Following a recommendation I received details of a shed that the customer wanted repairing as "the doors don't shut properly and some of the cladding is in need of replacement", an easy and quick job I thought until I saw the photo.
Yes, I probably though the same as you but up for a challenge I arranged to view the shed in person and advise on the best course of action.
On closer inspection the shed (not too close as it was full) it wasn't in too bad a shape, the roof had bowed where the front of the shed was slowly rotting into the ground and the lean-to at the side was being held up by the ivy growing over it but the sides clad in corrugated steel were still sound as were the beams holding up the roof.
The good news was that it could be economically saved; it was agreed that the lean-to would be removed with a new wall built and the front replaced with like for like cladding with a window each side of the door. The customer wanted the look and feel of the shed to be retained and didn't want it to look like a new shed at the end of the rebuild. This meant that where possible the original frame was to remain along with the bowed roof line.
Before arriving on site for the first time the owner had cleared the shed to allow better access to the front and side that were to be replaced. In clearing the building it exposed just how badly rotten it was, not only was the front of the shed rotten and coming away from the main structure but the whole shed had pitched forward. Where the lean-to was in the side of the shed ivy had grown into the shed causing further damage and had also pulled the roof out of alignment in one of the corners (something else to add to the list).
The first step was to remove the rotten cladding from the front of the shed whilst taking care not to remove any part that was still structural.
With the cladding and other rotten wood removed it was possible to see just how the shed had been originally constructed. It was clear that whoever built knew what they were doing as the concrete foundations were still serviceable and didn’t need any remedial work before the side of the shed could be put back.
Replacement uprights were cut to length and fitted next to the original uprights ensuring that the shed remained standing during the process. The shed measured nearly 7m wide but only had 3 supports either side of the door. Normally I’d fit more uprights spaced between 400mm and 600mm apart but the repair was on a budget and the shed has stood for the last 20 or so years so like for like replacement was the order of the day.
The cladding comprised of 22mm by 200mm pressure treated sawn planks (chosen to add structural integrity to the building) and whilst they would be fitted closely together the wind and rain needed to be prevented from entering the shed and damaging the structural timbers so a breathable and waterproof membrane was wrapped around the new frame.
The process was then repeated for the other side but with the added complication of ensuring that a rose bush in front of the shed was not damaged (albeit some pruning took place in order for it to be growing outside, rather than inside, the shed) so where possible the build was completed from the inside of the shed.
Windows needed to be fitted and the client wanted something simple and cost effective whilst letting in as much light as possible. Large perspex sheets were selected and rather than being fitted vertically as per the original windows it was decided to fit them horizontally to maximise the spread of light.
After fitting the internal window frame the waterproof sheeting was cut and secured to protect the shed stud work with cladding then applied to the front of the building. Due to the bow in the roofline each piece of cladding was unique in length.
With the front now watertight (albeit lacking doors) it was time to tackle the lean-to at the side of the shed. With the lean-to left in place, to provide support to the shed as well as to keep the torrential weather out, the remnants of the side of the shed was removed.
Luckily the only support for the side of the shed (and the one holding the roof up) was still in OK condition so it was a simple matter to install a new timber frame that supported the the side of the shed and also brought the frame in line under the roof tiles. Because of the movement of the shed of the years as it slowly rotted it did mean that the wall was no longer square to the front and rear of the building but it was now water tight and ready to last another 20 years. As per the front of the shed waterproof membrane was then wrapped around the frame.
With side wrapped and waterproof it was time to remove the lean-to before nailing the cladding onto the frame. This I assumed, wrongly as it turned out, would be a quick job as most of the lean-to was either missing or rotten. Even after cutting away every part of the lean-to that was attached to the ground, due to the decades of ivy growth, it would just not fall down so out came the heavy duty gardening tools. Some time later there was enough space to to nail the cladding to the frame. The original perspex cladding, whilst not pretty, was left in place to maximise the light and reduce costs however new watertight fixings were used to replace the original rusty ones.
After cladding the corners of the shed and completing other finishing touches it was time to manufacture new doors. These were constructed out of the same construction grade timber that had been used throughout the build and were also lined with weatherproof membrane to prevent the weather from blowing into the shed. Large T-hinges were used to attach these heavyweight doors to the shed and a surface bolt was fitted to the secondary door.
Once the doors had been hung the last jobs to finish the shed were install new guttering and concrete threshold. Fitting a gutter is normally straightforward, the bit of guttering with the downpipes is always the lowest point with the rest of the gutting sloping gently towards it. Once again however, the bow in the roofline presented opportunities for problem solving and a laser line was used to ensure the gutter ran in the right direction. The concrete threshold was straight forward enough, a sub-base was laid and compacted before a damp proof membrane was fitted and a layer of concrete poured over the top.
Having worked through some of the wettest weather seen this year the refurbished shed was finally ready to be handed back to the owner who was over the moon with the result, was pleased that it turned out how he'd envisioned it and that it retained its rustic charm whilst still being of a high standard.
If you are in Sidmouth or the surrounding areas (Seaton, Lyme Regis, Honiton, Budleigh Salterton or in between) and have a shed that needs a bit of TLC or would like a new one to be built then call today on 07479 481 441 to discuss your requirements.
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