So the novelty of working in near freezing conditions is wearing off a bit, even our tools don’t work well when it gets that cold, example being our planer, the rubber rollers harden and lose their grip and can’t feed the wood through. This weekend it will hit a balmy 1°F/-17°C and it’s not much different inside the house.
After years of working on the house, evenings and weekends, I find myself at a bit of a loss as to what to do, so I’m trying to think of projects that can be done in the comfort of our kitchen and the first project that I’ve been working on is restoring the the newel post which is the large post at the bottom of a staircase. We will probably junk most of the stair case so it’s nice to keep at least some original parts.
This post has been pretty abused over the years but I hope to restore her to some former glory. I suspect the post originally came from another house as it had been painting white and had period fixes (square nails). This post was on the ground floor so it doesn’t need to be perfect. The bottom was resting on soil and is pretty rotten so I’ll chop that off and add a new section.
Every night, after work, I’ll crack a beer and start scraping and sanding. I use Bahco scrapers with their carbide blades and they are great. You have to be aware of the grain of the wood and apply light pressure. As for sanding I’m loving these flexible 3M sanding sheets which seem to last and last.
Tonight I removed a pretty decent sized dent from the post by using a steam iron, lots of videos on youtube but this one is pretty good. I spent about ten minutes and I think I got about 80 – 90% of the dent out which is good enough for me.
After sanding I filled the many small dings and dents with West epoxy, then applied a dark walnut stain before adding a few light coats of satin polyurethane. I’ll probably sand back lightly and then apply a couple more coats. It’s not perfect, but I’m happy with it. Eventually I’ll replace the rotten wood at the end.
Another project is to clean up the basement joists. The joists have hundreds of old nails in them (which we are removing) and are littered with the old knob and tube style of wiring. Not sure whether this wiring is original to the house as there is evidence of gas lamps upstairs. Interesting article from Goshow Architects in which they talk about the pros and cons of K & T wiring.
I may try and remove some of the knobs without damaging them and use them for cabinet handles etc. as per these Pinterest ideas. Currently they are a bit of a pain to remove without breaking them.
Lastly I’ve been milling wood for our sash windows. A while back we got this great thermally modified wood which is very rot resistant, unfortunately it isn’t thick enough so I’ve had to run it through the table saw, jointer and planer before I can epoxy the pieces together and after all that I still need to run it through the planer and table saw again. It’s a bit of a faff, especially as each window requires ten finished pieces. Next time I’ll find some thicker lumber. I can recommend the Bora clamps, they do need a really strong grip to open, but your hands strengthen up.
As the end of the year draws nigh, I’d like to recap on what we’ve been up to over the year, highlighting any highs and lows.
January
We started the year well with a generous donation of brass window hardware from the Architectural Resource Center in New Hampshire. Thank you Bob that was extremely generous and it was a big ray of sunshine that we needed badly.
February
In February we restored some drafting chairs which we picked up for a decent price. They didn’t look great with dents and gouges and supposedly one of the chairs was missing some parts – turned out to be a spring which I replaced for less than a dollar. We removed all the old paint, filled in all the gouges etc. and then stained the wood. All in all they turned out pretty good and will serve us for many years.
March
In March we picked up a lovely old Craftsman drill press built around the late 1930’s. This will probably see us both out! There is something in these old tools that feels most pleasing, visually and functionally.
April
With spring in full swing we planted a Magnolia tree and named it “Big Nan” after my grandmother. Aimee had a Magnolia tree when she was young and so did Big Nan! It’s probably grown 9″ since we planted it and had some nice blossoms.
Spurned out by the generous gift from ARC we also started making a prototype sash window and came up with some rather pleasing hidden sash pockets.
We finished off April with prep work for the ground floor pour. First steps were to remove a huge amount of sandy soil and rather too much chiseling away of footings – glad that job is over.
May
We continued with basement prep and I finished off our test sash window, which I’m pleased to say turned out pretty good.
We started the month off with a huge load of gravel for the basement. We had two loads delivered and in total we shifted about 20 tons of the stuff in the wheel barrow, that took a good few weekends and evenings. In the process we removed the staircase so it wouldn’t get in the way of the pour. Prior to the gravel we dug trenches and installed some electrical conduit so after the pour we could thread the power lines into the electrical room.
I ordered a bit too much gravel so I decided to lay down some footings for a small patio wall in front of the house. Digging the trench was a bit of a pain as we had already dumped about 3′ of soil from the basement on it so the trench needed to be about 4′ deep. Anyway that got rid of some of the gravel, the rest we will use in our french drains. In addition this footing will be used to dump any excess concrete from the pour – no point in wasting it.
We followed this by leveling the gravel (to within +/- 1/8″ – it took us about a week to do this) and then hired a compactor for the day to compact it.
Decided to lay some concrete for the patio footings as we wouldn’t have that much spare from the pour and also because soil was starting to fall in etc.
This month was all about pour prep, we had to cut back a lot more of the footings but eventually got the vapour barrier and foam insulation down and started to put down the rebar mesh.
I happened to share the time lapse of us installing our Stego vapour barrier with the nice folks at Stego Industries and in response Dave Kartunen, Media Consultant at Stego, came to video interview us. Lovely chap supporting a great product. Can’t wait to see the final interview.
In preparation for the pour we had our work inspected by the local building inspector and it passed. We waited for a few weeks and Al Riozzi (AJR Masonry) finally managed to do the pour. We were thankful as it was starting to get cold and concrete doesn’t like the cold.
After it had cured we noticed that they hadn’t gone all the way to the walls, odd I thought but we patched that up. I then began to notice that some areas seemed uneven so we took some random measurements and found a height deviation of 1 & 3/8″ (later revised to 1 & 1/18″).
To get a better idea of what was going on with the floor I divided it into a 2′ grid and with the help of friends, Paul and Sue, took depth readings, you can see the results in this post.
I exchanged a few emails with Al Riozzi (AJR Masonry), but at the end of the day he didn’t seem to want to fix it even though he said that 1 & 1/8″ was unacceptable. His argument was that the pour was over 4 & 1/2″ deep (as stated in our first contract) and it was, it was probably 4 & 3/4″ and this was caused by the compaction of the gravel. Al Riozzi did note this two weeks before the pour and he also commented on it on the day of the pour, saying he would have to order extra concrete, so there shouldn’t have been any surprises there. To cut a long story short Al Riozzi and his team underestimated the amount of concrete and just tried to blend away the difference and then tried to blame it on us. Watch the video of them laying it, they aren’t even checking the depth against their laser.
We were very disappointed that Al Riozzi (AJR Masonry) didn’t have the integrity to admit his mistake and fix the issue. We spent months prepping the basement and I think we did a very good job, all to be spoilt by shoddy and amateurish work in half a day. I would not recommend this Saugerties based contractor whatsoever. Something is broken in this world.
It’s getting pretty cold here and I have to say that our enthusiasm for the project is flagging. I’m still finding projects that I can do at our apartment such as restore our old basement bannister post and mill wood for our sash windows.
So in reflection we started the year off on a high with the generous support from Bob at the Architectural Resource Center and Stego Industries and are unfortunately leaving it on a low with the poor workmanship of Al Riozzi (AJR Masonry). We’re doing the best we can but it’s getting harder to bounce back from knocks.
Here’s to a healthy, peaceful and cheerful 2022 to all of you that have been following our progress. I special call out to Chris and Ian who are constantly giving us positive feedback – thank you, it means a lot.
With the help of old college friends, Paul and Sue, we surveyed the height of the ground floor. I was taking samples every foot, but that was taking too much time so I enlarged to a 2′ grid. Using Surfer, a plotting app, I was able to produce the following contour map (contours are at 1/16″ increments and the higher the number the lower the floor is). Although it might not be obvious from this chart, the largest deviation we found was 1 & 1/8″ (not 1 & 3/8″ that I mentioned in a earlier post).
We’ve just reached out to Al Riozzi (AJR Masonry), who we hired for the pour and look forward to his reply. Researching into a solution, looks like our only option is to use a self leveling compound, though you have to be quick and have a decent sized crew to help mix and pour as you only have about 20 minutes working time.
If you look at the contour map, you’ll see low spots top left, bottom left and top right so we may be able to three separate pours of the self leveling compound and live with the slight deviation in the center.
This is an amusing video on the pitfalls of self leveling compound, How not to level a floor, though my brother Ian did point out that the chap isn’t laughing.
Seems we have some height issues with our pour and we have areas which differ in height by at least 1 & 3/8″. It doesn’t seem that we have a single isolated high spot, rather we have low and high areas. This week I’ll do a more detailed survey and take readings every foot or so in a grid fashion.
We spoke to some knowledgeable friends about this deviation and they said it was unacceptable, so we’ll contact Al Riozzi (AJR Masonry) in the week and see what he has to say and hopefully they can take care of it with self leveling compound.
So I didn’t didn’t have to keep checking that my measuring stick was completely vertical I made a 2-axis gimbal out of pvc pipes, some machines screws, part of a sewing reel and a dowel rod. Using this I can just place it and the dowel rod is always vertical.
I marked the deviations on a piece of paper and the higher the marker the lower the floor is etc.
So if you’re looking for a mason or concrete firm look NO further than Al Riozzi (AJR Masonry).
Yes we got our concrete pour on Friday!!! Big thanks to Al Riozzi (AJR Masonry) and his crew who did a great job! This was a big big day for us and has taken about three months to prepare for and we got it done just before winter sets in. It’s been quite the slog and so pleased this is behind us now. As a reminder this is how the ground floor looked in April.
Final thickness of the concrete was about 4 & 1/2 – 5″ which is a decent thickness and we also added rebar mesh supports to lift the rebar and radiant tubing to the top third of the slab, this will make the radiant heating system more efficient and responsive. We also managed to drop this new floor by about 5″ giving us a little more headroom.
This is the crew, I didn’t catch all their names but pictured (in no order) is Al, Anthony and Pat, and I have to credit Pat with the “Adirondack wheel barrow chair”, it looks really, really comfortable and it’s portable!
The last few shots were just before the pour and shows how we used small supports (known as chairs in the trade) to lift up the rebar mesh and Pex tubing. Concrete guys don’t really like these but Dave from the building department wanted them and I think that was a good call.
For some reason the video camera shut down before they had finished with the power trowel. I think they did three passes, using two different sized machines.
Post pour, if the pictures look a little steamy that’s because it was steamy. Temperature was about 70°F and steam was coming off the concrete. Al did say to expect this as it’s an exothermic reaction. We also have a few heaters to make sure the temperature doesn’t drop too low – tonight it’s dropping to almost 0°C, brrrrr.
For some reason they didn’t add concrete all the way to the edges, probably something we should have discussed beforehand. Anyway we filled in these areas this weekend and are misting the concrete to improve the cure. There are some areas where you can see some deviations in height but overall it appears pretty flat and we’re happy with the results.
In about a month, when the concrete is fully cured, we will apply a coat of epoxy, probably colored, to add some protection and to smooth out any imperfections, but this is only if we can warm up the area to about 50° which is doubtful. Maybe we can install the rest of the radiant heating system, that would be cosy 🙂
This morning we had our pre-pour inspection with Dave from the city and thankfully we passed. We’ve let our concrete guy, Al Riozzi (AJR Masonry), know and he is going to try and fit us in next week, currently there seems to be a shortage of concrete, but fingers crossed.
Temperatures are now starting to hit freezing but I feel we can combat that with a few electric space heaters but once we start to drop to about 10° below there would be no chance of that as our house is far from air tight with broken and boarded up windows etc.
I started the test at about 1.30pm yesterday with a shade over 75psi and today at 8.30pm (30 hour time lapse) the pressure is at 71psi. I’m hoping the drop is due to colder temperatures than yesterday and pipe expansion. I’ll leave the system like this over the next few days and monitor. Fingers crossed.
I did mean to put a clock behind the gauge but I forgot so the video doesn’t have many moving parts!
P.S. We have our inspection this Friday so really hoping we get the thumbs up.
Updates
Nov 1st update. 70 psi (52 hour time lapse). Still putting this down to colder temperatures.
Nov 2nd update. 69 psi (58 hour time lapse). Maybe we do have a slow leak. I’ll spray all the connectors with soapy water tomorrow.
Nov 3rd update. 65 psi (80 hour time lapse). Sprayed all the connections with soapy water and found one tiny leak so tighten up that one connector and charged the system to 80 psi.
Nov 4th update. 78 – 79 psi (104 hour time lapse) which for now I’ll put down to pipe expansion.
Nov 5th update. 78 – 79 psi (138 hour time lapse) hopefully holding steady.
Bought an air inflator today and started pressure testing the pex system. There were a few obvious leaks and they were fixed by tightening some fitting. Pressurised the system to 75 psi which is a lot more than the operating pressure but is what’s recommended. I’ll check back tomorrow and fingers crossed it will be at the same pressure give or take a few psi to account for changes in ambient temperature and pipe expansion.
I’ll update this post tomorrow evening with the results. Fingers crossed.
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