Category: National Hardware Show Grant

Well, the final couple weeks were hectic and full of change.  We finally have the store reset, at least for now, and the cafe installed.  As the budget dollars ran out we found creative ways to finish the project using supplies on hand.

The countertops are built out of birch plywood and then clear coated with Helmsman Polyurethane.   

We custom built the table tops out of OSB, 1/4 underlayment and scrap lumber.  We used paint sticks for the edge banding.

The final touches are going into the kitchen, the hood is installed, electrical is complete, gas lines are hooked up for the burners.  All that is left is to put all the equipment away.

Cafe is coming together.  Still working on organization and flow.  I imagine that will last into the summer and beyond.  There are always opportunities to improve!  But ready or not, our grand opening is in just a couple days…

Our current store is a collection of three buildings that were built over a 20 year period.  The east section was originally built as a free standing sign shop.  We purchased this building in 2014 and gutted it so we could add it into our store.  We left the sewer and water stubbed out of the floor and hid it under our birding display.  It sure came in handy as we started to plan for where the cafe would go.

So we cut a channel in the concrete for the grease trap, floor sinks, floor drains, sewer lines and water line.  Thanks to Ryan and Lana Weaver for helping make the cuts and to D&J Construction for providing the saws to do the cutting work.

It took a couple of weeks to work through getting the water and sewer lines in and inspected.  Now we will be able to fill the backfill and pour new concrete over the channel.  Next up is new walls…

Phase 1 of our building project is finally underway.  A couple years ago we tore

down a couple of sheds that were in disrepair.  We had left a broken, uneven concrete pad that we would store fencing materials.  We started by busting up the remainder of the pad and hauling it out.

While we were prepping the pad, we were also busy working on

footings for the new storage building we are calling “The Barn.”  We then set concrete block for our stem walls.  Once we were done with the stem walls, we laid a rebar grid 24″ on center that tied the footings and pad together.

Finally, the day arrived for pouring the concrete.  The concrete company sent concrete with air pumped into for an outdoor pad.  That wasn’t

an issue until we started to finish the pad.  We pulled out the power trowel and the concrete started flashing off quickly on the edges, tiny holes started to appear and the pad wouldn’t smooth out.  We are not sure why the concrete company sent that mix as they had provided the concrete the week before for the footings and they knew we were building an enclosed structure, but after some yeoman effort by the guys, we got a decent pad.  So many thanks to Jake, Jake & Derek for

working with it and making a smooth pad.  It was a stressful and tiring day to say the least.

So never take anything for granted when working with others.  Communication is critical to get the best results.

When we put in our submission to the National Hardware Show for the opportunity to receive a $100k grant to grow our business, our plans were a bit different than where we are today.

In our initial planning we were going to add 900 sq.ft. to the back of our store to house the Cafe.   As we continued to refine the cost of building the addition, it became clear that the budget was not large enough to handle the building and the necessary restaurant equipment and accessories.

So after several iterations of designs, layouts and planning, we settled on constructing a 1275 sq.ft. building that we have come to call “the Barn.”  Our plan is to build it on top of an area that once had storage sheds.  They were torn down several years ago because of disrepair.   Once we clean the remaining broken concrete pad out of the way, we will be able to start building the Barn.  Our plan is to stock items that do not need climate control and that Customers generally ask for by name – feed, fencing, lumber, concrete, insulation, pipe, nails, rope, etc.

Our design inspiration for the Barn is the following building:

Ours will differ in that we will be using a mono sloped roof for maximizing the distribution of rain and snow.  We will utilize a parapet across the front to make it appear as a flat roof.   The original Gagon’s Lumber, the business that we have built upon, opened in 1903 with a parapet look from the road.  We are excited to be able utilize that design element.  We will utilize galvanized corrugated paneling for the walls, though we will run them horizontal instead of the traditional vertical. 

The porch on the front is a close match to what we will do.  This will give us an area to store mulch, soil, compost and fertilizer outdoors but undercover.  We will also use Suntuf polycarbonate panels to allow light into the area.

The Barn is the first phase of the project.  Upon completion we will be able to move merchandise into that building.  Once that is done, we will re-lay out almost our entire store.  Only tools and nuts and bolts will be spared a move.  We haven’t finalized all of the locations for each of our departments, but the major ones like Paint and Seasonal are set.  Others will be somewhat fluid as we work through the process.

Once the store is reset, we will be able to begin work on the Cafe and its kitchen.  The floor will need to be cut to run water and sewer into the kitchen.  We will then construct walls to separate the cleaning and storage areas from the cooking and food prep areas.  We intend to keep them as low as possible to make the space feel open.  So what was once Paint, Housewares, Sporting Goods and Outdoor Cooking will soon become the home of our Cafe.

By shifting to building the Barn instead of the addition in the store, we estimate that we will save approximately $25k.  While every project has some unknowns to contend with, we are optimistic that we have looked at the variables and have come up with a good plan to stay on budget and deliver an exciting venue for people to enjoy.