Outdoor Projects

Most Popular DIY Projects of 2016

December 31, 2016 by Eileen 54 Comments

The end of year is always so bittersweet – reflecting on all of the amazing memories, but grateful to move on from some others.

One of the best things this year was our blog. We have always loved sharing our home projects with others, but documenting them as been amazing!

We even started including some of our more crafty endeavors.

Creativity definitely inspires more creativity.

My love for organization inspired a few of Ash’s garage projects this year. While, Ash’s constant repurposing “junk” has rubbed off on me.

I love that we continue to inspire each other.

Here are our best DIY projects from 2016. In true New Years Eve style, here’s the countdown:

#10 – CD Tower to Pantry Shelf

This CD tower was ready to be kicked to the curb, until Ash had the brilliant idea of using it for built-in pantry storage.

He cut a hole into a pantry wall, used a cool little gadget to search inside, knocked more of the wall, and inserted the tower.

#9 – Ice Cream Sundae Gift Box

Wrapped in a pretty little box and adorned with ribbon, this Sundae Gift Box was a hit!

Much cheaper (and cuter) than ordering from the store, it has everything you need to make a sundae.

It’s a perfect gift for those who need a little happiness 🙂

#8 – Built-In Bookshelf with a Window Seat

Hands down, this is my absolute favorite of our DIY projects. In just a few weeks, Ash turned a boring old wall into a complete dream.

Not only does this built-in beautifully store all of the books I have collected, but it’s bright, airy, and gorgeous.

Not to mention the window seat, which is aesthetically pleasing and the cabinets below are awesome storage.

#7 – Chalk Paint Makeover

The before and after on this one is shocking! My dad’s jaw dropped, and he is usually only impressed with Ash’s projects.

This was my first experience with chalk paint, and I am sold. 2017 will definitely be bringing more chalk paint makeovers. This was one of our DIY projects with the biggest transformation.

#6 Picnic Table

Ash blew me away with this one too – as he built this in ONE day!

The table top and bench seats are made of composite decking – a durable, safe material that’s easy to clean, and is easy on the eyes.

We’ve had it in the yard for about five months now, and it looks just as great as it did on the first day. If you are looking for DIY projects that are cost-effective and simply, build a DIY picnic table.

#5 – Kitchen Cabinet Makeover

Our kitchen got a major makeover this year, as we gel stained the cabinets, painted the walls, and installed tile backsplash.

Yet as far as cost goes, you can’t beat it.

I was hesitant to take on such a big project, but I started small (with the bathroom vanity) – and went on to completely change our kitchen’s look.

#4 – Building a Shed

When Ash told me that he was going to build a shed, I laughed – I thought he was joking! He only had a few DIY projects under his belt, and building a shed is like building a house!

However, his motivation, attention to detail, dedication, and love of learning resulted in this beautifully built shed.

I am still in awe.

#3 – Wedding Wine Basket for First Year Milestones

This sweet wedding milestone wine basket has been on the trend this year!

It’s a creative, personal gift, and I’ve done all the work for you – as I’ve included all of the printables I used for free!

It’s so much fun to make that I’ve been waiting for more friends and family to marry, so I can make more 🙂

#2 – Green Rain Barrel

After watching me lug gallons of water down the backyard to water my plants, Ash created an eco-friendly rain barrel.

Using a trash can, he made a system that collects rain water to reuse. Thus, eliminating my trips back and forth and saving good water!

# 1 – Folding Workbench

Tired of working on the floor, Ash finally had a chance to build a workbench of his own – which was a dream of his.

Always thinking of how to save space, he came up with a floating design that doesn’t compromise any structural integrity.

Through being featured on sites such as Life Hacker and Make, it brought tons of visitors this year, thus earning our number one spot.

Well, that’s all, my friends.

Wishing you a very happy new year!

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.

Six DIY Weekend Projects That You Will Love

September 19, 2016 by Eileen Leave a Comment

With the cooler weather coming in, it’s the perfect time for weekend DIY projects. There’s something about the crisp, clean air that motivates me to accomplish more.

If you are anything like us, you are probably looking to get a few fall projects under your belt too.

The best projects are weekend ones, as I also love a project that only spans two days!

Plus, you can start and finish something amazing before the Monday morning blues set in.

From garage storage to backyard updates to kitchen upgrades, we are sharing quite a few home projects that only span a couple of days.

My personal favorite is the outdoor picnic table – it turned out so beautiful and we saved hundreds!

So, without further ado, here are six projects that you can complete over the course of the weekend.

1. Outdoor Picnic Table

Ash built this picnic table in just one day!

Imagine my surprise and delight:)

It was simple to make, and the results were beautiful. We especially love the composite decking on the tabletop and the seats, as it involved no staining or sealing – and provides a nice safe material to have meals on.

As for cost, this was a steal ($160!) compared to the cost of this type of outdoor furniture at the landscaping and home improvement stores, and it looks just as wonderful. It was definitely one of our favorite weekend DIY projects.

For a step-by-step tutorial, read Building a Picnic Table in One Day.

2. French Door Pantry

In our old house, we had an eyesore of a pantry.

It was nothing more than a nook of shelves with drawn curtains. It was nothing short of awful.

In sprucing up our house for our move, I was looking for ways to make our kitchen look less dated, without updating the counters and cabinets.

The idea of putting French doors then hit me. Ash agreed – he loves my design decisions…:)

We found a reasonable pair, installed them, and painted them white.

I couldn’t have been happier to see those awful curtains go – it was definitely a rags to riches moment!

It took a mere weekend of work, and I’m sure the nice folks who bought our house are enjoying them.

Check out the before and after along, with all the nitty gritty details in From Rags to Riches: Updating the Pantry.

3. Folding Workbench

Building a Folding Workbench for a Weekend DIY Project

This project was one of Ash’s favorite weekend DIY projects because he checked an item off his bucket list, as he finally built his own functional workbench.

It’s definitely a fan favorite, as it’s been featured on quite a few sites, including Life Hacker and Make.

In his post Constructing a Folding Workbench with Storage, Ash shares his plans (it’s an Ash original!) and explains not only this thought process, but all the necessary steps for you to build your own.

It only took two days, and Ash has been reaping its benefits ever since!

4. Sliding Garage Shelves

Ash and I are a little storage-obsessed. I’ll admit that I have a little Christmas stuff addiction, although I won’t even admit how many trees I have.

And, Ash, well he never throws anything away.

In his defense, he creates some really cool things from his hoard collection – including a built-in pantry shelf made from a CD shelf.

Thus, we could never have too much storage.

In our garage, we had a 20-foot corner of space between the wall and the fridge, and Ash turned this into 70 feet of space with stacked, slide-out storage shelves.

These shelves are awesome, storing some of our holiday decorations.

The slide-out feature provides easy access to boxes in the back, along with easy steps up to the top.

Not to mention, Ash created bonus shelving with the leftover wood.

If you love storage space as much as we do, check out Creating More Garage Storage.

In just a weekend, you could have yourself your very sliding storage shelves, just in time for the holidays.

5. Wooden Mower Wagon

Build a Utility Cart in Just One Weekend

Inspired by a trip to the strawberry fields, Ash had his mind set on building a trailer for his riding mower.

He figured he could haul yard waste to the curb more easily and even take the family on a few tractor rides.

His vision became a reality with this custom-built wagon.

When he finished the wagon, no one but Zeus was around – so he got the first ride. 🙂

Ash gives all the details, from basic construction to assembling the axles to hooking up the hitch connection in his post How to Build a Wagon for a Riding Mower.

After using it all summer, Ash found it more helpful than he originally thought, and he’ll continue to use it this fall bagging up all of the leaves.

6. Boardwalk Pathway for the Backyard

Thinking about tackling a wooden pathway project? It’s easier than you think. With just a few hours of work, Ash created a perfect path from our patio into the backyard.

Prior to this boardwalk, there was a narrow pathway with a few uneven rocks, so this was quite an upgrade. It took a little digging, but it was completed in a just a weekend – making it a perfect weekend DIY project.

After a year, it gets used each and every day and is holding up great. Looking for a boardwalk solution, read A Wooden Pathway for the Backyard.

All of these weekend DIY projects were tackled in just one weekend.

Make your Monday a little happier next week, knowing you created something awesome during your two day break.

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!

How to Make a DIY Yard Utility Cart

July 30, 2016 by Ash 45 Comments

Whether you need a wagon, a garden cart, or a lawn mower trailer, this simple DIY cart can do it all. This easy tutorial will show you how to build this yard cart complete with simple wagon steering.

Ever since I got a riding lawn mower, I’ve been waiting for the chance to do something really cool with it (other than cut the lawn, of course).

We had recently went to a farm to go strawberry picking, and they shuttled us to the field in a hayride. I joked to Eileen that I should build our own hayride to pull the family around the backyard.

But then I got thinking how useful a DIY wagon cart would be, especially for my yard work (and previous yard work – like the boardwalk we just made).

So, as many great inventions once started with a mere joke, so did my next project.

I was going to build my own lawn tractor cart. The following tutorial will show you exactly how to make a wagon too – complete with simple wagon steering.

Planning the DIY Utility Wagon

I was really excited for my DIY garden cart. Aside from the original purpose of a wagon ride around the yard, it could really help me save time in many other tasks (particularly when refuse pickup day comes, and I had to haul 10 heavy bags of grass clippings to the curb).

I looked at many commercial lawn mower wagons, trailers, and utility carts in the past, so I had a pretty good idea of how to make a wagon.

In the past, I had once considered buying a wagon utility cart, but never got around to it because of the cost and small sizes they came in. If you’re wondering how to make a wagon, keep reading for all of the wooden wagon construction steps. It’s really quite simple.

The actual construction of the DIY wagon was not going to be that hard. It was just a platform with a fence.

Since the DIY wagon was completely custom-made, the wheel system needed to be built from scratch. I had a rough idea of what the wagon steering assembly entailed. But I still how to figure out exactly how to to make an axle for the wagon.

Wheels would need to be mounted to an axle, which would be mounted to the base of the wagon.

Even though I knew this, I still had lots of questions, such as what would prevent the wheels from sliding off the axle, or the axle from flying off the wagon?

How to Make a Yard Utility Cart

I did a lot of research on wheels, axles, and bearings and gained some exceptional knowledge on wheeled machines. I made my list of materials and started my wooden wagon construction.

How to Make an Axle for a Wagon

In learning how to make an axle for a cart, the following steps will show you the materials you need and how to put the wagon axle together. First, each axle consisted of some pillow blocks, washers, shaft collars, end caps, and wheels.

Materials for Building the Wagon Steering Axle

My homemade wagon steering axle system would be comprised of the following:

4 pneumatic tires
4 locking pillow blocks (explained below)
2 axle rods
4 locking shaft collars
4 axle rod plastic caps
a number of spacing washers

Pillow Blocks for Building the Wagon Steering Axle

A pillow block is a support pedestal used to mount a spinning axle to a flat surface. It contains a bearing that lets the axle spin independently of the mount.

The ‘locking’ feature of the pillow block is just a screw that you tighten that prevents the axle from sliding out of the bearing.

The pillow block housing comes with attachment holes to let you bolt it onto a surface (in my case, the underside of the wagon).

Here’s a picture of one of the pillow blocks I used (The bearing on top fits into the blue housing below, and the axle rod slides into the bearing):

Spacing Washers for Building the Wagon Axle

In learning how to make a wagon, it’s essential to understand how the wheel parts go together.

First, the two locking pillow blocks are secured to the wagon. Then the axle is inserted into the pillow blocks and locked into place with the block screws.

Before the wheels can be put on the axle, some spacing washers need to go on first.

It’s generally a good idea anyway to use washers to separate spinning parts, but I needed them specifically to enforce a minimum distance between the pillow blocks and the wheels.

If I didn’t put a small distance between the two, then the pillow block mounting bolts would be too close to the edge of the wagon, and risk splintering the wood, or worse, ripping right out the side during usage.

Wheels, More Spacing Washers, and Shaft Collars for the DIY Wagon

So after the spacing washers were put on, the wheel comes on.

After the wheel comes another spacing washer, and then a locking shaft collar.

This is essentially a fat ring that you slide onto the axle rod and becomes immovable once you tighten a screw on it. It’s a lot like the locking mechanism on the pillow block.

The shaft collar is the key part needed to prevent the wheel from sliding off the axle.

Shaft collars come in a variety of flavors. I chose to go with a 2 piece clamping collar. This type of collar comes with two half circles that screw together to form a ring.

I chose this type because compared to other types of shaft collars, it provided a larger amount of force to the axle to prevent it from moving.

Here’s a picture of the shaft collar I used:

End Caps for Building the Wagon Steering Axle

Finally, after the shaft collar comes the axle rod plastic cap. This is just a cap that you hammer onto the edge of the axle. However, it really has 3 purposes.

First, the axle rod has some sharp edges on both ends, so I didn’t want it digging into things and doing damage.

Second, it provides an additional layer of locking protection to prevent the wheel from sliding off. Albeit the locking shaft collar will do its job just fine, but it never hurts to have something extra to re-enforce it.

Finally, it finishes off the wheel setup giving it a nice aesthetic look.

I did a lot of shopping around online and found the best prices to come from Zoro.com and Amazon.

Also, I got some great deals on Amazon for 10” pneumatic tires and some ⅝” bore pillow blocks.

The rest of the parts came from Zoro. Additionally, I made sure that all the parts fit on the axle size I was using, which was ⅝”

Here is a picture of the assembled wheel structure (see what a nice finishing touch the end plastic caps give):

Here’s a close-up of the pillow block and the spacing washers:

How to Make a Wagon Chassis

With the wheels for the lawn mower trailer completed, I could focus now on the wagon platform.

This step of the DIY wagon was going to be a piece of cake.

Chassis Materials

The lawn mower trailer wheels were going to be mounted on 1 ft blocks of 4 x 4s. Those blocks would be attached to a rectangular frame made of 4 x 4s.

I planned on using pressure-treated wood for these foundational 4 x 4s. They were going to be underneath the DIY wagon and exposed more to insects.

Any structural damage to the foundation would be catastrophic so pressure-treated wood seemed a necessity.

However, knowing that people would be riding in the utility wagon at some point, I didn’t want them in close proximity to the chemicals used in PT wood, so the DIY wagon floor and above would be regular wood.

Also, I did plan on using deck stain on the lawn mower trailer to protect it from water and weathering.

On top of the frame would be some 2 x 8 planks for the floor of the wagon.

Attached to the perimeter of the wagon would be a fence made of 2 x 4s.

Finally, the rear of the garden cart would have a swinging gate to allow easy access into the wagon.

Here’s my TinkerCad design of the vision I had in mind:

Chassis Design

In building your own lawn mower cart, the rectangular frame underneath the DIY wagon needs to be strong, as it will comprise a majority of the foundation.

So I used half lap joints to secure the corners of the frame (see my mailbox post where I used a center lap joint).

I made repeated cuts with my circular saw to get rough cut of the joints.

Then I used my chisel and hammer to clean up the cut, and smoothed it down with a sander.

Here’s a picture of a half lap joint in the process of being made (for efficiency and consistency, I clamped two 4 x 4s side-by-side to get 2 joints cut at the same time):

Here’s a picture of the lap joints completed, and the rectangular frame is ready to come together on the DIY utility cart:

To connect the joints securely on the DIY wagon, I used wood glue and lag bolts.

I also wanted the lag bolt heads flush with the surface of frame, so I used a Forstner bit to carve out smooth holes to countersink the bolts.

Here’s a picture of the completed frame of the diy cart bolted together with glue:

Forstner bits are awesome. I just added them to my tool collection and have been using them in a lot of recent projects.

Here’s a close up the holes they made for the bolts:

To complete the foundation, I attached the 1 ft blocks that the wheel axles would be fastened to.

They needed to be firmly attached, so I used wood glue and two 6” bolts to make a strong connection.

Here’s a picture of one of them:

Making the Wagon Floor

Next up was the floor of the lawn mower trailer. I used 2 pieces of 2 x 8s for the center, and 2 pieces of 2 x 10s for the ends.

I attached them to the 4 x 4 frame with some countersunk deck screws.

Here’s a picture of attached floor while building the wagon:

Attaching the Wheel Axles

In learning how to make a wagon, the moment of truth came.

It was time to attach the wheel axles to the frame of the DIY wagon. I bolted the pillow blocks tightly and flipped the frame over.

Would the frame roll smoothly… (drum roll please).

Yes it did!

Here’s a picture of the attached wheels and frame on the lawn mower trailer:

Here’s an underneath close-up of a pillow block mounting to the frame:

I could stop right now and have a gigantic skateboard, but the fun was only beginning. It was time to build the wagon fence and gate.

Building the Fence and Gate on the Lawn Mower Trailer

This part of the DIY wagon project was really easy.

I just cut a number of 2 x 4s. Some were attached to the 4 x 4 foundation frame to serve as posts, and the rest were used as cross pieces screwed into the posts.

For the swinging gate on the homemade wagon, I used some 1 x 3 wood leftover from a previous project.

I made the wagon’s rectangular gate frame with some pocket holes using my trusty Kreg pocket hole jig, and some wood glue.

Here’s a picture of the wagon gate in progress:

Here’s a picture of the DIY wagon with the finished fence and gate (it looks great, doesn’t it?):

Attaching the Hitch to the Lawn Mower Trailer

Prior to starting work on the utility cart, I had done some research on how to actually connect it to the mower.

I found a contraption that let me attach a 2” diameter hitch ball to the back of the mower.

They’re called universal garden tractor hitches.

I also found an adjustable tow bar that would bolt onto a sturdy metal vehicle bumper (like some Jeeps). This would be perfect for my wagon.

I could bolt the connection to my DIY wagon, and attach the other end to the hitch ball on the mower. In theory it sounded good, so I hoped it worked in practice.

Here’s a picture of the hitch and tow bar linking the utility cart to the riding lawn mower (the tow bar can be easily detached on either end when not in use):

Now it was time to test the riding lawn mower and the DIY wagon together. I started up the riding mower and slowly let the brake go.

It started pulling the DIY trailer without hesitation!

I was worried the engine would struggle, but it did not. I did a few laps around the yard and my lawn mower was pulling the DIY trailer perfectly.

The First Ride on the DIY Wagon

Now, I just needed a test subject.

After all, what’s the fun in pulling around an empty wagon?

Eileen was on the phone, and I was anxious to try out the DIY wagon with someone. Then I looked at the house and who did I see looking out at me but my dog Zeus.

Perfect timing!

Here’s a picture of me testing out the lawn mower trailer with my first test subject:

I later applied some deck stain to the non-pressure treated wood, and the utility cart was completed.

Since learning how to build a wagon, I’ve given many rides in the backyard. I’ve also hauled many bags of refuse to the curb in minutes with this DIY wagon, saving a lot of time.

It does take a few minutes to hook up the wagon to the mower though. So I don’t always use it attached.

Although, it works just fine as a stand alone utility wagon when I don’t feel like hooking up the hitch.

Now for some pictures of the DIY wagon hard at work.

This was was taken when I needed to move a lot of equipment into my storage shed from the garage.

What would have normally taken me several trips, took just one with the utility trailer:

Here is the DIY wagon hauling 10 bags of refuse to the curb.

I used to use my wheelbarrow, but that would only hold 2 bags at a time. It pales in comparison to the wagon. This DIY cart holds so much more, as you can see (below):

Finally, here’s a glamour shot of the DIY cart functioning as it was intended: as a riding lawn mower tractor trailer.

Time and Cost of Building the DIY Garden Cart

The total cost of my DIY wagon project was around $120. The garden cart was one of my most fun projects to date, and best of all, it was completed in just a weekend.

If you are looking for some help with the yard work or a fun fall ride, follow this tutorial on how to make a wagon that functions as a utility cart, wagon, or trailer, and you’ll be up in running in no time!

Utility Cart 3 Year Update

The wagon has held up great. It’s amazing how much the wagon holds, in comparison to my old wheelbarrow. It’s also perfect for loading up things from the garage that need to go out to the shed in the yard.

The tires on the wagon lasted several seasons. However, they started to lose air after last winter and cracked.

Instead of simply replacing them though, I felt like it was a good opportunity to upgrade the wagon.

Since I found myself pushing the wagon around the yard more than I thought I would, I decided to swap out the front wheels with ones that swiveled in the front.

I was thrilled with the upgrade, as it made pushing and turning the wagon by hand very easy. If you are going to push your garden cart around by hand, I definitely recommend starting out with front wheels that swivel.

Building a Picnic Table in One Day

July 7, 2016 by Ash 54 Comments

When we were getting our yard ready for spring, we took a trip to our local landscaping center to look at their plants.

On their patio, they had an array of beautiful outdoor furniture. Eileen sat down at a picnic table she liked, looked at the price (a very high $450), and said to me, “I bet you could make this.”

I nodded, thinking about all of the creative things Eileen and our son do in our yard, like having backyard picnics, bubble-making, and painting.

Having a DIY picnic table in the middle of the backyard would be perfect.

Plus, I’m always up for a good woodworking project.

Researching Picnic Table Plans

I did some research online for how to build a picnic table and ended up choosing the first one that came up – PopularMechanics.com.

It seemed simple to construct and the design plans were of a high caliber. The best part was that this picnic table plan called for using composite decking for the tabletop and seats.

This eliminated any concerns I had about having to use pressure-treated wood in close proximity to foods, or having to spend time staining or sealing the surface of the DIY picnic table.

Cleaning the composite decking on the picnic table would be a cinch too. It was a little more expensive than using real wood, but it was worth it.

The rest of the wooden picnic table (legs and supports) would be regular pressure-treated wood, so costs would still be low overall.

The specifics of how to build a picnic table is outlined pretty well in the source website, so I’ll just recap my picnic table building experience.

Overall, it was quite a fun project to work on, and best of all, I accomplished it all on a Saturday (albeit a long Saturday from morning to night).

DIY Picnic Table Material Order

I printed out the materials list from the website, and then I placed order on Lowes’ website for in-store pickup.

I normally don’t like doing store pickup for lumber because you are at the mercy of whatever employee is selecting your wood.

This usually means a random assortment of quality, with crowning knotty boards.

Money-Saving Tips

However, I found an awesome deal on eBay for multiple $15 off $50 Lowes coupons, and they were valid online only.

Using an Excel spreadsheet, I distributed all the materials across 4 separate orders to total just over $50 each.

Then I purchased 4 of the coupons on eBay for a mere $4 (coupon codes were emailed to me immediately after purchase) and placed four Lowes store pickup orders. Just $4 on eBay saved me $60. Not bad! The Lowes guys didn’t mind when I went to pick up the order either.

Here’s my car full of wood after the lumber excursion to Lowes (ignore the concrete and the pipes – they are for an upcoming shade sail project):

I did have to get some wood cut in the store for the picnic table. I ordered several 12 ft pieces of composite decking and I knew that wouldn’t fit in my car.

So I had an employee cut them in half for me. Having the store cut your wood is convenient, but it’s not always worth it.

Their cuts aren’t that accurate, and sometimes you have to wait a while to get help.

Additionally, there seems to be a trend starting in stores to charge you for too many cuts.

Always thinking of how I can save money, I brought a measuring tape and a handsaw in case I decided to cut the picnic table wood myself in the parking lot.

As it turned out, a thunderstorm appeared out of the blue when I got to Lowes, so that forced my hand and I had to have them cut it for me. They usually charge 75 cents for the cuts, but they waived it.

How to Build a Picnic Table

The first step in my how to build a picnic table project was to cut all the wood. So when I got home, I spent an hour cutting all the wood according to the plans. This hard work resulted in the picture below.

Doesn’t it look like a kit just waiting to be put together?

The next step in building a picnic table is to put together the picnic table’s legs:

Here comes the tabletop support:

Next up was the pair of seat supports for the DIY picnic table:

Here are the five pieces of the picnic table project that would soon come together to form the table’s skeleton:

I clamped some of the pieces together and picnic table project was now three dimensional:

With the seat supports attached, it was starting to look like a picnic table now:

Here I used a diagonal support beam to prevent the picnic table’s legs from shifting inwards:

Here I had to reinforce the structure with some 3.5″ galvanized carriage bolts to support the weight of people and tabletop loads:

It wasn’t too early to take the DIY picnic table for a test drive. Here I am taking a break from the work:

Finally, the crowning moment of the project came when I attached the composite decking on the DIY picnic table.

I highly recommend using a countersinking bit for pre-drilling the holes for the deck. I believe they make special screws for composite wood, but I didn’t have any.

At first, I used regular deck screws, and without a countersink bit, they did not look good after the head penetrated the wood.

Unlike real wood that compresses under the screw head, the composite material made a really ugly blemish on the surface.

After trial and error, I found the countersink bit did a wonderful job carving out a notch for the screws.

I used my router and a round-over bit to smooth/bevel the edges of the deck wood:

Finally I completed the DIY picnic table. Eileen helped me move it into the backyard. It was extremely heavy, but that was just a testament to its quality.

Here’s what the picnic table looks like in its element (notice our garden planter and rain barrel in the background).

The total cost of this professional quality DIY picnic table ran us $140, but that’s after a $60 discount via the $4 eBay coupons.

I estimate a pre-built picnic table of this quality would have cost a few hundred dollars in the store and even more at the landscaping stores!

If you are thinking about buying a new picnic table for your yard, instead learn how to build a picnic table with these plans and tips. We are absolutely loving the DIY picnic table, especially the composite tabletop.

Our DIY picnic table is already getting a lot of use and is sure to be a hit at our next BBQ.

How to Build a Wooden Walkway for the Backyard

June 30, 2016 by Ash 35 Comments

When we moved into our new home, we had an amazing backyard, but it was missing one thing – a clear path from the patio into the backyard.

The patio was somewhat secluded with a row of bushes around its perimeter. To get out to the grass, you had to use a little rock path.

Right away, Eileen mentioned how this “walkway” wouldn’t work for our family. The rocks were uneven and the ground had a sharp decline.

On top of that, the pathway was so narrow, as the bushes had grown bigger than probably anticipated. She was worried about our little one tackling those rocks or our dog scampering through the bushes each time he went out.

Eileen had some solid points, so a new walkway got added to the list.

Pictured below is the best before picture we have. Unfortunately, it doesn’t give much of a picture of the little rock pathway, nor does it give a good feel of how large the bushes had grown and just how narrow the walkway was. Better than no picture?

Planning the New Walkway

The solution we decided on was to relocate one of the bushes to another part of the yard, and to install a boardwalk type pathway into the yard from the patio.

Transplanting the bush was easy.

I just dug around the root system until I was able to lift the plant out of the ground. I dug a comparable hole nearby and plopped the plant in, packing down the dirt and giving it a good watering.

We filled the old hole with dirt, and raked the ground really well to prep it for the new walkway.

I predesigned the walkway on TinkerCad to get a feel for how it would come together and also how much wood we would need to purchase.

The patio was at a higher elevation than the yard, so there was going to be a slope to the walkway.

Here’s a picture of the 3D plan for the walkway (grey part being the patio, and the green being the grass):

With most outdoor projects, the walkway was to be built with all pressure-treated wood.

This was especially important for the walkway as it was going to be in direct contact with the ground allowing easy access to bugs.

For the structure, I planned to bury four 4 x 4 posts at each corner of the walkway.

The upper and lower posts were to be connected with a 2 x 4 support beam which the boardwalk planks would screw right into.

Here’s a picture of underneath the walkway, showing the support beams:

How to Make a Wood Walkway

Construction went smoothly for the walkway. I first cut the corner posts to length. Then using a post hole digger, I dug 2 ft deep holes for each post.

At the bottom of each hole, I packed down a layer of gravel to provide a sturdy foundation for the posts. Then I just dropped in the posts and filled in the surrounding space with dirt.

I also used an 8lb tamper to pack down the dirt really well around the posts.

I then cut the support beams from 2 x 4s and screwed them into the buried posts.

Afterwards, I cut the boardwalk planks from 2 x 6s and screwed them into the support beams.

Finally, to weather-proof the project, we put down two coats of deck stain.

The wooden walkway construction was now complete.

Pictured below is the completed boardwalk, with the family member that uses it most 😉

Here’s another shot, which shows a little more of how the wooden pathway connects the patio to the backyard. It also shows the slope.

Using the Wooden Walkway

A year later, we are still so pleased with how the wooden walkway turned out.

It was the perfect solution to the narrow path problem we once had. It’s perfectly sized, regarding its width and its steepness. Toddlers can handle the slope very well.

It’s very sturdy and it doesn’t get slippery in the rain or the snow. Slipping has not been a concern; however it is down the road, I can always adhere some grip tape to the wood.

Best of all, the boardwalk did not cost much or take very long to make. We spent under $50 and completed the project in one day.

If you are looking to build a wood walkway for your yard, it’s budget-friendly, sturdy, and holds up great. You won’t be disappointed!

How to Beautifully Fix Up an Old Mailbox

June 23, 2016 by Eileen 14 Comments

Having recently moved, we loved our beautiful new yard. It was spacious and neatly groomed with lots of seasonal foliage.

However, there was just one thing that needed a fix – our leaning mailbox. When I opened the box to collect our letters, the mail would literally fall right out.

To make matters worse, the wood on the mailbox post seemed to be rotting. And, there was the day that the mail was covered with ants.

Here we had this amazing yard with an eyesore of a mailbox. I was on a mission to fix the old mailbox.

Here’s a closer picture of our mailbox before the makeover. You can’t tell just how badly the mailbox was leaning in this photo, but you can see how badly the mailbox needed to be beautified.

I was hoping Ash would take on this mailbox fix project soon, but he was preoccupied building the shed.

So, I did want I do best, and I got project “how to fix your mailbox”rolling.

Planning Mailbox 2.0

To kick off fixing up our mailbox, I did what I usually do for exterior projects: I went on a few walks around the neighborhood looking at other mailboxes, deciding what I wanted for version 2.0.

Taking walks around your neighborhood is almost like searching through Pinterest. You can see what you like, see what you don’t like, and make an idea work for you.

For our updated mailbox, I decided on the classic look of a white mailbox post with a black mailbox, as it really made the red flag pop.

To keep the mailbox momentum going, Ash made the material list, and I offered to pick up the materials.

I love using Home Depot’s store pick-up, especially for heavy items, since the materials are already pulled aside and placed in a cart.

Then, all I have to do is get them from the cart to the car, which usually is not a problem.

This time, I struggled a little with the 6 ft posts – they were a lot heavier than they looked! Yet, I managed, as I was determined to not catch our falling mail anymore.

With the materials for the mailbox now laying around the garage, Ash started working on the new mailbox post. Victory!

How to Build a New Mailbox Post

The mailbox post design was fairly simple. It consisted of 2 perpendicular pieces of 4 x 4 pressure-treated wood joined together with a lap joint.

The vertical 4 x 4 would have about 2 feet submerged into the ground for support, with the remaining 4 feet above ground. The horizontal 4 x 4 served as a mounting piece for the mailbox.

Finally, a shorter piece of 4 x 4 ran diagonally below this horizontal 4 x 4 to provide additional support, stability, and aesthetic appeal.

The first step of the mailbox post process was cutting the 4 x 4s. After, Ash created the lap joint.

This joint was very simple to make and was very strong. It involved cutting out half the thickness of 2 pieces of wood, and combining them together, as in the diagram below:

Next, Ash had to cut the grooves.

He used his 7 1/4″ circular saw, with the depth of the blade set to half the thickness of the 4×4 (so 1¾”).

Then, he repeatedly ran many perpendicular cuts into the wood, staying within the confines of the outlined groove. This left him with slivers of wood that he easily removed with a hammer and chisel.

Finally, he used a small Mouse sander to smooth out the carved groove, since the chisel left it a little rough. If you happen to have a set of dado blades for your table saw, you can also use those to cut the lap joint groove. (I’ll have to remember that when I need a gift for Ash.)

After repeating the process for the second piece of 4×4, he applied some construction adhesive to the grooves and merged the 2 cuts. He further strengthened the joint with 2 lag bolts.

Using 2 more lag bolts, he attached the diagonal support piece to reinforce the mailbox arm. The new mailbox post now had its basic design.

How to Paint the Old Mailbox and New Post

I then applied 2 coats of white exterior paint to the mailbox post and let it dry overnight.

The next day happened to be Sunday, which was perfect for replacing the existing mailbox (no mail delivery). We didn’t want our mailman puzzling over where to deliver our mail.

The old mailbox came out quickly. I unscrewed the box itself and put it aside for some refurbishing.

I removed the red flag post and sprayed the metal mailbox container with some black exterior spray paint.

If you are looking to fix your mailbox – fresh paint works wonders.

How to Install a New Mailbox Post

As the paint was drying, Ash used a sledge hammer and pounded the old rotting mailbox post out of the ground.

We started to think about how to securely install the new post, so we wouldn’t have to deal with another slanted mailbox down the road.

The old post was just stuck in the ground with a long metal spike, and over time, it started leaning forward. So, in figuring how to fix our leaning mailbox, we decided to use concrete.

So, Ash prepped the new mailbox post by partially screwing in some lag bolts at the bottom.

These bolts would be engulfed in concrete and provide some extra grip to prevent the mailbox post from lifting up out of the concrete.

They would also give the mailbox post a lot of stability and help prevent any wiggling inside the concrete over time.

He then dug a 2 feet deep hole where the mailbox post would be going. Then, Ash made the hole about 1 foot wide for the concrete.

Of course, Ash sent me to Home Depot again for a 50-pound bag of concrete mix for fixing up the mailbox post. (Good thing I have practice from those 40-pound dog food bags!)

Before mixing the concrete, he had to get the mailbox post in place and leveled properly. He dropped it in the hole and used a level to get it standing straight up.

Then using some scrap wood, he nailed on some temporary wooden supports to keep the mailbox post in place.

For the concrete, Ash emptied the mix into the wheelbarrow. Then, he used the original packaging box as a measurement cup and added in the correct proportions of water per the directions.

He gave the mixture a really good mixing with a shovel until all the chunks were gone and a nice flowing slurry of concrete was left. After, he tilted the wheelbarrow and carefully poured the mixture into the mailbox hole.

Ash let the concrete dry for most of the day in the hot sun. By evening time, he was out working again. He removed the temporary supports from the mailbox post and gave it a gentle push.

The brand new mailbox post stood very firm and straight in the concrete.

Happy with the results, we covered the rest of the hole with extra dirt and packed it down tightly with an 8 lb tamper.

How to Finish Up Fixing the Mailbox

For decorative purposes, I had purchased a pointed plastic fence post cap to install at the top of this mailbox post. It made the mailbox look so stately.

Sized to fit a 4 x 4 mailbox post, it went on very easily. I secured it in place with some small screws.

Then, we attached the freshly painted mailbox to the new post, and adhered some exterior numbering stickers for the address.

Here’s a picture of our fixed up mailbox:

Our slanted eyesore of a mailbox became a stately structure almost overnight.

We now had a beautiful mailbox which suited the rest of the yard. This fixing up our mailbox project that had a huge impact for minimal cost and effort.

If you are looking to fix your mailbox, you can’t go wrong with price or simplicity. The total cost was under $20. We completed it over the course of a weekend. A prefabricated mailbox of this quality would cost at least $80. If you are looking to fix your mailbox up, doing it yourself is definitely the way to go.

The best part? Our mailbox stood perfectly tall at 90 degrees – which meant no more falling mail. You’re welcome, mailman 🙂

How to Install Shed Siding and Roofing (Phase 2)

May 22, 2016 by Ash 11 Comments

Everyone has been asking for the nail-biting conclusion on how to build a shed, so here it is! If you missed the first part, check out Shed Project Part 1.

My plan of building a shed from scratch has come a long way from some sketches on Post-It notes. I started on the shed’s foundation with concrete blocks. Then, I worked my way up through the shed floor and got the wall frame standing firm. If you haven’t read Part 1, be sure to check it out!

After a short break to work on some side projects around the house, it was time to continue building the shed so I could move the riding lawn mower out of the garage.

How to Build a Shed – Installing T1-11 Shed Siding

With the shed wall frame in place, it was time to install the exterior siding part of building the shed.

I used T1-11 plywood siding for my DIY shed.

T1-11 siding is very popular wood paneling siding for sheds. T1-11 plywood is thick enough to be used as the actual wall itself (versus using a thinner plywood sheathing and separate siding).

Also, T1-11 siding (similar to the T&G plywood used for the floor) also has special grooved endings to help the sheets overlap and make a tighter seal at the seams.

Installing the shed siding for your framed structure does more than just enclose it.

At this stage, the framed walls were still wobbly and were not square with each other. The shed siding corrects all of this for you.

When you install the first piece of shed siding onto each wall panel, you use that first piece to align the edge of the wall panel.

Once the wall panel is aligned with the shed siding, you nail them together and that wall panel is squared and locked in place.

Getting Ahead of Myself

Remember earlier when I said I used L brackets to tightly secure the 4 wall panels together, and it backfired?

Well, prior to installing the shed siding, my shed wall panels were not wobbly. They were held very firmly in place because of the L brackets at the corners.

It took me a few minutes to figure out why the walls were not budging when I tried to line up the edges with the shed siding. So I had to undo a lot of the L brackets from the corners to get the shed siding to install correctly.

Once the shed siding was up, I reinstalled the L brackets.

As for the window openings, I initially installed shed siding that covered them up completely.

Once the shed siding was securely in place, I used a mini circular saw to cut out the opening (I highly recommend a compact circular saw for your tool collection – it’s much more convenient than a full sized circular saw and also very precise).

I made another mistake related to the shed siding too. The wall studs in the panels are spaced 16” apart (pretty common construction standard).

The 16” spacing starts at one end of the wall panel. Yet, depending on the length of the wall panel, it could end abruptly, forcing you to place the ending stud at an arbitrary distance.

When installing the shed siding, you always have to start on the end of the panel where the 16” spacing begins (not where it ended prematurely).

Starting on the correct end of the wall panel ensures that every 4 ft wide shed siding sheet ends on a wall stud.

I luckily did this for the 3 sides of the shed. However, the right side of the shed, I did not start siding on the correct end.

Because of this error, I had several pieces of overlapping siding that did not have a wall stud behind it.

Lack of a wall stud at the seams meant there was no way to tighten the overlap between the shed siding sheets and left a gap for rain and bugs to come in.

So rather than re-siding that wall panel, I left it as is, and installed some additional wall studs to nail the seams into.

Rain, Rain Go Away

I worked on building the shed all by myself. Since it was a solo project, it took me longer to finish because it was just me building it. During this time, I had an issue with heavy rain water causing parts of the shed siding to swell and bulge and pull away from parts of the foundation.

After it had rained, I noticed that there were 2 slight dips in the flooring around the edges of the shed foundation that caused rain water to puddle and remain there.

In that same area, some of the shed siding was bulging on the outside. I did some research and found out that unprotected T1-11 plywood siding will start to warp if left exposed to standing water.

So this puddling water was warping my T1-11 siding.

My solution was to drill a few tiny holes into the center of the floor dips to let the water drain. After the next rainfall, I checked the shed and there was no more water puddles.

My T1-11 plywood siding has never warped since.

As for the existing bulges in the shed siding, I could not leave them like that because it would let bugs in. So I used a bar clamp to force the shed siding back into place, and secured it with a few nails.

Shed Roof Construction

With the plywood shed walls finally up, I could start working on the roof.

This was a big milestone for my DIY shed project as it meant the “drying out” period could start (when water stopped entering the interior, and it could soon become usable space).

How to Build Roof Trusses for a Shed

The shed roof required a number of trusses to be built.

The trusses are the shed roof framing, which are the triangular supports mounted on top of the structure that the roof sheathing or plywood is nailed into.

I had to build thirteen individual shed trusses to span the length of the shed.

Here is what the shed trusses look like up close:

In building trusses for a shed, I followed the directions in the shed plans to construct them.

My miter saw really came in handy for building the shed roof, as there were lots of angles to cut.

Where each segment of the truss met another segment, I sandwiched that part between two pieces of plywood and nailed it together securely.

I read a great tip online about constructing the shed trusses. Similar to the framed wall panels, I built them on the floor of the shed. However, this time I use the shed floor to make a jig for each truss.

I needed each of the trusses to be identical to the next. So I built the first truss carefully on the shed floor.

Once completed, I screwed scrap blocks of wood in the floor at strategic parts around the truss.

I lifted the finished truss up and a perfect jig remained on the floor to construct the next one. I didn’t have to spend time measuring and aligning the truss segments.

Next, I just placed each segment into the jig and secured them with the sandwiching plywood.

The blocks of wood screwed into the floor meant that the truss would be a perfect replica of the original one.

How to Attach the Shed Trusses

Attaching the trusses to the shed structure was not as simple as dropping them onto the top and nailing them.

Because of how they rest on the framed walls, there was not much surface area to work with to nail them down securely.

I did some research online, and a common technique was to just toe-nail the truss to the shed (drive some nails into the truss at an angle to penetrate both the truss and the shed structure).

I tried this, but I was not comfortable with the connection it made. There was too much movement, and it did not feel safe to leave it like that.

My solution was to use L brackets on the sides of the trusses and heavy duty 6-inch TimberLok screws driven in from underneath at an angle.

The screws were what really did the job. The L brackets really just held the truss in place so it was easy to drive in the screws. I love the TimberLok screws.

With all the extra TimberLok screws leftover from the shed, I use them in so many projects now (such as my folding workbench and sliding garage shelves) that require a really strong fastener.

Here is a view of the trusses from outside:

How to Install Roof Sheathing on a Shed

Next came the shed roof sheathing. I used ½” 4×8 OSB (oriented strand board) plywood for the shed roof.

The trickiest part of this shed building step was actually getting the plywood sheets onto the trusses. I would recommend getting some help for this part of the shed construction. The shed roof sheathing was very heavy and large to do by yourself.

I was very eager though to get the roof on, and unfortunately no one was around at the time to help. I went through several failed attempts to get the sheets up by myself.

Eventually the technique that worked for me was to lift each plywood sheet up and in between the trusses. This required quite a bit of strength.

Needless to say, I was very sore afterwards, but it was worth it.

Prior to lifting up the plywood sheets, I had screwed scrap siding into the overhanging part of the trusses, giving the lower trusses an edge.

This ensured that when I dropped the sheets onto the trusses, they would not slide off the bottom and fall to the ground.

One by one, I lifted and nailed each sheet down to the trusses in a staggered pattern provided in the plans.

Here’s a picture looking up into the trusses after the plywood sheathing was laid down:

Installing the Drip Edge on a Plywood Shed

With the plywood sheathing nailed down, I installed a drip edge on the overhang of the shed.

A drip edge is specially shaped metal flashing that helps keep water on roof away from your structure, and not run down the side.

Here’s a close up of the metal drip edge on the plywood shed:

Laying the Roof Paper

After the plywood sheathing came roofing felt paper. The roofing paper came in a large roll that I cut into 16 ft segments.

I started at the bottom corner of one side of the roof, and worked my way up. I nailed the roofing paper into the trusses using roofing nails with large plastic caps in the heads.

The caps really gripped the roofing paper without tearing it.

I also liked that the caps for the roof were bright orange. It helped me locate the trusses after the paper went on (it’s important to try and keep your weight above the trusses to avoid doing damage to the sheathing).

I covered both sides of the roof with paper and left the apex for last.

There was a little gap between the roofing sheathing at the apex where the two sides of the roof met. I was a little worried about leaks, so I thickened up the felt paper by applying two layers on the apex.

Here’s a picture of the apex with the extra layer of roofing paper (there are some shingles installed already, but I’m getting to that next):

Installing Shingles on the Shed Roof

After the felt paper, I moved onto the shingles. I’ve always wanted to work with shingles, so I was really looking forward to this learning opportunity.

After a lot of roofing research, I felt confident to proceed in knowing how to put shingles on a shed.

Coincidentally, part of our home’s roof was being replaced at this time by a roofing contractor due to a leak, so I talked to the guy for a little bit and he gave me some useful tips and confirmed that my plan for the shed’s roof sounded solid.

I bought 25-year asphalt 3-tab charcoal colored shingles from Home Depot.

I estimated I needed about 6 bundles of shingles. They are sold in packs called bundles, and each bundle covers about 33 sq.

The individual shingles are rectangular in shape with 3 tabs (as seen in the picture below):

The black line running across the center of the shingle is a tar line.

Shingles overlap one another, and when the sun heats up the roof, the tar line softens enough to adhere to the overlapping shingles.

Applying Starter Shingles on the Shed Roof

To begin installing shingles on the roof, I first had to apply starter shingles.

Some shingle bundles come with special shingle strips called starters that lack the 3 tabs and are just one continuous strip.

Because shingles always need to overlap each other, the first row of shingles on a roof needs a special starting strip, or else the tabs would rest directly on the felt paper below and expose it to the elements.

My shingle bundles did not have any starters, so I just made my own.

I used a utility knife and cut off the tabs from a few shingles. I cut just below the tar line.

Nailing Down the Shingles

With the starter strips made, I nailed them to the bottom edge of the roof, making sure the tar line was on the bottom.

I made sure to extend the shingles about an inch off the edge of the roof. This overhang is important to prevent water from running off the shingles and down the siding.

I know that the metal drip edge was installed below to prevent this, but this was just an extra measure of protection.

After the starters were installed, I was ready to install the regular tabbed shingles.

I overlapped the starter strip with the tabs from the other shingles and drove 4 nails per shingle just below the tar line (with two at the ends and two above each tab slit).

I worked my way across the shed roof to complete the first row. The last shingle in the row needed to be cut, but I left it intact for now, with plans to cut all the excess later.

To start the next row of shingles, I had to offset the first shingle so that the tab slits rested on the middle of a shingle tab below.

If I did not offset the starting shingle, then the tab slits would line up with the slits in the row below and increase the potential of water seeping through the shingles unto the roofing felt.

So using a utility knife, I cut off about 1/6th of the shingle.

I continued this process row-by-row until I got as close as possible to the apex of the roof.

Then I hopped over to the other side of the shed’s roof, and repeated the whole process (installed the starter shingles at the bottom, and worked my way up).

Here’s a picture of the shingles so far:

Finishing with a Ridge Cap on the Shed Roof

The last step to finish installing the shingles on the shed roof was to cover up the apex and form a solid ridge cap.

Once again, I had to cut the shingles to make special pieces for the apex on the shed roof.

Just like the starter strips, I cut off the tabs below the tar line.

Then I nailed each strip across the apex, perpendicular to the rest of the shingles on the sides.

As I worked my way across the apex, I overlapped each strip so each overlapping one covers the tar line on next one.

Here’s a picture of what the apex looked like after installing the shingles:Here’s a picture after installing the shingles on the roof (Eileen just put on a coat of primer on the siding too):

Priming and Painting the Shed

Speaking of primer, Eileen took care of all of the painting on the shed – from choosing the color to the last brush stroke.

And, painting the shed was a project by itself.

The shed took a lot of paint which we greatly underestimated. Here I was thinking how far a gallon of paint went on drywall when repainting a bedroom.

Needless to say, a gallon of primer barely touched the surface of the raw plywood siding on the shed. The plywood soaked up so much of the paint.

So, we went back and purchased a 5-gallon bucket of Zinnser brand primer. Eileen ended up painting the shed with 3 coats of primer.

After the primer, Eileen went on painting the shed with 2 coats of grey exterior paint.

The grey paint on the shed really made it pop, but more importantly, served as a thick protective barrier for the siding against water.

So in total, the shed required 5 coats of paint, taking about a week to complete.

It was well worth the time and effort though, and since Eileen did the painting, I could keep working on other shed tasks.

With the shed now primed and painted, next up was building a ramp for the riding lawn mower, building shed steps for the storage entrance, building doors, and installing the windows.

To keep reading to see how the shed turned out, check out the final post – Shed Project Phase 3 (Building Steps, Ramps, & Doors).

How to Fix Up an Old Lawn Mower

April 24, 2016 by Ash 14 Comments

As the days warmed up and the grass started growing again, it wasn’t too long afterward when it was time to awaken my riding mower from its slumber. When a nice sunny day came, I went out back to the shed, hopped on the mower and turned the key.

Nothing happened. I turned the key again, and again. It was just making a whirring sound. I couldn’t even try applying the choke because the engine was not even trying to turn over.

After trying a few more times, I was dismayed.

I knew I would have some trouble starting up the mower after the winter break, but not like this. It was clear that today was not the day for mowing. It was time to do some investigation and perform some mower maintenance.

I bought the used riding mower on Craigslist last summer. I got a great deal because it was 20 years old and was showing a lot of cosmetic wear. However, the previous owner kept up with the maintenance, and it ran pretty well for its age.

I was also not too of how to fix a riding lawn mower because I had confidence in my repair skills (having brought some old push mowers back to life at my previous home with some replacement parts).

How to Fix an Old Riding Lawn Mower

To prep for my maintenance project, I tracked down the mower manual online, located the consumer replaceable parts and ordered them online.

Then I put together Ash’s grand maintenance plan for reviving your riding mower, as outlined below.

1. Spark plugs and battery
2. Oil filter and oil change
3. Air filter and precleaner
4. Fuel filter
5. Clean out mower deck
6. Replace mower drive belt
7. Lubricate
8. Check tire pressure

Here’s a picture of the left and right side of my mower engine, with some of the areas above outlined:

1. Spark Plugs and Battery

The first thing I did was check for activity in the spark plugs.

Using a special spark plug socket, I pulled one of them out, still connected to the battery, and turned the key. There was no spark. I tried another spark plug that I knew was working (from my push mower), and still no spark.

This led me to believe the battery was low on juice. I had a 12 volt car battery charger, so I was going to try recharging it. It made sense that the battery would be low as the mower had not been run for a few months.

Before I recharged, I wanted to rule out a bad battery (incapable of being recharged). I tested the battery with a volt meter and got 12.4 volts which was actually normal. Any lower readings (especially in the 11 volt range) would have suggested a bad battery.

So I hooked up the battery to the recharger, setting it to 10 amps with an automatic shutdown on full charge. An hour later, the recharger said the battery was ready. I hooked it back up to the mower and tried starting the engine. Still no luck.

So Eileen picked up a new mower battery for me at Lowes (they seemed to have a better selection than Home Depot). I got a 275amp battery (suggested for mowers up to 21hp) making sure that the positive terminal was on the same side as the old battery (or else the wire hook ups would not reach). Here’s a picture of the new battery installed:

Here’s a picture of the exposed spark plug (which I was able to remove using a special socket):

We did bring in my old battery to Lowes for recycling. They give you a small discount (which covered a core charge fee for a new battery purchase).

We also picked up two new spark plugs. I installed the new battery and spark plugs and tried starting the engine…

Success!

The starter motor did not hesitate at all. The flywheel immediately began spinning, trying to start the engine. It did take a few tries to get the engine running, but eventually got it going. That leads me to the next maintenance steps.

2. Oil Filter & Oil Change

Now it was time to change the oil and oil filter.

I located the oil drain plug and setup a funnel and plastic container to collect the old oil. I then removed the oil dipstick from above, loosened the drain plug and out came the oil – pouring out slowly.

When the oil stopped coming, I screwed back in the plug and went to work on the filter. I put a rag under the existing filter to catch any oil that would spill. I twisted the filter and pulled it out of the mower.

Good thing I had the rag in place because a lot of oil came out of the filter. I grabbed the new oil filter, put a little oil on the gasket and screwed it into the mower.

Now it was time to pour in new oil. I poured nearly two quarts of 5W30 oil (picked up at the nearby gas station) down the oil dipstick hole, pausing every now and then to take a measurement with the dipstick to make sure I didn’t overfill.

Here’s a picture of the new oil filter and drain plug:

3. Air Filter and Pre-cleaner

Next up was the air filter and pre-cleaner.

It’s important to have a steady flow of filtered air entering your engine. Disruptions to this flow can lead to lack of power, excessive fuel consumption or problems starting up.

You can normally clean out the old filter, but I had no idea how long the existing one was in there. Therefore, I disposed of the old one and replaced with a new one.

Accessing the filter was easy. I just removed a wing nut and the metal housing. The air filter itself is just a cylinder with wire mesh and a paper filter.

The pre-cleaner is a piece of sponge wrapped around the filter. I unpacked the new pre-cleaner, and following the installation instructions. I moistened it with some motor oil and wrapped it around the new filter. Then, I replaced the old one on the mower engine.

Here’s a picture of the new air filter and pre-cleaner installed (without the metal housing so you can see it):

4. Fuel Filter

Now for the fuel filter. It’s recommended that you change the fuel filter on your mower once every season.

There can be lots of impurities in your gas tank (think about all the times you opened the tank lid for a refueling with grass still settling from the blades), so a season of mowing can clog up your filter.

Using the mower manual, I located the filter on the engine. If you’re having trouble finding yours, just follow the fuel line from the gas tank to the engine. The fuel filter is along that line.

To remove the filter, I first clamped the fuel line in between the filter and the tank. I didn’t want fuel dumping out of the tank once I removed the filter. I also put a container beneath the filter to catch any excess gas stuck in the line and filter.

Then I removed the hose clamps holding the filter in place and pulled off the fuel line. Luckily no fuel leaked out. The tank must have been nearly empty. I then attached the new filter, making sure the arrow indicating direction of fuel pointed towards the engine.

With the fuel lines clamped back onto the filter, I removed the temporary clamp pinching the line and installation was complete.

Here’s a picture of the new fuel filter installed:

At this point, the engine was now ready for the upcoming season. I turned the ignition key and the engine fired up without hesitation.

I didn’t even have to apply the choke. Then, I let the engine idle for 10 minutes to make sure it ran okay and didn’t have any fuel or oil leaks. After, I took it for a test drive, and it drove like a champ.

5. Clean out mower belt

Now onto the mower deck, which was giving me some trouble. While mowing the front lawn, I noticed a lot of squealing noises coming from the belts in the deck. Also, the collection bags were barely filling with grass. It got so bad that I actually had to disconnect the automatic bagger because the tubes were getting clogged with grass.

I switched to side discharge for the grass, which meant I spent a lot of time raking up the grass when done. Finally, a few times the engine actually died with the blades engaged.

After inspecting the mower deck, I concluded that the three problems I had stemmed from a worn mower belt and debris wedging against the belts. The debris particularly was causing a lot of friction with the belt and putting strain on the mower, causing the engine to stall out sometimes.

This also impacted the bagger because the blades could not spin at full speed and expel the grass fast enough. The belt also had clear evidence of being worn down. There were lots of cracks, and I was surprised the belt hadn’t broke already.

Removing and Cleaning the Mower Deck

To address my mower deck issues, I first removed the deck from the mower. It was not that difficult.

Following directions in the manual, I located and removed some retainer springs holding the deck pinned into the mower chassis. Then I slid the deck out from under the mower.

Here is a picture of the deck removed from the mower.

Technically I didn’t have to remove the mower deck to replace the belt. However the debris was really hard to reach and was easier to remove this way. I also wanted to take the opportunity to inspect the blades and underneath the deck.

Once I opened the deck, I removed all the debris with ease. There was a lot of it too, from packed dirt to wads of dried leaves. I could see why the belts were making so much noise. I’m sure it was a fire hazard too, with friction from the belts heating up the dried leaves and possibly igniting them.

Soon the deck was looking very clean. I flipped it over and inspected underneath. It wasn’t too bad under there. I just used a flat screwdriver to scrape off some grass patches that have been building up over time.

Sharpening the Mower Blades

When I checked out the blades, they were extremely dull. The sharp part was actually round and smooth. All this time mowing the lawn, I could have just whacked the grass with a baseball bat.

So I removed the 3 blades with a socket spanner, clamped each one in place and sharpened with my Dremel and a grinding stone bit.

After I sharpened both ends of the blade, I stuck a bolt in the blade to see if it was properly balanced. If either side of the blade dipped, it meant the blade was imbalanced and would cause a lot of vibration when spinning. Luckily, I did the job evenly when sharpening and the blades were balanced well.

Here is a picture of a blade clamped down right after I finished sharpening it (see how the sharpened part gleams):

Here I am reattaching the sharpened blades (I made sure to wear gloves so I didn’t cut myself):

Here’s a close-up of the mower deck showing some of the debris that I had to remove (it was a lot worse before):

6. Replacing the belt

Now to address the worn out belt. I took a picture of the belt route with my phone and then removed it. I installed the new belt matching the route from my picture.

Mower deck maintenance was now complete. I slid it back under the mower and reattached the retainer springs to secure it to the chassis. I started up the motor and engaged the blades. Nothing happened. Oh no, what happened? The blades did not spin.

I looked underneath the mower and discovered the belt had too much slack. I compared the new belt to the old one and saw that the new one was slightly bigger. Unfortunately, this model mower did not allow you to adjust the tension in the belts, so the new belt was unusable for me.

I ordered the correct part number online, but it was a third party belt. I should have spent the extra money for a factory replacement instead. Disappointed, I put back in the old belt, so I could at least use the mower and ordered a factory belt in the meantime. I’d install it in a few days when it arrives.

Let that be a lesson, be wary of third party replacements especially when the price looks too good to pass up.

7. Lubricant

I had almost completed my maintenance plan. Then, I applied all-purpose grease to a few key areas on the mower.

I used the mower manual to identify these areas, and applied grease where needed. A few areas also required silicone lubricant, which I was lucky enough to have a spray can of (I use it to keep my foosball table rods spinning like new).

I broke in the new lubricated parts with a drive around the yard, making sure to turn the steering wheel a lot. The neighbors must have worried what state I was in zigzagging the mower across the yard!

8. Tire Pressure

The final step was to check the tire pressure. I grabbed a pressure gauge from my car’s glove compartment box and compared the mower tire pressure to recommended specs in the manual.

They were a little low, so I used a bicycle pump to bring them back up to the correct PSI. Low tire pressure will cause excess drag when driving, and consume more fuel, so it’s important to keep your tires properly inflated.

Finally, the mower was in proper working condition for the new season. I documented what parts I replaced along with the date. This way I would remember for next season the parts I replaced.

Not everything in my maintenance plan needs to be done every season. I just wanted to hit all my bases this one time, since I had no way of knowing what the previous owner did.

If you are in a similar position, wondering how to fix your old riding lawn mower, then go through the above checklist. It’s been tried and proven.

Look out tall grass, I’m ready for you this season!

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Outdoor Projects

​#9 – Ice Cream Sundae Gift Box

Inspecting the Used Snowblower

Fixing an Old Snow Blower

Disconnecting the Craftsman Carburetor

Removing the Snowblower Carburetor

Spark Plug and Starter Cord

Snowblower Engine Oil

Final Craftsman Snowblower Maintenance Tips

2. French Door Pantry

3. Folding Workbench

4. Sliding Garage Shelves

5. Wooden Mower Wagon

6. Boardwalk Pathway for the Backyard

Planning the Sun Shade Sail

DIY Shade Sail Installation Materials and Cost

An Uphill Battle with a Rock

Getting Closer…

Digging the Shade Sail Post Holes

Rain, Rain Go Away

Preparing for the Concrete for the Shade Sail Posts

Mixing the Concrete for the Shade Sail Posts

DIY Shade Sail Installation

Shade Sail 3 Year Update

How to Make a Yard Utility Cart

How to Make an Axle for a Wagon

Materials for Building the Wagon Steering Axle

Pillow Blocks for Building the Wagon Steering Axle

Spacing Washers for Building the Wagon Axle

Wheels, More Spacing Washers, and Shaft Collars for the DIY Wagon

End Caps for Building the Wagon Steering Axle

Chassis Materials

Chassis Design

Building the Fence and Gate on the Lawn Mower Trailer

The First Ride on the DIY Wagon

Utility Cart 3 Year Update

DIY Picnic Table Material Order

Money-Saving Tips

How to Build a Picnic Table

Using the Wooden Walkway

How to Build a New Mailbox Post

How to Paint the Old Mailbox and New Post

How to Install a New Mailbox Post

How to Finish Up Fixing the Mailbox

How to Build a Shed – Installing T1-11 Shed Siding

Getting Ahead of Myself

Rain, Rain Go Away

Shed Roof Construction

How to Build Roof Trusses for a Shed

How to Attach the Shed Trusses

Installing the Drip Edge on a Plywood Shed

Applying Starter Shingles on the Shed Roof

Nailing Down the Shingles

2. Oil Filter & Oil Change

5. Clean out mower belt

Removing and Cleaning the Mower Deck

Sharpening the Mower Blades

7. Lubricant

8. Tire Pressure

#9 – Ice Cream Sundae Gift Box