Sunday, February 12, 2017


Last post I got the deck finished and the South walls up, it is now starting to look like a Caboose.

The North and East walls were put up then the East 12' roof beam and roof panels.
 After the roof panels were in place the East Cupola end wall panels could be installed on top the roof.

 The operation was moved to the West end where the 17' long roof beam had to be lifted and placed using the scaffold and cable come a long.
 The beam hanging on the scaffold looking at the completed East end.
 Above and below are pictures of the beam supports that I fabricated from 2" square tubing and 3/16" plate steel. Two (2) of them support the upper and two lower roof beams. 
 The beams fit in a notch built into the end walls on one end and on the post on the other.
 With the beam in place the roof panels were installed.
 Another angle of the 2 post's and upper roof.
 I put the first 4 roof panels up on the West end then installed the East Cupola end wall so the upper roof beam could be put in while the scaffold was set up.
 The upper beam was hoisted up and set in place.

 The rest of the roof panels were pulled up onto the roof by using a extension ladder leaned against the side of the building and pulled up with a strap by hand.
 All the panels are in place.
 This is a look at the interior looking East to West.
 The "Rustic Red" metal siding offered a new challenge in doing all the work by my self as they are 9' and 12' tall and had to be fit at each window.
 It's slow going but it's getting done.
 Hold down straps were added at 6 locations on both sides to guard against any wind loads that may occur.
 The windows are all vinyl double pain and the roof and trim will be "Ash Gray".
We are expecting weather to come in over the next few days so things will be delayed a little bit. Karen got both porch's painted with deck paint to protect the wood.

Thursday, January 19, 2017


Last Friday my Son (Mitch) & Grandson (Alec) drove from northern California to pickup the 69 Mustang.

 They brought a U-Haul trailer to take it home.
 Alec did the honors while dad supervised.
 Got it loaded up without any damage.
 Strapped down with safety chains in place. 
 They are very pleased with the restoration that took over a year, it will be in the family for a long time.

The rain lasted through Monday the 9 th so we waited until Tuesday the 10 th to pick up the wall and roof panels. This is the second load with the truck and trailer at Air-Light.

 The Company name is Wanessa-Sue Inc. and the building is all made with the Air-Light panels so I could see how to put all the panels together, that and very good instructions from Wanessa Sue.
 I unloaded the panels with my tractor and moved them into the shop so I could use the overhead hoist to sort them, then to load them into the truck and hauled them around the house to the Caboose.

The track  channels were lay'ed out and screwed down then the first two panels were installed. I moved my rolling scaffold onto the deck to make it easy to reach the top of the panels and top cap. The tarps in the foreground covered the deck during the rainstorm.

 Extensions were added to the scaffold and a cable come along used to handle the 12' tall panels as they are to big for one person to handle. I was able to get the two 12' panels in place the second day.

 The third day I got the next four 8' panels in place with all the attachment plates and top channels installed. The panel are held together by the tongue and groove and 3" X 5" plates at the joints, bottom and top. All plates, sheet metal corners, top & bottom channels, screws and fasteners are supplied with the panels.
 Braces were added to support the walls as they are being installed.
 On the forth day I moved all the wall panels out of the shop to the caboose deck because the installation sequence of "A" South side, "B" East end, "C" north side and "D" West end will not allow access to move C & D in after the B end is in place as you can see the only access is through the gate on the West end for any thing that must be brought in by truck. After the panels were moved I got the East end panels installed.
This picture was taken this morning after the rain had started that is suppose to last for several days so I will have to wait for the weather to continue.

Thursday, January 5, 2017


The last post we were waiting for the deck to be made as it was delayed by a breakdown of a piece of equipment at AirLight Building Panels. I was able to pick them up last week and got them installed.
The two cross members were added before the deck went down.

 The deck is attached to the frame by using 7" self drilling screws at each panel joint with a plate that ties the two panels together and a screw with a flat washer at each stud cross member  (50 screws).
 The floor panels lock together with a tongue and groove joint and are 4' wide X 12' long X 5 1/2 " thick. The openings at the 4 corners will be cut out and boarding steps made and installed.

 Next 4 X 8 X 1/2 particle board was screwed down and wood flooring will be installed on top of it.
 For access we will be able to step off the rock wall on to the platform.
 No vapor barrier or insulation is necessary as it is built into the floor panels.
 We had a rain storm after the deck was complete so I covered ti with tarps to protect it until the wall panels are installed, they should be available next week.

Tuesday, November 29, 2016


The grading, retaining wall, steps, foundations and frame are complete and the fence has been relocated. Two cross members will be added as soon as I get the measurements for the two interior posts that will support the roof center beam.

 200 - 60 lb. bags of concrete were used to do the wall,steps, foundation's and fence posts.

 We have decided to use Pre-Insulated Steel Framed Structural Panels to build the entire structure - floor,walls and ceiling/roof. Below is a mock up of the wall section that is made with steel frame injected with expanded polystyrene beads creating panels from approximately 6 inches wide to 48 inches wide, and a maximum height of 12 feet.
 This is the roof beam that will support the 18 roof panels with a small pitch.

 Above and below is a section of wall panels that show the upper and lower "C" channels that secure the panels and the tongue and groove  between panels that make them air tight. The studs are laid flat on opposite sides so no hot or cold is transmitted through the metal.
 Karen and I are in front of a mock up wall that shows that any shape or opening be made.
 The pictures below show how a completed building is constructed when finished. This building is on a concrete slab with the AIRLIGHT  walls and ceiling / roof panels.
 The company that makes these panel is AIRLIGHT Building Panels in Kingman AZ. 
 We were going to build the caboose with lumber then when we went to the Veterans Day car show we parked next to a antique fire truck with a sign AIRLIGHT Building Panels and ask for information on them. Then the following week we went to the manufacturing location and found out the entire building could be built including the floor, that will hold +20,420 lbs. that's 5105 per foot, and all the panels have an effective "R" value of 30, we were sold.
 The owner, Wanessa, was able to provide a proposal that was within our budget with some drawings I had done of the floor plan and some elevations. We have made a deposit and Wanessa will proceed with final drawings.