Whoohoo!! Finished up the greenhouse frame last night!
Another success spawned from some messy scribbles on a yellow legal pad. Here's our design sketch. Dimensions at 6' wide by 8' long, and modified to be 6.5' tall at the center, so Steve wouldn't have to duck to stand inside. Well that, or so I would have some space to hang a disco ball and some christmas tree lights :-D
The base is made from pressure treated lumber to prevent rot, as it will come in direct contact with the ground. We'd rather never handle the stuff again if we can avoid it. The warning labels on pressure treated lumber are scary. Ugh, chemicals.
The hoops are made from 1/2" 16' lengths of PVC. Five tightly secured hoops give plenty of strength to support plastic.
Step one: Cut all the pieces.
I want to mention here that the fabulous chop saw is a loan from our awesome neighbors, the Jordans. We'd still be hacking pallets to pieces with a handsaw, and have crazy pop-eye arm muscles to prove it, had it not been for that chop saw. We are SO thankful!
Step two: Put together the 6' ends with attached door frames and gussets.
Mom, if you are reading this, I want to tell you that those L-Brackets are the best thing that you bought me when you sent me off to college. The close runners up being the hammer, which has disassembled a ridiculous number of pallets, and the screw driver, which I used to attach all the hoops to my garden beds. I love you!
As you can see, we used L-brackets, in conjunction with 2x4 gussets to hold the frame together at it's base.
Here's Steve, attaching the gussets to the door frame.
We used screws throughout the entire structure so it would be easy to disassemble and move in the future.
Step three: Attach the ribs to the base and the spine.
We attached a spine to the top of the door frames, to which we pipe-strapped the PVC hoops for extra stability. Hoops are also attached by pipe straps along the base. The hoops will give shape to the greenhouse when we cover it in clear plastic.
The final product! A beautiful finished frame, waiting in the driveway to be covered in plastic.
Here's a close up of the gussets holding the base frame together, as well as the pipe straps attaching the PVC hoops to the frame.
Another shot of the door frame gussets.
We attached the spine to each door frame with a spacer between the two, which gave the inside of the greenhouse some extra height and allowed the PVC hoops to more easily retain their natural curve.
Although the frame is complete the greenhouse is far from finished. We still need to make about 40 PVC clips to hold the plastic to the frame. The clips are the same as the ones used to hold plastic to the hoop houses, just a size larger to accommodate the larger PVC used on the greenhouse.
Steve's dad sent him his Dremel tool, which has this nifty little sander attachment. This worked so much faster than sanding all the sharp clip edges by hand. I did exfoliate a few of my fingertips in accident though. Ouch.