Shack Construction – Part 3/4 (Insulation, Drywall And Finish Construction)


Insulation and Vapor Barrier

Insulation And Vapor Barrier

The next step in our shack construction project was to install insulation and the associated vapor barrier. We also marked out the operating desk footprint with tape on the floor to get a better “feel” for the final configuration and ergonomics of the room. We then brought chairs into the room to ensure that we would have adequate room for both of us to “move around” within the shack. With these steps done, the drywall was installed and the taping and mud steps completed.

Drywall Work

Drywall Work

With these steps done, we installed a suspended ceiling in the room with provisions for recessed lighting. We took steps to limit the “drop” of the ceiling to only 4 1/2″ to ensure that we had plenty of ceiling to floor clearance in the final room.

Suspended Ceiling

Suspended Ceiling

Next, our electrician installed the lights in the ceiling which created better lighting in the room for the remaining finish work. The next part of the project was to install a hardwood floor in the room. We have used a Flooring System from Kährs in other parts of our basement and had excellent results with it so we decided to use the same system in our shack. The flooring “floats” on a pad that acts as a vapor barrier between to concrete floor and the hardwood. The resulting flooring is very durable and looks great. We also installed our Geochron lighted map at this point and finished all of our electrical boxes.

Hardwood Floor

Hardwood Floor

At this stage of the project, we turned the finish carpentry over to Jim and Bob Bourassa (rwbjr@charter.net). They did an outstanding job with the moldings and other finish work.

Finish Carpentry Details

Finish Carpentry Details

They created some very nice custom details for our shack such as the finish molding around our cable conduits where they exit the walls by our operating positions.

Finished Cable Ducts

Finished Cable Ducts

Bob Bourassa built a support structure for the top of our operating desk and installed the associated cabinetry and end panels.

Operating Desk Frame

Operating Desk Frame

Next, Bob fabricated a custom top made from Corian Material and installed it. Note the openings in the back and corners for routing cables under the desk.

Completed Operating Desk

Completed Operating Desk

Bob also installed the storage cabinets and drawers and Brian, our electrician installed under cabinet lights to finish this area. We also installed the smoke and alarm system detectors in the room and integrated them into our alarm system.

Storage and Display Area

Storage And Display Area

The HVAC folks also completed the installation of the in-room A/C unit and heat pump.

In Room A/C & Heat Pump Unit

In Room A/C And Heat Pump Unit

And  finally the door and associated moldings were installed.

Shack Door

Shack Door

We also put some work into finishing the area outside our shack. This shows the stairwell which leads from our shack to the rest of the house. Note how well the wall that we added to create the room has blended with the original first floor wall by the stairwell. Again, Bob did a very nice job with the railing and tread molding in this area.

Stairwell from Shack to House

Stairwell From Shack To House

With all of these steps complete, our local building inspector paid us a final visit and gave us our occupancy permit which completed the construction phase of our shack. The final stage was to fit the room with all of the infrastructure and equipment to make our shack operational. This will be the subject of the next and final post in this series.

– Fred (AB1OC)

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