Week 53

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

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Lakes

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

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

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future patio

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

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

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brick slips that need changing

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

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shame to change this as well

Hinges are going on the doors.

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big doors and big template

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

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

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future loo

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

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

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

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snip snip

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

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centre spot of the whole house

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

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wedges and separators
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where is the centre tile?

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

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

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ditramat under the tiles ready for grouting

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

Week 48

Goodbye scaffolding! It took three days to get all the gear down, and now we can see the whole building.

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scaffold neatly stacked and ready to depart

No scaffolding in the way means that Terry and Josh can get on with building the roof for the garage. This is a wiggly little beast that has had Terry brushing off his thinking cap to calculate the pitch of the flare. The flare determines the soffit width, and the soffit width determines the supporting post position, and all this is constrained by the location of the neighbour’s fence. And don’t forget the guttering…. Much hemming and hawing occurring this week, and even Dave was onsite to have a look and a ponder. In the end, we all reckoned the best way to build it was just to get on with it and see how it fell. So we all left Terry and Josh to it, and by the end of the week, they had a plan that matched the flare the same pitch as the rest of the house and he reckons the guttering will just kiss the border just like the old house used to.

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the first truss on the garage
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building the garage
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more trusses from the back of the house
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and even more from the front

Lee, Sean and the groundworks team have been back with their digger to make the rainwater drains meet up to the soak-away in the garden. There are six downpipes at the back of the house that all run to the inspection port. It was a little odd to see the this thing poking its head up above lawn-level, but the plan is to cut it down to as low as it can go, and if we ever need to rod the downpipes we’ll have to find it and dig it out to get access. This is ok with me. I regularly used Douglas’ old set of rods to sort the drains in the old house, so a bit of potential digging on the off-chance that these need sorting isn’t going kill anyone.

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inspection port
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groundworks return
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nimble digger
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garden massacre but the camellia is undeterred

Now that we’ve sorted the design on the fireplace and have signed off on the plans, it’s down to the guys to build it. But there are still a number of trades to coordinate: stone, joinery, fireplace, general building, electrics. There is a lot to this piece. I had my first foray into sourcing stone this week having gone to the stone yard to have a look at some off-cuts. I hope the inside does justice to the outside.

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lots of stone
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chimney symmetry

It’s always a challenge to walk around site and to visualise what it will look like when finished. It’s hard to resist taking photos of general stuff going on, but equally hard to figure out where the best vantage will be for the “before” or “during” snap to compare to the finished “after” one.

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during?

Nicola’s design is being finalised, but here is a quick working-drawing teaser.

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The plasterers work hard when they’re onsite–we just need a final push to get it done and then the architrave and skirting can go up. In preparation for that day, Clive is staying out of their way and has got a great system set up in the master bedroom for the task of painting miles and miles of wood.

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family room ceiling — tick
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kitchen with plasterers’ platform
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living room with tray ceiling and bags of plaster
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ground floor ceiling protrudes until the landing apron is installed
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Osmo-ed architrave
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relief grooves in the backs of the tall oak skirting
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Clive loves his Osmo

We’ve come up against a stumbling block with shower trays. The current ones we’ve chosen are expensive, and two don’t fit. One of the wells made for them to drop into is slightly too small and we’d like to see if we can grow it. This shouldn’t be too much of an issue, until you take into account the underfloor heating. Risking making a hole in the pipes set in concrete to chip out the necessary extra 100 mm would be catastrophic at this point. So we’re trying to figure out other alternatives, one of which might be a wet room type of thing. Tim can’t start tiling until the trays are down so we’ve got to get our skates on to sort this out or the whole programme will suffer and we’ll push everything back weeks. The jury is still out while we research other options, so in the mean time, here is a photo of the shower in the girls’ bathroom.

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where’s the waste, Wally?

You would think that choosing colours would be the fun but, and it is. But agreeing on colours is another matter. And nudging the kids to make decisions about their rooms is proving a challenge too. Tim says to paint the whole thing white and wait with colour until the rectification period is over and the inevitable cracks are plastered over. This makes a LOT of sense, but it is so tempting to just paint it its final colours and get it done. With our usual speed of making decisions on this project, it may be after the warranty period before we finally decide, so Tim just might get his way after all. And by then, Tim will be sailing off into the sunset, drink in hand, remembering fondly the lovely job he did at St Anne’s and it being ancient history!

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tableau of indecision
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Josh needs a new pair of boots

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Week 47

We have a flue!

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no jolly men in red suits today

Actually, it’s a flue liner, not to be confused with the identically named but made of pumice ‘flue liner’ that was already installed with the chimney went up. All very technical, but for the past few weeks, Dave has been developing the plans to make this thing work.

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These are the best laid ones of the bunch…
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installing the cowel at the top
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all set to go

Terry and Josh have made a start on the garage roof. This first requires brackets to be attached to the wall on one side and onto the brickwork on the other. They were making good headway until they got called to build a new skin to a wall in the hallway later in the week.The problem was a very small area of single skin which was going to make the place thermally inefficient and vulnerable. This issue had been brewing for a while as we’d been waiting for approval from the warranty company with this wall design and with a little pushing from Ben, they finally approved the thinnest version which is great because it allows more of the oak frame to be exposed. But it’s a problem no longer, as the thing is now built at long last, and the plasterers can get on and finish it off.

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Terry’s garage roof brackets
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thicker wall

Aaron’s been in to finish the first fix wiring. The wires have been capped and cased all over the house, and they’re making maps of were they are under the plaster so we don’t end up sticking nails through them when we put up artwork.

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breaking a few eggs before the omelette is finished

Once Aaron was done, there was a whole gang of new plasterers that came and put the ceilings up. It’s very high tech with laser sights and grids of brackets to hold up the suspended ceiling that hides the electrics and plumbing under the concrete upstairs floor. They’ll still be about 2.8 m off the deck.

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straight line gizmo

One last trip around the scaffold to check out the finished roof.

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can’t resist taking another of these pix
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cloaking tiles
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a mortar snake through a hole in the slate (these just flick off)

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lead dormer cheeks
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pencil lines showing the handmade workmanship

The doors arrived at long last. It took four guys to lift them off the truck, and they came pre-assembled in their frames. James, Terry and Josh will fit them next week which will make the building will be almost air tight. This will not be a small undertaking. As you can see, we have yet to choose a doorknob in the centre. Clinton actually bought a brass casting kit a couple of years ago, and we’ve got some thoughts, but it’s got to be good. No pressure!

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colossal front door (it’s upsidedown)

The plasterers are just about done upstairs and will move downstairs next week. Like the rest of the house, it’s not been straightforward: there are some fiddly bits like in the upstairs hallway and some enormous swathes like the stairs wall and the whole of our bedroom. They’ve done a great job, but they’ve got to get a wriggle on to finish downstairs before the floor goes down.

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master ceiling
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plaster in the master bedroom
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hallway looking east

 

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hallway looking west
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stairs area
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lunch pail

And then the scaffolding came down….

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a good before picture of the knot garden

 

 

Week 44

 

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James and Spencer discussing the roof

The roof is almost finished. Spencer asked me if I was happy with the course of cloaking tiles that will sit between the oak gables below and the roof tiles above. He’s added a layer of Welsh slate secured underneath to prevent the roof from wobbling as the oak settles. They’ll be mortared in when they’re laid next week, and the gap between them and the roof tiles will be filled as well. The carefully installed leadwork finishes the job.

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junction of tiles, slate, cloaking, and lead
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cloaking mockup that will go up and up
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leadwork
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clothed and unclothed

The gutters went up later in the week. They’re powder coated aluminium which will last and last with any luck. Aluminium is made in longer lengths than cast iron which is great for the long runs without dormers–easier to make, easier to coat, and easier to install. Although the guy I spoke to who was working with long sections of it up on the scaffold late on Friday said it was very very cold as a material to handle. Yes, at 2C it would be. They’ve installed around all the fiddly dormers, and the downpipes will go in when the scaffolding is down. In the meantime, they attach giant bags to where the downpipes should be, so that water still collects and stays off the face of the building until the job is complete.

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dormers with burlap hats on
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long runs of guttering on the east side
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pieces cut to length and ready for fitting

 

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guttering installed just in time–this is slushy snow in standstill traffic…lovely!

It’s the middle of a bitter cold spell with snow off and on all week, but none of it sticking, so it’s just disgusting outside with no snow-joy. Phil the plasterer says that they need it to be 5 degrees and rising for plaster to set. Part of their job is to physically stand there and watch it set to even out imperfections, so this is taking rather a while, more like days than hours, it being all in cold and slo-mo.

There are ten individual 2.5 m tall panes of glass in the hallway at the front of the house. If we do decide to go with the fancy automated curtains we’ve got in mind, we’ll need holes drilled and wires for power setup through them. James had the unenviable task of drilling the structural oak as close as he could to the windows given the body of the drill. So faced with this tricky job of messing around with the expensive and carefully engineered oak, he simply bought a new drill bit for the job, lined it up, and with his typical levels of cool, just got on with it. It looks bizarre to see shavings of precious structural oak now adorning the surfaces of the lower beams. I’m glad I wasn’t there to watch.

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cable hole

The back of the house is looking more like a house. Terry is still up the top, round the sides, inside, outside, and up and down ladders all day long cutting bits to go just about everywhere. Meanwhile, Josh is in full voice doing the same. There is more than enough to keep both of them very busy and loads of disco tunes to keep them going.

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back of the house

We welcome Nicola on board this week. She’s the garden design expert and will draw up a plan for the front and the back. This is timely because I had the good fortune to meet James the landscape gardener and Andy with the driveway materials, both to discuss what’s happening outside. So a plan is where we want to start, especially with the hard landscaping and tree-planting as there is a certain level of commitment involved in those pieces, and that will come to fruition in the coming weeks. For once we’re doing something in the important-and-NOT-urgent-box, and not in our usual space of important-and-urgent.

Meanwhile, what colour of driveway would you like? The most cost-effective range is the 6mm aggregate which requires a 16mm base rather than the 10mm aggregate which requires a 22 mm base. Less material means less labour as well as less of the stuff in the first place which equates to less money (hopefully).

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10 mm is too big, 3 mm is to small, so 6 mm is just about right

Another visit to the forge to end the week to have a discussion with Tony about some very minor tweaks to the curlicues.

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look closely for snowflakes falling in Betchworth

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We had a good chat about his current job, how he started his career and what happened to allow him to start working in a place like this 27 years ago. I think he is enjoying working on our project as he seems to be a specialist in odd and interesting metalwork staircases. We’ll go back another time when the fire is on and he’s making our pieces.

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the anvil has seen many years of action
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Tony and Clinton discussing the ups and downs pattern

James is preparing to fill in the brick slip panels soon. He’s given one of them a start, but the specialist epoxy mortar we chose back in Week 31  needs a special gun for application rather than a trowel, so he’s waiting on its delivery before continuing. There is leadwork to fill in beforehand anyway. Meanwhile, Clive has been cutting bricks like there’s no tomorrow.

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Clive’s been cutting bricks and tiles

I hope the view through the building will always be this good. Maybe if it’s good now with bags of plaster, ladders, and light fittings hanging off the ceiling, it will be even better when it’s all tricked out with furniture when you come down to make a cup of tea in the morning.

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Week 31

2016.11.11 - 1.jpgMid-November and it’s getting really really cold. The rental house’s main valve to the ground floor radiators decided to give up the ghost this week just to make things interesting. Not quite a frost on the inside of the windows state of affairs, but it’s certainly cold underfoot when making that first cup of tea in the morning. But this is NOTHING compared to early dark-o’clock onsite.

Walking back from the station on Monday, we decided to pop in for a look at progress and found James and Terry accumulating questions in preparation for Dave’s visit on Thursday. Much scratching of heads ensued over the valley detail at the front and considering the fallout of whether we wanted a sloping ceiling in the front bedroom. The valley is covered with lead (remember climbing on the old roof of St Annes #1 armed with a broom and a jetwash to de-leaf the flat section of roof over the tower??), but the section is long and flat lead covering a space of more than 5′ tends to shrink.

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rogue beam

Much to everyone’s relief, Dave came down to site on Thursday as part of his new and improved double-time for this job, and he and Terry figured out a way to ditch the long beam, sort out the lead, and start designing a flat ceiling for more storage in the front bedroom. After these tweaks, it’s full steam ahead with the roof.

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Josh, hasn’t James told you it’s -5C out there?
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Josh and his fan club

Terry and Josh are putting up timbers for the battens to be attached next week. I can’t believe Josh is still in his shorts!! But I really like the combo of wooly hat on and legs out. They’ve been spending most of their time hand-cutting truss parts for the non-standard 50-degree angle roof and creating supports for the fiddly dormers. The game plan is to finish most of the dormers before James gets the more fun job of fitting the oak facias and stained soffits in their wake. Terry says the building will look transformed with these bits on. We’ll wait and see next week.

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dormer corner
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kids’ bathroom window dormer

One of the details that we’ve signed up for is the kick out on the foot of the roof. It’s a little flare right at the end and kind of a Blair Imrie/Frank Chown style point.

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kick

Nice to see Mick, Johnny and Tom back to lay bricks that will live above the soffit. It will only take them a couple of days into next week to finish off. The wet mortar sits all around the kick boards. We’ve still got a pillar to build around the back, so maybe they’ll be back to do that when the garage roof is ready to go on.

We’ve had a choice of resins to use for the brick slip panels in the oak frame. The warranty company wanted us to use this stuff instead of mortar to fix the bricks to the boards and also to point them up. The idea is to limit the possibility water ingress. A sensible solution and there is all of one singular company in the whole of the UK that does this kind of thing –just a little bit niche. We’re going with ‘natural’ instead of ‘buff’ or ‘chalk’. It’s not bad and looks the real deal.

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these don’t quite match…
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… but this one is better

I haven’t had the chance to bother James with my usual million onsite visits this week because most of work and the fact our house-time has been taken up with kitchens, tiles, stairs, wood floors, doors, sanitary ware and electricals. We’re also debating about whether to put sliding doors between the kitchen and family room. The main thing is that the normal double doors in the spec eat up a bunch of space when they get opened, so it limits the size of furniture for the room. I’ve started cutting scaled bits of paper to ‘furnish’ the room and test stuff out. Sketchup is great but it doesn’t give anyone else a chance to fiddle, so we’re going old-school. I’m sure there will be many evenings and much wine required to get this just right.

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which purple bit of paper makes the best fit?
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the door opening in question

One day soon we’ll get around to thinking about landscaping. The hardest part of the plot to figure out is the bit on the north side of the house under the beech tree. We sadly cut down the cherry tree that we planted with such great hopes in 2000, so now there’s not much between us and next door except air. We’ll want to have something against the fence and preferably rising above it for privacy and to emphasise our house. There’s not much light or much water in the space which makes planting anything you want to keep alive problematic. Paving? Water feature? I’ve got to do some reading on suitable plants…. Allison, got any ideas?

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garden challenge