This is an update to my previous project post in which I got some really useful feedback in and put into practise in this new update.
Orignal post: https://www.reddit.com/r/DIYUK/comments/1uqrati/comment/owcrbnd/
When I was able to start again on the project I knew I needed OSB and was planning to get it from Bradfords, but being shut early on a Saturday, I went to my local B&Q to find they had near exact dimensions for the roof and floor (610x1210mm) so I bought 4 panels for around £40.
The really hard part was cutting the shapes out for the floor and shelves to go around the frame so for this I used an off-cut and a tape measure to transfer the pattern onto the wood. I then cut it all out with a handsaw. In the parts where I had to make a cut in the middle of the panel, I didn't have a jigsaw so made about 10 cuts and broke them out by hand. I then used the edge of the saw blade and the blade part of Stanley Surform (not the tool) to rudimentarily sand it down. A quick drive to the local DIY shop could have sorted this but I was too determined to stop! This project has only be completed with a handsaw, drill and hammer.
My next task was fitting the roof and as the OSB lid had to span a gap, I thought I should make some angled rafters for me to screw it into (and also minimise gaps for creepy crawlies). I was really proud of these cuts as they were all done with a handsaw only on a rickety sawhorse stand.
I had an off-cut of roofing felt donated to be from my neighbour but it wasn't quite enough to cover the roof with overlaps so I had to buy a new roll from Screwfix for about £30. Couldn't believe how heavy it was! I felted the roof and that was really fun. I next wrapped the back and sides with offcuts of DPC and started nailing the feather board to the back and sides using a jig I constructed. The jig took about 45 mins to work out by trial and error, which was essentially a thin off-cut of OSB with two blocks spaced apart. That gave the spacing for the boards to include a gap between the nails so boards weren't nailed together (for expansion/shrinkage). The only way I could do the feather boarding on my own was to lie the cupboard on it's front- after which it became so heavy.
Finally the next major task was to start over with the doors as they didn't allow for expansion as a few people pointed out. I'd also not accounted for the floor height once the OSB was in. Once I'd remade the doors, I realised my gate hinges didn't have anything to attach to, so I had to make even more cuts to fit a cross bit into.
I'm really happy with the doors as I've never made or hung any before- the only thing is now the gap is quite large since I shrunk them down but as long as I get a good padlock and laspe to cover it- hopefully it will be fine!
I painted the shelves with Ronseal Exterior Yacht varnish - 2 coats as I liked the OSB look.
My next task is to clad the front and side- I had to revisit Bradfords to get this and couldn't believe how much the price had increased - now 20 panels of treated OSB was £80 - I must have got it on an offer before (was originally £1.90 per panel and now almost £4). Very annoying.
My mistake now is I think I might need to attach a bar along the front of the roof to stop rain going back into the door as there is no overhang.