Week 33

The lid is on!

Hooray, the guys are in the dry. The big holes for the windows will need to be filled in, but that will be after Christmas. In the meantime, that thin sheet of Tyvek stuff is what matters. Josh and Terry are spending most of their time creating noggins for the ceilings under it, and the roofers put extra battens on which to fix the tiles over it. The guys tell me that the tiles will be on before Christmas too. Now, THAT will be amazing.

It poured with rain on Monday, but the roofers persevered and managed to get some very soggy sheets fixed in their places.

2016.11.26 - 1 (1).jpg
lid
2016.11.26 - 4.jpg
ceiling skeleton in kids’ bathroom
2016.11.26 - 5.jpg
east-most bedroom
2016.11.26 - 6.jpg
terry cutting some noggins as the light fades

 

The oak frame is starting to look a little lived in, a little too lived in really with the odd bit of scrap falling from the top to the deck. So James has covered the vulnerable parts of the frames to give them some protection.

2016.11.26 - 1.jpg
covered frame

We’ve decided on a combination of black stain on the soffits and Osmo varnish for the facias. James has been painting, and they’ll be cut to size and brought upstairs for fitting next week.

2016.11.26 - 2.jpg
sheets of soffits
2016.11.26 - 3.jpg
Osmo Hall

A few short late-afternoon visits in the week allowed some time for some photos around the site. But most of our time has been spent at the computer and immersed in catalogues choosing stuff and fleshing out the Fixtures and Fittings schedule.

2016.11.25-1.jpg
light on lofty beech branch, 5 metres up

2016.11.25-2.jpg

 

2016.11.25-3.jpg

2016.11.25-6.jpg

2016.11.25-7.jpg
through the vaulted ceiling at the join between two ridgelines
2016.11.25-8.jpg
Hi Josh!
2016.11.25-9.jpg
lit bridge on the way home

2016.11.25-5.jpg

Hard on the heels of Birthday Week last week comes Thanksgiving. I remember inviting my parents-in-law down for Thanksgiving dinners in the early 90s when I first moved here and was still a little homesick. They were very forgiving about having a Christmas dinner served to them a month early for no other reason to appease their daughter-in-law, and I’m grateful for their patience. I kind of gave up doing it after a few years because I decided it’s not the turkey that’s important, it’s the four days off in a row, the travelling and travelling-related-drama, and all-American-ness of it that I missed. This week, with the kids doing their after school classes, Clinton doing Scout-y things and me driving laps around Surrey dropping and collecting children, the night kind of passed us by. So I was determined to retain a small part of the whole exercise–through pumpkin pie, of course.

It’s a weird time to be American and in the UK after the horrible election. For once the geographical distance feels huge both socially and politically as well. I don’t run around feeling “American” but I like to be part of a community. This past week has left me wondering what that community truly is, and what its trajectory might be. But the process is what’s valuable ultimately, and it’s important that the kids still connect with their American side. So to maintain that connection in a positive way, Gemma brought in a piece of the pie to her Scout “International” evening, and Gregory might be starting to grow an interest in his political side. Incremental gains.

2016.11.26 - 1 (2).jpg
Tim is first at the pie

 

 

 

 

Week 32

Mid-November means two family birthdays back to back. Happy birthdays to oldest and youngest.

A slow week onsite, but much activity with choosing fittings offsite. The roofers had no end of trouble from the wrong stuff arriving to fix to the roof, to a blowout on the A3 coming up from Portsmouth, the combination of which means they didn’t really get stuck in. The lid should be on by next week.

2016.11.19 - 3 (1).jpg
it’s the wrong battens, Grommit
Terry, James and Josh used Dave’s spec to build out the valley section in the front adjacent to the structural oak frame. It will be covered in some sort of lovely new flat roof material and edged in lead. Should look like lead from the ground, but it won’t shrink and it will be all modern and, er, lovely.

2016.11.19 - 1 (1).jpg
leaf-collection area

2016.11.19 - 2 (1).jpg
dormer over kids’ bathroom
We found a lovely chap in Betchworth to restore the lantern out the front of the house. Most of these specialist blacksmiths seem to be based in Selkirk or Edinburgh, so it was quite a moment to find someone who will do the work within a 30 minute drive. The lantern is an original copper piece, and my temptation is to get it all shiny again. But I think Nature might have other plans, because I’m told that in 6 months time, it will look as tarnished as it does now. Maybe with a bit of lacquer to ward off the elements? 

With the extra time gained from lack of roofers, James and Josh brought the lamp down without getting electrocuted. The blacksmith is going to take the frog (the struts holding it up) off the lamp, get it sandblasted, and finally fix some pipework for the electrical cables. Rewiring will replace the current arrangement which is to run flex from the house underground, up the cast iron pole, through the hole at the top, past the nest of blue tits, and continue through the lantern from bottom and hang a lightbulb from the inner reflective plate.  A little investigating how to keep copper looking all coppery is in order.

2016.11.19 - 1.jpg
the only thing holding it on was putty in the collar
Another totally unrelated copper thing but completely cool is the West Ford Ring which circles the earth making it look a bit like Saturn. It was intended as a large Cold War era radio satellite when it was launched in 1963 to protect the America’s long-range communications from the scary Russians, and clumps of it are still floating around in low earth orbit. I’ll bet THEY’RE all nice and shiny without any nasty oxygen to fugly them up.  So here’s a physics question… why is copper a good material for this idea?

West Ford Project
tiny copper West Ford Project needles

what was

headlessWistful moment: it used to look atmospheric, being the only light on our little section of road! Hopefully with a little TLC, it will be restored to its former awesome state. It’s not exactly an urgent issue, tackling this bit, but it’s one of those things that will make it really nice to come back to.

With the roofers having their troubles, the guys onsite had a thorough cleanup. It’s looking more and more like a House and perhaps less of a Site.

2016.11.19 - 3.jpg
master bedroom

2016.11.19 - 4.jpg
side of the front frame
2016.11.19 - 5.jpg

2016.11.19 - 6.jpg
back of the house with the kick at the foot of the roof
With roofers changing the order of proceedings, we’ve left the time-lapse camera in situ, so your fix of the day-by-day will have to wait until next week!

 

Week 31

2016.11.11 - 1.jpgMid-November and it’s getting really really cold. The rental house’s main valve to the ground floor radiators decided to give up the ghost this week just to make things interesting. Not quite a frost on the inside of the windows state of affairs, but it’s certainly cold underfoot when making that first cup of tea in the morning. But this is NOTHING compared to early dark-o’clock onsite.

Walking back from the station on Monday, we decided to pop in for a look at progress and found James and Terry accumulating questions in preparation for Dave’s visit on Thursday. Much scratching of heads ensued over the valley detail at the front and considering the fallout of whether we wanted a sloping ceiling in the front bedroom. The valley is covered with lead (remember climbing on the old roof of St Annes #1 armed with a broom and a jetwash to de-leaf the flat section of roof over the tower??), but the section is long and flat lead covering a space of more than 5′ tends to shrink.

2016.11.11 - 2.jpg
rogue beam

Much to everyone’s relief, Dave came down to site on Thursday as part of his new and improved double-time for this job, and he and Terry figured out a way to ditch the long beam, sort out the lead, and start designing a flat ceiling for more storage in the front bedroom. After these tweaks, it’s full steam ahead with the roof.

2016.11.11 - 3.jpg
Josh, hasn’t James told you it’s -5C out there?
2016.11.11 - 4.jpg
Josh and his fan club

Terry and Josh are putting up timbers for the battens to be attached next week. I can’t believe Josh is still in his shorts!! But I really like the combo of wooly hat on and legs out. They’ve been spending most of their time hand-cutting truss parts for the non-standard 50-degree angle roof and creating supports for the fiddly dormers. The game plan is to finish most of the dormers before James gets the more fun job of fitting the oak facias and stained soffits in their wake. Terry says the building will look transformed with these bits on. We’ll wait and see next week.

2016.11.11 - 5.jpg
dormer corner
2016.11.11 - 6.jpg
kids’ bathroom window dormer

One of the details that we’ve signed up for is the kick out on the foot of the roof. It’s a little flare right at the end and kind of a Blair Imrie/Frank Chown style point.

2016.11.11 - 1 (1).jpg
kick

Nice to see Mick, Johnny and Tom back to lay bricks that will live above the soffit. It will only take them a couple of days into next week to finish off. The wet mortar sits all around the kick boards. We’ve still got a pillar to build around the back, so maybe they’ll be back to do that when the garage roof is ready to go on.

We’ve had a choice of resins to use for the brick slip panels in the oak frame. The warranty company wanted us to use this stuff instead of mortar to fix the bricks to the boards and also to point them up. The idea is to limit the possibility water ingress. A sensible solution and there is all of one singular company in the whole of the UK that does this kind of thing –just a little bit niche. We’re going with ‘natural’ instead of ‘buff’ or ‘chalk’. It’s not bad and looks the real deal.

2016.11.11 - 11.jpg
these don’t quite match…
2016.11.11 - 9.jpg
… but this one is better

I haven’t had the chance to bother James with my usual million onsite visits this week because most of work and the fact our house-time has been taken up with kitchens, tiles, stairs, wood floors, doors, sanitary ware and electricals. We’re also debating about whether to put sliding doors between the kitchen and family room. The main thing is that the normal double doors in the spec eat up a bunch of space when they get opened, so it limits the size of furniture for the room. I’ve started cutting scaled bits of paper to ‘furnish’ the room and test stuff out. Sketchup is great but it doesn’t give anyone else a chance to fiddle, so we’re going old-school. I’m sure there will be many evenings and much wine required to get this just right.

IMG_4203.JPG
which purple bit of paper makes the best fit?
2016.11.11 - 10.jpg
the door opening in question

One day soon we’ll get around to thinking about landscaping. The hardest part of the plot to figure out is the bit on the north side of the house under the beech tree. We sadly cut down the cherry tree that we planted with such great hopes in 2000, so now there’s not much between us and next door except air. We’ll want to have something against the fence and preferably rising above it for privacy and to emphasise our house. There’s not much light or much water in the space which makes planting anything you want to keep alive problematic. Paving? Water feature? I’ve got to do some reading on suitable plants…. Allison, got any ideas?

2016.11.11 - 12.jpg
garden challenge

 

 

 

Week 30

2016.11.02 - 1 (2).jpg
Black Pond

We’re really lucky to live here.

The roof continues to grow, ungrow and regrow. Dave and Terry spent some time last week discussing the design of the dormers, and as a result the first one they built had to be rebuilt. But Terry, James and Josh worked hard despite the drop in temperature and by the end of the week, they were all there despite the rain.

2016.11.02 - 1.jpg
truss forest
2016.11.02 - 2.jpg
sketch and trusses cut into the structural oak
2016.11.02 - 3.jpg
hand built trusses
2016.11.02 - 4.jpg
gratuitously nice shot of frame
2016.11.02 - 5.jpg
roof, scaffold and row of dormers
2016.11.02 - 6.jpg
up close and personal with a dormer

Part of the unbuilding included a set of trusses above the front bedroom. They were originally Palladian trusses, but this didn’t allow for storage. A little scratching of chins all round and we decided to switch to a cut truss. They arrived this week.

2016.11.02 - 7.jpg
loving the storage option
2016.11.02 - 8.jpg
sunset through the roof
2016.11.02 - 9.jpg
complicated cuts

The solid oak subframes arrived onsite–hooray! They have one coat of oil, and the next will be applied in situ. James and the guys had to carry each one from the road into the dry by hand. There are 72. I can’t move ONE they’re so heavy. How they did it I’ve got no idea. There are three piles in the garage and two in the kitchen, and there they’ll wait until the lid is on the house.

2016.11.06 - 1.jpg
shrooms on the way home

 

Week 29

This week was all about kit.

On Sunday we scooted down to Plumpton to visit a marble shop and look at basins for the ground floor WC.

2016.10.28 - 1.jpg
downstairs sink?

We got all distracted by some awesome marble for the floors as well. I tend to veer off into silvery-grey and Clinton tends to like the beige colours.

On Monday we said goodbye temporarily to the brick team. They’ll be back to fill the gap under the roof between the current course and the roof itself when the roof gets built up. They’ve probably been onsite longer than anyone: maybe Nic was here as long but its close.

2016.10.27 - 1.jpg
thanks Johnny, Tom, Paul and Mick (and Dave and Glen offsite today and missed their photo-op)!

We took a couple of days to pay a visit to our windows. They’re made in The North.

2016.10.27 - 3.jpg
are we in Scotland yet?

Grantham is nowhere near Scotland, neither is it part of The North at all if you speak to anyone in Harrogate, but it’s still a long way from Kansas, and it felt quite North to me (cue GoT reference here).

The windows are cut, welded and polished before being blasted, treated, waxed and polished.

2016.10.27 - 5.jpg
masses of extruded bronze gets replenished every couple of weeks
2016.10.27 - 4.jpg
bronze extrusions are cut to size
2016.10.27 - 6.jpg
rough welds
2016.10.27 - 8.jpg
one of the expert welders, either Jimmy or Jimmy
2016.10.27 - 14.jpg
the other expert, Jimmy
2016.10.27-10.jpg
what these guys don’t know about welding isn’t worth worrying about

2016.10.27 - 18.jpg

2016.10.27 - 19.jpg

2016.10.27 - 7.jpg
polished welds
2016.10.27 - 17.jpg
blasting
2016.10.27-1.jpg
post-blast

Now for a good dunking.

2016.10.27-11.jpg
patina bath

2016.10.27 - 20.jpg

2016.10.27-3.jpg

2016.10.27 - 16.jpg

There are four tanks of different chemicals, and each stage is timed down to the minute of how long the frames sit in each tank of goo. They use an alarm system and headphones so the operator knows which windows come out when.

2016.10.27-12.jpg
timing chart
2016.10.27 - 9.jpg
wax off

2016.10.27-4.jpg

It was great to meet Ken who showed us around the factory, and he introduced us to Martin the shop floor manager. The two of them introduced us to our windows! Ta-da! How amazing to finally see the windows actually existing. My first correspondence with Ken was around May 2014, so this project has been a long time coming, we’ve had much hemming and hawing over whether to go expensive bronze or not, and Ken must be jolly relieved to see the project come to fruition and get us out of there!

2016.10.27 - 10.jpg
our job!

2016.10.27 - 11.jpg

2016.10.27 - 12.jpg
proud
2016.10.27 - 13.jpg
every opening is numbered to match the drawings

2016.10.27-7.jpg

2016.10.27-8.jpg
everything gets treated–even the hinges
2016.10.27 - 21.jpg
more of our job with bound glazing beads standing all ready to go

2016.10.27 - 22.jpg

2016.10.27 - 23.jpg
Ken and Martin showing us #62

2016.10.27-13.jpg

2016.10.27-14.jpg

2016.10.27 - 15.jpg
doors are made in another (larger) area

That was the frames in a nutshell, and I haven’t even got to the glass yet! They buy the glass in, and then it’s inspected, hand cut to size, toughened, glazing bars installed and then vacuum sealed and cleaned. It’s quite a precision process and uses some of the best machinery in the country to do the job.

Andy runs the glass area, and Ken and he showed us around.

2016.10.27 - 24.jpg
curves are cut with this machine
2016.10.27 - 25.jpg
the lead glazing bars are cut from rolls and soldered on to one side of the glass
2016.10.27 - 26.jpg
each join is soldered
2016.10.27 - 27.jpg
offcuts are recycled, same with the glass
2016.10.27 - 28.jpg
we’ve gone for this kind of oblong bead that looks more hand-welded
2016.10.27 - 29.jpg
satin glass for the obscured bathroom windows

We knew the window package was just about the most expensive bonkers thing on the menu for the house. Everyone we spoke to, when we tried to value engineer the build early on, quite rightly suggested that we bin the bronze and go for a most cost effective (and normal) aluminum or wood window. I’m very grateful to Ken for showing us around and letting us see first hand that the job they do is not just about the materials, but more about the craftsmanship and the dedication to doing an excellent job. We were blown away.

Delivery date onsite is 09 Jan 2017.

2016.10.27 - 30.jpg
and we got a night away as well–what’s not to like?

Before venturing back down South, we paid a visit to an artisan metalwork shop with the idea of making some balusters for the stairs out of some sort of metal. Little did we know that we’d hit hip-and-trendy metalwork central. They cast all sorts of door handles and things out of all sorts of metals from their little showroom hidden upstairs in an old-fashioned industrial estate just outside Nottingham. I have my eye on a door push for the front door which is cast from an actual twig. Watch this space.

2016.10.27 - 31.jpg
twigs

We even got to go to Belton House for a coffee before the sun set.

2016.10.27-6.jpg

2016.10.27-15.jpg

All good things must end, so back home we went.

2016.10.27 - 32.jpg

And back onsite… James, Terry and Josh are working to get the dormers exactly right.