Week 46

Most of the action this week occurred behind the scenes. Lots of planning and sorting and choosing more than cutting, sticking and building. We’ve chosen a fireplace, paid bills, decided on tiles, placed thermostats, chased electrics, considered ironmongery and built-in furniture, and we started thinking about wardrobe build-ups, kitchen pendants, sofas and curtains. I thought we were doing well with box-ticking until Tim asked for confirmation of colour choice for the paintwork. I think I need a lie-down….

Spencer is pretty much done with the roof, and now he and Jackson are on to the more decorative bits. One of these is the scalloped lead-work around the windows. There are 16 downstairs and 10 upstairs runs of this lead, all of varying length. There is nothing at all normal or even and symmetrical about this house. The lead was installed when the oak subframes were put in. It serves a very useful function in keeping the brickwork section underneath waterproof, but it’s an artisanal job to make it look pretty.

It starts with a scored out scallop.

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a satisfying OCD moment
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Jackson and his compass

Then the scallops are cut with actual scissors to make the shapes.

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Spencer practicing his cutting out skills

Each cut-out is rolled up and hammered into place.

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house2017.02.24 - 6.jpg The guys wear gloves because of the chemicals in the lead. Working with this stuff all day is toxic–lead poisoning is a real thing, and the preservatives on the surface are well-yucky.

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ooooo…
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…ahhhh

We’ve opted to keep a layer of PVC on the course between the plinth and the vertical brickwork to protect the plinth from stuff dropping on it from above. All it takes is a stanley knife to remove it later on.

Plastering is the name of the game in other areas of the house. And in the few rooms where they are not working, Terry and Josh can get on with the window boards. Must say, they look lovely next to the subframes. They’re both treated with this Osmo oil which will bed in and soften in colour over time. We’re putting the stuff everywhere on all the oak except the huge structural pieces–architrave, door linings, the lot. We’ll even slap it on the oak underside of the first floor overhang outside. James hates it only slightly less than the black stain on the soffit boards.

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window board

Another interesting piece is the brick inlay panels. They’re not herringbone, but everyone calls them The Herringbone Panels–even us. Actually, with my Pedant Hat on, they’re Askew. But this is alright with me! (Sorry). Clive painstakingly sliced each brick to a skinny sort of depth, and we’ve bought this fancy adhesive for them to stick them on. Like the oak cladding last week, this is not quite functional, well, not at all, but it looks awesome. They’re doing a brilliant job setting, pinning, gluing, and mortaring them into place.

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There are fifteen panels to make: 5 across each apex front and back, 5 across each paired square below them, and 5 below the windows in the hallway. That’s a lot of work, and I feel somewhat guilty just writing this in all the time they’re spending making the panels, but they are taking enormous pride in how it’s turning out. They took a day off the scaffolding when storm Doris blew through, the front and some of the back are mostly done.

I don’t usually go on about it, but I take great pride in looking at other houses with this similar non-herringbone brickwork, whose designers have decided to use a different brick from the rest of the house because it can be bought in, and thinking that our guys have simply taken the time and made the effort to do a brilliant job. Anyone with eyes can see that it’s a total pain to have spent days and days cutting these really thin slices to carefully stick on the boards, which is what James and the guys have done. But the finished effect will be seamless with the brickwork in the rest of the house because it’s exactly the same brick. It’s a bespoke house that everyone  onsite is on board with to make it as good as it possible can be. And THAT is the bit that’s amazing.

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lonely roof while Doris blows through

Week 45

Early birds, these guys. On my way to meet the electrician at a lazy 7:30 am, I saw that they’d already had a delivery that was just departing down the lane.

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oak cladding in morning light

More oak arrived late yesterday via Neil and his Land Rover with trailer; it’s always a pleasure to have him onsite. These pieces will cover the steels in the master bedroom, a design compromise that sits a little uncomfortably only because for the rest of the house, the wood is structural, and this isn’t. But with Neil’s skill in fabricating, and Josh, Terry and James’ skill in installing, I doubt we’ll be able to tell any difference between the cladding and the real deal at all in years to come. It looks very fresh at the moment when put up next to the stuff that’s been up for six months. Neil clearly spent ages on the comprehensive installation manual for the guys too. I’m sure they’re grateful!

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instruction manual
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Terry’s not putting it up on the wonk, it’s the lens distorting the angles
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curved beam to match detail in the hallway

Meanwhile, work carries on around the rest of the house, and it’s crowded. Plasterers, roofers and electricians have been in all week, and I’ve been interviewing fireplace experts, interior designers and joiners.

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fitting plasterboard from the vaulted section

The best bit of the week was our topping out ceremony. We, well, Tim really, decided it would happen when the last ridge tile went on. Originating in Scandinavia, this is an event that usually happens on bigger projects and usually involves chasing out evil spirits with branches of evergreen plants, and blessing the building for its future occupants in some way. Rather than inviting a random druid priest around or sticking the odd sprig of fir tree up the top of the scaffolding, we tried to keep it simple.

Our solution was that we signed the final ridge tile.  We got out our white pen and scribbled as a family, then got Tim, Ben, James, Terry, Josh, and Spencer to sign as well. So Spencer carefully left the last space empty for us to fit on the very front of the house. Excellent! It was a two-part event with fizz and sausage rolls on the Thursday as Clinton couldn’t be there for the actual fitting on the Friday. Everyone from the roofers to the tackers were there. Matt, Gillian’s boyfriend even joined in. Clinton said a few words of thanks, we armed Tim with the camera for some family snaps, and then we tucked right in!

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Gemma setting up the buffet
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builders buffet
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it IS Oxshott after all
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thanks, guys…
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… from all of us
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underside of the ridge tile
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future residents
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Gemma and fake fizz

 

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we even had waiting service

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The A-Team: Ben, Jackson, Tim, Clive, Blake, Dave, Mike, Josh, Terry, James, and Spencer

So it seemed only fitting that after all these festivities and thank-yous that we actually got the signed tile on the roof.  The girls, Matt, and I spent a lovely sunny morning in Roofing School with Spencer (well, me watching them more than doing anything constructive).

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up on the scaffold

 

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Spencer prepares the area for the final tile
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Gemma lays the tile

Can’t say that our efforts contributed anything special, but it will be lovely to think that at least we had something tangible to do with the build as we look up at the front gable forevermore. The layers of cloaking look great, and the rest of the roof is just about there. Next week will involve Spencer doing a little tidying with other, lower, ridges, which leaves the scaffolding coming down Thursday or Friday!

 

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final tile in place
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cloaking closeup
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“How are we going to get the leaves off THAT, Mum?”
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can you spot the venting tiles?

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roofing signature

 

 

 

 

 

Week 20

Friday

We say goodbye to Nic and Justin and thank them very much for everything they’ve done for us. They’re great guys, keeping the build rolling along all together despite significant challenges that would flummox any mere mortal, and they still manage to make us laugh. Best of luck in the future, guys.

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Welcome aboard Tim and James!

We created a test panel of roof tiles to see if a mix might be better. Generally, the panel of vertical hanging tiles is lighter than the ones on the roof on most houses, and we’ll choose these if the price is right. At the moment, we’ve got to come up with a decent percentage blend so Tim can go and have it priced.

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Up until now, we’ve been trying to fit an AV system in the living room which is perfectly  normal you might think, but the challenge is to wedge it in above a fireplace. We’ve stalled out over the past few weeks in trying to get advice about combustable materials and convection venting grills, and as a result we’ve kept the team from building the far wall with the chimney. We’ve now made enough decisions to let the guys crack on with the wall. But the final design is still up for grabs!

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It’s awesome to see scaffolding up and steels in. The first floor planks are due to arrive in the second week of September with any luck.

Thursday and before…

Apologies for losing a few weeks in here.

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distraction
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steels!

The view out the family room will take some TLC…. It’s not exactly jaw-dropping at the moment and probably not good enough to prompt the kids to avert their eyes away from the TV. The garage makes a super tea-hut/meeting room, but it makes an awful window.

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view out the family room

The oak frame is busy getting built in deepest Sussex and will go up at the end of September. In the meantime, the guys have finished all they can do on the porch.

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the front porch is looking nice

I’ve learned a LOT about chimneys, flues, regulations and what’s on the market. We’re aiming for a cassette woodburning fire. This requires a 150 cm flue and a Class I chimney. A traditional open fire would require a 9″ flue and a much larger chimney. Given how close we are to the fence, it’s obvious that we’ve had to limit our choices in this area.

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chimney is covered in insulation with the red tags.
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chimney flue
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rebuilt rear bay–notice any difference?

Paul brought a sample of the oak subframes for the bronze windows to the last meeting. It’s enormous.

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sample oak subframe

 

 

Week 17

Thursday

All hands on deck.

Russell and Chris the Farmer (gotta love spellcheck; he’s a Framer) came to site to check it out for delivery, progress, etc etc. The poor dog was left in the car, but we checked him at regular intervals. We should install a kennel during the build! Dave and Paul came up for their monthly architectural check and also to give Paul the opportunity to have his first look at the project. Dave said he hadn’t been on site when it was sunny yet–the last time he was here, the place was a swimming pool on that torrential day with fire trucks and neighbours getting flooded. Of course Nic, Ben and Justin were there too, so donuts were bought, the sun was shining and we (they) sorted out a few rough edges to fitting the oak frame.

This included lots of hemming and hawing about connecting the existing brand spanking (gorgeous) new brickwork with the oak in the rear bay. Any little change has enormous ramifications on windows and roof, then with steels and oak as well. So it’s good to have as many eyes as possible checking the build to ensure no Grand Designs moments.

The structural oak should go up in the first week of September. That implies the build will be up to roof level. That’s a lot to do in four weeks! We took Russell up the road to pick his brains and have a good look at the larger new-build with a similar design. He pointed out a few good things like some shifting and splitting at the peg holes. It’s comforting to know that he’s doing his best to avoid these things. He said that our structure is a self-supporting piece, and this is different from the facade that is on the larger house. It’s a design departure with a few more chunky bits of oak sticking around, but it is a more honest approach to what the building actually does. Kinda goes with the ethos for the rest of the house.

Wednesday

A cheeky evening visit to check on what can happen in a day.

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We’re missing a few super-specials, but Nic will track them down
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going up in the study
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have finally chosen the fireplace so the guys can carry on with the blockwork
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front on garage side…
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… and the plans
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the first door in the study at the back …
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… and the plans

It’s great to see the first dummy doorframe up!

Tuesday

Really? Week 17? The original timescale was 36 weeks. Everyone agrees that was optimistic, but still, we should be almost half way there in theory. Reality is a little behind, but the gap is closing. The biggest landmark is: The Windows Arrive 5 December [capitals necessary]. This is a line in the sand, and I wouldn’t want to get anywhere near messing Martin around! They go in close to last because he doesn’t want to get any plaster, paint or damage on or done to these bad boys. Neither does anyone else I’m sure.

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rear bay up to plinth

This week is a great week for progress as the brick work is getting up to the plinth which is one of those details that are not cost effective, require a bunch of extra effort and expense, but which make the house really special.

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a lovely set of jointing

The jointing is slightly different in the special bricks to avoid any water collecting and freezing and finding its way into the building.

We’ve got expansion joints in the brickwork too. And you can see the insulation panels pinned to the brickwork using the red pogo-stick ends. These joints sit behind the rainwater pipes that sit in the brickwork nooks and run through the plinth. Complicated brickwork or what?! We’re really pleased with the choice of bricks, and I’m sure the skill in laying all these brings the whole thing to life.

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expansion joint in nook

In the background it’s a whirl of decisions. Everyone says this and I didn’t quite realise that it’s as relentless as it is. A real Surrey-Struggles moment I know. Ben, Dave, Justin and Nic are being super patient with our general slowth. It’s serious Scout season as well and half the family was awol planning the trip last week and is currently roaming the wilds of Dartmoor until Saturday. So, just to make myself feel better, we’ve done roof and hanging tiles, a bathroom schedule, preliminary M&E design, garage door, and fireplace (finally, hooray). We’re almost ready to close out the design of the drawing room, the kitchen contractor, and the flooring and joinery schedule including the front door. Just keep swimming.

Been learning Sketchup to get a handle on the fireplace options. We are doing none of these:

Week 13

Friday

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steamy lane

Last year it was 37 C and people were convinced global warming was to blame. This year it’s 17 C with torrential rain and people are convinced global warming is to blame. Makes it tricky for laying bricks, but the guys are cracking on.

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back door

The walls of the house will be filled with this insulation. It’s foil backed and gets slotted in between the brick layers. Cozy!

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insulation tower

The site has been so soggy that they’ve built a raft out of pallets for the brickies to stand on while they build. I think it’s a nice feature that we should consider in the landscaping….

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the whole site from the front

The 6mm raked joints take a bit longer to build, but they look lovely in the sun. The bricks look more irregular than we thought which is exactly the style we’re after. The original-many-moons-ago spec called for reclaimed bricks, but they’re bonkers expensive and sized with imperial measurements! Ours were always a compromise, but it’s been a good one. I hope we make as good a decision with the roof tiles. The rainwater notches look great–can’t wait to see the plinth detail bring it to life.

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the whole site from the back

Thursday

Site meeting about 2:00 with Nic, Ben and Justin in our used-to-be-garage which actually makes a nice meeting room. Ben and I met Trevor the M&E guru. We sited boilers, gas spurs and foul drains and discussed the merits of separate manifolds for underfloor heating and towel rails. All good stuff. I’ve got some homework to do this weekend in making some final decisions before the floors are laid and the pipes are literally set in concrete (or below it anyway).

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where would YOU site the gas meter?

But my main homework is to sort the fireplace so we can tell the masons how big to build the hearth. I’m late and it’s not good!

 

Wednesday

Tuesday

Monday

Lucky 13–now that the awful weather has changed for 30 seconds, we’re seeing progress. The bricklayers have arrived!

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vertical!
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artsy stacks

The brickies will run the outer walls all the way around the building, then Lee and the ground-guys will lay the DPC. Clearly the DPC is VERY important given the events of last week. Then, I gather it’s all systems go for some serious vertical progress.

In the meantime, Grandma’s yellow rose is still hanging in there, and we’ve got another guest tonight.

Week 9

Friday

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taken from the fireplace in the living room
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taken from the south west corner of the house
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looking all across the back of the house

This test panel of bricks is a complicated affair:

  • the dry mortar is bucket handle joint with a normal mix of lime, cement and sand as per the specification
  • two courses above that is the West O sand mix with a slight recessed or raked mortar joint
  • the top three courses above that is the Betchworth sand mix with a 5- 6 mm recessed joint.

As the top courses dry, they’ll end up lighter than the bottom half of the panel. You may remember that last week, we were concerned it was too dark so we got in a couple of different sands. One of them has more aggregate in as well. We like the deeper recess, but we’ll have to wait until the panel dries to make a decision on the mortar.

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test panel Mark II

We’re also now reconsidering the brick. I know this is extremely poor timing, but it’s such an enormous part of the project we want to be sure to get it right. So off I went taking Toothless for a massive journey into deepest Sussex to check out the bricks below. Ours is the furthest to the right. We quite like the Tumbled Multi, but at some point we’ve got to adhere to the conservative system that is what we like vs what we have to spend! A project for the weekend is to reassure ourselves that this is the right brick for the right price.

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Thursday

Wednesday

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the theme for the day

The brick layers have been in and have laid up to the reds in the living room. They put lintels across gaps where the pipework will exit the building.  Check out the red laser sight on the tripod in the middle of the room.

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Lee and his crew will dig the last trench tomorrow; 8+ square metres of concrete arrives around 2:00 pm. Next week it’s laying the ground floor and pouring the garage floor. The crane is scheduled to spend the day with us on Tuesday, and Nic will have to post around a note to the 11 neighbours saying that the lane will be blocked for most of the morning. That is,…. if the brick layers have a dry enough time of it to lay on the foundations. The crane will lift the huge T sections onto the reds, then the blocks will fit in between. The final bit for Lee is to set these blocks into a loose concrete muck which is poured on top. I don’t know if he’s responsible for the DPC membrane, or if it’s another crowd.

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taken at the end of the day
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where did the foundations go?  Ahh.. under all that mud
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external (left) and internal (right with reds) walls
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olde worlde kit

Apparently one of the bricklayers kept hitting this exact spot and getting all religious about it. At volume. It’s pretty deep!

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Midway between ankle and knee deep
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sinking Dizzy
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there must be a witty caption about this but I’m struggling
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artsy muddy wheel
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some of the drivers need to watch the bend at the top of the lane

One of those nice shots of the lane; this one with the new blossom getting shot off the tree by torrential rain onto the tarmac.

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And on the way back, randomly in front of the temporary digs….

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bye

In the meantime, we’re looking at the oak subframe in detail.

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rear gable
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front gable

Check out the meerkat next door (1:28)….

Tuesday

Lovely day if you’re a duck. Here’s driving to the site….

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Monday

It’s a lovely bank holiday today with stormy winds out of the East and torrential rain forecast for tomorrow morning:

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Thankfully, we spent some of the weekend making a nice little shelter for the camera. So fingers crossed, there won’t be any more water accumulating in the housing and creating a foggy picture, and we’ll have lovely clear timelapses going forward.

Lots of other bits of the weekend were spent reading contracts, checking out local completed house projects like ours and investigating Arts and Crafts style points (including the bio of local architect transplanted from Scotland, George Blair Imrie who designed the Wisley labs–a long favourite of ours).

It’s meant to be a busy day onsite tomorrow with the brickies arriving first thing. Hope they bring their flippers and snorkels.