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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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

 

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 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 43

 

 

 

 

The roof is almost completely done. The colour is great, the guys are working hard–even on a Sunday, and the leadwork is gorgeous. The guys tell me there are loads of cuts which is slowing progress at this stage. You can hear them cutting from across the train tracks into the woods as we walk up to site. Most of the cut tiles are fitted all around the fiddly dormers that were built, needed a redesign from Dave, unbuilt, rebuilt, and now leaded and tiled. Loads of effort but they really make the building.

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leadwork over oak and under the tiles
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fiddly

Tony has been busy experimenting with the curlicues on the balusters. He works out a listed building that has always been a forge since it was built in the 1400s , and he’s working in tandem with our joinery company that I visited back in Week 24. The joinery company works in the complete opposite way with a spotless factory full to the brim with machination, lasers and CNCs. You couldn’t get a pair of trades working more differently. And they’re both getting on famously! It would be nice to think that we’ve started a symbiotic relationship in stairmaking here.

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Gregory visiting the forge with me
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CAD drawings to scale for Tony to work with (that’s our lamp in the back all restored too)
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ta-da!

The stair design is super complicated with three types of balusters, intricate oak interim newel posts, and all the other bits of the stairs like treads, goings, aprons, strings and nosings. It’s an artform. One of our decisions to make was about the thickness of the upstairs flooring: 15 mm or 20 mm? This had a massive implication for the staircase which has a 10-week leadtime. 5 mm! But it has a big effect on stairs. It was a job for Ben to coordinate all these overlapping decisions in the correct order so everything arrives on time. Not inconsequential, and I’m glad I’m not doing it (I couldn’t).

So I’ve had my sharpies out to ensure that everyone knows exactly where each type of item is going. This might sound pedantic, but it’s not a simple task to create this masterpiece when its taking two manufacturers, Ben to coordinate, Tim to purchase, and James onsite to make the whole thing work.  Ultimately it will be a really special part of the house.

Another Big Thing going in is the bronze double doors to the back bay. They look great now, but I know that when the glass goes in and the lead lines don’t match, I’m going to really have to work on my non-cringe attitude towards it. But, …. it’s the way it is, it’s in the drawings, and we’re leaving it. But before all that happens, we’ve got to protect the casements, so the doors are drilled and fitted, and then they’re tucked away in the garage for safekeeping until the rest of the building is watertight or at least until the wet trades are out of the building. Access will be an issue too when these go in because we don’t want the whole of everyone to be opening and closing them all day long, nor do we want to have them propped open and potentially bashed into accidentally.

There are masses of guys onsite every day now, and parking is becoming an issue down our tiny little lane. Most of the neighbours have been super patient and we’re grateful for that. It’s only temporary! James even got his shears out to cut back some of the overgrown (we haven’t lived in the house for almost two years now so no-one has been around to do this) shrubbery across the way so that cars can pass more easily.

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liability?

We’ve had MANY meetings about electrics. But a single team will be onsite now to finish the first fix. In hindsight, we should have been much more proactive in wiring this house from the start. We should have got sorted with lamps, circuits, control and all permutations of data and TV sockets that are going in, right down to the smoke alarms long before we put spade to earth.

One of the questions Paul asked today was what height do you want the doorbell? Well, what height SHOULD you put a doorbell? It was all down to Clinton pointing his finger at Paul’s shoulder through an imaginary doorbell and saying, “Here.” So the guys got their drill out and put it through the building at Paul’s shoulder-height. Effective, but bonkers.

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electrical pow-wow
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wiring for the study
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“Where do you want your outside lights, Madam?”  “Er,…. ?”
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cloaks closet / IT hub

The screed for the front floor was laid on Friday to set over the weekend. The guys moved the ladder to the other side so we all avoid the area until it’s rock-solid.

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screed
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hi-tech job this screed laying

 

Meanwhile the plasterers are in the bedrooms making them look like, well, rooms. They covered up the windows with masses of really thick black tape and card to protect them. This is all well and good, but the house is now completely dark. They’ve brought in masses of lights to help, and these are good because they highlight every imperfection. Clearly, there aren’t many imperfections when they’re done. They’re a totally jolly team which is amazing considering it’s totally hard and messy work. They’ll be in over the weekend (which is awesome) so that it goes off in time for Monday and all the chaos that ensues for next week.

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electrical cutouts
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portable lighting
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blackout
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a LOT going on this week
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all packed up after plastering

It’s lovely to just walk around and see what’s changed from day to day–even down to where they put stuff. I think that we’ll be using the house in much the same way as they do; they’re putting their gear out of high traffic areas, just like we’ll be doing when we move in. I’m taking notes….

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OK so maybe we won’t store off-cuts in the master bedroom…
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tableau of M&E and insulation in the kitchen
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Dizzy has been onsite from the beginning and is now residing in the kitchen

Week 42

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Roof tiles arrived this week. Spencer and his team used the tile-escalator, or Bumpa, to haul 10,000 tiles up to the roof. That is TEN THOUSAND. A totally bonkers number.

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We’re very happy with the colour. Although we didn’t use a huge mix of colours in the end, having gone for mostly Heritage, Michelmersch, they still look really mottled when they’re on, and that’s the look we were going for. The colour changes a lot in the light, and it will darken over time.

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frozen tiles
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they frost up on the north side of the house

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Josh with saw, not enjoying puzzle-piecing the insulation

Josh, Terry and James are cutting up bits of insulation to fit in the rafters. Not a super fun task, but they’re getting on with it bravely. In fact, it’s their absolutely least favourite thing to do in the whole build because they’ve got to get all dolled up in their anti-dust gear complete with masks and as much full-length coverage as possible to avoid fibres sneaking into clothes and itching all to hell. And we’ve got tons of the stuff. Some of the long sections will have rolls of insulation, which gives a small respite, and these will be installed after the plasterboard ceilings are put up so they don’t drop down through the gaps.

Once the solid insulation is installed, they tack up large bits of fancy tin-foil to make it even cosier.

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tin foil ceiling in back bedroom….
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… now covered in plasterboard later in the week

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A small issue percolated to the surface with lining up the glazing bars on the west and north faces in the front landing first floor bay. We’re still discussing how to deal with it. But the rest of the windows are going in nicely.

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We’ve got another issue with the glazing bars in the back of the house too, and this is more of a design thing. They don’t line up either. But is it a problem at all? Architects would probably recoil in horror and shout “Of course!”, but this is a one off house, right? It’s the crack in the pot in the great grand scheme of things. Making them line up would require masses of redesign from the bricks to the subframes and on to replacing windows and frames. Tim reckons that once it’s decorated and furnished we won’t notice it so much. He’s probably right. My plan is to plant the heck out of the garden so you see through the windows (obvious but important here) into awesomeness.

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is it a problem?

The kitemarks were such a bugbear at the beginning of the build with the warranty company insisting that they were visible ON EVERY PANE. There are 98 panes. That was clearly not the option we wanted, and after many flurries of emails, we got them printed discretely just behind the glazing bars, just like the window company does on all their other jobs (that probably don’t use our warranty company).

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the hallowed kitemark

It’s still below freezing but at least it’s sunny and as warm as it can be for the guys working on the back of the house.

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The view straight through the house is still pretty special.

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back to front
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through to back

It’s still been freezing every morning, so here’s a gratuitous picture of the frosty Common.

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Before Christmas we had the pleasure of meeting Nick Archer, an artist in Rye who we’re going to commission to create a work for us on this wall. He’s done amazing large scale works with colour which is his speciality, and lots of his pieces are bought by corporations with large lobbies that can fit them. We’ve fallen in love with a particular piece of his below. We’ve even moved the electrics in this room so you see the painting from the kitchen instead of a black screen of tech. The painting will bring the whole downstairs together.

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future home for a Nick Archer painting …
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… and Nick’s “Stranded” which is similar

As a testament to the cracking-on vibe that is occurring onsite, the roofers and a window guy are onsite on Saturday. This doesn’t happen very often. Spencer and his team are enjoying a little winter sun and practicing their catching skills. I’m told they’ll even be around on Sunday to load more  tiles up to the roof–no cutting or noise to annoy the neighbours, just generally getting on.

There were 20 guys onsite on Wednesday, a world record for St Anne’s!, and around 15 for the rest of days in the week. Lots of juggling with cars, gear, deliveries and tea.

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action stations

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there’s an X on every fifth course to show where extra nails have gone for building control

Inside is looking very different day by day with the addition of each window. We can start to set our minds to decorating this beast, and thinking of things like curtain returns and furniture.

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Some of the windows died en-route to their final destination which is sad considering all the love that goes into each one. But it must go with the territory and there’s only one dead soldier so far.

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The pipework to bathrooms in the first floor has been installed on the ground floor ceilings throughout, and it pops through the floor when needs be.

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pipes, windows, & electrics
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waterworks in the study ceiling

One cool thing in the underfloor heating is the sensor setup. Tracks in the screed were avoided to install a sensor unit that fits between the pipes and connects to a programmable unit on the wall. This unit controls a zone, and there are units dotted around the house. Will be neat to use!

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shower room sensor spot

Another M&E thing we’ve got is a mechanical extract that runs from a central hub to each wet area and the coats closet with all the electrics in it. This unit will raise the circulation in the house so we don’t get condensation and then mould; part of building regs and calcs on the size of the building…. (?)

There was a debate early on about how to cross the vaulted area with the MEV pipes to the shower-room on the west side of the building. At the time we talked about possible fixes such as boxing it in around the apex of the master bedroom ceiling, or adding a second extractor fan for just that bathroom, and all sorts of complicated ideas–none of which were particularly enticing. But in the end James got the guys to run the pipework over the entire ceiling between one roofline and the other. Pretty impressive!

The photo with the silver MEV pipework shows the underside of the roof having been tiled, and the right side still to finish. You can see the lovely blue sky through the Tyvek  and battens on the unfinished side and more blue sky all along the ridgeline.

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silver MEV pipework

The front of the house upstairs is pretty dramatic. James and the guys continue to put up extra Tyvek and insulation whenever they can to protect it. These are the most precious windows ever! And it’s great to know that they think so too.

There is still a teensy bit of floor to left screed still because the team had brought just slightly too little gear with them last weekend. They come up from the south coast to do the work and they have to do it when the site is not overrun with subcontractors. They must have been horrified to find they’d come up short. They’ll come back soon, and it will be good to be finished to cover those delicate pipes.

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landing looking west
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landing looking south through the master bedroom

The lone windows guy installed the side lights to the front door today. At least it’s a little warmer this morning on the north side for him. And the forecast is good going forward, so here’s hoping for a good few weeks with lots of activity!

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Week 40

New Year, new resolve, ….. we WILL be living in this house before this year is out. Having seen the potential of this place in 1999 and bought it and moved in by Feb 2000, we’re finally going to have this noose around our necks lifted. We’ve hemmed and hawed for so long about the most cost effective way to renovate or fix or whatever, and we’ve lived in such an ambiguous state for so many years, that it’s quite incredible to think that it will ever be FINISHED. Don’t get me wrong, I’m sure there’s finished, Finished and FINISHED, but just to have a house that doesn’t leak and looks half way decent will be a huge improvement on previous years. After all, the kids know nothing else!

And of course, it will be way better than half way decent. You can see from the time-lapses that there is a bunch of activity onsite these days: electricians, carpenters, flooring, heating, windows….. It’s starting to really crack on.

The window guys started on 9 Jan, so all the oak subframes had to be installed beforehand.

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family room
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they will eventually fade to grey

James has kept a bit of celotex on the sills to protect them once they’re in.

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shocking weather
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door frames being built and getting installed

Terry and Josh have been quietly getting on with wardrobes upstairs and kitchen framing downstairs.

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kitchen studs

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The window guys arrived en masse in a team of four or five depending on the day. The last time we saw this gear was up North, and it’s weird to see the frames and glass in the house at long last.

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test pane

One of the guys was a specialist pointer: each of the windows has a silicone bead running around the frame between it and the oak and another between the frame and the glass. I’ll get a macro shot of the beading next week, but there is a precise technique and the finished product is gorgeous.

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waiting patiently for installation
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master bedroom
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master pane
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brave man with a hammer

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master bedroom from inside

There are still loads of things to do around and about. The roof tiles should arrive this month, but since it’s a stand-alone piece outside the Critical Path, it kind of doesn’t matter when they go on. The building will look very different when it’s got its hat on.

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roofline

The first floor is being covered with celotex insulation prior to the underfloor heating next week. Wednesday is screed day, and this works perfectly with the windows guys because they’re awaiting delivery of more gear from Grantham which arrives the following week, so they’ll take a little break from this job while the floor sets. All very time-dependent and complicated.

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bathroom

We had a stairs meeting this week with Tony the Blacksmith and Colin and Gary from the joinery company. The goal was to sign off on the plans and get into production which is 10 – 12 weeks from sign to installation. Tony brought models of his spindles and had a great conversation with the joiners. In a total Goldilocks moment, we’ve decided to use the middle sized section of spindle. Plans were signed, and production lines confirmed, so we’re looking at end of March to see these in real life. Tony says he’s making progress with the lantern as well.

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oodles of spindles

It also snowed this week.

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disgusting weather
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frozen camera housing
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snow on scaffold through the new windows
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door handles
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front bay–with windows (most of them…)

https://youtu.be/5GacEAXtvVMhttps://youtu.be/QKmUF9l0b4whttps://youtu.be/t4UgZs9S9-ghttps://youtu.be/-t7Jhgjy5Vg

 

 

 

Week 36

Hip Hip Hooray it’s week 36!Screen Shot 2016-12-15 at 16.59.08.png

Well,……

Tim said early on not to worry and that the Christmas lights would be on. And they are! We’ve got a tree with lights–what’s the problem?! The roofing guys even built us a present out of battening to go under the tree.

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Tim’s present

Despite the amended programme, this has been a big chunky cracking-on kind of week. First of all, the saga about the levels not quite matching up in the first floor between the front oak structural frame and the rest of the house came to a close. The fix was debated (for five weeks) around our architect and structural engineer, the warranty company (mostly the warranty company) and the oak structural engineer, and finally, they reached an agreement on how it was to be built. James and the guys have built and sealed shuttering around what will be a slab of concrete set in situ. The metal mesh that gives it structure arrived today, James has bound all the intersections with little bits of wire, and now all that’s left is to pour and set over the Christmas break.

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pre-pour

Masses of celotex is being laid to insulate the ground floor. On Monday (Tuesday?) next week this will have a web of underfloor heating rods wound round and round, and before we break for Christmas, the screed will be poured.

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each piece is cut to shape with a teensy power saw
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kitchen space
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wipe your feet first

They’ve removed the scaffolding in the hallway and you can see from the floor right up to the rafters. Terry’s done a marvellous job making it safe with a designer hand rail.

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Josh and celotex
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Terry’s fancy banister
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Ben and Keith chatting about the concrete slab

The electricians have wired up most of the upstairs, and now there is a web of grey cable run round the rafters. There has been some discussion about where the shaver sockets will go in the bathrooms, and I’m sure this is just the first of many decisions that will be made on the hoof. (We decided in cabinets in the kids’ bathrooms and on the wall above the tile in ours in case you’re wondering.) They’ve even got a sweepstakes on how many times I’ll change my mind on socket locations in the house. Five was the first guess, three was another, and even a very optimistic zero was mentioned. We’ll see. Just don’t want the whole place looking like Swiss cheese so I’m trying my best not to dither. One of the jobs on the weekend is to run round with a can of spray-paint and set the locations of sockets and switches.

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Sparkys’ debate

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The leadwork is starting to be installed around the window frames. The large frames in the kitchen and family room won’t be in until the new year because the floor screed needs to dry out and we don’t want to damage them.

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leadwork before it’s scalloped

I usually get time to visit site in the afternoon, and since sunset starts around 2:30 in what’s now mid-December, the light is usually really good for a while. It’s obvious that the oak frame and the widows are pretty special and make this build unique, and that the quality of the workmanship is excellent. This quality issue partly accounts for why it’s gone over schedule.  But sometimes I’m amazed at just how gorgeous the whole thing is, and it’s quite humbling to just sit and have a look. I’m sure the builders think I’m nuts just standing there and staring.

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a glimpse of future awesomeness

James has finished the panels, and they’ll be sealed in with compriband and fixed to the frame. But they’re right in line with the sunset, so it makes the whole thing reflected a lovely pink.

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back frame

The valley is all set for tiles.

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valley

The front is starting to look like a House.

I even had time for a few artsy shots.

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building on a December afternoon

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Week 24

Friday

A visit to the joinery company that is doing the stairs, the oak subframes for the windows and the external doors.

Paul is our Area Manager and he’s always said to come on down and have a visit. As we’re getting to some crunch points with decisions, it sounded a great time to scoot to Andover to have a look. Today I got the chance to meet Gerald the MD, and he and Paul both took me for a tour of the factory before sitting down to talk design.

The factory is enormous. But it’s family run and has grown from a shed to a business with over 60 employees in a generation. There are 28 guys on the factory floor spread out into separate areas. There is a room for the initial cut as the laminated boards arrive from Germany, another for making tenons and mortice joints, another for windows, another for painting, another for stairs, and another for doors with CNCs, lathes, wrapped finished pieces and components all neatly placed in stacks per job. I’ve probably left out a few rooms,….but the guys were really busy as we went around, and everyone was really friendly and very patient with my picture-taking.

I was thrilled to see our job taking up (a large part of) the floor!

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window subframes

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… and more window subframes with joints
Laminates are used for the uncut beams so there won’t be any knots. They’re cut to section size on the outside dimensions, then they’re sliced on the remaining dimension to length, and finally, the mortice and tenon joints are cut in. Gerald fitted one of our subframes all up and assembled for me to have a look; the joints are seamless and the facing sides beautiful.

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our job. all three stacks with little white labels waiting to be cut
There are over 70 windows in the house, and each requires more than four bits of wood to make the subframe. Some of the larger pieces, like the sills, are made of two pieces with an air gap in between them to let them bend and settle on installation (I think?!)

We’re having clear Osmo coated frames and doors to retain the natural look of the wood, but it was still awesome to see the painting room. The windows are suspended on a series of hooks strung up to a yellow motorised track. They trundle past the guys to get a good coat of paint (150 microns a layer) and continue on to the other side of the wall to dry. Water is spritzed in to keep the paint from drying too quickly, so the room feels slightly tropical. This waterbased paint takes about 1.5 hours to dry, but our clear Osmo will go on with a brush and take 3 days to cure entirely.

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the painting room

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some stairs (not ours yet) and CNC
The stairs will be cut on a giant laser-guided CNC machine. I got to see a partially-build curved staircase made of gorgeous walnut; Paul had wanted to check the progress on it as he’d seen it the week before and it’s great to see these things evolve. Each piece for every job is drawn up, plugged into the computer and CNC’d to fit together perfectly. This particular job was gorgeous, and the whole operation is a real engineering marvel.

I’ve come away with some samples of different sized newell posts, a picture of cross sectional balustrades, two actual balusters to think about, and a lot of information about the front door from a discussion with Paul, Gerald, and Sean the Main Technical Manager. It’s going to be a busy weekend thinking through all this.

From Andover back to base, I had a chance to climb up the scaffold and have a look at the new bedrooms.

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West Wing

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east wing

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door to front bedroom

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back bay, pre-oak
What was the name of the first lady to fly across the Atlantic? What was the name of her airplane? What was the name of the Japanese city that was spared the atomic bomb and why? What were the names of those bombs? We’ve already nailed the name of the plane that dropped them along with the name of the guy who broke the sound barrier. We did moon landings a few weeks ago, and I’ve overheard a discussion about the bass line in Eagles songs when the guys first came onsite. I probably need some help brushing up on general knowledge if I spend too much more time onsite….

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Paul and Dave: pros
https://youtu.be/PfuIcSZRgdA

Thursday

Back to Sussex we go!

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Bluebell Railway from the car park
Another breathtakingly gorgeous drive in the time machine to visit our oak structural frame. It gets loaded on Friday and will be onsite on Monday. I will miss this drive! Neil gave me a tour of the pieces, and in particular wanted to show me the showstopper piece he sourced for us.

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ta-da!
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The single-piece curved beam is a success. 2016.09.22 - 3.jpgThe alternative would have been to cut it out of
a very large section like he showed me in the sawdust on the floor. This would have been super expensive and not quite as nice because the grain would have made a horizontal trace to follow the growth of the original plank. The more cost effective alternative would have been to have cut two or three pieces and join them, and this is what we had specified originally. The many-pieced bends are what you see around town with other builds of this design. Ours will be the only single piece beam. Whoop whoop!

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backs of brick infill bits

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more of our job
There are over 60 pieces for the rear bay alone. They’ll be stuck on the back of a lorry over the weekend, then up to us on Monday early a.m. They’re all labelled (red pen for front and green pen for back), and it’s great to visualise where the bits will fit in according to Dave’s drawings.

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upside-down cross piece for gable with window rebates on the top

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er, … a truss strut
It’s amazing how casual they are about taking these enormous beams and cutting chunks into them. They tell me that all the hard work, i.e. measuring and planning, has already been done, so this is the easy part. Very impressive!

On the way back, I put the anchors on as I passed the Bluebell Vineyard shop. A quick u-turn later and I was in the car park alongside a very Californian looking setup with tasting room and a nice few rows of well-tended vines. All was well, and then a great big tour bus from Eastbourne carrying a large number of pensioners arrived. I thought I might have just enough time to buy a bottle of their finest before they wandered in, but they were quick, and I was too late. My bottle of bubbles will have to wait until next time. And I think there just might be a next time because we’ve got designs on a nice countertop shelf for the basin in the downstairs WC. Back to Neil’s this autumn I think!

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from idyllic Sussex….

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… to rainy base for our Thursday site meeting
Paul the electrical guy was due to arrive, but he was stuck on the M25 unable to move. Apparently a crane (nothing to do with us!) blew up into a massive fireball on the M40, and travelling anywhere near London was a bit of a no-hoper today. We look forward to meeting Paul another day.

We also welcome Claire aboard the good ship St Anne’s. She’s designed an awesome kitchen, and she was onsite this afternoon to measure up and ensure that the drawings matched reality. Apparently this isn’t always the case, but on this job the plans and the build match decisively. She’ll now make up a set of drawings for review, right down to the lights, sockets and tiling. We’re looking forward to that!

Monday

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Continuity–hooray! James is back onsite overseeing everything in his first pair of consecutive weeks in the job. Things are ticking along smoothly; but the brick team is running out of vertical interior walls to keep busy before the oak frame is installed next week.

We had a massive site meeting of the minds today: Dave the Architect, Tim the Contractor, Tom the Steels guy, Neil the oak guy, Paul the joinery guy, and of course James the Site Manager, Ben the Project Manager, and me tagging along trying to learn as much poss. Today’s lesson was: What’s a padstone? For those like me who have not a clue, these are extra strong blocks (not bricks) that the steel lintels sit on. Double doors require a steel above them to support the brickwork above, for instance. The brick team need to know the dimensions of the steels so they can set these padstones in the right places. Should be fine, right? They’re on the drawings. But if the steels are still somewhere between the drawings and physical arrival, the brick team usually waits until they’re onsite to line them up or they risk unbuilding what they’d already built off plan. And as luck would have it, this part of the project coincided with the engineer’s summer holiday plans, so we’ve been delayed in getting them even on paper. We’ve been playing the game of keeping the brick team onsite doing the interior blockwork when they’d really rather be getting on with setting the padstones and building the exterior walls. Next week, hopefully.

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crowded house
There was much discussion of how the oak frame will tie into the brick work. The frame is a really special thing–it’s meant to be completely self-supporting. As in, if you put it all together in the garden, it would stand up by itself. I totally respect the integrity of the structure and think it’s really important to have it do what it looks like its doing, and not pretend. A nice part of the build. We’re all looking forward to seeing it go up, so next Monday will be an exciting day.

There is a large A-shaped steel on the rear of the building between the oak frame and the brickwork that has yet to be finalised and manufactured, and this will be mainly to support the roof ridgeline. The roof is a very complicated thing, and although much of today’s meeting was spent discussing erecting the oak frame, Dave was on hand to make sure we don’t mess up the roof dimensions so that the pitch of steels matches the pitch of the oak once it’s up. Exactly. Tim wants to minimise the number of crane-days (too right, they’re bank), so it’s quite a job to line up the trades requiring cranes all on the same day/s. There are steels, oak frame and floor panels to juggle.

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front gable
One decision that had to be made today concerned the bowed beam on the front porch. We’ve spent a lot of time trying to get the look of it right: how thick, where to place it front to back in the frame, what circumference the bend should be…. But just to make things interesting, Neil arrived today with an idea. He said that he’s very lucky in that he has the luxury of spending time (he’s been part of the job since February, so that’s a while!) sourcing pieces for his jobs from all over Europe, and that he had found the Perfect Beam for this job. The one he’s picked is bent at just the right angle across the whole of the piece so that the grain follows the bend beautifully, and the beam can therefore be made of one piece. Previous designs had two or three chops in it to achieve the right bend. Dave says the chopped approach would make the build look like a pub. St Anne’s Arms? Clearly the single piece is the better option. It will be slightly skinnier as a result of The Perfect Bend, and it will now match the width of the vertical beams between the windows rather than the chunky vertical corner pieces. I’m sure this will all make sense when it’s up, and I imagine it will look quite elegant.

Ben says it will be amusing to watch me give tours of the finished product. He reckons I’ll be waxing lyrical about the cunning oak-brick tie-ins and the effective placement of the cranked steels when really all they’ll really be interested in is the nice paintwork and some colourful vases. We’ll see if I will be able to contain myself….

In the meantime, Mick, Paul, Dave, Glen and Johnny just keep happily laying more and more bricks…..