Tag Archives: carpentry

Notes, 29 Dec. 2015

Above, Granite Security is back on site installing the security system, control hubs, connecting wires to circuit boards. Here’s one of the control pads near the front door, powered!

Shane installs the first door handle set -- on the door to Steven's office.
Shane installs the first door handle set — on the door to Steven’s office.
Cris from Ranserve installed the last panel of what will be Jadin's shower, tensioning it into place with 2x4 lumber. It took a long time to get all the parts on site for what should have been a simple kit with everything stuffed into three or four boxes for shipping.
Cris from Ranserve installed the last panel of what will be Jadin’s shower, tensioning it into place with 2×4 lumber. It took a long time to get all the parts on site for what should have been a simple kit with everything stuffed into three or four boxes for shipping.
Pivot 90 degrees from the shower in Jadin's bath and, cool!, Cris installed the vanity cabinets and bridge storage box.
Pivot 90 degrees from the shower in Jadin’s bath and, cool!, Cris installed the vanity cabinets and bridge storage box.
We used the same configuration -- two vanities with a bridge in the middle -- upstairs in bath 3.
We used the same configuration — two vanities with a bridge in the middle — upstairs in bath 3.
There's a similar configuration in the master bath. These vanities are wider, as is the bridge storage box in the middle.
There’s a similar configuration in the master bath. These vanities are wider, as is the bridge storage box in the middle.
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Kitchen cabinets, continuing

Chris and Yitzhak from Central Texas Custom Cabinets are on site today.

Chris is scribing and cutting cabinet panels and skins. He’s also installing more cabinet doors and cabinet pulls.

Yitzhak is contorting himself on the floor to measure, scribe and cut toekicks under all the cabinets.

Chris has his own web site. Click here.

Above, Yitzhak scribes the toekick under the pantry cabinets on the refrigerator wall.

Chris shows how he joined together the two maple panels that comprise the countertop in the pantry hallway. The maple came from wood stored by Steven that was not used in finishing out Sea Eagle; so we are taking a small part of the current house to contribute to the new house.
Chris shows how he joined together the two maple panels that comprise the countertop in the pantry hallway. The maple came from wood stored by Steven that was not used in finishing out Sea Eagle; so we are taking a small part of the current house to contribute to the new house.
Almost all of the doors are installed on the oven/microwave cabinets.
Almost all of the doors are installed on the oven/microwave cabinets.
Working under the island, Yitzhak test fits the toekick.
Working under the island, Yitzhak test fits the toekick.
Working at the table saw outside, Yitzhak slowly cuts the 1/4-inch-thick material to size.
Working at the table saw outside, Yitzhak slowly cuts the 1/4-inch-thick material to size.
Two runs of toekick, cut to size and ready for gluing into place.
Two runs of toekick, cut to size and ready for gluing into place.

 

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The first step

Emerald Hill is now turned over to Luis, stairbuilder.

He is turning hickory planks, carefully, deliberately, into risers, treads and nosings, cutting wood with what has to be the smallest, most-underpowered, beaten-up, portable Black & Decker table saw, set up outside on the front walk, on a dreary, overcast and sometimes wet day, matching his skills and tape measure against a 7-inch thin-kerf blade. He bought the machine used, he tells Steven, at a flea market 10 years ago, he thinks. He’s burned through many larger, heavier, more powerful table saws, but this is the machine he comes back to with trust. It’s the story he will scribe as he builds the stairs over the next four days.

The table saw is mounted to a plywood slab.
The table saw is mounted to a pine slab.
Luis trims down the dimensions of a plank of hickory to create the first riser.
Luis trims down the dimensions of a plank of hickory to create the first riser.
He checks the fit.
He checks the fit. The board is long. He will take it back outside to the Ridgid chop saw to cut down to size.
He nails the first riser into place.
He nails the first riser into place.
The stair treads come with a bullnose. Jacquela and Steven have asked for a square nosing. Luis trims off the rounded edge.
The stair treads come with a bullnose. Jacquela and Steven have asked for a square nosing. Luis trims off the rounded edge.
The bullnose after it is cut off.
The bullnose after it is cut off.
Luis begins to test fit the tread, using a cutoff template to ensure the tread extends no more than 1/4 inch past the front of the riser.
Luis begins to test fit the tread, using a cutoff template to ensure the tread extends no more than 1/4 inch past the front of the riser.
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Notes, 20 Nov. 2015

Steven ordered from Amazon last night the Schlage deadbolts, door handles and levers, irrigation controller and other items that will soon be needed by Ron Dahlke and team. Buying the Schlage hardware at Amazon saves 30 percent over the same product at Lowe’s or Home Depot.

We're puzzling out how to properly install the bathroom vanities. There's a lower shelf that Cris and Ron carefully removed from this unit. Cris cut a template for the shelf out of MDF. When placed against the wall in the bathrooms, the shelf obstructs the plumbing cleanouts -- or the cleanouts are located inside the cabinet, which would force us to carve up the cabinet boxes. But ... the schematics for the vanities clearly identify how high to locate the cleanout on the wall behind the vanity -- instructions that were not followed. Which may force us to open up the walls, again, to have the plumbers relocate the cleanouts. Stay tuned.
We’re puzzling out how to properly install the bathroom vanities. There’s a lower shelf that Cris and Ron carefully removed from this unit. Cris cut a template for the shelf out of MDF. When placed against the wall in the bathrooms, the shelf obstructs the plumbing cleanouts — or the cleanouts are located inside the cabinet, which would force us to carve up the cabinet boxes. But … the schematics for the vanities clearly identify how high to locate the cleanout on the wall behind the vanity — instructions that were not followed. Which may force us to open up the walls, again, to have the plumbers relocate the cleanouts. Stay tuned.
Enrique continues sealing nail holes with wood putty.
Enrique continues sealing nail holes with wood putty.
Out back, the garage foundation team continues packing sandbags and compacting the road base.
Out back, the garage foundation team continues packing sandbags and compacting the road base.
After bringing the road base up to the proper height, they begin shifting the form to square out the back of the garage foundation.
After bringing the road base up to the proper height, they begin shifting the form to square out the back of the garage foundation.

After discussion with Ron, Steven approved the quote for 26 square feet of red glass tile that will be used for the backsplash behind the cooktop.

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Ticktock

From the Oxford Dictionary: “A piece of journalism that presents a chronological account of an event or series of events.”

Steven visited Emerald Hill three times today while also working from his desk computer and by phone — at 10 am after dropping off Jadin at school, at 2 pm to meet with Ron and before meeting with Renee at ProSource to select tile for the kitchen backsplash and master shower floor, and again at 4 pm after leaving ProSource and before Jadin “walked home from school.” Here are photos from the evolving day.

During the 10 am visit, Julian is hammering out a concrete tile at the entry that was damaged during construction -- to be replaced.
During the 10 am visit, Julian is hammering out a concrete tile at the entry that was damaged during construction — to be replaced.
Testifying to the quality of work done by the tilesetters, it took an electric jackhammer to chip out the tile.
Testifying to the quality of work done by the tilesetters, it took an electric jackhammer to chip out the tile.
At 3 pm, the tile has been replaced -- and is cemented into place, along with the two tiles closest to the front door.
At 2 pm, the tilesetters are gone and the tile has been replaced — and is cemented into place, along with the two tiles closest to the front door.

In between the 10 am and 2 pm trips to Emerald Hill, Steven received the first quote for the two-bay garage door from Cowart Door Systems.

At 10 am, Cezar Ernesto, left, and Ernesto Jovini are packing sandbags with roadbase for the middle island of the new garage foundation.
At 10 am, Cezar Ernesto, left, and Ernesto Jovini are packing sandbags with roadbase for the middle island of the new garage foundation.
At 3 pm, after compacting the roadbase in the center of the island, they are checking for loose fill and filling gaps.
At 2 pm, after compacting the roadbase in the center of the island, they are checking for loose fill and filling gaps.
At 330, they are compacting again.
At 230, they are compacting again.
At 4 pm, the middle island is finished. Cezar and Ernesto have begun to form the third island with sandbags and use the Bobcat to deliver more roadbase.
At 4 pm, the middle island is finished. Cezar and Ernesto have begun to form the third island with sandbags and use the Bobcat to deliver more roadbase.
At 230, Aaron arrives from the cabinet shop to test fit the horizontal storage bench that will be installed in the front entry. Ron helped Aaron pivot the bench into position while Steven stood back to use his hands to take this photo.
At 230, Aaron arrives from the cabinet shop to test fit the horizontal storage bench that will be installed in the front entry. Ron helped Aaron pivot the bench into position while Steven stood back to use his hands to take this photo.
At 4 pm, Enrique on the painting team is using wood putty to file all the nail holes in the trim installed by Shane and Peter, the carpenters. This photo was shot with Steven's cameraphone, which opted to almost focus on the ladder in the foreground.
At 4 pm, Enrique on the painting team is using wood putty to file all the nail holes in the trim installed by Shane and Peter, the carpenters. This photo was shot with Steven’s cameraphone, which opted to almost focus on the ladder in the foreground.

At 4 pm, Kathleen reported by email that Ranserve had received the wire transfer payment of Draw #5 from SouthStar Bank.

At 530, by email, Ron Dahlke reports that ATS inspected and passed the wallboard installation.
At 530, by email, Ron Dahlke reported that ATS inspected and passed the wallboard installation.
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Notes, 18 Nov. 2015

Brandon Pettit from Thomas McCarthy Inspections inspected Emerald Hill today for SouthStar Bank, as part of authorizing payment of Draw #5.

Rain cleared out. Above, the construction team is back to compact the road base for the foundation of the new garage bay.

Julian and his team of tilers installed the last two tiles at the front door -- the two tiles closest to the door.
Julian and his team of tilers installed the last two tiles at the front door — the two tiles closest to the door.
And the kitchen floor is now grouted.
And the kitchen floor is now grouted.
Shane and Peter, the carpenters, have vacated the loft they were using yesterday as the wood shop. In fact, they are done with Phase 1, expected back in December.
Shane and Peter, the carpenters, have vacated the loft they were using yesterday as the wood shop. In fact, they are done with Phase 1, expected back in December.
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Upstairs in the wood shop

Shane and Peter relocated the wood shop upstairs to the loft, out of the family room downstairs. It’s messy work. Above, Shane shovels the sawdust and cutoffs into the trash bin.

Shane and Peter plan to finish phase 1 of the carpentry tomorrow. Today … they are blasting through casing installation around doors, and baseboard installation in rooms with tile or laminate floors where we don’t have to wait for the hickory flooring to be installed after Thanksgiving.

This is the square-edge shoe molding that Peter will nail to the baseboard in the train room and bedroom 4, atop the laminate flooring that we salvaged and did not demo.
This is the square-edge shoe molding that Peter will nail to the baseboard in the train room and bedroom 4, atop the laminate flooring that we salvaged and did not demo.
Peter on his hands and knees nailing the shoe molding to the baseboard above the laminate flooring in bedroom 4. Knee pads might help, but Peter refuses -- "they make my knees sweat."
Peter on his hands and knees nailing the shoe molding to the baseboard above the laminate flooring in bedroom 4. Knee pads might help, but Peter refuses — “they make my knees sweat.”
Sticks of baseboard cut to length, ready for installation in the master bath.
Sticks of primed baseboard cut to length, ready for installation in the master bath.
This is one of the details we sweated with Brett, the architect, Ron Dahlke from Ranserve, and Mike from BMC West, the lumber company. Steven and Jacquela wanted a deep casing around the doors, and a thinner baseboard, to create a "reveal" when the two different dimensions of wood are nailed into position. Here, in the master bath, is the first example of all that planning and selection, made real.
This is one of the details we sweated with Brett, the architect, Ron Dahlke from Ranserve, and Mike from BMC West, the lumber company. Steven and Jacquela wanted a deep casing around the doors, and a thinner baseboard, to create a “reveal” when the two different dimensions of wood are nailed into position. Here, in the master bath, is the first example of all that planning and selection, made real.
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Notes, 13 Nov. 2015

Above, Shane and Peter are fitting shelves and closet rods. Here’s the downstairs closet at the back of the entry hall.

Upstairs, Shane and Peter are now also trimming out the windows. Steven should have turned on the flash for this photo.
Upstairs, Shane and Peter are now also trimming out the windows. Steven should have turned on the flash for this photo.
The shelf in the closet to bedroom 4 is installed, with the closet rod coming.
The shelf in the closet to bedroom 4 is installed, with the closet rod coming.
Shane built the shelf in the closet to bedroom 3, and trimmed the scuttle to the attic.
Shane built the shelf in the closet to bedroom 3, and trimmed the scuttle to the attic.
Ron Dahlke is beginning to unpack the bathroom sinks, preparing to install these, possibly as early as next week.
Ron Dahlke is beginning to unpack the bathroom sinks, preparing to install these, possibly as early as next week.
Out back, the construction team dug the correct trench for the foundation beam -- the second trench in from the right. The first trench is in the wrong location and needs to be filled back in.
Out back, the construction team dug the correct trench for the foundation beam — the second trench in from the right. The first trench is in the wrong location and needs to be filled back in.
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Notes, 12 Nov. 2015

Above, Peter installs the casing around a passage that does not get a door — at the passage from the entry hall into the dining room/library. Beyond, in the entry, Shane installs window trim and baseboard. 

  • Ranserve submitted Draw #5 for payment.
  • Brett Grinkmeyer, architect, visited Emerald Hill today with his copy of Draw #5, to review progress and completion to date. His first visit in several weeks. “I’ve been following the web site to keep up,” he reports.
  • Ron Dahlke and Steven took advantage of Brett’s visit to ask for ideas on how to solve the grout lines that do not align in the master shower. Brett suggests a smaller tile — one, two or three inches, maybe four or five, laid as a mosaic, in a concrete black that matches the black tile floor that will be chipped out, or a complement to the gray wall tile that we hope to retain because taking it out is a much-larger removal project. Steven put a call in to Renee at ProSource to begin researching tile options.
Surveying and setting out string lines for the foundation beams at the back of the new third bay of the garage.
Surveying and setting out string lines for the foundation beams at the back of the new third bay of the garage.
  • Brett and Steven also pulled out a tape measure to doublecheck the dimensions of the garage extension as the beams are dug for the foundation. It is spot on.
  • Brett asks to photograph Emerald Hill for his portfolio. “Of course,” Steven replies.
  • Ron reports that the hickory flooring may be delivered as early as next week.
The electricians have been back, installing outlets upstairs. And the final LED light directly above the kitchen sink -- the smaller 4-inch fixture closest to the window, not the 6-inch fixture closer to the camera lens.
The electricians have been back, installing outlets upstairs. And the final LED light directly above the kitchen sink — the smaller 4-inch fixture closest to the window, not the 6-inch fixture closer to the camera lens. The angle of the photograph makes it appear as if the LED is not centered. It is.
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First look: New front door

Peter and Shane today installed the new front door.

The wood is remarkable; if Steven could stain or clear-coat it, he would — but Jacquela requires it painted red. And that’s what Jacquela will get.

Installation is a process -- test fit, adjust, level, plumb, chip out obstructing wood and brick, test fit, level, plumb, close door, open door, level door, square door, shim door, level, plumb, tack it into place, level plumb, shim, repeat as necessary. It took Patrick and Shane about an hour to meet their own high standard of approval.
Installation is a process — test fit, adjust, level, plumb, chip out obstructing wood and brick, test fit, level, plumb, close door, open door, level door, square door, shim door, level, plumb, tack it into place, level plumb, shim, repeat as necessary. It took Peter and Shane about an hour to meet their own high standard of approval.
For fun, Patrick and Shane took a break from hanging doors to build the first casing around an open passage that will not receive a door. Putty seals and obscures the joints between several pieces of wood. The putty will be sanded smooth, and the joint lines will disappear when primed and painted, yielding the appearance of a single piece of wood wrapping around the open passage.
For fun, Peter and Shane took a break from hanging doors to build the first casing around an open passage that will not receive a door. Putty seals and obscures the joints between several pieces of wood. The putty will be sanded smooth, and the joint lines will disappear when primed and painted, yielding the appearance of a single piece of wood wrapping around the open passage.
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