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Welcome to the story of my own personal Yellow Brick Road. This pictoral journey will chronicle the progress of one old barn and my determination to turn it into a modern day multi-track recording studio. Keep in mind, I'm female and have absolutely no history in construction. I know nothing. I also didn't have a budget for professional contractors. How does one lone woman tackle this? So, it was just him and I and the long road ahead of us. A blank canvas in the form of an unfinished building (formerly a barn and still attached to my home) awaited us. With a budget of between $5,000 and $6,000 Scroll down for the full story....
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For those of you who would rather skip the entire building process of how we got from Point A to Point B (believe me, it wasn't a straight line) then you can click on the above Spoiler Alert to see the FINISHED STUDIO as it looks today. However, I encourage you to read thru our building process, be it now or later, and see just how we got here. Some of it is rather comical, some of it inspiring. But it's your choice. If you're one of those who has to read the end of the book first, go ahead! |
In The VERY Beginning... |
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Let me start with a photo of the house BEFORE I purchased it. |
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This was how the property looked in April of 2004 before it was gutted and completely overhauled in a rebuild. It sits on a quiet residential circle in a small New Hampshire town. |
You can see the
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New Home - Summer of 2005 I arrived in July of 2005 and bought it as my very first new home purchase. |
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Again, you can see the barn in the left of the picture.
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This is how it looked in September after I moved in and put up a fence (by myself, I might add - another new learning experience!). |
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Phase ONE - The New Floor
(note: please click on each thumbnail picture and a larger photo will open up inside of a new window.)
| The Empty Barn | |||
The building is 25 feet long and 15 feet wide. The roof slopes from about 14 ft high on the east side to just barely 7 ft high on the west. These pictures were taken when we moved in and it was empty - before any work started. It was unfinished and "as is". |
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| The New Floor | |||
Our first concern was the floor. It was a mess. Crooked, broken, sagging, uneven, warped, and unstable. We decided to create a subfloor above it and support the new floor with cement footers that we dug into the existing floor and poured. Our new floor consists of 2x6 joists that are doubled in the center and on the west side. A single joist is secured to the wall of the east side. |
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Barn west floor1.JPG |
Barn north floor1.JPG |
Barn east floor1.JPG |
Barn south floor1.JPG |
| Wiring thru PVC piping | |||
Next came the problem of wiring. There's going to be two rooms and the barn will be divided into a control room and a live tracking room. Wiring will run between and within both. This was a major chess thought process of planning way ahead and altering those plans frequently when problems arose. We opted to get some PVC piping in 4", 3", and 2" sizes. I mapped out a fairly complex system of cabling and proceeded to try and lay it out between the joists. What a nightmare. I changed my control room and live room layout twice due to cable length issues as well as interference issues between the tube paths. |
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Barn Tubing5.JPG |
Barn Tubing6.JPG |
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| Going it Alone.....But | New Help Arrives | ||
At this point, I pretty much lost Scott for a time due to the demands of his job. So, I continued on using the knowledge he had taught me but also with the help of the John Sayers Recording Forum experts that turned out to be my lifeline on this project as well. I started a thread there called "Kathy's Barn Conversion" with the intent of asking a few questions here and there and it turned into 20 pages of posting that included expert advice, mistakes, learning curves, progress reports, invaluable info, and a lot of support and guidance from those with great minds who knew what they were doing. I thank them for saving me from myself many times. |
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A Detour In The Floor |
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So, as I'm continuing to map out the PVC tubing for cables and wires and trying to get it all laid out I post some of the above pictures on the John Sayers Recording Studio Construction forum. One day someone takes a look at the photos and notices the original old barn floorboards underneath the new raised floor we are making. He mentions that old wide planks like that could be worth a lot of money and that they seem to look in good condition. Others chime in the same and think they should be pulled up, even suggesting that if I don't sell them they could be planed down and nicely restored to use myself for the final studio flooring. I liked the idea of not only possibly getting some funds to further finance this construction but also the thought of having some of the original barn flooring from 1900 as my new floor in the finished studio really appealed to me. I've already dug up some old artifacts (such as horseshoes) that originated with the blacksmith that once lived here and I intend to incorporate those into the final decor on the open beams of the finished studio. History is fascinating and I love having those elements within my creative atmosphere. The job, however, seemed huge and not one that Scott was thrilled about (understandably). But once I closed up the new floor the opportunity would be gone forever and that nagged at me. So I went out there Super Bowl Sunday evening, grabbed a hammer and tested one to see what kind of nightmare I might be up against. To my pleasant surprise, the plank came up fairly easy as the nails pulled out with just a little determination. That was all I needed to set me in motion and the next day I began the project on my own. Two things occurred once I made this decision. First, the tubing progress not only had to be put on hold but almost ALL of what I had done had to be taken out of place and unassembled so that I could pull up the floorboards! Secondly, I had no idea that once those floorboards started coming up I would find yet a SECOND and even older original floor underneath. So, what did I do? Yeah, you guessed it. I pulled THOSE up too. And they were NOT as easy. What was left were bays of dirt - the bare ground. So there I stood- the tubing/cabling project halted, the new floor not progressing, and I'm digging up 100 year old boards. Talk about getting sidetracked. Here's a look: |
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| Old Floors 2 |
Stacked Old Floorboards |
Stacked Boards 2 |
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| Closeup |
The Longest Board Pulled |
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| Back On Track - Re-Cabling and Insulating the Floor | |||
| After the ordeal of pulling up the old boards I got back on track and began redoing the cabling inside of the tubing all over again. |
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Insulation |
Insulation 2 |
Insulation 3 |
Insulation 4 |
| Installing Two Layers of Plywood | |||
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We're finally ready to zip up the floor! By now I had done quite a bit without Scott and decided to see if I could attempt cutting and laying the plywood without him. It went well. Some sheets were harder than others simply because certain areas were completely cluttered with PVC piping coming up thru and those needed precise measurements on the plywood to cut out the holes for the piping. Other sheets were a breeze because they laid over open area. The first layer of plywood flooring was actually 3/4 inch OSB tongue and groove. After that was all secured down my buddies at the Construction Forum told me to place a layer of 30 lb roofing felt paper over it and then another layer of plywood. This would help with sound dampening. I laid down the roofing paper (cutting out the holes yet again for the tubing) and then began laying the final layer of OSB. This time it was 1/2 inch with no tongue and groove. The results are a super thick and solid raised floor. The next time Scott would come by we'd have something real to walk on! |
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30 lb roofing felt paper |
Felt paper 2 with 2nd layer |
Second layer complete |
Second layer complete 2 |
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Second layer complete 3 |
Second layer complete 4 |
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Phase One Is Officially Done! We Now Have A Floor. |
| The Back Wall of the "Live" Room | |||
So, after the floor ordeal, knocking out a few 2x4 walls should be a piece of cake, right? Sure. Except this is MY life we're talking about here. And there seems to be lesson and a problem to solve lurking around every corner. *sigh*..... By now, I've got Scott back with me for this stage of the construction. We start with the back wall which is where the drum riser will be built, the vocal booth, and basically where all the live room activity for recording will take place. I will sit facing it at the control room and desk area about 15 feet back. Our problem here is that we do have sloped ceilings. The right hand side of the wall is the shortest at 7 feet or so and the left hand side is up at 16 feet or so. The top plate of the framing would have to be sloped and each 2x4 timber along the wall would be a different size getting progressively taller as we go. Seems relatively simple when stated but factor in the age of the barn and how incredibly NOT square it is and you suddenly have inconsistencies everywhere. I went to my buddies on the Construction Forum and got some advice. We figured the slope at 15 degrees and cut the timbers at a slant. It all worked out but it was one of those head scratching days. Oh, and by the way, in the pictures below you'll see that there is already some insulation put up on the original barn walls which I did long before we started real construction on anything at all. After my learning curve, I did realize that the paper backed stuff was not going to work correctly there and for sure if the paper was used at all it was facing the wrong way. SO, I ripped it all out and took the paper off. I re-insulated the original wall cavities with pink only and THEN used new paper backed stuff for the cavities of the NEW interior walls. Error fixed. |
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| The Doorway | |||
There are two doors within the barn/studio. One leads right onto the back porch which then goes into the house. The second door leads strictly to the outside driveway. Both entries may have secondary doors installed for increased insulation in the future. The first step in that process was building the doorframe for the door that leads out to the driveway. |
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The Unframed Doorway |
The frame being built |
The Framed Doorway |
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| The Drum Riser - On My Own Again | |||
By this time I had lost Scott again to his busy schedule. Still needing a drum riser and a vocal booth I chose to tackle the easier of the two until I had some help again. The drum riser would sit in the far right corner of the sloped back wall. Since I have a Hart Dynamics electronic kit I didn't need to be worried about building a soundproof booth or cage that would normally be needed for an acoustic set. Therefore, a raised platform - a drum riser stage - was all that was necessary for my house kit. I went about it in the same way that I built the raised floor. I used 2x6 pieces to build the joists. I insulated the cavities and laid down the 3/4 inch OSB plywood flooring. It only took me an afternoon and was one of the easiest builds of this project. I hollowed out an area on the riser where the PVC piping was carrying 8 channel snakes to the control room area. These were for the Roland drum brain and for a Pro Tools 002 console that could be brought out to the kit for initial tracking of drums for when I was alone and playing both roles of drummer and engineer. I then laid the cable ends into the cubby hole and built the access door secured down with a couple of drywall screws. The drum riser was the last thing I did in May before becoming sick for the entire month of June and part of July. |
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The drum riser frame |
The drum riser frame 2 |
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The drum riser frame 3 |
The bay for snake cabling |
The drum riser insulated |
Covered showing cable bay |
The drum riser done |
The access door |
| Another Detour - Disaster Strikes | ||
| It's August of 2006. I've had the house about a year . We’ve already been thru one snowy winter in 2005 and New Hampshire had also been hit with massive rain storms and flooding in the spring that followed. But not to worry - the joists in the old unfinished ceiling of the barn always appeared dry as did the floor below. In fact, I was rather proud of my ancient, creaky, yet non-leaking structure. Do you see where this is headed? So, one Saturday night we get some rain - a bit of a downpour but nothing compared to the slamming we got in the prior spring. Sunday morning I go into the barn for something and what do I see? You guessed it. A huge puddle of water just to the left of the drumriser. You could have knocked me over with a feather. I saw the entire previous years work flash before my eyes. All I could do was hold my head in my hands and cry out, “No, no, no”. |
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I looked directly up above the puddle but could not see a leak. However, the beam and crossbeams were saturated. I got up on the ladder but couldn’t see where it was coming in from as the ceiling boards didn’t show one particular hole - just some wet areas. |
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| He grabbed a ladder and went up on the outside roof. When he got up there he discovered that the barn structure had NOT been re-shingled or re-roofed as the house had been. It was 20 or 30 years old. Although he could not see a specific hole he did see many cracks in the shingles and a nail sticking up in the general area where the water seemed to be coming in. | ||
Having absolutely no budget left and never fathoming in the prospect of a new roof I thought I was in serious jeopardy of finishing my new studio. But as luck would have it, he actually works at a place that makes this heavy duty roofing paper with adhesive backing. It’s about $75 a roll. He said he would bring me home 6 rolls for free if I wanted. He said it could be placed right over the existing shingles and since the roof is slanted towards the back of the property it wouldn’t even be seen. He then added that many porches, garages, and additions sometimes use this alone and never put shingles over it since this is 100% protection and shingles are more of a cosmetic touch. |
My fear of heights (being on a roof!), my complete lack of know-how, and the physical challenges involved dealing with 60lb rolls of roofing paper really raised the bar this time. I mean, come on.....at some point in time you just have to succumb to the fact that this is basically man’s work and I’m going to kill myself! But as it turns out, this wasn’t that time. Scott’s just wasn't available so I asked my best female friend if she was up for giving me a hand. To my surprise, she had no fear of being on a roof and said we could do it no problem. With some instructions from my neighbor on how to cut, measure, and apply the roofing we figured out our own system and completed the job in less than 5 hours. |
Instead of hauling up the heavy rolls on the ladder, we rolled it out on the driveway and cut to length the strip we needed. We then rolled that back up and took it up the ladder. Half the weight. |
| We then positioned it, temporarily secured it with rocks and peeled off one half of the adhesive width (it is manufactured so that the adhesive comes off half at a time from one end to the other). Once that laid down we folded it back on itself to expose the other half and pulled of the remaining adhesive. We continued on - overlapping each new strip on top of the last and securing the adhesive even more with roofing nails. I can now add roofer to my growing list of skills! We did it and I am so proud. And happy that I just didn’t try to patch one section. I can feel fairly secure that no moisture is coming inside. |
The New Roof 1 |
The New Roof 3 |
The New Roof 4 |
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| Running a SubPanel aka "The Trench" | |||||
Well, my health improved enough for me to realize that fall was on the way. Let me start by saying that I was in no way done with Phase Two yet - the vocal booth had not been framed and constructed as well as a couple of short sections of interior wall as well. But after being sick for half of the summer I had to switch gears while the New England weather was being kind to tackle the power situation. Here's a rooftop view of the area the trench needed to be dug. The line would run underneath the picnic table and the fence.
Things went smoothly for a while until I hit (you guessed it)......a problem. A couple of tree stumps and roots that had to have been calling this place home for many decades. But I got thru it with the help of a saw and some extra sweat. Then, noticing how cracked the driveway hot top was in general I had an idea. Figuring it was weakened over the years I took a hammer and just pounded the heck out of that section that was in the way. To my pleasant surprise it started chipping away! I finally lifted up an entire section and placed it aside. |
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The start and hot top area |
A further view |
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The main stretch |
The bulkhead cellar end |
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Pipe in the main stretch |
90 degree turn to cellar |
Up inside the barn walls |
A closeup |
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I, along with some help from my 79 year old grandmother (everyone should have a Nana like this in their lives!) filled it all back in with dirt and then a few weeks later the electrician came and we snaked in the wire and he hung the subpanel. |
I also wired the entire room with #10, #12, and #14 Romex for all of my power and lighting needs. See pic. |
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79 year old Nana pitching in! |
Future subpanel wall |
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| Back On Track - Resuming The Framing | ||
Now that the roof was done I concentrated on finishing the walls. I was still working alone as Scott's schedule was still hectic but he did check in on me to make sure my work was ok and see if I needed anything. First, I built a half wall to separate the "live" area from the "control" area. |
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I also built a cute little baby half wall that acts as a shelf/support for coming up the stair when entering the studio from the house door. |
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The last bit of framing that needed to be done was difficult. It was very high up and these small sections would not come down to sit on the floor. I had to think about how to attach them in such a unique situation. I had waited and put it off hoping that Scott would be back to do that part. But time was wasting away so I attempted it myself. I'm pleased to say I accomplished it and it still hasn't fallen yet so that's a good sign! |
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Ok, so are we done with Phase Two Framing yet? Well, no. The Vocal Booth hasn't been built at this point yet. We'll have to come back to this phase just one more time before it's complete but at this juncture I had to move onto something else. Let's go. |
| Insulation and Strapping | |||
At this point, I had already decided to do the drywall myself on the walls (more on that story to come). But I knew that drywalling the sloped cathedral style ceiling was out of the question. No way I could do it. So, I found a contractor for that part of the job Strapping????? What the HECK is that? Yeah, I had no clue. But I asked around etc., etc., and proceeded to borrow my neighbor's pickup truck, I bought 3 bundles of 12 foot strapping. No, it did not fit in the back of the truck competely so Nana rode home backwards in the passenger seat holding on to the wood coming thru the rear window with a rope. LOL!! A sight to see, for sure. The measurements to put this crap up? 16 OC everywhere? In a 100 year old crooked barn? It was SUCH a pleasure. I'm 5'2 and the highest point in my barn was 16 feet. Yes, I know what a ladder is. That's not the point. I hope to never have to do strapping again.
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| First - The Ceiling | |||
| Yes, these next pictures truly are the start of the beginning of the end. FINALLY.........the first drywall is put up. No, the vocal booth is still not built yet at this stage. But the light at the end of the tunnel is starting to break thru at this point. The contractors came in and zipped up the ceiling and I was a happy camper. |
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| Next - The Walls | ||
| Ok, so now the ceiling is up. Yay! I watched and learned and then went out and bought a dimpler for my screwgun.
It was time to start the walls and I really thought this was going to be a piece of cake. I mean, I had now built a floor - joists, plywood and all......ran tubing, run Romex wiring, framed walls, built a drum riser, repaired the roof, learned to use a nail gun, a table saw, a skillsaw and more. Screwing in a few sheets of drywall would be quick. HA HA HA.....ha ha........ha. It doesn't make much sense but it was absolutely the hardest thing I've had to do yet. Those couple of weeks were so frustrating and depressing for me. I really started losing all self esteem and thought I was an idiot. The simplest cuts would come out wrong. Of course, the barn being crooked didn't help but I can't blame it all on that. The angles of the sloped walls weren't helping either. Anyways, there were quite a few leftover scrap pieces of sheetrock from the job the guys did on the ceiling. Since I was doing double drywall layers I chose to use the scraps up on the first layer. That of course was the hardest because it was like putting a puzzle together. The second layer went a little better because I used more of whole sheets where I could. Still, this is one trade that I find very difficult and I haven't felt that way about any of the work I've done so far. Here's a few pics of the finished walls. The standard kitchen cabinet you see on top of the drum riser is eventually to be placed just
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| Framing The Vocal Booth | |||
By now, I figured Scott would be freed up to design and build the vocal booth with me. But time was marching on and I was impatient. I did. Alone. And man, am I PROUD of that one. I'd say it was my best achievement. One of the challenges for me was that it wasn't AND.......part of why I felt so good is that I also had to build the door frame as well. No help this time. I printed out the diagram the Recording Studio Forum had made for me months prior for another doorframe that Scott put together. Studying that and using what I even had to measure just right for the window opening, too. After feeling like such a loser during the previous drywalling experience |
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| Insulating The Vocal Booth | |||
Here's a couple of more pics showing the insulation going in. You'll notice there is no ceiling/roof on the booth yet in these photos. That I did not do alone. Scott came over and we built a type of subfloor with joists just like I did with the drum riser. We then hoisted it up onto the top and secured it. He left at that point and the next day I cut the plywood sheets for the roof of it. I used 3/4 inch and I put two layers down. Then of course, after adding insulation between the roof joists I put two layers of sheetrock on the interior ceiling, 2 layers of sheetrock on the exterior wall frames and two sheets on the interior wall frames. |
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| Sidebar! A Little Teaser Ok, you know that the good stuff is coming. The priming, painting, carpet and floors. THE FINISHED PRODUCT. Below is a picture of the corner of the barn that now holds the vocal booth. The second picture is the same corner, same view, but with the freshly primed vocal booth sitting right where the stove used to be. |
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| The Whitewash: Priming The Room | ||
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First Coat of Paint Ok, we're all built. Brand new raised floor, walls all framed in, fully insulated, drywalled, electrical and cabling done, drum riser, and vocal booth completed. My friend Scott joins me now again for the big event of getting it all painted. He actually does parking lot striping on the side and has a huge machine that sprays the paint. He brought it over and we loaded it with a 5 gallon bucket of some heavy duty white paint that was recommended to be used as a first layer primer before color. I used newspaper to cover the original wood beams and then he came in and let 'er rip. The following pictures show what looks like my own private white sanitarium! |
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| A Joke For The Nana.....and a Glimpse of the Final Product | ||
Ok......so you all know by now that the "Nana" has always been chipping in during this studio build. Elderly or not, she hauls 2x4s, transports strapping, digs trenches and even held up a few sheets of drywall for me. My buddy Scott has also known Nana since he was a teen (he is of course, all grown up and a police sarge in town and took Nana out on a ride a long one night which is a 'nuther whole story!)........so when Scott was spraying the studio with the white primer - he brought along one of his parking lot stencils that marks handicapped spaces and sprayed it right on the entry floor of the barn as a joke for Nana! |
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| ..The Same Finished Area | ||
Phase Six Painting is obviously not complete with just primer on the walls. But Scott and I did finish this phase a few Do you know how hard it is to paint one bold color on the ceiling and another bold one on the walls without having crooked lines at the meet points??? It was impossible. My solution was to put up white trim that separated the two colors (as well as separation between the walls and ceiling) and I think it looks quite sharp. But before we get to the Grand Finale we have one more subject to re-visit. |
| The Original Barn Floor Planks: Utilizing Them | Vintage Pic #1 |
Remember back at Phase ONE when I was building the raised floor I saved a pile of them from being buried and hidden forever. And then
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Vintage Pic #2
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When it came time to use them I had already decided that I did not want the wooden floor in the control room area under my chair. Here's what they look like now |
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| Since I only used some of them on the floor in the "live" area of the room I really wanted to utilize them on the walls to keep the feel of the barn alive. I cut and measured and secured them around the walls of the drum riser - halfway up the wall from the floor. Here's a couple of shots. |
Yup, we're done. I had a carpet company come in and install the silver carpet in the control room area. |
So.....are you ready to see it???? My handbuilt multi-track recording studio? Then come on in and.... |