The Cook Shed

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May 20, 2007
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Our youngest son spent some time working in Texas and became a little obsessed with brisket - eating and cooking. He eventually sketched out an offset smoker that could be built out of CMU blocks and talked me into finding a spot for this endeavor on our property. We first looked around my shop which is down the hill about 400' or so from the house but we ultimately decided closer to the house would be better. We found a shady spot at the base of the hill below the house and leveled off a small rectangle. Our property is bordered on one side by a creek and this particular spot is fairly close to the creek.

Rev1 of his design was built around Thanksgiving 2022. It was fairly crude but still resulted in some pretty tasty butts and briskets. He started off using a thin sheet of aluminum over the fire box (which burnt through eventually) and a clean sheet of OSB over the smoke chamber. Being out in the open, he often had to deal with a bit of rain, hard to avoid in the southeast in the summer. He typically cooked the briskets for 20 hours plus and had to tend to the fire every one or two hours. I would often help here and there but regardless it was a lot of effort to get them right. Butts are much more forgiving and take less time so that's what he used for trial #1.

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So fast forward to September 2023 and he is on Rev3 of his smoker (or pit as I like to call it). Everything is a bit larger and the firebox now has a fully open end and internal baffles between the firebox and the smoke chamber. The aluminum sheet has been replaced by a reinforced steel plate but the smoke chamber is still covered with OSB.

He cooked as many as 9 briskets at a time on this pit. He was quickly becomming a "favored son" to all of our tailgating friends.

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So some of you might be wondering about the title; I'm getting there. Our youngest son took a job in Chicago over a year ago so he isn't home as often as we would like. Last Thanksgiving while he was home we were discussing making the pit permanent. He had several suggestions to improve the pit and also to make it more versatile. To build a permanent pit we would need a slab, or at least I decided we would need a slab. At one point his older brother, the middle son, suggested that if we were going to pour a slab then we might as well build a shed like we have at our family hunting property. Well once we started using the "S" word (Shed), the imagination starts to run a little wild.

My father in law built a large retirement house in the middle of many acres in south Alabama, just off the Alabama River. Basically it's a few miles down a dirt road and 30 minutes from any semblance of civilization. Until his passing we spent a lot of time there with my wife's 3 siblings, their families, and all their aunts, uncles, and cousins. There was an additional "family" camp house that my wife's grandfather had built many years ago about a mile away so extended family was always around during hunting season. We still have the property but don't quite manage to get there lately as often as I would like.

We have a cook shed adjacent to the house which is a simple 17' square, open sided shelter, with a slab. It is constructed with 4x4 treated posts and conventional rafter framing. We have a couple of large smoker type grills there and many days have been spent cooking mostly chicken, hamburgers, Conecuh sausage, butts, and/or ribs. We would often run a coax out there and set up a flatscreen to watch college football games while we cooked. So this experience is the foundation of my middle son's comment when he said "build a shed".

Thankfully my wife and I have similar tastes and as soon as she joined the conversation she was all for the idea. I think in her mind, "anything to get the baby to come home more often" is worth the effort; plus she had also shared lots of fun times around her father's cook shed. So I started researching designs, dimensions, etc. and came up with a basic 14x18 open sided shed with an 8:12 pitch roof, 6x6 posts, and of course a slab. We also relooked around the property for locations but ultimately came back to the original location.

My only concern with this location is the fact that occasionally the creek will get out of it's banks. It doesn't happen often, maybe 3 times since we bought the property in Spring of 2020. I knew that my shop slab was a foot or more above the flood plane so I used that as a reference to assess the elevation of our shed slab. Unfortunately that was prohibitively high so I compromised and we have set the slab elevation around 18" below the shop slab. That's still above the highest level we have ever seen the creek get to and, even if it does encroach on the slab, there won't be anything there that a few inches of water will harm. Here's a photo in front of the shop with the creek out of its banks. This photo was taken in February 2024 shortly after we started preparing the slab for a shop lean-to extension.

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My son and I disassembled the pit while he was in town and my loose plan was to commence work on site preparation sometime after Christmas. Well there's a lot of time between Thanksgiving and Christmas and I often had time for my imagination to roam, in a manner of speaking. At some point my wife and I agreed that 6x6 posts would probably look a little wimpy so I bumped those up to 8x8 timbers. Now once you get to 8x8 timbers, you start researching heavy timber frame buildings and then things get interesting. Before you know it you are researching traditional mortise and tenon joints and scouring the internet for building ideas. At some point we decided this heavy timber pavilion was the general concept we were after and I moved on to materials and tools.

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My bride is from Chicago and I have a brother + sister that live there now ... Please let me extend my condolences to your son for having to live there.

Kudos to him for his fine taste and skills. Also, your house appears to be an exceptional home.

I am envious of such a space for family. I am going to go tangential ...
How do you control the insects so such a space can be enjoyed? We have space 10-20 yards off the kitchen that would be well suited for such a pavilion, but we find the insects ruin consideration of the concept.

Thanks
 
While still researching materials and tools, I ordered some backfill and aggregate in early January. I had already removed the topsoil which was a good thing as the slope was a bit much for the dump truck where I wanted the fill placed and he had to place it right where the shed was going. It was just half a load so I used my front end loader to move most of the material out of the way and then proceeded to bring the site up in short lifts. I would use the tractor with a full load of dirt in the bucket to compact each lift and slowly got the site up to grade. I had the aggregate (#57 stone) dumped near my shop on top of an existing aggregate pad. I invested in a Topcon commercial laser level a couple of years ago and it's absolutely amazing how I managed to live without one for so long. Really comes in handy when you're shooting grades.
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My bride is from Chicago and I have a brother + sister that live there now ... Please let me extend my condolences to your son for having to live there.

Kudos to him for his fine taste and skills. Also, your house appears to be an exceptional home.

I am envious of such a space for family. I am going to go tangential ...
How do you control the insects so such a space can be enjoyed? We have space 10-20 yards off the kitchen that would be well suited for such a pavilion, but we find the insects ruin consideration of the concept.

Thanks
He works just over the Indiana-Illinois state line and actually lives in Indiana. Not sure he would want to live or work any closer than that.

Bugs are sometimes an issue but that depends a lot on the time of year. We have a creek but no standing water so there's nowhere close for mosquitos to breed. Not that we don't have mosquitos but they are manageable except maybe right at sundown at certain times of the year. Some people though are much more sensitive to insects than others and it sounds like that could be the case for you and your family. When we lived in Tampa we had a pool with a cage. Took me a while to get used to it but it was absolutely insect free as long as you didn't leave one of the doors open. So maybe you should consider a screened in porch concept? We have one on the backside of our house which actually overlooks the area where we are building the cook shed.
 
... Some people though are much more sensitive to insects than others and it sounds like that could be the case for you and your family. ....

That describes my bride very well. Every bite generates a large uncomfortable welt for her.

Sounds like your son might have reasonably good access to future Bear games in Indiana. Plus, I65 is nearby which may afford a fairly direct drive home for him. i.e., Take the benefits where they present themselves.
 
For those of you that have no interest in pressure treated lumber specs or for those that want to go to HD or elsewhere and buy pressure treated lumber in blissful ignorance, assuming it is going to last forever, please skip this post.

Pressure treated lumber is specified by its Use Category (UC). The lowest treatment spec UC1 is "interior dry" and the highest treatment spec is UC5C which is "in saltwater" Marine Grade. Residential/Commercial use typically uses a different chemical treatment than Industrial/Marine use.

Residential use treatment uses Micronized Copper Azole (MCA) or just Copper Azole (CA). UC4A is specified as "ground contact" and must contain a minimum of 0.15 PCF (pounds of MCA per FT3 of lumber). There is a lot of interpretation on the interwebs about whether or not "ground contact" means you can put the material in the ground. I think it means you can but you have to be careful about how you do it. For example, don't encase a post in concrete with the bottom closed off and don't put timbers into ground that stays wet most of the time. I also don't think there's any guarantee that it will last more than a few years, and possibly much less depending on the circumstances. To get into the lowest freshwater marine grade category UC5A you need a minimum of 0.40 PCF of MCA or CA.

Industrial/Marine use follows the same UC categories but typically uses Chromated Copper Arsenate (CCA). It is also measured in PCF but the numbers don't directly correlate. After much consideration I decided I wanted the middle Marine use specification for my timbers. That would be UC5B, in ground freshwater or saltwater splash. That requires a minimum of 0.80 PCF of CCA. FWIW, to meet the highest "in saltwater" spec you need considerably more chemical: 2.80 PCF of CCA.

So after all that toing and froing, all I needed to do was find the material that met that spec. That turned out to be more difficult that I initially assumed.

Typical residential "ground contact" tag you will see.
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Saltwater splash Marine spec tag
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Nobody local to my area stocked any type of marine grade treated lumber. Some said they could get it but when I mentioned that I needed some 24' long 8x8s they either chuckled or they got this bemused look on their face. For the design we settled on I needed (3) 24' 8x8s for the plates and ridge beam, (15) 16' 8x8s for the main posts and beams and (26) 12' 2x8s for rafters.

I finally found all the material from one supplier in Gulf Shores, Alabama. I probably should have looked along the Gulf Coast to begin with given all the beach house construction in that area. And as a bonus, they could get all of this material in rough sawn timbers and lumber instead of dressed lumber. I mean it's a cook shed so it needs to be rustic and there's nothing better for that than rough sawn lumber and timbers (except maybe hand hewn but that's a whole different level of rustic). Also, bonus number 2, they could get the rafters treated to the same spec. And lastly, bonus number 3, all the material was quite a bit less than what I could buy dressed material for locally treated to the much lower residential treatment spec.

So a few days later we were off to Gulf Shores for the day. We use to have a condo there and my wife's sister and many of our friends live there so it's an area we know well. We went down early, loaded the material, had a nice fried shrimp and oyster lunch, visited with my wife's sister and our BIL and were back home by 6pm.

The night before we left I did a back of the envelope calculation and was a little shocked that the material would be around 6000 lbs (or more depending on moisture content). The trailer was within load limits without issue but the Navigator was probably at or a little over capacity. We had to position the load carefully to keep the tongue weight adequate but not overloaded. We got home safely and unloaded everything the next day. Took all the toys to get this timber off the trailer. Those 24' 8x8s are somewhere between 450 and 500 lbs.

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Since carpenter bees bore holes through the wood rather than eat it, I have seen them dive into pressure treated lumber without pause. Will this level of treatment have an impact on them? Or do you successfully control them via other means?

At the pace that your are progressing, will your son be cooking brisket for the 4th of July celebration?
 
What do saltwater rated 24' & 16' 8x8s cost? When I used to spend time in that part of the country I'd occasionally see them available and have toyed with the idea of a really robust pole barn since. Also curious about the bee resistance. I've had them bore in treated wood but it was pretty old and Lowe's/HD grade stuff.
 
Since carpenter bees bore holes through the wood rather than eat it, I have seen them dive into pressure treated lumber without pause. Will this level of treatment have an impact on them? Or do you successfully control them via other means?

At the pace that your are progressing, will your son be cooking brisket for the 4th of July celebration?
lol First mosquitos and now carpenter bees. These are reasons to not do something.

We have rough cut square columns on the front and side porches of our house and occasionally we get a carpenter bee boring a hole in those. I usually just spray some industrial grade wasp spray in the hole and later fill it with some similar colored NP1. Those columns are painted and I don't think they are pressure treated. They look like reclaimed material actually from a very large building. They do make traps for carpenter bees but I have never hung any to see if they work. No idea whether or not marine spec arsenic treatment will deter them but it's not a concern for me.

Not sure about the 4th as we still have to build the new pit once the shed is done. If not we will probably just have butts on the BGE. He's coming home for a week in late April and he is hoping to be working on the pit then and not the shed. Not sure I can make that timing as I still have a ways to go. Just how far will become apparent in a few posts.

What do saltwater rated 24' & 16' 8x8s cost?
In round numbers they were $213 and $155 each respectively. Just for comparison, Russell wanted $259 for ground contact spec Yellawood 16' 8x8s and that price was discounted from $275 retail based on my quantity. Those are of course dressed 8x8s (7.5x7.5).

I will show some photos as I get further into the details but every one of these beams is very straight except for one 16' beam which has a slight bow. I will use it for 4' knee braces so not a huge concern. When I say straight, I mean pull a string line on every corner straight. Now they aren't perfect 8x8s. Some faces are 8 1/8" and some might be 8 1/4" but that isn't going to have any impact on the building.
 
In round numbers they were $213 and $155 each respectively.

Not too bad.

And the bee traps do work. Only problem is as soon as you catch one, there's another to replace it. Badminton rackets work too but there seems to be no end to their numbers. My old house was cedar sided and they were pretty bad.
 
One other fact to be aware of when working with large pressure treated timbers; the treatment chemicals do not penetrate through the entire timber. It will penetrate several inches (or even multiple feet) at the end grain but maybe only 1 or 2 inches on the side grain, and it doesn't really penetrate heart wood at all. FWIW you are supposed to field treat any cut or borehole in pressure treated lumber. That is not something I have ever considered in the past. The best post cut treatment solution I could find was Tenino 17% Copper Naphthenate which has 2% copper, as metal, content. I bought a gallon and will use it on the rafter end cuts as they will be exposed but not sure about all the other joints yet since they will all be "high and dry".

I did want to avoid any field cuts on the embedded section of the posts to ensure that the original pressure treatment wasn't compromised. My target was to imbed the posts 3' to 4' from top of slab and have 10' above the slab. Given the proximity of the shed site to trees as well as my previous experience with hitting large rock outcroppings, it wasn't a given that I could get those depths. Only one way to find out, dig the holes before you cut the top of the posts off.

I have access to a 12" diameter, PTO driven auger that I could have used to dig these holes but I was concerned about hitting a major white oak root and irreparably harming the tree. Wasn't sure how valid a concern this was but since I really needed 12" square holes (or a 16" round hole) for these 8x8s, I decided to just hand dig them. I mean after all, it's only 6 holes right? My ideal post placement design was, again, 4' below the top of slab with 6" of tamped gravel underneath. So that equated to about a 3 1/2' deep hole from previous natural grade on the uphill side and something less on the downhill side. So just to get started, I staked out the center of the posts and dug test holes in all 6 locations. Did not hit a root larger than 1" and did not hit any large rocks; so far so good.

I then had one of those morning epiphanies that are often great ideas but are almost always disruptive. How much larger could I make this shed with the lumber that I have? My original layout was 14' x 20', outside of post to outside of post, with 2' roof overhang in all directions. Since I bought 16' beams for the short side tie-beams, the limiting factor to making the shed wider was the 12' rafters. Quick calculations and I could expand the building to 15' x 20' outside post to post. 15x20 are really nice dimensions because the diagonal is exactly 25; nice big round numbers for setting up a perfect rectangle in the field.

So off with the forks and back with the bucket. Added another 1' or so to the front of the pad and then commenced erecting batter boards so I could set up string lines. Batter boards aren't as critical as they used to be to get a structure level as everyone uses laser levels these days. They are or can still be very useful though for lining up posts, form boards, etc. and keeping everything plumb and square. I did opt to make these level since having level string lines makes field checking hole depth with a tape measure very easy. I set the height arbitrarily at 6" above top of slab.

After those were finished I dug out the three uphill side holes to my target depth (which is now 5' below those string lines) and amazingly did not encounter a single large root or rock. I would describe the soil as sandy loam with some clay content and was fairly easy digging except for the last 6" or so where I encountered very compact "hard pan". Having these holes dug allowed me to start working on the timbers on this side and I will dig the other 3 holes prior to working on those timbers.

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Probably a good time to talk about tools. So if you don't like to read about tools, then skip this post. Actually, if you don't like to read about tools then you probably shouldn't be wandering around in this section of the Forum. 😂

I have always enjoyed working with wood, everything from framing to furniture and have a lot of tools. I did need to add a few to get this job done though. I mean what worthy project doesn't need a special tool or two (or a dozen)? For once, I did try to limit my purchases to the bare essentials as I am pretty sure this will be a one and done project. If you were going to do this for a living then there are much better (aka more expensive) choices that one could make.

First off I needed to either get comfortable with doing a lot of hand sawing or I needed a portable saw that could cut at least 3" depth for the tenons. Several manufacturers make 10 1/4" and 16" beam saws. These are just very large circular saws in either worm drive or direct drive configurations. I never knew such an animal existed and have lived in a 7 1/4" circular saw world my entire life - amazing. I already have the Makita 36v 7 1/4" cordless worm drive saw and really like it so I opted for the 10 1/4" 40v worm drive Makita cordless. I never really considered a 16" version as that just seemed like a recipe for disaster. I guess if you were cutting larger beams, like 8x12 then it might make sense. So far the new Makita has worked really well and isn't particularly difficult to handle.

Next up are timber framing chisels. You can spend a lot of money on these and for these I went to the upper end. Since my mortise joints are all 2 inches wide, I needed a 2" chisel. Every article I read touted the 1 1/2" chisel as indispensable for timber framing so I bought one of those as well. I went direct to Barr Specialty Tools for these. They are hand forged in Idaho and are truly works of art. Seriously considering framing them and hanging them in my shop when I finish this shed.

You also need a heavy mallet that you are comfortable using. I have lots of rubber and various dead blow mallets but for timber framing you need a wood faced or rawhide faced mallet. On the advice of Mr. Barr himself I went with a Garland 40 oz rawhide mallet. It is very comfortable to use. I also bought a DMT diamond faced honing stone (fine and coarse) but these chisels are so sharp I am not sure I will need to use it for this project. Time will tell.

One way to cut mortises is to buy a chain mortise machine. They are not cheap. At the opposite end of the spectrum you can just cut them by hand with chisels. Given that this is a one and done project and I am also a mere mortal, I opted for the in-between solution which is to drill out the bulk of the material and then use the chisels to finish the mortise. There are lots of different wood drill bits and you will get both advocates and naysayers on the internet for every single type regarding their suitability for hogging out mortises. I opted to go with a special forstner bit made by Famag and called a "Famag Bormax". They are a German company and make them in metric and imperial sizes. I needed a 2" and an extension as my mortises are 5 1/2" deep. This bit has worked phenomenally so far for me even though many on the timber framing forums don't like forstner bits.

Some miscellaneous smaller ticket items. I needed a smooth cutting 1" bit for the pegs. I went with a 12" Wood Owl Ultra Smooth auger bit. It cuts fast and smooth. I might have considered it for the mortise hogging but they don't make this bit larger than 1 1/2". You need a good handsaw. I have lots of handsaws but many timber framers swear by a cheap Stanley 20" tradecut. I have to say it is sharp and fast and for the price disposable. You also need various squares, framing, speed square, combination, etc. I had everything but a large enough speed square so I picked up a 12" aluminum one. You also need (or at least I need) someway to drill straight holes for hogging out the mortises and also for drilling the peg holes. I looked at various portable drill presses but in the end went with some simple right angle blocks that you can use to guide the bit. They aren't perfect but so far they have been good enough. There is also a technique where you drill a hole in a plastic mirror (like a CD or DVD for example) and use the reflection to keep you straight. I haven't tried that yet but might give it a shot for the next batch of peg holes.

Then there are the tools that most of us have laying around: tape measures, large framing square, carpenter's pencils, etc. I can't really think of anything else I have used so far. Oh I forgot, broom(s), flat shovel, and a shop vac. Mortise and tenon joints make mountains of wood chips and sawdust.

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Entire books have been written on mortise and tenon joints so I won't bother with all the various techniques and nuances but will try to just stick to the essentials. To join an 8x8 post to an 8x8 beam you need to cut a 2" by 8" (or full width of the post) tenon 5" long in the top of the post and a matching 2" x 8" mortise 5 1/4" to 5 1/2" deep in the beam. These are the simplest joints that I need to make for my cook shed and there are 12 of them, 6 at the 24' beams to main posts connections, 3 at the king posts to ridge beam connections, and 3 at the king posts to tie beam connections.

There are two other types of connections in this design. The horizontal tie beam to main post connections will be fully housed connections. It's basically the same joint as described above but the horizontal tie beam will be inset into the main posts by 1" on each side. The inset transfers the sheer load from the 2x8 tenon to the entire 8x8 beam. There are 6 of these and they will be located 3" below the top of the main posts. So head clearance for the 3 horizontal tie beams will be just over 9'.

If the abovementioned joints (18 total) were the only joints in the shed then I could easily finish the framing in the next couple of weeks. Unfortunately and mainly only for design aesthetics, we are installing 45 degree knee braces on all the main joints. That's a total of 18 braces with a joint on each end. So those add 36 more mortise and tenon joints to the project; big difference between 18 and 54. :eek: Also these 45 degree joints are very different on the tenon ends of the braces. Plan on starting one today so will report back later on degree of difficulty.

This post pretty brings us up to current status. I have finished the 3 main posts and 24' plate beam joints on one side. Now I need to work on the 4 knee braces that will go in this assembly and then I can move to the other 3 posts.

I will go into further detail at a later date but it's worth noting that I have only drilled through each side of the mortises (24' beam in this case) and haven't drilled through the tenons yet. There is a technique called "draw boring" which is a very long subject. Basically it's a technique where you drill the mortises without the tenon, insert the tenon, pull the joint tight, and then mark the center of the mortise hole on the tenon. You then remove the tenon, offset that hole towards the beam end of the tenon (the shoulder) by a small amount, and drill the tenon. The effect is that when you put the joint together in the field and drive the pegs though they will slightly bend around the tenon and draw the joint very tight. Recommended offset is 1/16" in hardwood and 1/8" in softwood. I haven't gotten up the nerve to bore any tenons yet and I am putting this process off as long as possible.

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Only spent a couple of hours in the shop yesterday afternoon but I did manage to get the tenons on one knee brace cut. I think the layout took longer than the actual sawing. Very pleased with the results. The braces are cut from a 4' section of 8x8. I still have to cut the mortises but will cut the other three braces first and do all 8 mortises at one time since I have to separate the posts from the 24' beam and rotate everything 90 degrees to cut them. These mortises will be a little larger, 2" by just under 11".


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