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TOUGH LITTLE CABIN
Construction Plans in ASCII and .PCX Files
Designed, Illustrated and Written by Dan Jincks
Copyright Dan Jincks 1990
Box 155A, HCR 77
Annapolis, MO 63620
SHAREWARE - SEE NOTICE BELOW
*1
TABLE OF CONTENTS
SHAREWARE NOTICE
PREFACE
ABOUT THE DRAWINGS
OVERVIEW
BEFORE YOU START
WINDOWS, DOORS AND OTHER OPENINGS
FLOOR FRAME CONSTRUCTION
SUB-FLOOR INSTALLATION
WALL AND ROOF FRAMING
ROOF PLYWOOD INSTALLATION
ROOFING INSTALLATION
EXTERIOR WALL PLYWOOD INSTALLATION
INTERIOR FLOOR INSTALLATION
UTILITY PANEL INSERT - WOOD STOVE
INTERIOR PANELING INSTALLATION
INTERIOR CEILING INSTALLATION
FINISHING TOUCHES
*2
ILLUSTRATIONS
FLOOR PLAN (FLPLAN?.PCX)
DEVICE OPENINGS (OPENING?.PCX)
FLOOR FRAME (FLOORF?.PCX)
INSTALLATION OF SUB-FLOOR PLYWOOD (SFLOOR?.PCX)
FRONT WALL FRAMING (FWALLF?.PCX)
REAR WALL FRAMING (RWALL?.PCX)
END WALLS FRAMING (EWALL?.PCX)
ROOF BEAM INSTALLATION (ROOFA?.PCX)
ROOF FRAMING (ROOFB?.PCX)
ROOF PLYWOOD AND ROOFING INSTALLATION (ROOFC?.PCX)
EXTERIOR WALLS PLYWOOD INSTALLATION (OUTPLY?.PCX)
FLOOR PLYWOOD INSTALLATION (FLOORP?.PCX)
UTILITY PANEL INSERT FOR A WOOD STOVE FLUE (UPANEL?.PCX)
INTERIOR PANELING INSTALLATION (INPLY?.PCX)
*3
**********************************************************************
SHAREWARE NOTICE
All materials in this plan package are copyrighted by the author.
This means that it is illegal to make copies of these plans and
distribute them for your profit. You may freely distribute these
plans so long as they are complete and unaltered, and no fees are
charged for them, except copying costs - not to exceed $5. All files
must remain together whether they are computer files, or are printed
out. If these plans are used in an actual construction of a
structure, the user must register and pay a small fee of $15 to the
author. THESE PLANS ARE COPYRIGHTED SHAREWARE - NOT PUBLIC DOMAIN.
If the plans are to be used for construction, register before
beginning. Registered users will be notified of any corrections or
recommended alterations that may have come to light since the plans
were originated. Other plans related to this Cabin may also be
available. Registered users will receive notice of their
availability. Registered users may also order sets of Laser Printed
hard copy (super sharp 3300 X 2550 page resolution from vector
drawings and formatted typeset text); or vector drawings in Generic
CADD, or DXF format on 5 1/4" HD floppy disk. Up to two printed copy
sets and one drawing set on disk are available with each $15
registration. For printed copy add $5 per set. For drawings on disk,
add $5 and specify DXF or Generic CADD format.
TLCABIN BASIC REGISTRATION -- $15
TLCABIN PRINTED COPY ----- ADD $5 Each Set (Up to 2 per registration)
TLCABIN DRAWINGS ON DISK - ADD $5 (Specify .DXF or Generic CADD .DWG)
____________
TOTAL -------------------- PRINTED COPY ____
.DXF on DISK ____
Generic .DWG ____
Name _________________________________________________________________
Company ______________________________________________________________
Address ______________________________________________________________
City __________________________State_______ Zip ______________________
Make payment by check or money order in U.S. Currency to:
DAN JINCKS
BOX 155A, HCR 77
ANNAPOLIS, MO 63620
**********************************************************************
*4
PREFACE
The Tough Little Cabin was originally designed as an earthquake
emergency shelter. It has an integrated structure specifically
intended to withstand earthquake shock - even if your home doesn't.
There is plenty about that in the text below. What is interesting
about the design, is that it costs about the same as most weaker
structures the same size. And probably less then one with a fixed
concrete foundation. Since it is not tied down and is a reasonable
size, it can be transported. You can move it after construction or
take it with you if you move.
There is a host of possible uses for small buildings. It really
doesn't matter if you need it for an emergency shelter or not. If you
are thinking about needing a small out building you should consider
these plans. The design came from the actual construction project by
an experienced designer. They are not just hypothetical untested
plans from a pipe dream drawing board. It WILL work as described,
since it is described by how it worked out. If you haven't done any
full scale construction, this is an excellent project to get your feet
wet. These plans are complete and easy to follow - even for a novice.
Of the many possible uses, some might be: A storage shed, a camping
cabin, a kids playhouse, a gardening shed, an animal breeding shelter,
a spare room, a workshop, a construction site store room, a remote on
site office, a hunting shack, a hobby room (the author is using his as
a photography darkroom), and of course an earthquake emergency
shelter. Some of the following text is aimed primarily at the
emergency shelter usage, so just skim through those parts if you don't
need such a thing.
It's a strong long lasting design no matter what your specific needs
may be. The materials costs should be between $500 and $1000. The
actual cost will depend on factors like your shopping skills and the
local costs in your area. If you decide to use deluxe finishing
inside or out, the costs will of course go up. Detailed bill of
material listings are provided to allow you to work up an accurate
cost estimation before you make a commitment to the construction. A
tool list is also provided.
*5
ABOUT THE DRAWINGS
The drawings provided in this plan package are in the most universal
format and resolution believed reasonable by the author. They are 640
X 350 2 color EGA .PCX files. Each drawing was divided into 4 parts
so that a readable drawing could be assembled after they are printed
out. It was a compromise, but it was believed the most acceptable for
the largest majority of IBM computer users. Files in the .PCX format
can be viewed and printed by many paint programs, and 640 X 350
resolution is available to most 1990 users. (actually it is 640 X 348
for possible Hercules compatibility). A Shareware program called
Compushow or CSHOW can be acquired and used to view and print these
files. A special viewing script for Compushow is included. Place
this plan set in a directory called C:\CABIN and from your Compushow
directory give the command CSHOWS C:\CABIN\CABIN.SCR and a demo of all
of the drawings will be displayed. If nothing screens up, Compushow
may not be configured properly for you. Read the literature with
Compushow. CSHOW can also print the drawings out for you if you load
a printer driver. Again read the Compushow literature.
There are 14 drawings in a total of 70 .PCX files. See the table of
contents above, to see which files are for which illustration. There
are 5 files for each drawing. The file name of each ends with a
number. 0 is the unreadable overall view, and 1 - 4 are the readable
1/4 divisions of that drawing. To get readable copy, you must print
out 1 - 4 and piece them together. This is something of an
inconvenience for sure, but it is the best that can be provided in a
reasonably universal manner to all. These .PCX files are a bit crude,
but the dimensions were touched up to be clearly readable. They were
converted from vector files intended for 300 dpi laser printed pages,
so slight offsets and rough looking text did happen. As stated above,
sharp printed copy and vector based drawings are available to
registered users.
*6
OVERVIEW
This cabin is a tough free standing structure that has many potential
uses. It can be used as a storage shed, workshop, kids club house,
spare room, or camping cabin. The basic structure was designed to be
strong enough to withstand and survive the rigors of transport as well
as strong shocks associated with earthquakes. In addition to the
variety of everyday uses for this utility building, it can be relied
upon to serve as an emergency shelter in the event of a seismic
disaster (major earthquake).
Its construction requires only basic carpentry using readily available
standard building materials and standard carpentry tools. Most of the
construction techniques are fairly standard and all steps are
thoroughly documented. A few steps may seem a little unusual to
someone that has done some standard framing construction. This
structure is designed to withstand and absorb shock without damage, so
these slightly different methods should be tolerated and followed as
given in the instructions. If you insist on deviating from the plans,
be sure you are adding to the integrity and not creating stress
failure shortcuts.
Every effort was made to keep the material costs down while keeping
the strength to the maximum. It is designed to have a very long
service life requiring little to no maintenance. Of course it will
only be as good as the materials and craftsmanship that go into its
construction. Using low grade materials or being careless in doing
the construction could reduce both strength and longevity. Don't take
shortcuts that are hard to live with later.
If this cabin is to serve as an emergency earthquake shelter, certain
things need to be understood:
1. LOCATION. It is very difficult to assess all of the nasty things
that can be caused by an earthquake but some possibilities can be
anticipated. The whole world will literally be tossed around, so
things that are standing now may not be afterwards. Locate the cabin
well clear of other buildings and trees. Don't locate it on or near
the top or bottom of a steep grade. Don't locate it in a flood plain
since water may back up or surge. Uncontrolled fires can happen after
a quake, so don't locate it near a building, propane tank or brushy
wooded area. Keep it well clear of overhead power lines as well.
Just imagine that everything that can fall or burn will do so, and you
can assess your location needs from there.
Even if you don't have a good location on your property, there is
still hope. Since the cabin is transportable, you may be able to
"park" it on some neighboring property. A location may be able to be
rented for little or nothing. Be sure that you confirm this before
making the building and expecting something that may not be available.
Be sure that this alternate location is within walking distance of
your home since roads may not be passable.
*7
2. NON-EMERGENCY USES. It is very tempting to stuff a utility
building with stray household items. There is nothing wrong with
using it for storage as long as you realize the possible consequences.
What if you need it as an emergency shelter in the dark of night in
sub-zero weather? Are you willing to risk the time and effort
required to unload it? You or a family member may be injured and need
immediate shelter. Large, heavy unsecured items stored within the
cabin could do considerable damage as they get tossed around inside of
it during a quake.
Highly flammable materials such as gasoline or Coleman fuel should
NEVER be stored inside or near the cabin. Even fairly safe
non-flashing liquids like kerosene are best left outside if practical.
Otherwise pack them securely in a sealed plastic container within
another sealed plastic container. Propane is another very hazardous
item - leave it outside and turned off. In addition to the flammable
liquids themselves, devices that contain them should be emptied of all
fuel before storage within the cabin. This would include lawn mowers,
chain saws, Coleman appliances, etc.. This may seem strict, but in a
winter emergency situation you will need a heat source that
doubtlessly will come from a flame. If fuel is spilled in the cabin
during the quake, you would not be able to have a flame in the cabin
without risking a fire or explosion!
3. SECURITY. One very real possibility in a quake is that you and
your family may need to vacate your house instantly without any
warning or preparation. The cabin will become an emergency shelter -
but not if YOU cannot get into it! You will likely store things in
the cabin that you don't want to have "walk off" so they will need to
be locked up. If you get separated from the key, you have a problem
right in the middle of the emergency. Think ahead about this.
The solution will depend on how much security that is required. In an
area where things don't "walk off" you may leave the door unlocked and
just lock supplies in a cabinet with a combination lock. If you are
in a security problem area you will need to lock the door. You could
use a combination lock on a hasp. If you do use a key lock, stash a
few keys outside somewhere well away from any building. Don't forget
ice and snow can make some places a bad choice. It might also be wise
to hide a pry bar just in case the door should jam from the shock. If
your cabin is to be used as the kids club house or spare room etc.,
keep your emergency supplies locked in cabinets so they don't get
tampered with.
4. EMERGENCY SUPPLIES. To be an effective emergency earthquake
shelter, you will need to keep a stock of emergency supplies in it at
ALL times. This means that no matter what other uses you have for the
cabin, it will always be an emergency supply storage building to some
extent. The surest way to accomplish this, is to have permanent
cabinets that are only used as supply storage. Anchor the cabinets
securely to the structure of the cabin and pack them as if a moving
man might drop them off of his truck. Be sure first aid, lighting,
and blankets are immediately accessible. However that you use the
cabin on a regular basis, be sure that you don't block immediate
access to your first order emergency supplies.
*8
Other supplies of less immediate importance, such as food, could be in
cabinets that might be temporarily blocked by other activities. In
the winter months, be sure that spare winter clothes are quickly
accessible as well. In the fall, check the operation of your
emergency heating source and be sure that it is reasonably accessible.
Also be sure that you have at least a 2 week supply of fuel. A 2
month supply is best. Spare parts for heat and lighting equipment are
advised as well.
A good way to anticipate your emergency supply inventory is to imagine
planning for a 2 month camping experience. You will be dropped off
buck naked in the middle of winter with no chance of getting any
supplies - except what you have in this cabin. No utilities -
electric, water, sewer, etc. will be available on this camping trip.
It's just you and your well stocked cabin for 2 whole months! Stock
it well and with great care.
As you can see from the above considerations, there are a lot of
things that go into planning an effective emergency earthquake
shelter. The careful construction and proper usage of this cabin can
go a long way towards protecting you and your family from suffering or
perishing in the event of a major earthquake disaster. It cannot be
guaranteed that you, or the cabin will withstand all of the
unpredictable effects, but proper preparation may be the difference.
In addition to the basic instructions for constructing this cabin,
there are extra suggestions and safety options. There are many
excellent illustrations to guide the construction and it is tempting
to just build from the pictures, but please read the text that
accompanies them. Every step in these instructions were performed by
the author to build an actual cabin. The author is using this cabin
as his own earthquake emergency shelter in the New Madrid Fault
region, and is depending on it to work - just as you will.
*9
DISCLAIMER
The construction of this cabin is completely at your own risk. While
the author has made every attempt to provide you with a reasonably
safe structure using reasonably safe methods, the risks involved in
the construction and usage of the cabin are not within his control and
are strictly your own. If this is not satisfactory - do not attempt
the construction. If you do attempt the construction, it will mean
that you have accepted the condition that all risks taken, are
strictly your own. In plain English - This means that if you injure
yourself while building the cabin or it does not perform the way that
you expected it to, you cannot blame the author, and if you don't like
this arrangement, you should not construct this cabin.
If you find that something is missing, a dimension for instance, and
you are a registered user. you can write to the address below. A
reply will be given as quickly as possible. Be sure to be specific in
your letter about the nature of the problem. Address the letter to:
DAN JINCKS
TLCABIN QUESTIONS
BOX 155A, HCR 77
ANNAPOLIS, MO 63620
*10
BEFORE YOU START
The cabin can be put to many different uses when not being utilized
for an earthquake emergency shelter. That was the primary design
criteria for the plans you are now holding. The first illustration
(floor plan) shows how the interior space was planned to be utilized
by the author. The locations of windows, door, utility panel and
vents are based on this particular usage of interior space.
You may have an entirely different idea of how you wish to use your
interior floor space. The locations and numbers of windows, the size
and location of the door and the need for and size of the utility
panel could be adjusted for your own requirements. If you decide that
you might want to change things around, now is the time to do so -
before you start construction.
Any modification of the original plans will need to be reflected in
each step of the construction and the illustrations that follow will
not be entirely correct for you. Here are some basic do's and don't
to consider:
1. Keep the floor to front/rear wall to roof beam connections intact
at spacings averaging 24 inches, with the exception of 1 break in the
front wall structure for a door. (see the roof beam and front wall
frame illustrations)
2. Do not put a door in an end wall or exceed the openings
illustrated for the end walls.
3. Put windows in the front or rear walls between the wall beams,
with not more then 1 on the front and 2 on the rear. Do not break a
wall beam to install a window.
4. Fewer and/or smaller windows create a stronger structure than
putting more or bigger windows in. Eliminating any window illustrated
will be cheaper, warmer in the winter and increase the structure
strength. Of course windows are good in the summer and let in more
daylight.
5. The utility panel is optional. It is intended to serve 3
purposes:
A. It can be used to create a safe means of venting a wood stove.
B. The panel is removable so that the wood stove vent could be
installed in a home window to allow the use of wood heat if power is
down and your chimney is damaged.
C. Other devices may be installed later into the utility opening -
Such as a window air conditioner for a summer workshop or kids room.
If you decide to modify the plan beyond eliminating a window, be sure
to thoroughly study all illustrations so that you realize the
consequences of your changes. Always try to add structure rather than
take away from it. For instance if you go with a 4 foot wide utility
door and a lot of large windows (within the limits of the above
guidelines) increase the thickness of your exterior plywood to 1/2"
instead of 3/8" to regain some of the lost structure. The Device
Openings illustration shows the maximum recommended size openings.
*11
WINDOWS, DOORS AND OTHER OPENINGS
The cabin, as illustrated, has openings for 4 windows, 1 door, 2
overhead vents, and 1 removable utility panel. The openings shown are
for standard size pre-manufactured devices that were available at the
time, and in the area, that the original cabin was constructed. The
door opening is for a pre-hung 32" exterior door. The windows chosen
were single glazed aluminum frame type that were inexpensive. The
vents were inexpensive open/close louver vents made of aluminum and
intended to replace an 8" X 16" concrete block.
The actual devices that you can acquire, at a price that you like, may
be somewhat different in size. The device openings illustration shows
the sizes worked with and the maximum opening sizes recommended. It
may seem early in the project to choose windows and doors, but it is
not. It is recommended that you resolve your size needs now and
actually purchase the devices before you start. This recommendation
is because of inaccuracies and availability problems encountered by
the author.
On the original cabin: The front window size had to be altered because
an "available" window size turned out not to be available after all.
The vents turned out to be a different size then were quoted.
Construction progress was stopped because a window was late in
shipping. The only available doors were not what was desired and the
door ended up being constructed from a door blank and taking up the
better part of a day to install. There was a great deal of
frustration and time wasted that could have been avoided if they had
been acquired first.
A special note about the door. Pre-hung exterior doors are all
intended to open inward. This is standard and normal. An inwardly
opening door takes up a fair amount of precious floor space which may
not be desirable in this application (hence the special door on the
original cabin). An inwardly opening door might also be a hazard,
since if it stuck shut from an earthquake after-shock it would be more
difficult to force if you are inside. Pre-hung doors also had a
tighter fit then was desired, and appeared that they could jam too
easily.
Hanging a door properly from a blank is an art best left to the
experienced. If you want an outwardly opening door with a 1/4" gap to
resist jamming, it will need to be a custom installation. Either get
someone with door experience to help you, or hire a carpenter for at
least the door work.
The main purpose of the utility panel is to provide safe passage for
venting a wood stove. The utility panel opening (if you want one)
should have a height and width smaller then a window in your house.
That way, it and the wood stove, could be used in your house, until
normal utilities are restored. Even if you now heat your house with
wood, a masonry chimney is likely to be destroyed by an earthquake,
and you will need a safe temporary alternate vent passage. (see the
utility panel illustration)
The vents provide cooler conditions in the summer and a source of
smoke exit and fresh air if a wood stove acts up. They are highly
recommended.
*12
Windows are an interesting problem. You cannot do without them, but
they are a source of potential trouble. They are glass and can break
in an earthquake. Just broken windows in your house, from a winter
quake, could force you to require immediate shelter. If your shelter
windows break as well, it won't do you much good. You could replace
the glass in your shelter windows with unbreakable plastic
(polycarbonate or Lexan is best). You could also leave the glass
windows as they are and make plastic panels that fit the inside of the
frames behind the aluminum windows and only install them in the
winter. The vents can provide fresh air. That way as long as the
glass and plastic are both intact, you get double glazed windows and
only need to buy inexpensive single glazed windows. If the glass
breaks, you are still covered and broken glass will not invade the
cabin either. Don't make the plastic panels difficult to remove from
the inside, so windows can still be a emergency exit if the door
should jam.
Since the various styles and brands of doors, windows, and vents are
all different, these instructions will not give details about their
installation. Follow the instructions that accompany them. Get them
first - and adjust the openings to their true requirements before you
start.
*13
RECOMMENDED BASIC TOOL LIST FOR THE CABIN CONSTRUCTION
7 1/4" ELECTRIC CIRCULAR SAW (SKILL TYPE) WITH A CARBIDE COMBINATION BLADE
3/8" ELECTRIC DRILL (VARIABLE SPEED REVERSIBLE RECOMMENDED)
SPECIAL DRILL BITS - 1/4" AND 3/8" EXTENDED LENGTH
SCREW DRIVER TIP HOLDER FOR THE DRILL WITH A PHILLIPS TIP FOR THE DRYWALL
SCREWS
SABER SAW WITH FINE METAL CUTTING AND WOOD BLADES
ROUTER WITH A 3/8" - 1/2" SQUARE BOTTOM BIT
24" FRAMING SQUARE
12" COMBINATION SQUARE
15 FOOT OR LONGER TAPE MEASURE
SOCKET WRENCH WITH 1/2" AND 9/16" SOCKETS
ADJUSTABLE WRENCH OR 9/16" BOX END WRENCH
CLAW HAMMER
HEAVY HAMMER
CHALK LINE
PRY BAR
2 SAW HORSES
LONG STRAIGHT EDGE ( 6 - 8 FOOT)
LEAD PENCILS
FINE LINE FELT TIP MARKER
CORD(S) FOR THE ELECTRIC TOOLS
SMALL SAW - KEY HOLE TYPE
CAULKING GUN
METAL SNIPS
PHILLIPS SCREW DRIVER
WOOD CHISEL
UTILITY RAZOR KNIFE
STAPLE GUN
2 - 5 INCH OR LARGER "C" CLAMPS
6 FOOT STEP LADDER
*14
FLOOR FRAME CONSTRUCTION
Materials required:
2 - 16' 4 X 6 TREATED PINE (MUST BE STRAIGHT)
7 - 10' 4 X 4 TREATED PINE (MUST BE STRAIGHT)
11 - 8' 2 X 4 PINE
#16 COMMON NAILS (20 LBS. FOR THE ENTIRE PROJECT)
CARPENTER'S WOOD GLUE
18 - 3/8 X 5 1/2" LAG BOLTS
18 - 3/8" FLAT WASHERS
MASKING TAPE
General Instructions - The floor frame is the foundation for the
cabin. Therefore, it's quality and strength is of high importance to
the remaining construction. Use only straight high quality lumber for
the beams. Double check measurements, sizes and squareness as you
work. Follow the instructions carefully step by step.
STEP 1. Have your materials on hand.
STEP 2. Cut the 2 - 4 X 6 X 16' skid beams to length and cut the
wedges from the ends. This will require marking and cutting from both
sides to cut through the 3 1/2" thickness with a 7 1/4" diameter saw.
Keep the wedges for later use.
STEP 3. Cut the 7 - 4 X 4 X 10' floor beams to length. Measure and
draw lines on them marking the locations where the skids will be under
them.
STEP 4. Cut 28 - 2 X 4 pieces about 6" long (from scrap if
available). Be sure one end is cut square and mark it.
STEP 5. Measure and draw lines marking the locations of the floor
beams on the tops of the skids. Then nail down the 2 X 4 pieces on
each side of the floor beam positions.
STEP 6. Place the skids on a flat surface if possible, or use the
wedges to help level them. Place the floor beams on the skids and get
them all aligned properly. Use a framing square to square up
everything. Starting at the corners, toe a nail through the 2 X 4
pieces into the sides of the floor beams to hold them in position -
keep checking the squareness and positions as you work.
*15
STEP 7. Double check squareness and position of the beams. Wrap
masking tape around your extended 1/4" drill bit marking a depth of 5
1/2" and drill that depth through the floor beams into the skids where
they cross. Wrap masking tape around your extended 3/8" drill bit
marking a depth of 3 1/2" and drill that depth into the previous
holes. Using a router with a 3/8" to 1/2" square bottom bit, route a
recess around the holes in the floor beams 1/2" deep and large enough
to clear a 3/8" flat washer. Install 3/8" X 5 1/2" lag bolts with
washers into each hole and tighten securely. Remove the 4 blocks
outside of the end 4 X 4 floor beams, but leave the remaining 24
blocks in place.
STEP 8. Cut the 32 - 2 X 4 intermediate members for the floor beams
STEP 9. Mark the positions of the intermediate members on the floor
beams and nail them into place. The connections to the 4 X 4 beams
will need to be toed as illustrated. When installing the outer
intermediate members that are 3 1/2" from the end of the beams, use a
piece of 2 X 4 as a reference to insure proper spacings for the wall
beams that will be installed there later. Be sure the tops of all
pieces and beams are even.
STEP 10. Glue and nail the 2 end 8' X 2 X 4s into place using
waterproof carpenter's glue. Be sure the tops are even with the tops
of the 4 X 4s.
This completes the construction of the floor framing.
*16
SUB-FLOOR INSTALLATION
Materials Required: 3 - 4' X 8' SHEETS OF 3/8" C/D EXTERIOR PLYWOOD
2 - 8' 2 X 4 PINE (CAN BE REUSED LATER)
2 TUBES OF LIQUID NAILS ADHESIVE OR EQUIVALENT
#6 GALVANIZED BOX NAILS (7 LBS FOR THE ENTIRE PROJECT)
1 5/8" DRYWALL SCREWS (5 LBS FOR THE ENTIRE PROJECT)
2 - 3/8 X 3 1/2" LAG BOLTS
2 - 3/8 FLAT WASHERS
General Instructions - The sub-floor is both structural and a barrier
for the underside of the cabin. The fit does not need to be tight and
you might even want to drill 3/8" drain holes in each compartment for
condensation relief. To conserve materials, a gap will remain near
the skid beams. The tricky part of this operation is to get under the
frame. A method is suggested below.
STEP 1. Have your materials on hand.
STEP 2. If practical, drag the floor frame to the final location of
the cabin for the remainder of the construction. If you must move it
later, be sure to build it in a place that a truck can get access to
tow or haul it later. Use a rope or chain to assist dragging it.
STEP 3. To install the sub-floor, the floor frame must either be
turned over or propped up. Be sure that at least 2 persons assist in
this operation, since it is heavy! To prop it up, you will need to
temporarily install a couple of 2 X 4s as supports. Drill 3/8" holes
near the ends then drill 1/4" tap holes in the end floor beams of the
frame and bolt them together with the 3/8 X 3 1/2" lag bolts. Do this
on each end of one side. Leave the bolts slightly loose so the 2 X 4s
can pivot. Drive stakes (#1) into the ground on the side opposite of
the 2 X 4s. Lift the side of the frame (using 2 or more people) until
the frame is propped up. While 1 person steadies the frame, have the
other person drive a stake behind the base of the 2 X 4s and a nail,
near the lag bolt, through the 2 x 4, into the frame -leaving the
heads out a bit, so that you can pull them later. Study the
illustration before attempting this.
STEP 4. Measure the actual panel size for the center panels and cut
the sheets of plywood as shown in the illustration. Then verify their
fit.
STEP 5. Apply the Liquid Nails adhesive to the frame - one plywood
section at a time and nail it into place, spacing the nails about one
foot apart. Then go back and install a 1 5/8" drywall screw between
each nail driven. Do this one panel at a time, for the 3 center
panels and the three upper panels. Again, you can expect a slight gap
around the edges of the panels.
*17
STEP 6. Cautiously, remove stakes #2 and the set nails from the 2 X
4s and then gradually lower the frame back to the ground. Caution!!
Be sure this is done by 2 or more people it is heavy!
STEP 7. Remove the props from the frame and install them on the
opposite side of the frame and repeat step 3 to prop up the opposite
side of the frame.
STEP 8. Install the 3 remaining panels as described in step 5.
STEP 9. Lower the frame and remove the props from the frame.
STEP 10. Use wedges under the corners of the skids to flatten the
frame before doing the remaining construction. The flatness can be
tested by stretching string across the frame from diagonally opposite
corners. When the frame is adjusted flat, the string will just touch
at both of the ends and the center. Double check the flatness by
"eyeballing" the top of the floor beams from a number of angles. You
may wish to try to level it as well, but it is not critical to do so.
Flatness of the frame and squareness of future construction is all
that is required.
This completes the installation of the sub-floor and preparation of
the floor frame for future construction. Take care not to step on the
sub-floor plywood or you could break it loose.
*18
WALL AND ROOF FRAMING
Materials Required:
2 - 12' 2 X 4 PINE
7 - 10' 2 X 4 PINE
65 - 8' 2 X 4 PINE
#16 COMMON NAILS (20 LBS. FOR THE ENTIRE PROJECT)
13 - 3/8 X 5 1/2" MACHINE BOLTS
14 - 3/8 X 3 1/2" MACHINE BOLTS
27 - 3/8 NUTS
54 - 3/8 FLAT WASHERS
20 - 1/4 X 3 1/2" LAG BOLTS
20 - 1/4 FLAT WASHERS
CARPENTER'S WOOD GLUE
General Instructions - There are 2 different methods of doing the
remaining framing construction. Method #1 is probably faster, but
requires 2 people to raise the walls. Method #2 is probably best if
only one person is doing the construction work. Both methods will
give equally good results as long as careful attention is given to
dimensions, positions and squareness at each step of the construction.
First review both methods, and choose the one that suits you best. 5
pages of illustrations are provided to guide the construction of the
framing. Study them carefully before beginning, and refer to them
often. They are: Front Wall Frame, Rear Wall Frame, End Wall Frames,
Roof Beam Installation and Roof Framing.
*19
WALL AND ROOF FRAMING - METHOD #1
Procedure Summary - The front and rear wall framing is assembled as
units on a horizontal flat surface and then erected and attached to
the floor frame. The roof beams are then attached between the front
and rear wall beams. The end walls are then constructed as units on a
horizontal flat surface and installed between the front and rear
walls, and the floor frame. The roof framing is completed in place on
the structure. Finally the end wall additions are installed.
STEP 1. Have your materials on hand.
STEP 2. Locate a large enough flat surface to construct the front
wall framing. You can build the frames on top of the floor frame if
you place 3 sheets of plywood on top of it. It is not recommended to
fully install the interior floor yet, but you could temporarily attach
the 3 sheets of plywood that you will be using for that purpose. Put
the good side down until you do the actual installation later. They
could be cut to size (see the interior floor illustration) but it
would be best to do that after installing the end walls and verify
their actual sizes. If rain threatens, be sure to cover them.
STEP 3. List out and pre-cut all of the 2 X 4 boards needed for the
front wall framing. Measure, cut accurately and write the lengths on
each piece as you cut them.
STEP 4. Lay the main wall beams in approximate positions. Number
them and measure and mark the positions of to horizontal intermediate
members that go between them.
STEP 5. Nail together the main wall beams and the horizontal
intermediate members as shown, except for the upper 2 boards of the
door header.
STEP 6. Assemble the remaining parts of the wall frame. The boards
that are doubled up on the sides of the door opening should be both
glued and nailed as they are installed. Be sure the door, window and
vent opening sizes are correct before installing their surrounding
members.
STEP 7. Assemble and install the upper portion of the door header as
illustrated. Be sure the orientation is correct and use glue as well
as nails. Use "C" clamps to hold it in place as you nail it.
STEP 8. Make preparations to erect the wall. 2 persons are required.
Have 2 - 5" "C" clamps, a framing square and 3 extra 8' 2 X 4s (to use
as supports) ready near the floor frame. See the illustration on the
rear wall frame drawing. The assembled frame may be wobbly,
especially if you must carry it to the floor frame. Temporarily
nailing some boards across the top and front will stabilize it. (But
not below the bottom intermediate members) If you have put plywood on
the floor frame for a working surface, you will need to remove it to
erect the front and rear walls. You may wish to set the front wall
frame aside, and construct the rear wall frame before removing the
plywood.
*20
STEP 9. Erect the front wall frame and position it onto the floor
frame. The lower intermediate members will rest on the floor frame.
While one person steadies the wall, the other should install the
supports. Nail the support to the floor frame and clamp to the wall
until the squareness is adjusted, then nail the support to the wall as
well. Do the ends and then add a support near the center.
STEP 10. Adjust the bottom of each wall beam to properly match its
adjoining floor beam and drive 1 nail to hold the position. Recheck
and adjust the squareness. Finish nailing the wall beams to the floor
beams. Then drill through them and install the bolts as illustrated.
The heads of the outer 2 bolts will need to be recessed with a router.
Leave the supports in place until the end walls are installed later.
STEP 11. Construct the Rear Wall frame following steps 3, 4, 5 and 6
above, as they apply to the rear wall.
STEP 12. Erect and attach the rear wall frame following steps 8, 9
and 10 above. Be sure that it is installed with the right to left
orientation being correct. See the illustration - it is from the
outside.
STEP 13. Cut the 7 roof beams to size.
STEP 14. Starting on one end, install the roof beams one at a time.
Use "C" clamps to get the position and squareness (of the walls)
adjusted, then nail the roof beam to the wall beams. See the roof
beam installation illustration. Use the front wall as your squareness
reference and adjust the back wall to be parallel to it. Removing the
rear wall supports may be required as you work. After all beams are
in place, drill through them and install the bolts as shown.
STEP 15. Measure the exact opening size at the top and bottom of the
opening for the right end wall frame. Note the adjusted dimensions
for the boards used to create the outer wall frame. (A tight fit is
required for the inserted end wall frames.)
STEP 16. List out and pre-cut all of the 2 X 4 boards needed for the
right end wall framing. Measure, cut accurately and write the lengths
on each piece as you cut them.
STEP 17. On a flat horizontal working surface (as described in step
#2), nail together the 4 boards that form the outer frame. Then
install a recessed 1/4 X 3 1/2" lag bolt and washer into each corner.
STEP 18. Assemble the remaining parts of the wall frame. Be sure
that the window opening size is correct before installing the
surrounding members.
STEP 19. Erect and install the end wall frame between the front and
rear walls. You will need to remove any remaining wall supports to do
this. If it is a good tight fit, as it should be, you may need to do
some pounding to install it. The outer face of the end wall should be
exactly even with the ends of the front and rear walls. Nail it into
place and then install the 6 - 1/4 X 3 1/2" lag bolts and washers as
illustrated.
*21
STEP 20. Assemble the Left Wall frame following steps 15, 16, 17 and
18 above.
STEP 21. Erect and install the left end wall as in step 19. Be sure
that the right to left orientation is correct. The lag bolt within
the utility opening will need to be recessed.
STEP 22. Measure the tops and bottoms of the front and rear walls to
be sure that the tops are not spread. If they are, you will need to
compress them until they match. This can be done by starting at one
end and striking the wall beams, each in turn, with a heavy hammer to
work the gaps out of the intermediate members. A slight spread will
do no real harm, but this is your last chance to correct this and you
will be fighting any out of squareness later.
STEP 23. Measure, and cut to size, the 3 sheets of 1/2" A/C plywood
to be used for the interior floor. (See the floor plywood
illustration) Lay them in place, good side down, so that you have
something to put a ladder on. Don't install them yet, and cover them
if rain threatens before the roof and wall plywood is done.
STEP 24. Finish out the roof framing beginning with the 2 front and
rear end boards and then installing the intermediate members, and
finally the end pieces as shown in the illustration. The end pieces
are basically fillers, so they do not need to be exactly full length.
It might be a good idea to check the measurements of the opening sizes
for the intermediate members before cutting them.
STEP 25. Install the end wall additions as illustrated. Each board
length will need to be measured to be a tight fit. The fit should be
tight but not heavily forced. The outside faces of these boards
should match the outside face of their end wall.
This concludes the wall and roof framing.
*22
WALL AND ROOF FRAMING - METHOD #2
Procedure Summary - Each set of Front and Rear wall beams, and the
Roof beam between them, are installed individually to the floor frame.
Then the 2 long end boards for the roof beams are installed to set the
proper spacings between the beams. The intermediate members in the
front and rear walls are installed. The end walls are constructed on
a flat horizontal surface and then installed between the front and
rear walls, and floor frame. The roof framing is completed on the
structure. Finally the end wall additions are installed.
STEP 1. Have your materials on hand.
STEP 2. Cut to size the 6 front wall and 7 rear wall main vertical
beams, and the 7 roof beams. Refer to the illustrations for Front
Wall Frame, Rear Wall Frame and Roof Beams.
STEP 3. One at a time, install all 13 of the main wall beams to the
floor frame. Use a 5" or larger "C" clamp to position and square up
each one, and nail them into place. Then drill through them and
install the bolts as illustrated. Be careful that they are installed
on the correct sides of the floor beams.
STEP 4. Cut to size and install the framing boards and header for the
door opening area of the front wall. Install supports as shown in the
roof beam illustration for this operation and any other steps that
they are helpful. Glue as well as nail the doubled up boards beside
the door opening and the header boards. Be sure of the correct
opening size for you door before doing this.
STEP 5. Starting on one end, install the roof beams one at a time.
Use "C" clamps to get the position and squareness (of the walls)
adjusted. Then nail the roof beam to the wall beams. See the roof
beam illustration. Use the front wall as your squareness reference
and adjust the back wall to be parallel to it. Removing the rear wall
supports may be required as you work. After all beams are in place,
drill through them and install the bolts as shown.
STEP 6. Cut to size the 2 front and rear end boards for the roof
beams. Measure and mark the proper positions of the roof beams on
each board. Then carefully nail them to the roof beams at the marked
locations. Refer to the Roof Framing drawing. This will set the
upper spacing of the wall beams so be as accurate as possible.
STEP 7. Measure and mark the locations of the intermediate members
for the front and rear walls.
STEP 8. Cut to length and install all of the remaining intermediate
members and framing boards for the front and rear walls. Be sure the
vent and window opening sizes are correct for your devices.
STEP 9. Beginning with step #15 in WALL AND ROOF FRAMING - METHOD #1,
complete the framing of the walls and roof by those instructions.
*23
ROOF PLYWOOD INSTALLATION
Materials Required:
4 - 4' X 8' SHEETS OF 3/8" C/D EXTERIOR PLYWOOD
3 TUBES OF LIQUID NAILS ADHESIVE OR EQUIVALENT
1 5/8" DRYWALL SCREWS (5 LBS. FOR THE ENTIRE PROJECT)
#6 GALVANIZED BOX NAILS (7 LBS. FOR THE ENTIRE PROJECT)
100 SQ. FT. - 15 LB. TAR PAPER
1 BOX 3/8" STAPLES
General Instructions - The roof plywood is the first structure
rigidity locking step. The overall squareness of the walls will be
set by this installation, so take your time and get everything as
square as possible before you start. Recheck the flatness of the
floor first, and then square the walls. Use support braces to force
the walls square if needed.
STEP 1. Have your materials on hand.
STEP 2. Check and correct the flatness of the floor frame. Check and
correct the squareness of the walls.
STEP 3. Place panel #1 into position and temporarily hold in place
with a few nails. Don't drive them all the way down.
STEP 4. Measure the widths of panels #2 and #3. Cut and temporarily
hold in place with a few nails. Adjust all three large panels as
required to get a good square fit. If all 3 sides along the edges of
the roof frame don't seem to square up right, recheck and correct your
wall squareness as much as possible. If squareness cannot be
completely achieved, try getting at least 2 corners on one side
square.
STEP 5. Measure, cut and tack into place the remaining 3 panels.
STEP 6. Get all 6 panels adjusted to your satisfaction. One at time,
remove a panel, apply Liquid Nails or similar to the roof framing and
nail the panel down at about 12" intervals. Then go back and install
drywall screws between the nails. Be sure to screw down to every
portion of the roof frame under each panel.
STEP 7. After all panels are installed, staple down 15 lb. tar paper
over the plywood as soon as possible. Start from the back edge and
lap 4 to six inches. Overhang the paper about 4 to six inches on all
four sides and tack it to the sides so that the wind won't lift it.
*24
ROOFING INSTALLATION
Materials Required:
6 - 10' PANELS OF GALVANIZED CORRUGATED STEEL (1 1/4" RIB SPACING)
2 LBS. OF 1" DRYWALL SCREWS OR ? LBS. OF SPECIAL NAILS
1 TUBE OF CLEAR OR SILVER SILICONE CAULKING
General Instructions - The preferred material for the cabin is
corrugated galvanized steel panels. They are lighter then shingles
and require no maintenance for a great many years. The main
preference for steel is for fire safety. Even if a piece of burning
wood was on top of the roof, no serious damage would likely happen.
The same cannot be said for asphalt shingles. The size of the roof
was designed to allow quick and easy installation of readily available
10' panels. If you would rather use a different type of roofing, try
to use a metal material. Steel is the best. Some people think steel
gets hotter and makes the building hotter. This is not true. It may
FEEL hotter to the touch, but it actually releases heat much faster
then shingles do, so less heat passes into the structure. Light
colors or metallic finishes also reflect heat better then dark
finishes.
STEP 1. Have your materials on hand. Do this on a day with little or
no wind and wear heavy gloves while handling the sheets.
STEP 2. Position your first panel according to the illustration and
hold it down with 2 - 1" drywall screws. Drive the screws into raised
ribs, not the valleys.
STEP 3. Position and screw (with 2 screws each) the rest of the
panels as described in the illustration.
STEP 4. Once you are satisfied with the locations of the sheets,
fasten them down with 5 rows front to back and 4 fasteners per sheet
per row. The standard fastener for these panels are nails with
washers or lead caps but they may not work very well, driven into
plywood. The original cabin roofing was installed with 1" drywall
screws. Then each head was sealed over with silicone rubber caulking.
Which ever fastener that is used, be sure that they are driven only
into the raised ribs, not the valleys.
This completes the roof installation.
*25
EXTERIOR WALL PLYWOOD INSTALLATION
Materials Required:
10 - 4' X 8' SHEETS OF PLYWOOD (SEE INSTRUCTIONS FOR THICKNESS AND
TYPE)
1 5/8" DRYWALL SCREWS (5 LBS FOR THE ENTIRE PROJECT)
#6 GALVANIZED BOX NAILS (7 LBS. FOR THE ENTIRE PROJECT)
6 TUBES OF LIQUID NAILS ADHESIVE OR EQUIVALENT
DOOR, WINDOWS, AND VENTS
EXTERIOR FINISH - SEE THE INSTRUCTIONS
15 SQ. FT. OF 3 1/2" INSULATION
General Instructions - Before buying your plywood, some considerations
should be reviewed. First, how will you be finishing the cabin
exterior? Second, are you putting in windows and a door larger then
the plans show? The basic recommended plywood thickness is 3/8". If
your openings are enlarged, the plywood should thickness should be
increased to 1/2" instead of 3/8". The price difference is usually
not that great, and the strength increases considerably. Your choice
of exterior finish ranges from painted plywood to expensive elegant
siding. There is even treated plywood that requires no finish. If
you intend to install siding, basic C/D exterior sheathing grade
plywood is all that is needed. If you intend to just paint the
plywood, A/C exterior grade plywood would be best. A/C plywood may
cost almost twice as much as C/D, and by the time you include the cost
of the paint, it makes siding worth looking into.
The original cabin was sided with the same galvanized steel panel
recommended for the roof. It is tough, long lasting, fire resistant,
available, inexpensive and matched a nearby building. An appearance
that blends in with the location is a definite consideration. Siding
costs a fair chunk of the building cost and takes some time and
patience to install correctly. A time and dollar stretching
compromise might be to paint C/D plywood for now, and when extra time
and/or money become available, install the siding. Any way that you
decide to handle it, plan to put some sort of finish on immediately,
to weather proof it.
Installing the exterior wall plywood is what really sets the rigidity
of the structure. Be extra sure that the walls are square to the
floor, and it is not leaning. Recheck the flatness of the floor first
and then square up the walls by installing temporary supports as
required. Since you will be starting with the front and rear walls,
try placing the supports on the ends if you can. Don't put any
plywood on until you are absolutely satisfied with the squareness.
STEP 1. Have your materials on hand.
*26
STEP 2. Be sure that the floor is flat and the walls are square.
Adjust with temporary supports as needed. Install insulation in the
lower and end cavities that cannot be accessed from the interior after
the exterior plywood is installed.
STEP 3. Beginning on the back wall; measure, cut and place check the
first panel. (see the Wall Plywood Installation illustration.) The
panel should overhang the end, equal to the thickness of your plywood.
When you are satisfied with the fit, take it down and apply Liquid
Nails or equal to the wall frame that it contacts. Nail it into place
at about 12" intervals. Then go back and drive 1 5/8" drywall screws
between the nail placements. Be sure screws are driven into every
frame member behind the panel.
STEP 4. Cut the over all size of the second panel and tack it into
place with a few partially set nails. Trace the outline of the window
opening from behind. Take it down and cut the window opening except
about an inch in each corner, so that the panel is stable to handle.
Apply the adhesive to the wall framing. Nail and screw it into place.
Use a keyhole type saw and finish cutting the window opening when it
is convenient to do so.
STEP 5. Measure and cut panel #3 being sure it overhangs the end
equal to the thickness of your plywood. Glue, nail and screw it into
place.
STEP 6. Install the plywood on the front wall in the same manner as
above. Remember that it overhangs the ends as well. Note that panels
#2 and #3 have a staggered step around the window opening and that
panel #3 could be pieced to conserve material.
STEP 7. Install plywood on the ends in a similar manner as above.
Note that panel #1 on both ends will not quite extend to full height
in the upper front corners, and that a notch for the skid beams is
required for panels #1 and #2 on both ends.
STEP 8. Install insulation in the cavities under the eves.
STEP 9. Measure, cut, glue, nail and screw plywood panels under the
eves.
STEP 10. Optionally install trim strips on the front and rear roof
end faces, and under the roofing edges on the sides.
STEP 11. Either caulk and paint the plywood, or staple up 15 lb. tar
paper if using siding.
STEP 12. Install windows, door and vents.
STEP 13. Install any desired exterior electrical outlets, generator
input, electrical inputs, etc..
STEP 14. Install siding if that is the plan.
STEP 15. Temporarily cover the Utility Panel opening until in is
completed and installed.
This completes the exterior of your cabin. (Take a well deserved
break and admire your work.)
*27
INTERIOR FLOOR INSTALLATION
Materials Required:
3 - 4' X 8' SHEETS OF 1/2" (OR THICKER) A/C EXTERIOR PLYWOOD
1 5/8" DRYWALL SCREWS (5 LBS. FOR THE ENTIRE PROJECT)
2 TUBES OF LIQUID NAILS ADHESIVE OR EQUIVALENT
100 SQ. FT. 3 1/2" INSULATION
1 QT. OIL BASED FLOOR PAINT
General Instructions - Your floor consists of 3 sheets of plywood.
The type used should be A/C exterior grade. The thickness should be
1/2" minimum, and thicker if you intend to put it to heavy use. Flake
or particle board is not recommended because of formaldehyde release,
moisture expansion and less structural strength per pound. Insulation
should be installed in the floor cavities. Since the use of glue is
recommended, don't lap the backing of the insulation over the floor
frame. Drilling drain holes into the bottom of each cavity for
condensation relief is a good plan, but that will allow insect
invasion into the sub-floor area. The original cabin floor cavities
were heavily dusted with Diatomaceous Earth powder (fossil powder)
before the insulation was installed. This material is like broken
glass and razor blades to insects, and will eventually kill any that
contact it. It has an indefinite residual, and is harmless to humans.
It can be found at organic garden supply stores and possibly feed
stores. (it is used to kill intestinal parasites in livestock.)
STEP 1. Have your materials on hand. Check that there are no high
spots from the intermediate members. If there are, use a wood chisel
to remove them.
STEP 2. Drill drain holes through the sub-floor plywood and treat the
cavities with insecticide if desired.
STEP 3. Install insulation into the floor cavities. Don't lap the
backing over the floor frame.
STEP 4. Place panel #1 (a full size sheet) and center it. An equal
gap of about 3/8" to the front and rear, and equal distance from both
end walls. Tack it into place with a couple of drywall screws. (see
the illustration)
STEP 5. Measure, cut and place panels #2 and #3 so there is about a
1/4" gap by the end walls.
STEP 6. One at a time, remove a panel and apply Liquid Nails or equal
to the floor frame, replace and screw down with 1 5/8" drywall screws.
Place a screw about every 9" and be sure to screw to every member of
the floor frame. If the edge gaps are not covered by the wall
paneling later, you can caulk or install trim strips. (The gaps act
like expansion joints for shrinkage and motion displacement to help
prevent floor buckling)
STEP 7. Paint the floor with 2 coats of good oil based floor paint
and let dry.
*28
This completes the basic floor installation. A floor covering of your
choice can also be placed over it. Carpet is not recommended. If a
wood stove will be used, take care in your choice of floor covering
within 3' of it in any direction. It may be best to install floor
covering after any permanent cabinets or fixtures are installed.
*29
UTILITY PANEL INSERT - WOOD STOVE
Materials Required:
2 - 8' 2 X 4 PINE
1 - 4' X 8' SHEET OF 3/8" C/D PLYWOOD
1 - 3' X 8' SHEET 26 GA. GALVANIZED SHEET STEEL
1 - DOUBLE FLANGE COLLAR WALL PASS-THROUGH FOR A WOOD STOVE FLUE
1 - 100 CT BOX #8 X 1/2" SHEET METAL SCREWS - PHILLIPS HEAD
CARPENTER'S WOOD GLUE
SILICONE RUBBER CAULKING
General Instructions - A wood burning heat source is a valuable item
for camping or an emergency shelter. It is also a potentially
dangerous device as well. If not throttled back properly the stove
and flue pipe can literally get red hot. If either is in near contact
with an ignitable item, it will start a fire. Passing a flue pipe
through a wall requires special precautions to insure safety.
Commercially produced devices are available to do this, but they need
some help. The small double flanged collars for about $10 are
marginal at best. (insurance companies won't approve them) A utility
panel insert can be built that will prevent excess heat build up
around the flue exit. It is used in conjunction with the flange
collar for more positive safety. (although it has not been rated by
insurance companies) Wood stove operation and safety is something of
an art. If you don't have experience, find someone that does, to help
you get started. One serious mistake could burn the place down.
The principal behind the flue panel is simple. Keep the flammable
materials away and allow air to circulate to keep heat from building
up. Two hollow cavities with convection venting are created buy the
panel. The first is all metal and the second is metal covered wood.
This is in addition to the commercial flange collar device. A triple
safety factor. Be warm, but be safe. That is also the reason that
the floor plan has the door located well away from the wood stove.
STEP 1. Have you materials on hand. Refer to the illustration.
STEP 2. Construct a 2 X 4 frame that fits the utility panel opening.
This can be done right in the opening for good accuracy.
STEP 3. Glue and screw pieces of 3/8" paneling to both the front and
back of the frame. Use carpenter's wood glue (non flammable type) and
let dry.
STEP 4. Cut openings in the plywood as illustrated. Note the drawing
is showing both the inside and outside surface in each step. The
convection openings are only on the inside.
*30
STEP 5. Cut pieces of sheet metal to cover the entire face for each
side and set aside for later.
STEP 6. Cut pieces of sheet metal and install them to form a tunnel
through the 18" square holes. 26 Ga. steel can be hand formed and
then pounded down with a hammer. Install with nails because you will
not want screw heads sticking up later. Also try to overlap them in
the tunnel corners and screw them together. Seal the corners air
tight with silicone rubber caulking.
STEP 7. Cut the openings in the steel face panel, for the interior,
with a saber saw. Drill a hole in the center of each marked cut-out
to insert the saw blade and then cut an "X" diagonally from corner to
corner. Then you can fold the metal back and avoid sharp edges at the
openings. The center circle needs to be the size for your
manufactured flange device. The cut edges of the circle will be
rough, but covered later by the flange.
STEP 8. Screw the interior face plate to the insert and don't spare
the screws. Then turn it over and caulk around the face panel and
tunnel inside.
STEP 9. Temporarily install the exterior steel panel with a couple
screws and turn the assembly over. Insert the flange collar and use
it as a guide to mark the circle for the other flange tube opening.
Note that the flange tube openings are different sizes since one
slides into the other.
STEP 10. Remove the exterior face panel and cut the circle out for
the flange tube. Check the fit of the flanges.
STEP 11. Place a bead of silicone caulk around the tunnel opening on
the exterior insert face and replace the exterior metal panel and
screw them together - not sparing the screws.
STEP 12. Install the flange collars from both sides.
STEP 13. Install the completed insert assembly into the panel opening
with the convection vents inward. To hold the insert in the wall, lag
bolt pieces of bracket metal to both the insert and inside (and/or
outside) wall face of the cabin. You can now pass a flue pipe safely
through the wall.
This completes the utility panel insert for a wood stove. Again, have
an experienced wood stove user inspect your setup and show you the
proper safe operation of your stove. Don't be a burned beginner!!
*31
INTERIOR PANELING INSTALLATION
Materials Required:
10 - 4' X 8' SHEETS OF PLYWOOD PANELING
3 LBS 1" DRYWALL OR PANELING SCREWS
5 TUBES OF LIQUID NAILS ADHESIVE OR EQUAL (SEE INSTRUCTIONS)
General Instructions - Before doing the interior paneling, install any
electrical wiring desired and the insulation. The paneling should be
made out of plywood and be 1/4" thick minimum. It could be anything
from painted 3/8" plywood to fancy 1/4" interior wood grain paneling.
The interior paneling does add to the building structure, so attach it
well. Installing the insulation and using glue for the paneling
installation conflict with each other. The facing paper of the
insulation is usually stapled to the framing just where the glue is
applied. A compromise might be to limit the facing on the framing and
apply glue to only some areas of the framing. Use of glue is not
essential but highly recommended. In any case, install the paneling
with screws rather then nails. Screws are a much more positive
attachment means than nails.
STEP 1. Install any electrical wiring that is desired.
STEP 2. Install insulation in all of the wall frame cavities.
STEP 3. Beginning with the rear wall, cut the full width overall
panel for the center. Do not extend the panel into the gap between
the floor plywood and the wall frame. Open the window and remove the
screen so that you can reach through it from the outside. Tack the
panel into place with a couple of screws and mark as much of the
window as you can from behind it. Take the panel down and finish
marking the window opening and cut it out except about 1" in the
corners. That way the panel will remain stable until it is installed.
STEP 4. Install the center panel with screws at no less then 12"
intervals. Be sure to screw to every member of the wall framing.
Glue is recommended as well, especially around the window. Finish
cutting out the window opening with a keyhole type saw.
STEP 5. Measure, cut and install the outer 2 panels for the back
wall. Be sure that the vertical cut edges are on the outside wall
corners, not adjacent to the first panel.
STEP 6. Panel the front wall in the same manner as described above.
You will need a helper to mark the door opening from the outside while
you place the panel from the inside. The vents will need to be
measured and marked. The vent openings could be marked and cut out
undersize and then finish cut after the panels are installed, to get
an exact opening fit.
*32
STEP 7. Measure, cut and install the paneling for the end walls as
shown in the illustration. Since both panels on each end wall are
full width, install them from the center edges out. Any gap in the
corners can be covered with trim strips.
STEP 8. Install trim strips or caulk around the floor edges and wall
corners. Do not do anything to the tops along the roof.
This completes the interior wall paneling installation.
*33
INTERIOR CEILING INSTALLATION
Materials Required:
3 - 4' X 8' SHEETS OF PLYWOOD PANELING 1/8" THICK
1 LB. - 1" DRYWALL OR PANELING SCREWS
2 - 12' TRIM STRIPS (SEE INSTRUCTIONS)
General Instructions - The material for the roof paneling should be
thin and light 1/8" thick plywood paneling. Install any electrical
wiring and the insulation first. The panels can be 3 large sheets or
strips the width of each set of roof beams. The advantage of strips
is that it allows their removal to anchor beams to the roof beams to
build cabinet structures later. For this reason, using glue is NOT
recommended, at least not until after all interior structures are
completed.
STEP 1. Install any electrical wiring desired.
STEP 2. Install insulation into the ceiling cavities.
STEP 3. The ceiling panels will be sized and positioned just like the
floor panels. See the flooring illustration and instructions.
Measure the ceiling length. It will be longer then the 8' sheets.
Divide the amount over 8' equally on both ends. Using screws, install
the full size center panel.
STEP 4. Measure, cut and install the 2 outer panels.
STEP 5. Install trim boards along the front and rear walls. The trim
boards should be wide enough to cover the gaps left by the ends of the
roof panels. Use hefty size screws to install them.
STEP 6. Install trim strips or caulk the edges along the ceiling and
end walls.
STEP 7. Optionally install trim strips over the 2 seams between the
sheets for added assurance that the panels will stay up. If you are
installing strips instead of full panels, trim strips can be used to
cover all of the seams.
This completes the installation of the interior ceiling.
*34
FINISHING TOUCHES
The basic exterior and interior structure is now completed, but many
details still need to be completed. The details will be finished in a
different manner by each proud owner of their cabin to match their own
personal needs. Below is a list of items to consider.
VENT DOORS. The vents are probably not very air tight when they are
closed. A hinged interior door with a closure catch and a foam
compression gasket around the edges would create a positive seal.
SAFETY PANELS FOR THE WINDOWS. Winter panels made of rigid clear
plastic sheeting could be made for each window to reduce heat loss in
the winter. The best plastic is polycarbonate (Lexan) because it is
unbreakable and will not distort from normal heat exposure. The
panels should be installed into the window frame from the inside.
Make at least 1 of them easy to remove, without tools, so that the
window can be opened if needed.
WINDOW COVERS. Interior covers for each window made of gasketed wood
panels hinged to the wall above the window. The covers would provide
extra security as well as better insulation on really cold nights.
They can be held open by a catch on the ceiling, or closed and
retained by a catch on the wall. If a window is broken, it is a
simple matter of closing that cover until repairs are possible. This
cover would be used on the window above the beds if the optional bunk
bed were employed. (see floor plan).
STORAGE CABINETS AND COUNTER TOPS. The cabin furnishings will
certainly include some storage cabinets. These could be manufactured
ones or self-constructed ones. Regardless of the type they should be
securely anchored to the cabin structure. Vertical beams could be
installed from the floor to the roof beams for supports. At the very
least, they should be bolted to the walls and floor. Refer to the
framing illustrations to locate the main beams in the walls and bolt
directly to them.
BEDDING. Refer to the floor plan illustration for the bedding
suggestions. 3 twin mattresses could be stacked and employed as
needed. One pulled out on the floor beside and one above as a bunk.
The bunk option will require creating a support structure. An under
mattress plywood structure board can be stored against the wall behind
the mattresses when not being used. Then placed onto the support
structure when needed for the bunk. The support structure would need
to be anchored from floor to ceiling at the end away from the wall.
The addition of a panel to the support structure would form a wall to
create a closet or small toilet privacy area. Of course any toilet
would be a port-a-potty type, since there is no plumbing. Notice the
convenient location of one of the vents just above this possible
toilet area. Store plenty of blankets for the beds.
*35
HEATING. Any cabin or emergency shelter would require a heat source.
There are a number of possibilities, but any type of heater used must
require no external utility source to function (electricity or piped
in gas). All portable heaters are dangerous to some degree. Whether
it is wood, kerosene, or propane; they all consume oxygen and could
release deadly carbon monoxide. A vent should be open at all times
during their operation. Exposure of a flammable item to high heat
could start a fire, so be careful about the installation. Keep a fire
extinguisher on the wall. Anchor the heater and accessories very
securely. Never refuel with a flammable liquid inside of the
structure and store the extra fuel outside away from the building.
Have your setup inspected by someone that is experienced with your
type of heater - before you use it. Then test it, before you actually
need to rely on it.
LIGHTING. A portable lighting source is needed for the cabin.
Battery operated lights are great for occasional hand use, but a long
term lighting method will be needed. Kerosene lamps are probably the
safest and most reliable. Coleman fuel type lights require the use of
a very explosive fuel and need new mantles if banged around. The also
give off some radiation that is not safe for long term day to day
usage, and they are noisy as well. Whatever the light source, anchor
them securely and have spare parts for anything that can break or wear
out. The safety rules are the same as for the heaters.
PROVISIONS. Everyone has different requirements for provisions.
Food, water, and clothing are universal. Store these items carefully
and in sufficient quantity. Store water in containers that can
withstand the expansion of freezing. A method of treating
questionable water should be kept as well. Purification chemicals,
micro filters, or a distilling device are some possibilities.
Food can be in the form of dry grain products and/or canned goods.
The canned food should be in the ribbed steel cans that can withstand
freezing. Never eat from a can that remains bulged after thawing or
you risk deadly botulism poisoning. Grain foods should be stored in
sealed rigid containers and inspected occasionally for insect or
rodent invasion.
Store extra clothing. It can be some that you don't use anymore, that
is out of style or a bit worn. Extra shoes and winter clothes are a
must.
The cabin is a great place to store all of your camping gear when you
are not using it. The gear will contain most of the items that are
needed in an emergency shelter. Be sure that the Coleman fuel stays
out and any appliances are emptied.
The cabin is also a great place to store your tools, especially the
hand operated ones. They could be real handy in an emergency
situation. Especially store hammer, nails, hand saws, pry bars and
similar items.
Store first aid items on top for quick access.
Be sure heavy items are stored low and pack everything securely.
END
*36