Back in August, I received a call from some homeowners that were looking for a custom 10×12′ gambrel shed at their new residence. As the two were in the process of downsizing, George wanted a space to work on his drums. After some back and forth on design and material, we finally agreed on something feasible.
But there was a minor problem. The site currently hosted an old, beat up, metal shed. It was initially thought to be on a concrete slab; but that was false. So after coming to terms on the project, we had to make some adjustments for the foundation.
Laying Down Level Ground.
I presented the couple with 3 options. We could dig out the area for gravel and beams, build a new deck on blocks, or permanently install the shed into the ground. Since there was a slight downgrade and some water flow, gravel was the best option. It would keep the area in tact and allow the 10×12′ gambrel shed to settle.
The existing metal shed had a steel frame. So I incorporated it into the design to help lower the overall cost of the gravel. After leveling the area, I build a 120×144″ wood deck out of 4×4″ posts (or beams in this case) and some 2×4″s. I covered the frame with 3/4″ subfloor.
Framing Up the Shed Walls.
Once the debacle of the base was solved, I could focus on the walls. I decided to build them just over 6 feet. This allowed me to maximize the ceiling height inside. The gambrel shed walls went up pretty quick. Until I was asked if I could frame in a window and wall AC unit. I love it!
Adding Openings Created a Few More Tasks.
I didn’t have to alter much, just cut out a few wall studs. But it did take some time. So I asked George to help me save some time by shopping for a window at the re-home store in Olive Branch. He scored a decent dual pane for only $20.
Both additions required exterior trim work and sealing. This added a little bit more to the total. But the couple made it extremely easy to negotiate (fairly). In the end, we were both happy.
Door + Gambrel Roof Rafters.
The next step involved finalizing the door size and roof height. Since the customer wasn’t looking to park a tractor or anything inside the shed, I went with a 36″ (wide) door. The rise of the roof peak was exactly 3 feet.
I got all of the math done before measuring three times over. From here, I build a little frame on the shed floor to construct 10 identical rafters. I probably spent too much attempting perfection. But glad I did. They turned out well.
Constructing the Gambrel Roofing.
After each rafter was cut, I started working on (the consistency of) the roof height and spacing. I used 2×4’s for cross joist support and spacers. Staggering the spacers made it easier to install. Once everything was square, I secured the roof with 4″ screws.
Squaring the Roof with Plywood Sheeting.
It took some time for me to be satisfied with the roofing. There was a lot to check, including a level soffit ledge. But it made installing the plywood underlayment so much easier. The edges were square and only needed a few custom cuts.
I went ahead an extended the sheeting over the soffit edge to ensure there was no crease at the seam. Aside from the framing additions, the project was running smoothly.
Custom Shed Siding Install.
I finally finished the framing. From here, I could start wrapping the shed with primed siding panels. I knew I was going to have to cut around the rafters. So, I was not eager to get going. But once I got in a groove with the jigsaw, I was OK.
I wanted to start with the window side because it was going to require a little attention (that needed to dry). Some of the seams of the siding panels were a little rough. I recommend going with the Smart Side sheets. They cost about $6 more per sheet. However, the extended lifespan and quality is worth it.
The Little Details of Shed Siding.
In addition to custom cuts, I wanted to maximize the use of each siding panel. This took a bit of math as well. Nonetheless, I was able to use some smaller pieces on the gable side corners.
Installing siding onto doors can be tricky. But its not that hard if you have a good game plan and some experience. Since I’ve built so many sheds this year, the process was a breeze. I could use a helper here and there, but I’m OK.
Shed Exterior Finish Carpentry.
The last step of the siding phase was installing the trim work. This took a bit longer than my original shed estimate called for. I needed to add some quarter round and caulking to the window and wall AC unit.
Since I already had my angles from the rafters, I knew what the trim pieces needed to be. But it’s still not an easy task to get perfect. The last thing I wanted were seams that let water inside the Gambrel shed.
So I spent some time ensuring everything was sealed before painting.
Give the Gambrel Shed Color!
The last step was painting the 10×12 foot structure. With the 1/4″ grooves on the panels, I didn’t want the red paint to spread. So I decided to paint the trim first. I usually don’t paint, but I struck a deal with George. He promised to match my hours with drum lessons for my son.
It took a few weekends to paint the final coat. It took two gallons or barn red. I also added a little ledge above the door to ensure no moisture got in. To be honest, it’s pretty cozy inside!
