Week 82

My last post turned into a bit of a rant, so with this one I’ll do a complete 180 and focus on the really good changes in the build.

One of my pieces of advice for anyone starting a project like this is to plan the kitchen and the fireplace first. There are soooo many decisions that need to be made from soooo many trades that it’s best to coordinate a single plan before anyone arrives onsite with their spanners. The kitchen is a no-brainer for planning; with half a bijillion kitchen shops on the high street it’s one of Those Fun Things to do with a huge project like this.

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chimney plan

But the fireplace has just as many trades involved if not more. We made the decision early on to have the face sit flush with the wall and the chimney sit proud of the house.

And we decided that the fuel would be gas. Neither of these stuck, and we now have a false chimney breast with a wood burning stove. Marvellous. The design process has taken literally months, and I have managed to piss off my whole team, including my darling husband, so much with indecision and general questions that we removed it from the build and made it be a client direct package. Again, marvellous, but at least I’ve now got just me to please with no deadlines apart from those I set myself. The next deadline is Christmas, three months since moving in, and even that looks dicey.

We wanted a grand statement, more like a piece of art than just a hole-in-the-wall modern fire. Clinton has always liked CorTen steel, so Steve from Bradley Stoves ,who is doing the installation, recommended a guy called Toby to fabricate the steel cladding. Toby is doing another steel cladding job for Steve, and he runs Arc Fab Sussex in Lewes. Toby’s specialties lie in Big Things like narrow boats, railings, and bridges. He is also a trained artist so likes doing “little” jobs like ours. This “small” piece of steel will be 3 mm thick, 2.6 m high and 2.1 wide with cuts, curves, and supports to house the stove and the TV. Anyway, it was a pleasure meeting him and seeing the site, and now we’ve welcomed Clive the draughtsman on board to measure up so we can have it made.

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the goal
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part of Toby’s narrow boat project at the yard

But I’m getting ahead of myself. The stove has sat forlorn, half-installed by Steve’s gang for months while I got my act together coordinating the cladding. The family and I did some final measurements to make sure we were set on the dimensions before Steve’s crowd came up to build out the final interior of the chimney breast.

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think twice, cut once
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first bit of the metal carcass
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more carcass
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the carcass is filled with rock wool
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the whole thing is covered in 50 mm fireproof board

As well as building the skeleton for the chimney breast and cladding it in fibreboar, the guys also brought up the lovely piece of 30 mm thick Autumn Brown granite that we chose in the summer, now cut to size and all ready to fit. And because it’s St Anne’s and nothing ever goes quite to plan, they gingerly lifted it out of the van, and it broke into two pieces in their hands. Back in the van it went. Of course, the yard they got it from doesn’t have another piece big enough, so I spent a couple of harried days racing round Surrey finding a replacement match. Luckily, I found one in Hazelemere, and I’m waiting on confirmation of the final dims before committing to a size in the order.

Next up is drafting the final dimensions for the steel, fabricating it, weathering it, and installing. Clive is the draughtsman and does the drawings for Toby, so he drove up early one morning to Measure. This is no small undertaking as he takes on board all the risk if the beast arrives onsite and doesn’t fit (actually, if this happens we’ll probably end up rebuilding the innards). He’s a lovely chap who used to be a blacksmith in nearby Bookham. He’s got more involved in the drawing side of things recently but he still keeps his hand in the Making Process by silversmithing. Not so great for his wife who doesn’t wear jewellery he says, but fabulous for his daughter. Anyway, lasers at the ready, and he’s gone away to draw plans and liaise with Toby. If Steve can give us an install date by the time it’s built, the whole thing should be done by Christmas with any luck!

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can you find Clive’s laser line?

Other things brewing are fitting out the study with its desk and cupboards. We’ve got Barry onboard, and he’s been very patient with us while we work out the finances. We’ve got a simple idea, and it’s just a matter of pressing the go button.

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Barry’s plan for the study ..
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.. is an improvement on this!

Nisi installed the CCTV cameras a couple of weeks ago. After the wire-debacle, we’ve got some natty little grey cameras in three places all linked up to a DVR in the data cabinet.

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eye spy

They’re IR too, so we can track foxes scuttling around at night as well as any miscreants lurking in the shadows.

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I’m watching you, Wazowski

house2017.11.04 - 44The garden has totally taken over in the three years we’ve been out. All those lovely plants I tended for all those years, and all that awful lawn that turned to moss and we cursed over, are all no more. I have only ever once hired a professional to help out with any garden, during one spring when I was vastly pregnant with one kid or other and couldn’t get near the ground much less have any stamina to actually do anything horticulturally useful. But Nicola’s plan required the A-Team of landscape gardeners, so we’ve invited Mark and his gang on board to do the job. A few months back I put out a request for recommendations on Facebook, and almost everyone I know wholeheartedly recommended Mark. So we’re lucky to have him on board with Max, Duncan, Sam, and sometimes Wes & others, and they’re really cracking right on.

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clearing the front of the house including the cherry we planted in 2001
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pile of stuff and protecting the drive

After clearing the site, they brought in 60 tonnes of soil in stages. Robbie the driver got to know the lane really well.

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Duncan laying the soil
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ready for planting
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we’re going to have to watch the street-side for people doing some creative driving
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cleared and ready for setting out

It’s not quite accurate to call the front a “knot garden” as it’s more like a few squares with some defined borders. We’re using steel edges to delineate the beds from the path, and the path will be laid in National Trust-esque Breedon Stone. This is a self-binding aggregate that’s more like a path and less like pea single.

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the plan for the not-knot front garden

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the beds line up with the windows

We originally wanted a standard plant like a bay or a holly in each box, all lit up with fancy spots. But since Nicola has drawn this up, I’ve discovered Anthony Paul Landscapes on Max’s recommendation, and he does some lovely things including a hydrangea set in clipped box. So we’ve decided to blatantly copy that instead. Fewer lights = less cash required = fabulous.

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those rainwater sumps are still too high

One of the reasons we did the whole build in the first place was to re-site the garage in to a more normal part of the house, i.e. the front, and have the sunniest spot as a patio, i.e. the back. It is so lovely to finally see it come to fruition as a space where we can hang out rather than use as a parking space to bake a car or two in the summer sun.

Type 1 scalpings were next, and lovely new soil to the beds. The manhole covers were changed to ones that will have Breedon in them so they’ll disappear more.

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taking shape
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lighting cables under the Type 1
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incoming Breendon on the truck

 

 

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the plan for the back garden
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the geotextile membrane goes down first
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the side garden is broken up for fun planting

Max laid the paving so quick that I missed taking photos of it. The yellow Tracpipe is the gas for the fire-pit. Now that we know how long to cut it, we’ve got to get the plumbers back to do the gas work. I’ll try to book them in at the same time to cut the pipe install the whole fire pit thing all at once–saves two call-out charges.

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wooden edging in the back, rather than steel to save some cash
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one day this will be a fence
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building the step
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the side border along the drawing room windows
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a lawn!
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so lucky with the weather today–shorts in NOVEMBER

Pointing and bed prep will finish next week, then we can concentrate on planting. I’m due to go with Mark to choose a paperbark maple as a feature tree, and Nicola had Himalayan birch, coral bark maples and fruit trees in the mix too. There’s also a big hedge to plant. There will be a lot going on in the coming months, and this will happen in dribs and drabs when Mark’s got some time. We’re in no rush, especially since we’re not allowed to walk on the new turf until the Spring!

Week 61

Clinton celebrated a penultimately significant birthday on the weekend by going back to school: blacksmithing school. He’s always happiest when he’s making and building and doing. So with some stout shoes and safety glasses, off he went to the Quinnells’ at Fire and Iron to get stuck in to Make Stuff.  The course was about blacksmithing technique but with an artist kind of vibe; the goal was to take home a few cool pieces at the end of the two days. With a little guidance from the instructors, he’s gone and made something quite amazing, unique and special. You’ll have to wait for the great unveiling in a future post, but I will hint that it’s for the house.

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Iron Man

The long-awaited visit from British Telecom to attach the house to the rest of the planet was scheduled for Monday. Matt the Engineer arrived promptly first thing to rig up the line. Jamie got stuck in to finish off the trench, and James and I deciphered where the electricians had cunningly hidden the location for the BT box (spoiler: in the garage). So Matt got busy connecting, and Jamie filled in the trench afterwards. Apparently there’s a dial tone and everything!

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we love a good trench

Other outdoor work included laying more paving slabs and turning on the outdoor lights.

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replacing a wobbly slab

Steve’s team came to install the wood burner in the middle of the week. Cue much amusement from the guys wanting to know when the fish will be delivered. Installation went off mostly without a hitch with a little drilling out of the brickwork for ducting and a little bricking up for a base that the thing sits upon. It’s a closed system, so we don’t need air bricks to the room, but there is a need to supply air to the appliance itself, and another need to vent out the chamber so it doesn’t overheat, especially since we’re sticking a great big TV above it (eventually). The extra size of the exterior brickwork plinth at the bottom made it a little challenging for the guys to connect the bottom duct since it was so long, so they had to come back the day after and finish the job. It looks great as it is but we’ll add to it in time: eventually the build-out sections will be built bigger so the TV is set back behind the stove. We’re going to develop this design with Steve now that this portion of the job is complete, but at least it’s safe at the moment and passes all its HETAS requirements for building control. It’s a complicated design, but Dave’s watching over it, and it will be awesome.

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Rais 900 all alone
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where it will live
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woodburner, mid-install
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temporary buildout and ready to go

The mechanical ventilation system failed it’s commission a couple of weeks ago, which was slightly scary. The pipes are all running in the void between the concrete first floor and the ground floor ceiling, and getting to them now would destroy a ton of decorating. The system runs to all the wet areas including the downstairs coats cupboard where all the electrical controls are housed. The problem was that there wasn’t enough suction on the longer runs to the other side of the house and to the kitchen, so it failed its installation tests. We have been waiting on tenterhooks seeing how the company would deal with this, and they came back this week to fix it. Their solution was to fit a second motor in the loft to give it enough oomph. So now we’ve got double-spiders up there, all labelled up nice and pretty, and it sucks like fury. Hooray!

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fancy MEV

You may have noticed in one of the photos above that the exterior light was ON! Yes, the lights are on at long last. Lewis was characteristically sanguine about showing me the gleaming little LEDs and lovely warm Edisons outside, but I am pretty sure he’s kinda proud of getting near the end, and I think I even caught a sly smile or two in there somewhere. It’s another threshold of making the house look like a home.

I’ll take you on a tour of some of the mostly-finished rooms….

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shoes-off policy upstairs now that the floor protection is up
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Gareth’s room
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Gregory’s room
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first floor hallway
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the glorious linen cupboard!
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Gillian’s room
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up close and personal with a newel post
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boys’ bathroom with burglar PIR in hallway
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master vanity needs shifting to the right 100 mm

It was all looking marvellous indeed! But then… the heavens opened. This time last year, you’ll remember that the storm drains on the local roads up the hill failed, and my neighbours got flooded out with the grounds guys altruistically running bricks to them to raise their furniture before the water got to their beds and sofas. Since then, much repair work has been done, and one neighbour was able to move back in just after Christmas; the other is due to move back in at the end of the summer.

This year it was our turn for drama.

The water was either down to the oak frame or the windows, and it was only in a few places. First we phoned Neil who has built a bijillion of oak frames in his career, and he was totally cool about it. Although he’s never seen anything like it, he offered some suggestions and kept a cool head. He was down onsite two days after we called, and he agreed to do some sealing around the edges as a failsafe. He came with Grant and an enormous ladder on the weekend to put the CT1 in some gaps and seal it up, so we won’t be seeing this sort of thing again. The next step is to talk to the window company about the seals around the windows, but that’s a little more complicated because there are so many materials (mastick, sealant, bronze frames) to contend with. Ben’s on it and we should come up with a solution to cover that side as well soon. This belt-and-braces approach should mean we’ve got an air and water tight arrangement, and this is important as we look forward to the all-important Air Test for the SAP calcs in a couple of weeks.

The brick guys returned to repair the damage we did to taking out the piers, and to fill the extra holes the in the bricks made by the electricians in their quest to find good spots for outdoor lights and power. They should finish up next week so they’re only here for a wee bit, but I didn’t get away lightly…. “Who was the last man to walk on the moon?”, asked Paul in the morning. With a completely blank mind, I said Charlie Duke whom I knew was an astronaut, but I also knew was the wrong answer. I’ve even read Andrew Smith’s Moon Dust, and I SHOULD know these things! When I came back onsite in the afternoon to drop off some thing or other, it was “What’s so significant about the River Roe in the States?” Galling, because I’m American, and I’m sure he picks these questions because of it. I will leave you to go and find the answers yourselves!

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chipping out the decimated brickwork
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redoing their own work

And James has got all comfortable in his man-cave in the kitchen.

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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 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 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