Back to the Carport

Rain?
It looks like our heat wave has broken if only for a day.  It was overcast and somewhere below 100.  Maybe in the high 90's.  It also sprinkled TWICE today.  Enough to wet the pavement, but not enough to water any of the vegetation.  Earlier this week I decided the Crepe Myrtle tree in the back yard and some other tree I have no clue about really needed some water so I broke out the hose and have been watering each for about 40mins each day.  Perhaps my eyes deceive me but the look better.  Quite a few other trees have dropped their leaves in an effort to survive.

Carport fun
As mentioned in an earlier post, I've completed the insulation prep work.  The spray foam insulation install is scheduled for Weds, Sept 7.  Looking forward to it!

Given that, I decided to reward myself by doing something creative and fun rather than infrastructure related and...., well, HO HUM boring.....  OK, it's all fun, it's just that some stuff is more fun to do than others.  I opted to trim out the carport posts.

To keep things cool, I've put out my mighty Lakewood Industrial Commercial fan my friend Mike gave me a while back stirring up the air.  It's comfortable though still a little sticky.

The fan has been a savior through this summer as it really gets the air moving.  It sure beats those little K-Mart box fans we're so fond of buying (and tossing).

I started last week and and finished one post.  Today, so far, I've completed two and a half more posts.  It sure takes a long time.  Here's a before pic of the posts:

The dangling wire, one on each post, is for the post lights I described in an earlier post.  I think I'm going to go with the Craftsman style light light rather than the brushed nickel one.  Seems to better match the design of the house....or at least the roof anyway.

I started with cutting the old pseudo stucco exterior paneling I saved when I dismantled the one car garage.  Ya never know what you might need so I've saved quite a bit of the reuseable construction debris figuring I might be able to use it somewhere and I was right.  Not to worry though, I haven't crossed the threshold (yet) of being deemed a "hoarder".....though if they (the TV show) will pay to clean up the place afterwards, maybe I should try it.....

Anyway, I covered each post with the paneling and trimmed it out with some left over cedar trim work from the window install.  Here's a near finished result:

Each post will have a matching upper and lower trim.  

The vertical corners are covered in a styrene "L" moulding to cover the panel ends giving each post a finished look.  They're attached with brads and caulk.

Insulation Prep Completed

Spent the last three days in Dallas for work so no time on the house.

I completed the necessary prep work for upcoming insulation work which involved installing the last of the panels that will allow the spray foam to seal the interior from the exterior above the outside walls.

The installation of the spray foam is slated for Wednesday, Sep 7.  That will be a major milestone.

The next milestone...
The new attic AC system and new duct work.  That's tentatively slated for Monday, Sep 12, allowing five days for the foam to full cure and the interior of the house to air out.

Insulation Prep Continued

Monday, Aug 22, 2011
Spent the day inserting the bulk of the 84 end panels between the ceiling joists.  As mentioned previously, their purpose is to seal the opening at the top of the exterior wall leading to the outside eaves or soffits.  They'll serve as 'backing" for the expanding spray foam insulation that is applied to the underside of the roof deck.  The foam is sprayed down the roof between the joists and then across the end panel above the wall header.  As the foam expands, it will expand over and around the end panel sealing the gaps around the panel locking it firmly and permanently into place.

I was able to cut and install about 65 panels before having to quit for the day.  I'll finish the balance on Monday (I hope!).  I'm in Dallas this week and again next week so except for Monday, I won't make any progress and thus will not have much to post about until work resumes.

Tuesday, Aug 23, 2011
Relieved!  Just got confirmation from the foam installers want the job.  Will schedule it when I return from Dallas.

Insulation and Prep

As mentioned in prior posts....somewhere back there....this house must have been a nightmare to heat and cool throughout the year.  The thin paneled interior walls were open to the "attic" space and the batt insulation had been made useless in many areas by years of animal tracking and nesting.  During demolition in various places throughout the house I found evidence of the previous owners low budget attempts at stopping air infiltration (ie; plastic, foam, caulk, etc).  Having gutted the place, I could see immediately that all of their efforts were wholly useless.

I'm determined to do it the right way to maximize my comfort during my time there so I'm planning insulating the house with closed cell expanding spray foam insulation.  It's a bit on the expensive side but it will pay for itself in the long run by completely sealing every nook, cranny, and crack from the spoils of air and moisture infiltration.  Those two components are the prime culprits in making one feel uncomfortable in either hot or cold weather.

I've had quotes ranging from $9600 (no way!!) to $5300.  The lower end is about what I anticipated.  Standard batt insulation would probably run about $2800 but based on my research, I'd be throwing money down the drain every month all year round if I went that route.  I want comfort and economy in my old age!  Given the architectural style of the roof, closed cell spray foam is the best option.

With tight spaces like that, expanding spray foam
is really the only viable method of getting the
highest insulating "R" per inch.

That said.....
Over the last several months I've been focused on renovation priorities that need to be in place before the wall and ceiling cavities can be foamed in....which pretty much involves anything that touches an insulated space; exterior wall wiring, framing that touches the ceiling, windows, etc.  I'm pretty much done with all of the big stuff and have only to provide a closure backing for the above wall openings to the outside eaves.

Open to the eaves.
Between every set of ceiling joists at the top of the exterior wall there is an opening to the eaves.  Normally the outside edge of the eaves is sealed however, the eaves are temporarily open to the environs pending new exterior trim work that will seal them again.

In various places, due to roof leaks and corresponding wood rot the sealed nature of the eaves became compromised.  Holes formed allowing wildlife to gain access to the interior ceiling of the home.  Wow! A warm and cozy 'house' for every two and four legged creature (even I'd move in if I had the chance!).  Inevitably, over time their activities ruined the whatever insulating value there might have been not to mention the mess they made of everything.

Each of the interior side of the 84 openings will have to be sealed in order to provide a backing for the spray foam that will be sprayed into the cavity at the top of the wall.

Phase 1:  Let the fun begin.....
I started the process of sealing the openings.  It's boring work but it has to be done if the foam is to be installed properly.

First step was to cut 164, 5" long, 1/2" deep blocks of wood using some of the scrap wood piled up outside the house.  I'm sure the neighbors appreciated the 164 ringing zaps of my trusty compound miter saw.  Next was to nail each one to both sides inside of each opening about 2" back.  They will serve as a nailing stud for a flat panel that will serve as the backstop for the foam.

Glad I had my handy air powered brad nailer.  Even so, it took all day to accomplish this.  Next step will be to cut and install the flat panel inserts.

More to come.

Windows Install: COMPLETE!

Another milestone passed! 
The windows are all in and all trimmed out in rough cedar.  This was the first "round" house the installers, Ron and Tom, had encountered so they had to get creative in a number of places to stick with the curves and character of the house but they did an excellent job.

Today's activity involved installing the second of two sliding glass doors on the back of the house as well as completing all of the trim across the window wall.  The original slider had been damaged in shipment and had to be reordered and arrived too late last week to be installed with the others so the guys had to return to complete the task.

 They also installed the last piece of trim around the entry door.

The next milestone.....
And now....It's on to final preparation for the closed cell expanding spray foam insulation under the roof and in the external wall cavities effectively sealing the outside world OUT.....as it should be.

Windows Install: Trim Work

Day Two
Day two was spent installing the balance of the windows (except the one slider still pending arrival).

Day Three:  Trim work
With all of the windows installed day three was trim day.  Because the house exterior is stucco it was not possible to shoot nails through the trim without the risk of cracking the concrete surrounding the windows.  To accommodate that, all of the windows were installed flush to the inside wall framing which then exposed the outer edges of the wall studs which could be used to secure the exterior trim.

Excellent replacement of curved sill

A strip of wood was nailed to the stud in such a manner as to allow the exterior trim piece to be nailed to that.  With a combination of nails, screws and caulk, the exterior cedar trim was well secured to the walls.

When the color combination gels and comes together, the house and trim painted, it will look great.

There is still the last slider to install on the back side of the house.  As with the slider on the right side, it will involve replacing the support post and raising and leveling the opening.  Once completed then the exterior trim for the 18' wide glass and slider wall will be installed matching the rest of the house.

I was pretty impressed with the guy's millwork so I inquired about having them come back to complete the replacement of the fascia board trim around the entire house roofline and the carport.  It would probably look better and go a lot faster having them do it than if I did it myself.

Windows Install: Natural light

When the house was designed on paper and eventually built, for some reason there was no provision in either of the two bathrooms for a source of natural light.  I found it particularly odd given the Master Bath is on a stretch of outside wall that would have been perfectly suited for a couple of windows.  Maybe it was an option the original homeowners didn't select.  Pretty unforgivable in todays energy conscious environment.  Today it's certainly frowned upon to have to turn on a light every time you have to use the facilities or enter a room.

I like things bright and cheery and have been determined to introduce natural light wherever possible.  It makes sense on a variety of levels, not the least of which is the reduction in overall energy usage.  I opted to install skylights in several key places to eliminate the need to flip a switch; one in the entry hall, one in the guest bath, and two in the great room.  In the Master Bath, rather than a skylight, I opted to go with two windows to allow for light and ventilation.

Since my original deal with Lowes didn't involve cutting out the windows, after the window installers left, I took my trusty Skil Saw with masonary blade and set about opening up two window openings in the stucco.  Messy....but necessary!

Let there be natural light....finally!

  The windows are 14.5"x24.5".  I placed the lower window opening at face height (mine) so I could open it and look out.  For privacy, the lower section will be be frosted leaving the upper section clear to allow maximum light.

Nice view..... once the trailer and scrap pile are gone.

The installers will return tomorrow for round two.....

Windows Install: Continued

After pulling the great room window and sliders and then having to spray everything down with carpenter ant killer, while that dried the installers moved over to the kitchen picture window.

I opted to not have a shelf so it's flush
 on the inside

Looks good!  After I took this picture and reviewed it I asked the guys to add one more trim piece at the bottom of the window to even it out and give it some bulk.

Then it was back to the great room windows.

 The carpenter ants did a number on the center support posts to the degree that it was the windows and frames that were holding the roof up.  It was expected that they would have to be replaced so no big deal

The installers temporarily inserted the left picture window (right center window in the pic) in order to seal up the house overnight.  With the window temporarily in place, you can see in the next pic by the angled gap above the window to what degree the center supports had been eaten away allowing the wall and roof line to drop downward.  You can also see the old aluminum cased support post on the left.  The casing allowed the decay of the post to go unnoticed for years.  They'll take this window out again along with the left side slider, level the opening and reinstall both.

Wow!  Quite a drop in the roofline!

As mentioned, the Low-E tint component of the windows removes a significant amount of glare and will contribute to reducing heat transmission.

More to come....

Windows install: Carpenter Ants!!!

The Lowes installers pulled one of the sliders first thing.  Given the leaking roof, I anticipated nearly all of the center support framing was going to be toast due water and what would appear to be an active infestation of something.  When the Lowes Install Manager guy came out to do the measurements we talked about reframing where necessary.

WOW!
Anticipate as much as I did, it was still worse than expected!  The two 4x4 support posts and half the header on the right side were nearly dust from years of carpenter ant activity.  The continual source of water from the leaking roof and the untreated nature of the wood provided the ants with a veritable feast for years.  As soon as the slider was pulled free, and then again when they pulled the center picture windows out, there was a swarm of ants all over the place.  On the first sign, I made a fast trip to Lowes and picked up about six cans of Carpenter Ant killer.

On one of the center posts, when it was pulled out, about six inches from the floor up was pure dust and ant dump that just fell out of the aluminum casing.  It would appear that it was the aluminum framing alone that held the roof up.  YOWZA!

KILL!!

Exciting times!  More to come....

The windows have arrived!

Ah.  Progress!  

Got a call at 7am from Lowes asking for directions.  

The new vinyl clad, dual pane, low E ThermaStar windows by Pella have arrived!

The installers followed an hour later!

Soffit Repairs

Monday, August 8, 2011 (still)
For years the previous owners ignored various roof leaks to the degree and duration that eventually three different exterior soffit panels rotted through.

Not sure what the foam was for....

That took years of neglect to occur!

The new metal roof fixed the leak issue.  Now it was time to fix the soffits.  Pulling the panels down was the easy part.  All I needed was a crowbar, some muscle, and an umbrella!  The umbrella was to deflect the years of crap that built up in the eave cavity.  OK, I'm kidding about the umbrella.

I used the old panel as a template for the new one drawing a line around the perimeter of the old one and cutting it out.  Pretty simple.

Lovely!

Reinstalling was a bit tricky at first.  When working by yourself (I think I've said this before) you have to get creative in coming up with different ways to replace what otherwise might have been an able bodied assistant.  And to do it in a manner that you survive the task itself.

After three awkwardly failed attempts at raising the panel into it's proper place under the eaves (and having visions of being found days later, my foot sticking out from under the panel.......), I decided to regroup while I was still alive and take the time to analyze how to better accomplish the task.  It didn't take to much effort to think of something with the use of some scrap wood and on the 2nd panel, the ladder.  Eureka, a good combination!  I finally succeeded in getting the panel into it's proper place.  After the first one, the second one was even easier!

Perfect!

Not too bad!

Researching Home Networks

Monday, August 8, 2011

I spent a couple of hours at Lowes pouring over one of their Special Order catalog dealing with Home Networks.  Since the interior walls are completely open at the moment, now is the time to install a home network that will support PC's, Internet, wired and wireless, sound,  TV and HDTV, and any suggestion for future functionality.

I've been researching home networks via some of the better websites.  Dell has an excellent site that's been very helpful and informative: Home Network Learning Center .   It covers just about everything you might want or need in a home network so I now have a pretty good idea of what components are necessary.....but not yet enough to actually order them.  

From the Dell.com site.  Excellent resource!

After a review, I decided I'd better come home and research again.  So many options....

Turbulent day

Monday, August 8, 2011
I knew on Friday with the S&P downgrade, Monday was going to be a crappy day.  It was.  And I was distracted by it so I didn't really get much done!

The DOW Jones....or black Monday (again).

Today, Tuesday, it's all over the map in seemingly a vague recovery mode!

Misc stuff

Friday, August 5, 2011
Spent about 2 hours working on kitchen plug wiring.  It got too hot so quit for the day.

The Boss; making sure I know she's watching

Working this weekend so not much activity to post.

Another hot day!

Thursday, August 3, 2011

This pic taken on my return from Dallas.

Needless to say I didn't do any work on the house.

Not getting much done this week!