Week 58

Without going into too much drama about tempers flaring, lines of communication being tested, inspections on the edge and deadlines looming, …, despite all this, it’s all mostly going to plan. This week’s post will be mostly pictorial as I’m struggling to write anything at all coherent in the rush to finish this project. Loose ends include all electricals as we haven’t seen a blub a-flickerin’ yet, the entire fireplace concept, some of the big wood pieces from Neil, the sanitaryware, tiling and the drive. On the positive side, the Moldovian chippies Adrian and Vadim are generally fantastic and are busy getting on with doorframe, skirting and ironmongery. Terry and Josh finished the stairs too–I don’t think they’ll be in a hurry to fit any more capping in the hand and floor rails, but Josh remains undeterred, even when faced with a chisel in his hand and a trip to Epsom hospital. Didn’t stop him smiling when he returned to site to finish the day’s work.

The cornice company arrived early in the week and transformed some of the rooms.

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awesome coving, but, oops, poor decision on light placement
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does this work around the units?
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drawing room looking more formal

Finishing touches around the staircase are being decided with things like skirting beading, window/stair boards, and capping under the newels. James is great at making use of extra pieces to create some of the finishing touches. And it’s only when you see these things installed that you can get a feel for what the finished product looks like. Most things have been fantastic, and some require small tweaks, like the window board used on to top the plasterwork in the front bay. We’ve decided that the trim should have a profile more like the stairs, so this bit of boarding will be replaced, but it was excellent to have the flexibility and chance to check out the profile and have the option. This exercise prompted some deep thinking about what exactly we’re trying to do in the space.

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is it a window board or a stair board?

Likewise with the trim between the structural oak and the floorboards. Initially, I wasn’t keen to have so many different kinds of oak hanging around, so I didn’t want the trim in at all when we started the finishes. And James’ advice was not to have too many different trims or the whole thing looks cluttered. But now I feel that if each piece does what it’s expected, then it follows the ethos of honest materials in the house, and it should be ok to have a little bit of trim that matches around the house, and it will blend in better in time. We opted for the little bead around the structural oak in the photo. The floors remain protected, and the windows will have a layer of dust on until the final sparkle-clean, so it’s hard to tell what the final finish will be anyway!

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beading on the floor
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under-newel

Vadim and Adrian have been boxing in pipework and building wardrobes around them. We’ve decided on a semi-complicated painting scheme with the interiors being darker shades of each room’s trim.

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Gemma’s wardrobe
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Gillian’s wardrobe
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double checking the spec on ironmongery

Looking forward to snagging the kitchen next week. We’ll discuss a few trimming bits, and do a double check on things like the work-surface edge.

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discussion piece: is this pencil or bevel?

The bathrooms are looking good, but we’re finding a few things that could have been better designed. Like,…. the door slamming into the unit when entering the bathroom. We’ll have to install a rubber baby buggy bumper on the back side of the door along with advice to tell the boys to be jolly careful without entering their bathroom with too much energy (shouldn’t be a problem, they’re a bit slow int he mornings). Much consultation with Allison in the States and friends in the UK to generate a survey of vanity unit heights in an attempt to get ours right. We’ve decided 900 to top of unit is a good height–a little higher than most, so it won’t be our family keeping the local chiropractors in business.

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boys’ bathroom

In a dull moment, the guys found time to remove the plinth they’d lovingly installed before we changed our minds. Our MO seems to be build it, then remove it….

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plinthless fire

…. just like the piers!

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looks better now

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Clinton never really liked the piers in the front; they were only put there to carry the rainwater downpipes into the ground in a clean swoop. So, taking advice from the architect and structural engineer who both said that they weren’t critical to the structure, we decided to take the bold (= expensive) move to remove them. This leaves an obvious problem for the bricklayers who now need to come back and make these areas pretty again. But the overhang looks much less fussy now, and we’re happy with it. At least we were until a giant gaping crack appeared around the first floor cavity trays.

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omg

On further advice, we adopted a suck-it-and-see approach, and the whole thing looks pretty stable despite the crack. It hasn’t shifted since it first appeared, so should be ok. After all, there is an enormous great big steel holding up this side of the house, and the roof is all complete as one separate structure spread across the whole building. It SHOULD be ok. At least it is when I close my eyes. And a little mortar in the joint before we move in and all will be well. Right?

Lee, Jamie, Djokovich, and the groundwork gang were back to lay the paving for the patio. Their work was hampered by the water board inspector who deemed it fit to ask the guys to dig the main supply to the house a little deeper. This was an enormous pain which required un-building of the garage and some of the edging stones the guys had laid last week. The inspector didn’t stop there, took a deeper look at some of the work and started going off on other trench work depths, like the supply into the taps in the garden. He even had a go at some of the pipework internally, which never happens apparently. Usually the inspector has a cursory look around near where the water enters the building and leaves the M&E team to get on with things downstream. The groundwork guys have done hundreds of jobs like this without fuss, and the plumbing team was livid by the time the inspector finally passed it all, and all the trenchwork could be filled in. They’d none of them ever seen anything like it. Clearly this house has been jinxed from the start. The guy earned a few choice nicknames around site, and luckily for him some of the spare pieces of wood lying around didn’t get airborne.

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high water table in the mains trench
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on the positive side, slabs are looking good

We’re even venturing into town to look at furniture and light fittings. Mostly these experiences highlight that fact that neither of us like shopping very much, nor do we like going into town unless it’s work related. We’re much more country-bumpkins these days. Either we’re super boring (likely), or we just dread the time it takes to travel around aimlessly looking at one low-profile uncomfortable sofa after another. I think Clinton was definitely going to lose the plot entirely if he got close to one more Edison bulb singeing his retinas.  The best way forward is to continue on our current course of clicking our way through doing most of the furnishings.

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keeping the guys happy

Week 57

Deep breath. Another week. Lots happening onsite though. I’m thinking Pareto thoughts as we get into the last 20% and see lots and lots of little tiny things blossoming into Good Things and other parts turning into Snagging Things.

It’s all about stairs at the moment. The last newel came to site, and got chipped into the corner.

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cut newel

And the last baluster went in with the weird expanding foamy glue.

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ew
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the balustrade, pre-balusters
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empty handrail

Tony brought the long-awaited balusters to site on Tuesday. They looked a treat when he got them out of the van and laid them out carefully in the family room.

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Tony and his balusters

He’s rightly proud of them and set them out with enough room between them so they didn’t touch each other. We anticipated a smooth installation, and Tony brought Dave along to help. But when everyone was onsite and we all tried to negotiate Tony’s metal work with Terry’s wood work, James quickly realised that because stairs are installed sequentially, our plan to add Metal and Wood in parallel wasn’t going to work. Tony usually operates as a discrete trade that doesn’t rely on anything else going on after his work is installed, so when we decided that to avoid a lot of standing around and waiting while wood and capping were placed in line after each baluster, we all decided it was best that Terry install the whole thing, and Tony left, a little disappointed.

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the first one went in fine….
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pointy-down on its rail

The pattern is kind of complicated and made more so by having mirrored patterns along primary newels while retaining a consistent direction for the pig-tails (what Josh calls them). One small bit of trouble bubbled up upon inspecting the holes cut for the pointy-ups and curlicues. They’d CNC’d into the treads at the joinery base, but they were rounded, too small, and bereft of further drilling into the stringers. The holes were short so the lengths that Tony cut perfectly to size couldn’t be fit. Another reason that Tony went home early from the party.

This was potentially a bigger problem than working out the process of labour in the installation. The holes are meant to be square to accommodate the metal sections, and drills are generally round, so straightforward drilling out wasn’t an option. Could chip them in with a chisel?  In order to get the chippings out of the hole and keep a square profile there’d be no way to get a chisel down in there at the right angle to do the work. Much chin scratching and tutting all morning. Luckily, the joinery company sent down a lucky victim later in the week with a portable mortice chisel machine to sort it all out, and once that was done, Terry and Josh could get fitting, working their way gradually around the balustrade.

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too small and too roundish
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balusters on rails

More chin scratching occurred when we realised that a couple of the rails pointed the curlicues in the wrong direction. But that was quickly sorted. Between Terry and Tony, it was only me that was panicking for no reason at all.

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Terry flipped the pigtail by cutting the rail
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balustrade looking more and more finished

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did we have to go and make it this complicated?

Decorating continues on a pace. I read somewhere that when they’re midflow, it’s important to hold your nerve, make no changes, and see what the colour looks like when they’re done. I must admit to having to do just that at a few moments while Mike has had the brushes out. None of the colours are particularly contentious, all different shades of neutral. But I’m used to seeing all the walls in white, and some of the colours seem a bit, well, bold in large scale.

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tower mid Potters Clay 2 and Potters Clay 3
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Mike makes it look easy

The guys are putting in all the door handles as well. Graham has been very patient with our list of door furniture, and it’s incredible how many working parts and variations there are to doors. Bathrooms sets, locks, latches, flush bolts, roller catches, magnetic catches, exterior espag sets. And I still haven’t chosen a front door knob or a post box.

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levers and latches

There is a lot of dippy stuff going on behind the scenes to do with bathroom fittings. The WC basin is a freestanding floor thing, and fitting it is giving the guys kittens just because it’s a little unusal. How far from the wall, madam? How high for the taps? It’s almost in, and the water is live. They still have to tile the back of the room before installing completely, and that will be next week sometime.

Another problem was bath valves. Valves are the things that turn the water on in plumber-lingo, and we’d planned to have them drilled into the bath. But of course what’s on the architect plans didn’t quite match up with the bathroom order that we placed last October, and the holes had gone off into the ether. The logical alternative was to fit them on part of the horizontal buildout from the bath to the wall.  And this looked alright until we remembered the vanity unit that would stand between the user and the dials. So I thought, let’s just cut to the chase: I recalled what Dan had said about controls when we started talking about bathroom gear in the first place, and I opted for a simple manual shower valve for the bath. Martin was as great about it as he’s been since he’d picked up our job after Dan had left the company, and he did a straight swap that included two drives to Farnham (mine) to return and collect.

I don’t have any photos of this gear, but it’s really simple. In fact, it’s so simple that Trevor and Dave on the M&E side said that it wouldn’t pass building regs. Apparently there’s a pesky TMV3 (?) regulation that these valves do indeed need to be thermostatic and not manual so little-‘uns doesn’t get scalded. This whole bath tap thing has been a very long and boring saga which has included me looking for options on the internet on my phone in tiny-vision in meetings and in the middle of the garden trying to make a decision about taps that would work.

So instead of photos of bath taps and Surrey countryside, here are some pictures of things happening around and about the build this week.

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tools
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ensuite tiles, pre-grout
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lone pointy bits against beech
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they moved the ceiling pendant in the hallway

If I haven’t mentioned Rachel before, I’m really happy to finally mention her now. She’s helping with the interior design part of the project, with goddess-like patience, and at the moment it’s all about blinds and curtains. My good friend Lou paid us a visit on Friday and kindly helped me out (read: got roped in…) to measure each and every one. We counted 36 windows that need separate coverings. And there’s a long lead time on these, and as we’ll be moving in around the summer solstice (we’re at 51 degrees latitude up here in the south of England, so it’s very light, very early), it’s good to put these in the important and slightly-urgent box. I’ve made a list of priorities for these. I think we’ll be open to the world for a while if only for cost! At least the lane isn’t exactly the M25 for traffic …. Cardboard is underrated as a window dressing anyway.

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sample city

 

Week 56

The kitchen is in.

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There are a few teething problems, but I’m sure it’s nothing that won’t be overcome in time. The most imperative thing that needs a little attention is the presence of the hole that’s been drilled for the ducting. James had organised a massive 7″ core drill to be onsite for the job, but the work that was carried out didn’t use that tool, so we’ve got a preliminary hole for the moment. This will have a lovely grille over the front of it in a couple of weeks, and eventually it will be covered by hydrangea or otherwise. But for now, we don’t want any little beasties crawling in and making a home before we do.

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hole and bits

Terry and Josh have been working hard on the stairs. There is an incredible amount of chipping, gluing, measuring and fitting involved. And inherently, there is a lot of up and down, up and down, so it must be tiring. The bottom steps were set into place and they look ever so graceful. We can actually use the stairs now, but they’re still covered up with protection, and I think James will keep the ladder up as long as possible to prevent boots from risking accidental chamfering off of the square nosings. It’s interesting to see the scaffolding morph into different positions as required during a working day.

The fiddly CNC’d secondary newel posts arrived as well, and Mike and Clive have covered them in a lovely coat of their favourite, Osmo. They look a bit lonely off the stairs, but they look great in the pdf files–can’t wait to see them go in.

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tool bed
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secondary newels
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not-quite-fitted

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graceful first step

Some of the floor on the landing doesn’t quite meet up with the oak. It is extremely difficult to foresee these join details in planning the house, and lots of these things will emerge in the coming weeks as we race towards the finish line. So today’s decision was to choose a wood detail to act as a mini-skirting. We could have a full-height skirting just like the rest of the house. Or, we could fit a cut-down bit of architrave of the same profile as the rest of the house, or even a tiny bull-nose piece of oak that joins the floor and the beam. Since the structural oak remains the most substantial feature of the build, and the goal is to expose as much of it as possible, we’ve gone ahead and chosen the bull-nose, but as low as possible so we don’t have to chop the dowels, and as thin as possible so it doesn’t look silly.

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More site meetings, more baking. Ben’s been very patient with us over the time it takes to make these little decisions. Hopefully by the end of the project we’ll get the process dialled and each one won’t take so long. But for now, seeing bits and pieces in situ helps a lot, and sometimes this means climbing up ladders and holding bits of wood up to see how they look!

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keeping the troops going on cake at a time
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the things you do for clients, Ben

We finally bit the bullet and removed the oak collar on the clad sections in the master bedroom. Hands in the air, we fully admit to being over-enthusiastic with Neil when we designed the piece. Although the king-post and curved webs were awesomely built, and Terry, Josh and James spent a week installing it, we felt adding them was a decision made in haste so we asked them to take it down. I’m more than a little embarrassed about this decision, but it had to be done. Now it feels like we can breathe in the room.

The guys initially thought they’d have to take down a load of plasterboard and really fight with the screws that held the cladding to the oak. But in the end, they managed to cut the insulation and plasterboard in a nice straight line along some temporary battens put up temporarily alongside the cladding, and the oak was drilled out with a minimum of destruction. Very impressive. We now have to hang fire until Neil can manufacture the new cladding and get it to site. This stuff will be slightly thicker so it meets in the middle thereby covering up the central steel beam.

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… and we can finally breathe again

 

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makings of a really nice bird house from the old oak beams

The sun is swinging around towards the front of the house during the day, and it belts in through the front bay in the afternoons making all sorts of lovely shadows and lines.

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The bathrooms are getting tiled and painted, and the bedrooms are getting their dressing of trim in the skirting and wardrobes.

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Next week will see the groundworkers returning. They’ll start on the patio around the back, and they’ll swing up to the side of the house before they hit the front. Then it’s the all-important bridges. Tony the structural engineer is putting the finishing touches on the design before issuing instructions to Tim and his team. The goal at the moment is to devote resources to the interior as much as possible and leave the drive until last.

Tim had the club tiles moved up another rung this week. It’s a tiny little detail, and it took a lot of effort to move everything up just one course, but we’re very grateful and it looks great–thanks, Tim!

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front of the house
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back of the house in the sun

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We finished the week with a trip to Rye to visit Nick and see how the painting is coming on. He’s so accommodating and patient with our numpty questions, making us cups of tea, even talking about Gillian about her GCSE final piece and taking us for a tour of Rye Creative. It’s lovely to see the painting again and to have a little bit of input into the work. Gillian and Matt joined us, and after a lovely lunch at The Globe, we spent the afternoon wandering around Rye Harbour, dodging waves, looking for jellies and doing a spot of geocaching. The weather closed in near the end, and it was great to finally see Rye in a bit of sun for a while as in all the previous times I’ve been down there, I’ve been treated to a bit of horizontal rain and lashing gales.

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creating some new ideas
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tools of the trade
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big beach
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how do you work this thing again?

 

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Rye wall