Week 55

It’s official: we’ve Given Notice on our rental house. This event sparked a flurry of activity in the household. Given that we’ve moved out of the old house in the first place (after 15 years of living there–there should be a law that people are forced to move every five years in an effort to decouple themselves from years of rubbish that “is perfect for car-booting” or “I’ll save for the grandkids” (grandkids?? OMG what am I thinking?)), then to the first rental for 7 months and now to this one for what will have been the last year and half by the time we move again, there is no way on god’s green earth that I will cart around (and pay to be moved) old hosepipes, used bunk beds, boxes of duplo and out-dated TVs a fourth time. This just will not happen. The only thing for it was to get the kids on board and take everything out of the garage for a well-needed sort out.

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the boys are not quite on board

I have to admit that by later afternoon when we decided to ebay the barbie dolls one at a time, I kind of lost the plot.

The biggest event this week was the stairs. After Clive and Mike thoroughly Osmo-ed all the individual parts, they handed over to Josh, Terry, and James to gingerly squeeze them into the hallway. There were a few headaches along the way such as design of the last newell in the SW corner. It fits so that the corner of the wall is in the middle of the newell making it appear to kind of wrap around the wall. IMG_6320I’m not sure where the communication gap lay, because it never even hit my radar until I saw Colin onsite, but the post was delivered as if it were flush with the wall thereby leaving an exposed unfinished edge into the hallway. When the guys rang Colin at the joinery company around midday to ask what to do, I kid you not, Colin hopped in his car, zoomed up to site straight from  their base in ANDOVER! and sorted the problem immediately. I cannot believe he dropped everything so fast and made the solution happen. Terry says the new newell will be here early next week. This jaw-dropping effort, coupled with the effort made to give Tony the blacksmith scale drawings and meeting with him at his forge, have made the job a complete pleasure. Colin–you’re a rock star!

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the same awesome company made the stairs and door
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front room workshop
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forlorn stairs with added newell
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underbelly will be covered with plasterboard

How much do you think a solid oak staircase weighs? Clearly less than four guys can lift on a random afternoon in April.

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that looks healthy and safe to me

More bits were added as the week went on. You can see the long aprons that cover up the first floor buildup being installed at the end of the week on the time-lapse. Handrails, newells, starting steps, nosings, stringers…. stairs are a very esoteric thing when you consider all the measured parts. The guys have labelled each with a Sharpie on the edges to help so that they get installed correctly and to limit the chance of some going walkies. The fancy secondary newells are due onsite soon, and Tony will be back to fit the balusters around the middle of May.

Taking any chance to visit the forge again and see how Tony was getting on with the balusters, I was off like a shot on Tuesday to approve paint. All the parts are finished, and they’re ready for powder coating. I still have reservations about powder coating in principle, because it’s not the natural metal finish we were originally after. But solid bronze balusters would completely break the budget and steel would rust, so neither were ever a real option. With bronze, we would never have had the pleasure meeting Tony and learning about metalwork. The colour he’s chosen is a kind of off-black with tiny flecks in, and it’s more of a satin finish than a gloss. I’m sure it will be amazing.

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finished baluster
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working platform

It does feel like the space has shrunk in some ways, but since stairs give the house a backbone, it feels in other ways like they’ve always been there. Shame to see Terry’s temporary banister taken down!

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Clive and Mike have been painting things and they are concentrating on bedrooms. I haven’t gone into too much detail of how we ultimately chose these colours, but we found that it’s much easier to knock out what you don’t like than it is to choose what you do like. All the rooms are Marble White with trim in one of the darker shades on the Dulux Trade range. No Farrow & Ball here–they want £195 just to have a conversation, so we’re DIY-ing again like the lights. Mike calls each room by its shade: Mineral Haze, Quartz Flint (or whatever it is, clearly not enough headspace devoted to decoration, note to self, perhaps saving that £195 was a mistake…..), and I call them by the kid who will live there: Gemma, Gareth etc. They’ve pretty much finished Gemma’s bedroom and it will be great to see the others come to life as they work their way around the house.

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pre-paint…
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… and now the Potters Clay room (sorry, Gems)
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another room pre-paint

When choosing the skirting last year, we had a devil of a time working out which profile to use in the bedrooms. We wanted to save a bit of cash and make a decorative statement by using painted skirting, but we couldn’t find a profile we liked. After much costing and quoting (sorry, Tim!), we threw our hands in the air and found a company to make the same lambs-tongue profile as downstairs but in softwood. More expensive than off-the-shelf, but less than solid oak. It’s great to see them in, and amazing to see them painted at long last. I just hope it doesn’t look too twee or artificial in paint. The window subframes and the cills remain oak, and of course, the flooring is oak, so it should be a good balance in theory.

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Mike loves Osmo

Other random bits of the week include finishing off the hallways with skirting and architrave.

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And the WC buildup on the back plinth  magicked itself into completion. The drawing is actually with Dave, but James figured it was a simple amendment to make the cill and the top of the buildout be the same level, so he predicted where the additional boarding would go, and just built it. Looks fine to me.

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and he kindly left the pipes exposed for the plumber

The tilers have been beavering away in the upstairs bathrooms. This meant choosing the final position for the lights and mirrors so they can drill the electrics through the tiles. And of course, we have no idea what these mirrors or lights are yet, and less of an idea of committing to their location. Awesome planning on our parts as usual. Not. So double-quick to the internet and my graphics package to sketch out what was required. I think I’ve got it under control, but buying these things is pretty complicated as well because as this was our first foray into Fancy Stuff For The House and not just lumber and bricks, I wasn’t quite sure how the purchasing stream worked. As an exercise, it was good to get these things solid and communicated well to all parts of the team so everyone knows what to expect. In fact this whole buying thing sat alongside a review and future purchase of the electrical fittings which was interesting and time-consuming, but also rewarding because it’s forced me to know exactly what light goes where right down to the temperature colour and flange finish. This is a convoluted way of saying that although the tiling looks great, the work going on behind the scenes has been hectic.

I met Kevin onsite on Monday, and the guys have been putting up tiles steadily all week. By Friday they’d almost finished two bathrooms. By next week, it might just be most of the way there.

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lucky boys’ bathroom
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boys’ niches
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a “bold” colour in the master ensuite, says Rich
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accommodating my light fitting design in the master ensuite

Artur finished off fitting the kitchen and utility and left us this week, and handed over to Jason the marble guy who spent an afternoon templating the worktops. It will take about a week at least before they’re installed. We discussed in massive detail locations for the cuts for the hob and downdraft extractor, and it all hinged around fitting the ducting that runs from the extract, through its remote motor and out to the wall. The ducting quotes we got through originally were quite high, so I naturally tried sourcing it myself. Firstly understanding the function of each component and then finding a guy who would take the project (and my naivety) on board were interesting enough, but when it came to actually looking at the space onsite and taking responsibility for the spot where the colossal 200 mm diameter hole that’s going to be cut out of the brickwork for this part of the kitchen installation will be, I completely lost my nerve and quickly came to realise I was totally out of my depth. So I promptly handed this part back to Claire at the kitchen company. She was entirely professional and diplomatic, I would have been seething at some dippy client putting my project back a week, but it is now rather a hot potato as timing is an issue; the motor and its ducting are dropped in before the worktop is installed, so unless the gear arrives double quick, it might indeed hold up this part of the supply chain.  Full marks for enthusiasm on my part, nil for effectiveness.

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utility looking out
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utility looking in
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dot marks the spot
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virgin brickwork where a 200 mm dia ducting hole will live

Week 54

The roofers came back to relocate the club tiles and the whole tile hanging face is almost there. There are six rows above the club tiles and six rows below, but it still seems a little low, so I think they’ll be back. house 2017.04.26 week 54 - 1.jpg

And I haven’t taken a photo of the front door for a while, so just to remember what it looks like, here’s an image out of the winter shadow an in the sun now that spring is here.

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Other parts of the exterior of the building are coming along too. The nice weather helps to make the site look good, and the guys are doing a great job of keeping everything tidy. And when they’re in the middle of a job, most of the bits and pieces are kept together and out of other trades’ ways. It’s amusing to see little empires of woodwork, electrical bits, decorating, and piping in different rooms.

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artsy wheelbarrows
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electrical detritus in the front porch
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panels are coming on

The roofers finished the scalloping on the back windows. They’ve only got the garage flat roof and the club tiles to go.

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sunny scalloping on the back of the house

The garage door arrived–hooray! The installers were super jolly and put the thing up in a day. There was a massive design moment at the beginning of the project when we had to decide if to make the door high and bespoke as it is, or to make it a standard size with a brick soldier course on top. The higher door keeps the top in line with the tops of the windows along the face, but it was the expensive option, and I hope that you agree that it makes sense to spend the extra cash on the extra height.

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door arrival
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door installed

The plumbing team has been quietly getting on with the boiler and fittings all without any fuss whatsoever. It’s funny to come to site, say good morning to Sid who’s mostly been doing this final bit, and for him to get right down to business with a fast-paced “Now, where do you want this exterior tap?” These guys don’t hang around! But you can see that the services are all ready to go in a happy configuration of geometry.

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boiler arrangement
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tap located on the garage wall

The Sparks have been working hard on the trunking while the other trades are busy in other rooms. They’d rather be cutting out holes for LED down-lights, but this needs doing as well, so now the cables are set in trunking within the coats cupboard. How we finish this area is up for grabs as it’s not plastered. But trunking and plaster don’t usually mix and the whole wall will be painted to seal in the dust, then boxed in to finish it off.

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trunking

The kitchen arrived at the appointed hour without fanfare; just a couple of guys who quietly discovered that there was no trolley packed in with the kitchen units. The only solution was to carry each unit by hand, so Artur simply slung them on his back and carried them in. It turned out that he was in charge of fitting the units and most of the appliances as well in the coming week.

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that’s the kitchen in there
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bit of rubble doesn’t get in the way
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before the kitchen arrives
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the contents of the truck land in the kitchen space
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appliances and more kitchen units

Eventually Artur fitted the whole thing single-handedly. I’ve never had a kitchen this nice and it’s a real luxury. Or hopefully it will be if we made the right decisions. I said to Dave onsite this week that when asked if I was excited about all this recent action that a very large part of me doesn’t want to look at it while it’s being installed in case I change my mind or don’t like some part of the design. But the other part of me is jumping up and down inside and really excited about running the family from this little area.

Some bits like the humungous drawers make it feel really usable and very real. I recall Auntie Eileen saying she really hoped that I’d make a good go of the kitchen when we finally got round to doing the house. That was a very kind thought and I hope she would approve of this incarnation.

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magic drawers
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three days of work and it’s almost all in — amazing

We knew that the overhang on the peninsula was going to be tight with regard to the big dining table in the room, but it’s only now that the units are in that we can line up a mock table to get a feel for the size. One of the things yet to do is site the pendant and LED spots over it. This isn’t easy and requires a fair degree of commitment on table location. We haven’t quite decided where the lights should be, but one thing is for sure: the overhang and the table together don’t provide enough space to get around comfortably, so the overhang will have to go. That means my two bar stools will go too.

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burlap mock table

Part of the ironmongery order arrived last week and was installed while we were away. It’s nice to go around and be surprised by the existence of doors. Sometimes it’s the boundaries that make the space feel like well-defined areas. One nice touch was a set of parliament hinges on the family room doubles.

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that’a nice hinge

The shower trays went in while we were away too. We wanted the master ensuite tray to be 100 mm bigger than the well was built for, and this was always going to be a problem with the underfloor heating. The idea was to chip out enough of the concrete floor to accommodate the tray while avoiding puncturing the heating tubing set in the concrete. This was a tricky job that James wasn’t too keen on doing. I wouldn’t be keen on it either; I recall the words “catastrophic” and “potential” and “failure” being used in discussions about this bit. But it was done, and done very well as usual, and the trays are all in sitting in their seals of silicon.

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shower tray

The decorators started with the Marble White in the bedrooms, and the skirting went in.

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white on white in Bed 05

The stairs arrived as well.

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newells
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bottom treads
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CNC’d area to fit treads…
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… and the bit that fits into it

Lots of decisions behind the scenes, and we’re not keeping up with the pace. The pressure is on and everyone can see the horizon now!

Week 53

I thought I’d skip Week 52, the week celebrating one entire year of this project. Instead, we dragged our pasty selves up North to clear the winter cobwebs for a walking holiday with the family for the Easter Break.

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Lakes

The first day in Yorkshire was gorgeous: 15 degrees, sunny and beautiful.house 2017.04.18a - 1.jpg

We had the excellent good fortune of walking through Hutton Roof where we stumbled on a farm that had been converted into half stone yard and half car sales lot. We made an effort to find the showroom, and lo and behold it was 10 minutes from our cottage on the way into Kendal. We met Alexis who guided us through the stone she had in stock, and we fell in love with what will become our paving slabs for the patio. Should be nice. So amazing to spend weeks looking and looking for something down South, then finding the perfect stone when you least expect it. We also fell in love with some of the Lakeland slate, and while it’s outrageously expensive for the garden, we might consider it for some other areas in the house. I like the idea of sourcing this stuff from places we’ve been and people we’ve met rather than buying it out of a catalogue. And knowing it’s providence suits the building too–all very Frank Lloyd Wright-ian. I’ve been listening to a few too many design podcasts for my own good recently!

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future patio

The week before we left was hectic with many different trades on site.

Having made the decision to go with the plans on the brick slip panels in the back of the house where they were parallel to each other, we decided it didn’t look as great on the five side panels in the front. Clive and Mike knowingly stopped half way through the second one for us to have a look because they knew dang well that we’d only go and change it.

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brick slips that need changing

Lovely to see the tile hanging again. But the decorative club tiles need to be scooted up a bit and also wrapped around the left side of the building. This should happen in the coming weeks and then the towers can come down to make room for the drive.

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shame to change this as well

Hinges are going on the doors.

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big doors and big template

They’ve set up a nice little shop in the master bedroom with a stand and a template so they can crack through each door quickly. Have a look at the time-lapse for the doors getting lifted up through the hallway one at a time. They get through them ever so quickly!

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We’ve been dithering like fury to get the WC organised, to the frustration of James and Tim who are getting really tired of our start-stop approach. But as usual, simple is always best, the design is less complicated than the original layout, and next time you see this area, it will look less like the electricans’ storage area and more like a downstairs loo.

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future loo

Meanwhile Lee and the gang have been laying out the patio. It’s quite a job to set out the area in two dimensions, but once you consider the levels in the third dimension, steps up to the house to be even with the interior tiles, and then calculate the runoff angle for rainfall, the whole thing becomes a right pickle. Luckily, between Nicola planning beds around the building and Lee planning the runoffs to fall away effectively, the patio shouldn’t have any puddles that cause the tiles to discolour.

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side patio
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first go at painting out the back patio
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herb garden

Having moved the drainpipe away from the structural oak gable in the front of the house, the pipe needed to match the rest of its platoon and cut into the plinth at the foot of the building. With this one already built, James and Josh simply cut it out with an angle grinder. Clearly it needs finishing, but once it’s behind the drainpipe and the box hedge that will sit in front of it, maybe we won’t notice the cut bricks too much in years to come. Our instinct is to do it properly and rebuild the pier, but we’re going to give it a few weeks before we decide to spend the cash for such a drastic measure.

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snip snip

The tilers arrived this week. The first thing they did was see if the building was flat and square. Kevin was pretty impressed, and I suspect even James was a little surprised. He wasn’t actually on the job when the house was laid out–that was Nic, and all credit too him, it’s pretty near as dammit impressively square to a couple of mm. The only problem was a small area where the floors weren’t quite level. To check the floor flatness, Kevin scooted the 3m level over the whole floor and found a small high point between the family room and the kitchen. Lee was on hand for a consult, and before the morning was out, he’d shaved off the required few mm with a horizontal sander (wish I’d been around to take a snap of that), and the floor lined right up.

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centre spot of the whole house

They use these really awesome little wedges to set up the tiles to exactly the right height.

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wedges and separators
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where is the centre tile?

Last was a decision about how to lay the marble tiles. The Portnall stone is super varied in colour and has lots of veining, so we opted for a brick bond throughout. This makes the whole thing a little less uniform, but it wasn’t Kevin’s immediate suggestion. Hope we’ve made the right decision, but we really won’t have a chance to see the floor again until the protection is up.

Tile, seal, grout, seal. And then protected with lots of padding on top so no one mucks in any stones or gear across it and ruins it.

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ditramat under the tiles ready for grouting

I’m looking forward to seeing what has happened while we’ve been away, and I’ll be approaching the build with a renewed enthusiasm.

Week 51

Ben had the drone out and it’s great to finally see the roof in its glory. Here’s a visual progress report from the get go.

And these….

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DCIM100MEDIA

Tony had the fire on early in the week, so he kindly invited Ben and me to have a look at making balusters. Each of these is completely hand made by drawing out the bar to a point, then curling it very carefully to match the test piece precisely. Incredible work and much labour involved. Tony has Dave in to do the hammering and finishing, and anyone with eyes can see that their years of working together on projects like this make it seem so easy, but in fact it’s a lot of unspoken expertise involved to make each baluster. There are a lucky-13 curlicues that are framed by straight ones going either up or down. Should be amazing to see when it’s done.

The joinery company making the stairs have been brilliant in supplying Tony with scale drawings of each piece. Colin has travelled from Andover to Betchworth (more than once!) to deliver the drawings and talk about the work with Tony so that the joined up staircase between the two completely disparate trades are installed seamlessly at the end of April. Can’t wait!

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Tony and Dave working to draw the bar into a point

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checking the curve by eye
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bending vice

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forest of balusters
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a proper working forge
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sorry, can’t stop taking photos of these

Meanwhile onsite, the wood floor arrived. Usually, they hoist the planks up box by box, but the ceilings are a little high for that here, so they were hoisted up two planks at a time–it took a while.

First the guys prime the floor, then they lay a layer of latex which acts as a barrier between the concrete floor and the wood. They mix this bucket by bucket onsite. Then a really thin membrane of foam is cut to shape, and finally the floor is put on top.

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the wood arrived, hooray!
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primer coat
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latex milk
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mixing gear
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pouring latex on a primed section of floor
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spreading around by hand
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Gillian’s room with the finished floor

The services are being installed gradually. We’re waiting on the water board to come and inspect its trench, so although James doesn’t like leaving it open for health-and-safety, it has to be left until they drop round. The boiler should arrive soon; the flooring guys need it so some heat can get into the floor to dry it out. So we were very pleased to see the gas company arrive and install the meter in the hedgehog box around the side of the house. After the drama of last week’s engineer unable to install, this took a grand total of 10 minutes and the guy was off. And the three-phase upgrade for the electrics will be in the middle of April.

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not a hedgehog
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ready for electrics

The Sparks are in cutting holes in the ceiling. There is so much to this electricity piece, and we haven’t even chosen any fancy fittings yet. Here’s a challenge for you: next time you’re in a place with small LED ceiling lights, go ahead and have a look at the geometry of their placement. The glossy mags always say to hire a light designer because you yourself as a layperson could never hope to achieve a good effect: what you’re lighting, how you’re lighting, when you’re lighting, controls….. The Sparks want things in grids, as do the architects. We’ve opted for a DIY approach to tweaking Dave’s placements just a little in order to centralise some of the fittings around architectural features like doorways and cupboards. I’m no expert at this, and I hope that I will remember fondly this m.o. when I’m not too upset at the finished product but instead, basking in the glow of the thousands of pounds saved that I didn’t pay to the lighting designer. (Fingers crossed, obvs.)

The guys use their laser sights and chalk lines to get the rows straight. This doesn’t please the decorators who then have to wash off the chalk because the dye runs into the paint, especially if the paint is white. Like on a ceiling. Where the lights are. Duh.

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takes a day to set out
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and another couple to drill

The non-herringbone panels on the side of the house are coming together. I had a total 4 am brain-fade about the side panels which are not at 90 degrees, but rather are offset and parallel to each other. I texted James about it suspecting they’d have to rip off the half-laid panel, but he replied with a photo of the plans which clearly show the bricks in parallel. Glad someone’s on the case! And note to self: consult the plans before hitting the panic button.

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brick slips

But there are still a bunch of gaps in the design. The biggest one is the fireplace, and Steve came up from deepest Sussex again to speak with Dave and me about how to accomplish what we’re after for the surround. We’ve made it enormously complicated, and probably unfeasible from an engineering point of view. We’d like a floating stone mantle–but how to fix it? Lots of head scratching, and to be honest I’m about to give in to a simpler design. This room was never designed to live in, mostly to look at, and this is disappointing as we should have thought about it more from the start. The windows are too close to the fireplace wall to put units in, and the building regulations put so many restrictions on measuring out non-combustible zones that it’s all very tiresome. We’re at that last 20% that takes 80% of the effort. But it will be beautiful, the workmanship is great, and it’s only complicated because we the clients are trying to squeeze too much in. Much better to simplify, pare back and let the features in the room breathe a bit. Watch this space.

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blank wall, blank heads

Another bug-bear is the garage roof. The guys have done a brilliant job at getting the end to just kiss the fence, so the dimensions are perfect. But how to support it is another kettle of fish. The original (built, then unbuilt) brick pier was a thing of beauty, but it didn’t give us very much room to get around. So we’ve opted for an oak post on a smaller plinth instead. In the meantime, there is a slightly bendy Accro holding the roof up at the spot where Terry says holds the max load. But this still leaves us a little short on space to get around. Do we place the final post off the sweet spot either towards the building or away from it and add a stiffening bracket? Can we? Or do we suck it up and just stick a post in?

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jury is out on replacement to bendy Accro

Last week’s tile-hanging design query was bottomed out, but this ended up being just a case of making sure everyone was looking at the same revision. The flare at the bottom will be great, and the roofers will fit in the tile hanging when they next have a gap in their diary. It’s a stand alone piece, and not mission critical–which is refreshing!

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flare supports