then I poured some paver base into the bottom of each hole to give the concrete and the shade sail posts a solid foundation to rest on.

I poured enough paver base for approximately 3” deep and packed it down tightly with a long scrap of 4 x 4 wood.

Here is one of the finished holes, with the gray paver base at the bottom:

Here’s a picture showing some of the lag bolts screwed in the posts for anchoring:

Afterwards, I dropped the shade sail posts into the holes. Then, I used several strips of scrap wood to serve as temporary supports for the posts.

I used a level during this process to make sure the sun shade sail posts stood perfectly straight.

With the posts resting in the holes, stationary with the temporary supports, I could mix and pour the concrete.

Mixing the Concrete for the Shade Sail Posts

I worked with concrete to erect our rebuilt mailbox last year, so I was confident in my concreting skills.

Instead of just 60 lbs of concrete used for that mailbox though, I’d be using 320 lbs (4 x 80 lb bags) for this.

I started with just 2 bags at a time in my wheelbarrow. I kept adding in more and more water with my hose, mixing each time with my square head shovel, until I got a slightly runny consistency that I liked.

Then, I made sure to give the concrete a thorough mixing. I didn’t want any unmixed powder pouring down the shade sail post holes and creating weak spots.

Here’s a picture of the concrete being mixed in the wheelbarrow (notice one of the wooden 6 x 6 posts in the background with the temporary support strips keeping it in place):

Pouring the Concrete for the Shade Sail Posts

After the concrete was mixed thoroughly to my satisfaction, I poured it into the first shade sail post hole.

It was a little tight to get the wheelbarrow tilted into the hole, so I shoveled the mixture into the hole, which actually gave me a more even fill.

When all the concrete was emptied, I repeatedly stuck the shovel into the concrete to make sure it was packed down well and to remove any air bubbles.

I repeated the whole process for the other post, and now both shade sail posts were resting in concrete.

Then, I gave the concrete 48 hours of dry time and then packed down any remaining post hole with dirt.

The shade sail posts were in there very firmly, with 160 lbs of concrete holding each support post in place.

I left the posts alone for another few days to work on some other projects. Even though 48 hours was the recommended dry time, a few extra days couldn’t hurt.

The shade sail posts were going to be subjected to large forces once the fabric was tensioned down, so I wanted to make sure the concrete was ready for that.

Here’s a picture of the two mounted poles. The shade sail installation was certainly moving along.

We were having our deck restained for the party (it had deteriorated to the point that bare wood was showing).

So I asked our deck contractor to stain the shade sail posts as well to match. Next up, it was was time to install the shade sail.

DIY Shade Sail Installation

Now came the exciting moment. It was time to install the sun shade sail.

I could start installing the hanging hardware and secure the shade sail fabric.

The hanging hardware shade sail installation kit consisted of several stainless steel eye hook pads, carabiners and adjustable turnbuckles.

The eye hook pads were bolted to the wall studs on the house. I had previously purchased some heavy duty eye hook bolts for the 6 x 6 posts.

Looking back, I could have just used some more of the eye hook pads that came with the hanging hardware kit instead.

For tensioning the shade sail fabric, I used the adjustable turnbuckles. These turnbuckles provide two hooks on either end.

As you turn the middle adjustment piece, the hooks extend or retract, depending on the direction you turn. They are perfect for sun shade sails to get the correct tension for your fabric.

Here’s a picture of the hanging hardware on the 6 x 6 support post during the shade sail installation:

Here’s a picture of the hanging hardware for the shade sail installation on the house.

Notice that I had to use some carabiners to increase the length a little:

The turnbuckles were all tightened to roughly the same settings, and the shade sail fabric felt well tensioned.

Our DIY shade sail installation was now completed at this point, and we were very happy with the results.

It took me little over a week to complete the sun shade sails project.

Although most of the time was spent scratching my head over relocating the 500 lb rock, and waiting for the concrete to dry.

The shade sail installation project was completed for $150, just as I had estimated.

Here are some pictures of the completed summer shade sail on the patio:

Using the DIY Shade Sail

The shade sail works great and has been keeping our patio nice and cool. It was perfect for the party too.

It takes just a few minutes to set up or take down.

The posts are obviously permanent, but we have plans to turn them into solar powered lights. Stay tuned for the post 🙂

I will note though that the effectiveness of the shade sail changes during the day as the angle of the sun changes.

It’s most effective when the sun is directly above.

Other times, the shade it casts is not always 100% over the covered area. It still provides a lot less sun than if we had nothing at all, but it’s not complete coverage.

During winter or heavy storms, we can easily take the sun shade sail fabric off. Then, we just store it until the warmer months.

Snowfall would be too much weight for the structure. And, extreme gusts of wind could put unnecessary stress on the supports.

Rain is not a problem though.

The shade sail fabric is made to allow rainwater to fall through and not pool at the top. They also make shade sails that are waterproof.

Overall, we have been so pleased with our new sun shade sail on the patio, despite the rocks and rain I was thrown during the DIY shade sail installation.

The shade sail provides much needed cover from the sun during the hot summer months. Additionally, we spent such a small amount of money compared to what an awning or screened porch would cost.

We highly recommend sun shade sails for the easy installation and great price.

If you are looking to get more shade on your patio for a budget or to cover a kids play area in a sunny yard location or even to give farm animals some shade, definitely check out sun shade sails.

I’m sure you’ll be impressed.

Shade Sail 3 Year Update

It’s been three years since we installed the shade sail and its posts. Everything has been holding up great.

The shade sail stays up all summer, and then we take it down and store it in the shed during the winter months.

Once in a while, we get a bad wind storm, and we usually take it down then too.

The shade sail posts have held up perfectly. They barely even look weathered.

One of our favorite things about the shade sail is how flexible of a space it gives us.

We get great shade from it on our patio. It’s perfect for parties and outdoor entertaining on warm days.

But, looking out our back windows from inside the house, the shade sail obstructs the view of the backyard – especially the gorgeous sunsets.

That’s what we love about being able to take the shade sail down.

If we turned our patio into a covered porch, we wouldn’t get that same flexibility.

So all in all, I highly recommend sun shade sails. We’ve even had a few readers who have installed the shade sails over kids’ sandboxes and over a chicken coop, too!