Week 29

This week was all about kit.

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

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downstairs sink?

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

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

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

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

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are we in Scotland yet?

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

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

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masses of extruded bronze gets replenished every couple of weeks
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bronze extrusions are cut to size
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rough welds
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one of the expert welders, either Jimmy or Jimmy
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the other expert, Jimmy
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what these guys don’t know about welding isn’t worth worrying about

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polished welds
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blasting
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post-blast

Now for a good dunking.

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patina bath

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

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timing chart
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wax off

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

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our job!

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proud
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every opening is numbered to match the drawings

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everything gets treated–even the hinges
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more of our job with bound glazing beads standing all ready to go

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Ken and Martin showing us #62

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doors are made in another (larger) area

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

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

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

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

Delivery date onsite is 09 Jan 2017.

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and we got a night away as well–what’s not to like?

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

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twigs

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

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

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

Week 10

Friday

Wandering back from the house over the train bridge, Gareth spotted a lock on the railing. It’s just as atmospheric as the Pont des Arts…. apart from the dog poo.

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will this be the first of many?
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from the back door through to the lamp-post
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Game of Stones

The guys are finishing off the edges which requires a lot of cutting and mucking in. They’ll be doing this into next week too. Then the edges will be filled in with some of the earth that’s piled up in the back by the current garage. Apparently the brick layers will like their work areas level with no big dips to fall into or step over, and they arrive next week. The bricks are delivered Wednesday, and that will be a big day logistically for a few reasons. We’ve decided to dig the soak-away in the back garden rather than plumb it through the house. This is for the rainwater runoff from the back of the house and the original plan–it’s not going to be too big, only 3m cubed, but it’s landlocked on the other other side of the house. The alternative was to run it under the house and into the ditch, but we’d need a permit and some other permissions for that option as well as an £87 fee to the Council for the change. To get that all dug and sorted in the same week that the bricks arrive is a good puzzle for Nic. He’s thinking about forklift to ferry the bricks around the neighbours to the back of the garden. It’s going to be fiddly!

The garage is a total rock solid bomb shelter. It’s got an unbelievable amount of concrete in there, all because of next door’s conifers. An engineering marvel!  The contractor has recommended a concrete floor rather than a thin screed to avoid cracks. I’m not sure when the pour is scheduled, but there is a LOT of steel in there and it’s all ready to go.

Apparently all clients at this stage worry that their house is too small. Lee reckons that sticking a sofa on the blocks will show how big it is and will alleviate all concerns. It’s jolly big enough–we have to remember that our main constraint is budget, so we were never going to go all gargantuan, and it’s about the same size as the previous house. The flip side of a normal, non-huge house is that the garden remains an ok size.

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We’re about to choose the hanging tiles. And of course we’re still dithering on the mortar colour.

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hanging tile shortlist

Thursday

Crane Day!

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morning

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early afternoon

Wednesday

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tomorrow’s project arrived

Tuesday

The walk over was very murky tonight. Thunder booming softly from far away.

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looking north, up the line

Today ten tons of hardcore arrived and it was spread out around the garage. More will be dropped on the earth before the beams go down. Lee and the guys added more concrete and reinforcements to the garage and set up the foul drains.

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behold the kitchen drain
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WC drain

The test panel is drying out. Now we get to choose tiles! Which is your favourite?

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which goes best?

Looking forward to concrete beams for the ground floor arriving tomorrow with any luck, and crane to lay it all on Thursday.

Monday

Week double-digits. Coming out of the ground bit by bit.