The House That Frank Built

OK sports fans! This moment has been many years in the making. The moment when I, and only I, will bust out the structure of our house with the intention of EXPANDING our living space and making a fantastic en-suite (master bedroom-master bathroom) in a manner that puts HGTV to shame! Because this is a big task, and I needed to focus all of my spare time on it, I haven’t made a blog entry for a while. It’s either work on the house and generate material for the blog, or write the blog and make stuff up. I prefer the former. I took 2 weeks of vacation to accomplish this bodacious task, and I got most of the way through. At least I put up the walls and the roof trusses. But it took another 4 weeks of my spare time to finish the roof structure, put the trim on, and finally cover the roof.

Phase 1: Demolition.

As with most building projects, the first part is the demolition. I know I’ve been talking about demolition a lot, so I won’t bore you with too much more of it. As with most demolition projects, the best course of action is to work from the top down, and to disassemble whatever you’re demolishing in the opposite order that it was built. Because the bedroom extension will also result in extending the roof (sleeping under the stars is OK if you’re camping), I began by stripping the shingles from a portion of the roof. My biggest concern was roof safety. If there is anything dangerous in this endeavour, this is it. So I took some time to get the proper equipment: roof jacks, scaffolding, and a safety line with a harness. Yes, it cost a few bucks, but it’s cheap insurance. As I have mentioned in previous posts, I’m a bit obsessed with safety. The other nifty tool that I got was a roofing shovel. This tool has a notched spade that you ram underneath the shingles to get under the roofing nails, and a fulcrum that allows you to pop the nails right out. The technique is to start at the top of the roof, and after you pry off the ridge shingles, you get a start on the shingles at the top and then just go to town. That being said, even with the right tools and safety equipment, it’s hard, tedious, and somewhat messy work.

Safety harness and safety line. It's kind of a PITA to work with, but it sure provided me peace of mind. This is what all the pros use now.

Safety harness and safety line. It’s kind of a PITA to work with, but it sure provided me peace of mind. This is what all the pros use now.

Roof safety: Roof jacks to provide a solid base for working.

Roof safety: Roof jacks to provide a solid base for working.

Roof stripping complete. Took me all day.

Roof stripping complete. Took me all day.

 

Next was the trim. One might think that removing trim is no big deal. But it was to me because I had to get way up high and had to bang and lever stuff around, keep my balance while precariously perched on the scaffolding and ladder, all the while making sure that whatever fell down didn’t fall on me. The other bad news was that we were experiencing a record heat wave, so that meant that every push and pull was accompanied by beads of sweat in my eyes, lack of energy, and dehydration. I kept trying to drink as much water as I could, but there’s really no way to keep adequately hydrated while doing heavy physical labor in 96 degree heat.

Roof overhang and trim removed.

Roof overhang and trim removed.

Now, on to the messy part: Knocking down the walls. This part of the demolition worried me a bit. I didn’t want to spend a lot of time cutting stucco vertically on the wall, but I needed to get the wall down in pieces that were not so big they would damage the subfloor when they would inevitably come crashing down. I first had to knock down the gable wall, first by taking down the triangular portion of the gable by splitting it at the top plate, and then taking down the vertical walls. Since the side walls are load bearing, I had to build a temporary structure to accept the load. Also, I only took down one of the side walls at a time so only one side of the roof was unsupported. Because I didn’t want to have to cut stucco while precariously balanced on a ladder from the outside, I decided to pull the wall down from the inside. Since I know that the easiest way to cut the stucco is when the stucco is lying flat, I decided to yank the whole wall down and then disassemble it. Sure enough, with all of that weight of the stucco, it came down with a big crash! This turned out to be a very bad thing because I, like a dummy, did not think to put temporary bracing under the joists of the bedroom floor. Here is the result:

Gable wall demo complete. What have I gotten myself into?

Gable wall demo complete. What have I gotten myself into?

Temporary bracing to transfer the roof load to the floor. Too bad I didn't complete the job by constructing concurrent bracing to properly transfer the load from the underlying joists to the slab foundation below.

Temporary bracing to transfer the roof load to the floor. Too bad I didn’t complete the job by constructing concurrent bracing to properly transfer the load from the underlying joists to the slab foundation below.

Wall before demo.

Wall before demo.

Wall after demo.

Wall after demo.

Minor damage from the downfall of stucco. I had a surprise coming.

Minor damage from the downfall of stucco. I had a surprise coming.

Joist failure as a result of not properly transferring the load to the foundation. I'm going to put a bag over my head when I call my engineer for recommendations.

Joist failure as a result of not properly transferring the load to the foundation. I’m going to put a bag over my head when I call my engineer for recommendations.

Cracked joists. I needed to deal with termite damage anyway, so really no extra work. But I sure feel dumb!

Cracked joists. I needed to deal with termite damage anyway, so really no extra work. But I sure feel dumb!

Phase 2: Build the walls.

One of the tricky things about building on a second floor is that you actually have to get the building materials UP to the second floor. This meant spending the better part of a day tediously pushing lumber, mostly one piece at a time, up a ladder and onto the second floor. I had to plan ahead to make sure that I had all of the lumber for the entire build, including the interior framing and plywood, because I did NOT want to struggle hauling this stuff up the indoor stairs after I closed in.

Lumber delivered. Now, to get it up to the 2nd floor!

Lumber delivered. Now, to get it up to the 2nd floor!

Building a standard wall for a house is pretty straightforward. You layout and cut the lumber, build and sheath the wall while flat on the floor, and then raise it up. The easiest way is to start by carefully aligning your sole and top plates, and then doing the layout of the studs all at once. This not only saves time, but more importantly, helps to make the wall square because all of the top and bottom measurements are the same. The next thing to do is to make a “kit” for all of the framing lumber. This not only includes all of the studs, but also the headers, sills, cripple, and jack studs for the window and door openings, as well as the framing for each corner. From there, it’s a simple matter of separating the sole and top plates, scattering in the pre-cut parts, and then methodically nailing them together. It’s important to follow a nailing schedule, meaning that the prescriptive codes require specific sizes and spacing of nails for a given assembly. For example, a stud to sole plate or top plate can be two 16d nails driven longitudinally into the stud (“face nail”) or three 10d nails driven in from an angle (“toe nail”). Fortunately, the County of San Diego has a convenient summary sheet of all of these requirements, which the plans inspector “suggested” that I include as part of my building plans. I took the hint.

Wall lumber cut to length and organized to form a "kit". I did this for the lumber for all three walls.

Wall lumber cut to length and organized to form a “kit”. I did this for the lumber for all three walls.

All kit parts need to be labeled so you don't get confused. These are labeled "C/O" for "cripple" stud (window), and "outside" because the top is cut at a 5º angle to allow for water drainage from the sill.

All kit parts need to be labeled so you don’t get confused. These are labeled “C/O” for “cripple” stud (window), and “outside” because the top is cut at a 5º angle to allow for water drainage from the sill.

The next thing to do is to sheath the wall. In many building situations, it’s better to put the wall sheathing on after the walls are raised because you can do some adjustments for dialing in plumb and square, and you can apply the sheathing in a fashion that overlaps the structural assemblies to add some strength. However, it’s more difficult to fool around with large pieces of sheathing, particularly plywood, when you’re trying to hang it vertically. Putting the plywood on the walls while they were still on the floor was a no-brainer for me as a one-man-show. One thing I learned about walls is that 2×4 lumber can be pretty flexible on this scale. You have to use a big sledge hammer to bang stuff around, but it’s important to square things up before you put the plywood on, because once the plywood is attached, it ain’t movin’!

Lastly the wall needs to be raised. There are lots of pictures of construction crews all gathering around a wall, and with a mighty “heave ho”, the wall comes up. Not possible with just me doing the heaving. Fortunately, there is an outfit (Qualcraft) that makes something called a wall jack. This operates much like the old-fashioned car jack that you used to hook under your bumper to change a tire. But instead of a metal jack shaft with teeth, it uses a long 2×4 piece of lumber. It’s pretty ingenious, and here is a short video and some pictures:

Wall jacks in position, ready for action!

Wall jacks in position, ready for action!

Close-up of wall jack. 2x4 screwed into the floor prevents kick-out.

Close-up of wall jack. 2×4 screwed into the floor prevents kick-out.

 

Last wall up, ready for trusses.

Last wall up, ready for trusses.

Phase 3: Place the trusses.

Now that the walls were up, it was time to get some help. The trusses, by themselves, are not particularly heavy, but they are difficult to handle and are fragile if they are handled while they are flat. Fortunately, the same co-workers that helped me place the big beam I needed for my garage portal were willing to spend a morning yanking these bad boys up and securing them into position. I only had 4 of these, but we had a little trial and error at first, so it took a little longer. I also had them come back to help me with the gable wall. Now, it was up to me to finish detailing the front of the roof line with outlookers and blocking.

Last wall up. Things are beginning to take shape.

Last wall up. Things are beginning to take shape.

Trusses delivered.

Trusses delivered, ready for installation.

My "crew". Their help was indispensable in completing this phase of the project.

My “crew”. Their help was indispensable in completing this phase of the project.

Trusses are up!

Trusses are up!

Gable wall and outlookers in place.

Gable wall and outlookers in place.

Phase 4: Finish the roof.

Finishing the roof was actually a two step process. I first needed to get the trim boards placed on the ends of the truss overhangs and outlookers. These are called “barge” rafters, and these were particularly long and heavy. I spent an entire day messing around with scaffolding and engineering a “third hand” to hold the rafter while I put it in place. But when I found it impossible to even the the board up there by myself, I knew it was time to call my crew back for another session. Sure enough, in about 3 hours, we were all done. Finally, I was able to get the roof sheathing in place. If this were a flat surface, this job should have taken about 3 hours. But because it was on a roof, I had to laboriously move around and reconfigure scaffolding, haul materials up and install them, and then move onto the next part. Getting the plywood up for the roof sheathing was also challenging. I decided to make a simple lifting fixture from scrap 2x4s that I screwed onto the plywood, and then used a rope to pull up the plywood. I also set up a couple of long boards to help the plywood slide up to the roof. This lifting fixture also proved valuable in placing the plywood because it gave me some leverage. Note that I had to place on piece of plywood at a time using this method, so, again it took a long time.

Another thing I learned about working on a roof is that it’s physically hard! That’s because you constantly have to fight against gravity because you’re working on a slope. Plus, there’s no shade (duh!). So, in addition to it being hot, all of that up-and-down and muscling the plywood in place really wore me out. In the end it took about a week (!) to finish the roof. But I liked the result.

Outlookers in place, ready for the barge rafters. Note the "3rd hands" to the right and left of the scaffolding on the outlookers.

Outlookers in place, ready for the barge rafters. Note the “3rd hands” to the right and left of the scaffolding on the outlookers.

Barge rafters in place. Beginning to look like a house!

Barge rafters in place. Beginning to look like a house!

Shiplap appearance boards are on the roof overhangs to match the rest of the house.

Shiplap appearance boards are on the roof overhangs to match the rest of the house.

Roof all done! Looks nice.

Roof all done! Looks nice.

The inside. This is going to be a nice bedroom!

The inside. This is going to be a nice bedroom!

The proud builder and his creation.

The proud builder and his creation.

Phase 5: Install the connectors.

Actually, installing the connectors is something that I did as I went, but I wanted to highlight the fact that the days are gone when you can simply use nails to build a house. Modern house construction uses metal connectors almost everywhere, especially between major components (e.g., foundation to first floor, first floor to second floor, second floor to roof). There are hundreds of connectors to choose from, but that was taken care of during the design phase, so the ones that I’m using are all in my plans. Each connector has a specific fastening schedule (number and type of fasteners), so you have to be pretty meticulous. I made copies of the specification sheets for each connector that I used, and highlighted each one and keep them in my permit book so that when the inspector comes by, I can show him what I’m working to. I really did learn something when I prepared for my inspections in the Navy!

Metal connectors for the roof, studs, and top plate.

Metal connectors for the roof, studs, and top plate.

Connectors between gable and front wall. I still need to add connectors between the wall and the rim joist on the bottom.

Connectors between gable and front wall. I still need to add connectors between the wall and the rim joist on the bottom.

I’m hoping the pace will now pick up with the roof, windows, stucco, and HVAC contractors coming in. Stay tuned!

 

And The Walls Come Tumblin’ Down — A Short Discourse In The Art Of Demolition

Demolition. The word itself evokes images of fire and brimstone, mass destruction and the wailing masses. If you watch some of the home improvement shows on TV, you’ll typically see the homeowners doing some wailing of their own, albeit of a different ilk. Take that sledgehammer and just beat the living daylights out of everything you see and you’ll be a REAL remodeler! Well, I am here to tell you that what makes good reality TV makes a horrible approach to a demolition project. Swinging a crowbar and acting like a drunken oaf is a waste of time, effort, and money, and a more thoughtful approach can save you all three.

Enter the “art” of demolition. As with most things in life, a good demolition project starts with a good plan. It turns out that there is a lot to consider: How much and of what type of demolition byproduct will be produced? How do I get rid of it? How big of a dumpster do I need? Do I need a permit? (Typically you need an encroachment permit if you use  dumpster that goes on the side of the road.) Am I dealing with any hazardous material (e.g., lead or asbestos)? What are the areas to be demolished and how do you account for the new structure(s)? How does the demolition sequence affect the building sequence or vice versa? Am I removing any load-bearing structure that will need temporary bracing? What tools are best and do I have to obtain any? And this is not an exhaustive list. Is demolition a DIY proposition? Well, I guess that depends. If it’s a small project like remodeling a bathroom, then it definitely can be DIY. If you’re busting out a load bearing wall and building an addition, then it can be DIY, but you’d better have some previous experience so you have a pretty good idea of what you’re doing. If you’re going to demolish an entire house, well, that’s probably not DIY.

Equal in importance, or perhaps more, is safety. I cannot emphasize this enough. Perhaps I’m a bit anal when it comes to safety, and my background in industrial and military environments has given me a certain viewpoint about it. There are two ways to approach safety, protection and prevention, and it’s important that you incorporate both approaches because they work hand-in-hand.

First, protection. Protection is all about minimizing the dangerous effects of a hazardous environment. To be more specific, you need to protect yourself physically from the potential dangers of your work. Of all the protective gear that you can get, eye protection is probably the most important. Unless you’re reading your plans or answering your smartphone, I can think of very few construction activities that do not involve the potential for stuff flying around and getting in your eyes. Next on the list is probably gloves, followed by hearing protection and foot protection. For demolition in particular, breathing protection becomes a big deal, as does a hard hat. If you’re going to deal with hazardous materials, like lead or asbestos abatement, then add protective coveralls to your outfit. This is by no means an exhaustive list, so the best approach is to think carefully about safety before you start the job and make sure you’re properly outfitted.

Prevention means stopping a hazardous situation from existing or developing, and this requires constant thought about what you’re about to do next. If you’re going to be working on a ladder, then make sure it’s properly situated and don’t exceed the recommended standing height (i.e., don’t stand on the top step). Keep clutter to a minimum so you don’t trip and fall. That’s quite important during a demolition project, so the orderly and periodic removal of debris should be part of your plan. Make sure your cords from your electrical tools are out of the way so you don’t cut into them. If you’re going to work on the second story or roof, then consider renting scaffolding. Safety when working with power tools is all about prevention, and one must be constantly aware of where the dangerous parts of the tool are so as not to injure yourself or others. To sum up, I would say that prevention is more of an attitude and state of mind. You have to make it a priority and, really, always be thinking about it.

Wow. All that talk about safety got me fired up! Was it good for you too?

Now onto the real deal. Removal of a stucco wall that formed a balcony (i.e., a pony wall) outside my master bedroom was first on the list. While it may be tempting just to take a sledgehammer and wail away, there really was a much easier way to approach it. The first thing I wanted to do was to prevent the debris from falling on my new sidewalk, gate, and railing, so knocking down from the inside-out was a non-starter. What I decided to do was to disassemble it in basically the reverse order of the building, and then take it apart into smaller pieces that could be tossed onto the driveway. This meant taking off the top trim, which I would use later to weight down some visqueen on the driveway, giving me a large target to toss the debris onto, while helping to protect the driveway.

DSC_0039

House with balcony, before demo.

Balcony trim and top plates on a sheet of visqueen. This helps prevent damage to the driveway when I toss stucco slabs over the side.

I then pulled off the stucco from the inside of the wall to expose the framing. There is a technique for stucco removal, which I learned from my favorite stucco guy on YouTube, Kirk and Jason Giodarno. Here is a video:

There are two key elements to this technique: (1) cut the stucco into small enough sections so that you can move them around  — stucco is heavy!, (2) cut THROUGH the lath (wire mesh) that holds the stucco together. If you bash stucco with a sledge, you’ll get a bunch of stucco turds all connected by the underlying lath. Totally impossible to work with!

A 7″ grinder with a wet-dry masonry wheel. Essential for demolishing stucco.

Stucco all cut into sections for ease of removal.

First slice of stucco removed.

 

Inner balcony stucco removed.

Once the stucco was off the inside, I pulled up the lumber that connected the tops of the studs (top plates). I then cut the stucco from the inside, which is easier because the lath is closer to the inside, so you don’t really have to cut all the way through. Once I made another cut spaced by two studs, it was an easy matter to pull the section of stucco and studs inward. The weight of the assembly and the leverage I was able to provide caused the lath at the bottom to fail, and the whole thing just plopped down in front of me. Now I could knock off the studs and cut through the lath to make the stucco slabs small enough to handle.

Balcony debris. Because of the sequence, I had to walk over this stuff until I opened up a hole in the outer stucco so I could toss this stuff onto the driveway.

First section of outer stucco is removed. This gives me a “window” to toss the debris onto the driveway without having to lift it up and over.

The balcony wall safely in the protection of the dumpster.

The front of the house sure looks different with the balcony removed.

 

With the outside done (to a point), I started the demolition of the master bedroom which is really the main part of the remodel. Because I am a diligent homeowner, knowing that I had an older home, I tested the popcorn ceiling for asbestos. Actually, I was also motivated by the $25,000 fine that might be levied against me for improper asbestos disposal by the EPA. Sure enough, I had asbestos, so I needed to take some precautions. Now, before I get into the details about this being a DIY job, I want to make a few disclaimers.

  1. I have formal training and experience in asbestos removal and remediation from my Navy days. The older engine rooms used asbestos to keep the steam pipes insulated, and because I was the officer in charge of maintaining an engine room built in the 1950’s, I needed to know my shit.
  2. I have formal training and years of experience in handling and disposing of hazardous materials (HAZMAT) and nuclear waste.

Having gotten that off my chest, allow me to say that proper and safe removal of an asbestos popcorn ceiling isn’t particularly challenging from a technical standpoint. You just have to use some common sense and understand exactly what the hazards are so that you can protect yourself, and others, against them. The main thing to remember about asbestos is that it is the airborne particles that cause all the problems. And they are big problems. Basically, any asbestos particles that you inhale will stay with you for the rest of your life. They become embedded in your lungs and you can’t get rid of them, and their sharp edges provide a constant source of irritation that can eventually develop into mesothelioma and lung cancer. So, airborne particles are the enemy. Let’s go back to my original safety mantras of protection and prevention.

To protect yourself against asbestos, you need to be fully covered in a HAZMAT coverall with a hood, wear disposable gloves, have full goggle eye protection, and a respirator with filters.

All suited up for asbestos! I needed to have one hand ungloved to take the picture. Otherwise, I'm ready to go!

All suited up for asbestos! I needed to have one hand ungloved to take the picture. Otherwise, I’m ready to go!

The good news is that you can buy an asbestos removal “kit” online (PK Safety) for around $30. Since the popcorn material is usually low in asbestos (2% – 3%), you do not need a fully sealed, forced ventilation suit and mask (yes, I’m familiar with those as well). So, you’re getting off easy.

To prevent, or at least minimize contamination, there are two things that should be done. First, seal off the area, meaning tape some plastic over the door(s) to other rooms, and put a plastic dropcloth on the floor. This dropcloth simplifies disposal because you just wrap it up and double bag it, popcorn and all. Second, use some water from a garden sprayer to wet the popcorn. This not only helps keep the asbestos from getting airborne, but also makes scraping the damn stuff off pretty easy.

One last thing before I suited up was to make sure that I had EVERYTHING I would need at hand. Once you suit up and start, you don’t want have to stop in the middle because it’s usually difficult to get out of the suit, and even harder to put it back on (if you don’t destroy it when you take it off). Go to the bathroom, even if you don’t feel like it.

You’re welcome.

Tools for asbestos removal. A garden sprayer and scrapers. Pretty basic.

Tools for asbestos removal. A garden sprayer and scrapers. Pretty basic.

Trash can all ready to load the asbestos popcorn. Getting this ready before I suited up saved me some time and aggravation.

Trash can all ready to load the asbestos popcorn. Getting this ready before I suited up saved me some time and aggravation.

So, I mentioned that removing this stuff was not technically difficult. Just spray some water onto the ceiling to cover an area that you can reach with your stepladder, and take a wide-bladed scraper and ease the stuff off in big strokes. Then clamber down the ladder, being careful not to slip on the goop that you just plopped on the floor, move the ladder, and start again. Did I mention that the coveralls get hot, and that your goggles fog up and get poopy popcorn on them that you have to wipe off and you still can’t see? You get the picture. Technically difficult, no, but tedious and uncomfortable, yes. Much like other things in life, eh?

First section of asbestos popcorn removed. Note that the ceiling is saturated with water in the area that I'm working.

First section of asbestos popcorn removed. Note that the ceiling is saturated with water in the area that I’m working.

The bedroom ceiling free of that nasty asbestos popcorn.

The bedroom ceiling free of that nasty asbestos popcorn.

Once all of the ceiling is scraped, you need to roll up the poopy popcorn in the plastic dropcloth and stuff it all in a big garbage bag. You will probably have to do this by sections because of the volume and weight and use several (3-4) large garbage bags. Remove your coveralls and gloves and stuff them in the last bag. Then seal with duct tape and double bag.

Now it’s time to dispose of this crap. Fortunately for me, my city has a residential hazardous waste disposal program, so all I had to do was take it to them and they unloaded the bags of objectionable material from my Prius for free and thanked me for being a conscientious citizen. One last word of caution: make sure you know the rules for disposal in your jurisdiction as there may be some extra costs and procedures. It’s probably a good idea to do this beforehand.

So, for a $30 hazmat kit, I did the work myself and saved about $1,700. Not bad for a DIY’er on a Saturday morning. But, again, I have formal training and experience in this sort of thing, so, if you have ANY DOUBT about what you’re doing, PLEASE engage the services of a professional!

On to drywall removal. This is where the home remodeling shows on HGTV show the owners having at it with sledges and crowbars. Good for them. I hope they got their exercise for the day. Conversely, I decided to use an easier method, which involves using a sawzall to cut the drywall into smaller panels and then use a crowbar to yank from the back and pop the nails out. This results (mostly) in large sections which are much easier to handle. However, before you plunge you sawzall into the wall, you really need to try to figure out where your electrical, plumbing, and telephone/cable/data lines are so you don’t cut them. The best method is to cut out a little section of drywall by hand near where you know these services are and get an idea for which way the lines are going so you can avoid them. As more of the wall comes off, it becomes easier to see what’s behind and where it’s going. For safety, its a good idea to kill the electrical power to the area you’re working on, just in case you run into an electrical line.

Essential drywall removal tool. You need to use this first to locate your hidden service lines before you attack with a sawzall.

Essential drywall removal tool. You need to use this first to locate your hidden service lines before you attack with a sawzall.

The drywall is cut into sections to ease removal.

The drywall is cut into sections to ease removal.

Because of the cuts, the drywall comes off in big slabs. For the most part, at least.

Because of the cuts, the drywall comes off in big slabs. For the most part, at least.

All drywall removed.

All drywall removed.

 

Finally, structure removal. The first piece of business is to make sure that know whether you’re removing a load bearing structure or not. But what does load bearing mean and how can you tell the difference? The the answer is sometimes not so simple. Sure, the exterior walls support the roof and/or second floor, and that load has to be transferred through the walls to the foundation. But without a more nuanced understanding of structures and mechanics, well, the explanation is beyond the detail that I wish to chronicle in this blog entry. I reserve the right to wax poetic on structural theory and practice in the future. In the meantime, if you don’t understand it, then hire somebody who does know and follow their advice. You don’t want your roof to fall down upon you and ruin the rest of your day. Plus, you will be very sad.

The wall I had to remove was NOT load bearing, so that simplified the process significantly. Again, I approached the demolition with an eye to safety, simplicity,  and ease of removal. The wall was attached to the bottom chords of the trusses by some cheap connectors, so all I had to do was to pry out the nail securing each connector to the truss. But, since I didn’t want the entire wall to fall down on me, I used my sawzall to cut the double top plate so that the wall could be lowered in sections (and handled by one person safely). Each wall section came down smoothly, and from there, it was simply a matter of banging apart the structure with a hand sledge (a.k.a. “engineers hammer”) so that I was dealing with individual pieces of lumber. The good news here is that (a) I was able to salvage some of the longer timbers for use in a support that I will have to build when I bust down some exterior (i.e., load bearing) walls in the future, and the remainder I was able to give away for free on Craigslist, which minimized my dumpster waste. Here are some pictures.

Wall framing cut into sections for ease of handling by one person. Note the section of framing on the floor.

Wall framing cut into sections for ease of handling by one person. Note the section of framing on the floor.

Section of wall framing on the floor, ready to knock apart.

Section of wall framing on the floor, ready to knock apart.

Wood I salvaged from the framing demolition. I advertised it for free on Craigslist, and it was gone in a day.Wood I salvaged from the framing demolition. I advertised it for free on Craigslist, and it was gone in a day.

Is it safe to come in?

Is it safe to come in?

 

 

This was our bedroom?This was our bedroom?

I know you say it's going to be great. I'll believe it when I see it!

I know you say it’s going to be great. I’ll believe it when I see it!

My First Electrical Work, But First I Build A Workbench — Now How Did THAT Happen?

As I’ve mentioned before several times on this blog, all major projects will take some unexpected turns. I had a good head of steam going with finishing the front yard, but, in the back of my mind, I had one piece of unfinished business. When the inspector came by back in December to OK the burial of services, we discussed the ground for the electrical system. He suggested that I check what kind of grounding system I already had in place, and I might be able to use it with no further work on my part. Well, to do that, I had to remove the drywall from the back of the main electrical panel, and to do that, I had to take off all of my tools from my pegboard and unload my workbench. So, because that was a big job, I kept putting it off. But now that I was getting ready to pour concrete, I had to get this resolved. I surely did not want to have to bust up newly poured concrete!

The first step was to unload and dismantle my workbench. It was kind of a POS to begin with because I used cheap prefab cabinets made of fiberboard. Maybe OK for a rental unit, but the cardboard drawer bottoms really didn’t hold up to heavy loads like tools and boxes of metal fasteners. So it was destined, at some point, to go. But what to put in its place? I mean, any self-respecting DIY’er needs a workbench! All kidding aside, your workbench is an essential tool, if for no other reason to lay out your work and materials. So, now I had to build a workbench. I wanted to get this done quickly, but the more I thought about it, I did not want to just build a “throw-away” bench. Was there a design out there that was relatively quick and easy to build, but would be something that I could keep and use for years to come? The short answer was yes. In fact, there were plenty of them. The Internet is chock full of designs, but also, because I use a 3D modeling program called SketchUp, there is a tremendous online presence which has a bunch of pre-designed models just waiting to be used. Turns out that woodworkers use SketchUp a lot, so I was in luck.

I found a really nice design by Tom Caspar of the American Woodworker magazine. This was a very functional workbench, made of common lumber you could get from a big box store, and it had a number of features of a traditional master carpenter’s bench, including a large face vise, a tail vise with provisions for bench dogs, and a tool tray. I added a couple of shelves and some retractable casters, and voila! A functional, inexpensive, and easy to make workbench. OK, well inexpensive is relative. I probably spent about $500 on materials if you include the vise hardware and casters, but I see these “works-of-art” workbenches made of hardwoods and fancy hardware that sell for $2,000. I’ve also known other woodworkers that pay that much for just the raw materials (good hardwood is expensive). Actually, I don’t understand why there would ever be a market for a pre-made master woodworker’s bench. If you have the woodworking skills and interest to actually use a bench like this, well, you would just make it, right? I mean, isn’t that what woodworking is all about? Unless you’re just a pretender. Some things will always remain a mystery to me.

Easy to make is also relative. I have a pretty well-appointed woodworking shop with a table saw, drill press, jointer, planer, bandsaw, lathe, and dust collection system (ShopSmith). (I really like my ShopSmith and have used it ever since I bought it back in 1990 — I think it’s a great solution for a complete workshop in a small space.) I also have a sliding compound miter saw that is mounted to a workstand (that I built). I also have a special jig for my circular saw that guides it accurately when cutting sheet goods — just like a panel saw. So, with all of these tools, and a number of years of experience, I found it to be relatively easy, and I put it together in a couple of weekends. Here are some pictures,

Picture of the plans

Picture of the plans

Finished Workbench With Tools

Finished Workbench With Tools

 

 

 

 

 

 

 

 

and a link to the PDF set of plans:  TOM’S TORSION BOX WORKBENCH REV 1.0

Finally, it was time to move all of the tools from the pegboard and empty the drawers. I was able to find some nice plastic storage tubs which fit very nicely on my shelves in my new workbench, so I was actually able to keep the garage fairly well-organized. I tore out and broke down the cabinets, pulled out the old shelving and pegboard, and prepared to demo the drywall. My first cut showed that there was no ground wire coming out of the bottom of the electrical panel. Not good. So I kept tearing down drywall until I found what looked like the grounding wire. It was a #4 aluminum wire (bad) that obviously was headed upstairs to the plumbing system (bad again). I was hoping to find a ground to the rebar of the foundation (also called a Ufer ground), but no luck. So, I had to go back to the codes to figure out my options. Here is what I found:

#4 Aluminum ground wire won't be enough to handle a 200A circuit. Plus, it's grounded to the plumbing system which is no longer allowed. So, I need a new grounding system.

#4 Aluminum ground wire won’t be enough to handle a 200A circuit. Plus, it’s grounded to the plumbing system which is no longer allowed. So, I need a new grounding system.

An example of the crappy electrical installation in my home.

An example of the crappy electrical installation in my home.

 

 

 

 

 

 

 

 

 

More code violations! If I can, I'm going to replace every wire in this house! Especially because they're aluminum.

More code violations! If I can, I’m going to replace every wire in this house! Especially because they’re aluminum.

 

 

 

 

 

 

 

Turns out that I had already done a lot of research. I knew that there was a possibility of not finding a good grounding system and that I would have to install a new one, so I started looking into what that would take several months ago. A residential electrical system needs a good, low impedance connection to the earth for several reasons. (1) The earth ground will help protect your house and all of your electrical/electronic devices by dissipating high voltages that could occur due to a lightning strike or an electrical surge on the electric grid. (2) The earth ground serves as a zero voltage reference to help keep voltages constant at your appliances and receptacles, and serves to dissipate stray charges caused by static electricity build-up. (3) The ground allows a return path from your electric service panel to the electric utility’s supply transformer to correct imbalances in your electrical system. (WARNING — TECHNICAL STUFF AHEAD!)

Your electrical system connects to the electric utility through a “transformer” which is a relatively simple device that, through the magic of Maxwell’s equations, takes high voltage (typically 7,500V) from the electric transmission lines, and converts it to lower voltage (240V) suitable for residential use. This transformer splits this voltage into two legs using a center tap on the secondary windings of the transformer as a common return line. Hence your electric panel has two voltages available: 240v across the ends of the transformer, and 120v taken from one end of the transformer to the center tap. This center tap is called the “neutral” and, in theory, if all loads on both sides of the transformer are balanced, the neutral current is essentially zero. However, that’s rarely the case as the various circuits in your home draw from either one or the other side of the neutral (center tap) and some times they’re on and sometimes they’re not. So there is ALWAYS some current flowing through the neutral, and the grounding of the neutral to earth allows a return path for these “stray” currents to go back to opposite winding of the transformer via the ground on the transformer side.

Well at least I think I understand it.

Back to installing the ground. Because of the dry conditions, the best ground you can get in the southwest United States is a Ufer ground, or more appropriately called a “concrete encased electrode”. It turns out that the rebar in your slab and foundation makes a pretty good ground to the earth because concrete is conductive and the large surface area exposed to the earth provides a good, low impedance connection. But that didn’t do me any good because I’m not pouring a foundation. Another option is to use the water supply system provided that it is conductive. Even though the code allows it, this can be problematic because (a) somebody can always come in and install a non-conductive fitting (e.g., PVC) and (b) my water supply line is covered by a protective plastic sleeve to help prevent corrosion, which makes it useless as a ground. So the best option was for me to use grounding rods.

Grounding rods are 8′ copper encased steel rods that are driven into the ground. Normally they are driven straight in, but if you have rocks in the way, this can be problematic. So, if you run into rocks, you can drive the rods at a 45° angle, and if you STILL run into rocks, you can bury the rod horizontally at a 30″ depth. So, I decided to go with a rod grounding system that consists of two, 8′ rods driven at least 6′ apart (2x length, or 16′ is best) and connected with a continuous #4 solid copper wire. From the Internet I learned that the best way to drive these rods was to pony up the bucks to rent the largest hammer drill you could carry and rent a special rod driving bit to go with it. This YouTube video showed somebody driving the rod in about 40 seconds, but I really didn’t think I would be that lucky. Nevertheless, I procured the necessary materials and tools and merrily went to work.

The first attempt was about like I expected. Although I was hopeful at first, the rod stopped about half way in, so I had to do some digging and, through some  imaginative extrication work involving a pipe wrench and swearing, get the damn thing back out. At least I learned how to climb up a stepladder cradling a 40# electric jack hammer and lifting it up to gingerly rest on the top of the rod and then balancing the whole affair and hammering it in without falling off the ladder and breaking my neck. With that bit of confidence under my belt, I relocated the rod and tried again. Same result. So now, I knew I had rocks about 4′ deep and the next step was to drive at a 45° angle. I extracted the rod using the same methods mentioned previously, except for double the swear words, and relocated the rod and tried again. This time it went in farther, but still stopped. So I decided to dig the 30″ trench and just bend the end in to fit. However as I started to dig, I found out that the trench was running into existing buried electric, phone, and cable services. So I had to stop and, once again, extract this stupid rod.  It just looked like it was shaping up to be this kind of project with multiple problems and no real end in sight. Not that I’m inexperienced in this situation.

So, I did some more measurements and figured out where the rods should go so as not to interfere with existing services and maintain a minimum of 6′ spacing regardless of whether I had to bend the rods over or not. With low expectations, I tried to drive the rod for the 4th time and, by God, it went in. Like a hot knife through butter! Just like the video. So I was lucky, and being never one to turn down a lucky streak, I tried again with the second ground rod. It was going in pretty good until about the last 18″, and at that point I was loathe to give up the fight. So I put some serious ass into that jack hammer and the rod started to move slowly. I kept with it until my fillings were about ready to fall out, but hey, I got it all driven in. No need to trench or remove the rod and try again. I was all done!

Well at least the hard work was done. I had to unwind the copper wire, secure it to the rods with acorn nuts, and then put the wire in a little bit of PVC conduit so it would be protected from damage from where it exited the grade to where it went into the house. Here are some visuals:

Getting ready to drive my ground rods. I wanted to drive 3, but I ran out of wire because of where I had to locate the first 2 rods. Only 2 are required per code.

Getting ready to drive my ground rods. I wanted to drive 3, but I ran out of wire because of where I had to locate the first 2 rods. Only 2 are required per code.

Ground rod driven at 45º with proper ground wire installed.

Ground rod driven at 45º with proper ground wire installed.

 

 

 

 

 

 

 

 

 

Grounding Electrode Conductor (GEC) must be one continuous wire. (Splices must be either welded or use approved specialty connectors.)

Grounding Electrode Conductor (GEC) must be one continuous wire. (Splices must be either welded or use approved specialty connectors.)

 

 

 

 

 

 

 

 

Now with the ground in place, I’m all set to finish shoveling and leveling the final grade and get some gravel in to get ready for the concrete pour. The inspector came in yesterday and took a look and said I was good to go! Now, onto the backfill and concrete pour! Good thing that I checked all of this out ahead of time!

Masonry — How To Learn A New Skill!

Let’s face it. If you are a dedicated DIY’er, then you have to be willing to take on new projects which stretch your skills. Otherwise, you wouldn’t make any progress on the DIY highway. The reason that I say “stretch” is that expanding your skill set really means building on your existing skills.

There are some fundamental skills that anyone who builds must have. You have to know how to measure. You have to know what it means to be level, square, and plumb. You have to know how to think in 3 dimensions. For example: if you’re cutting a board into 24″ sections, then you have to take the kerf of the saw blade into account. Thus, you need to measure 24″, 48-1/8″, 72-1/4″, and so on. If you don’t, then every cut will be 1/8″ shorter than the previous one, and that can add up! Or you can cut and the repetitively measure. That’s what I tend to do (easier to keep track of, but takes more time). Building is fundamentally a creative art and, as such, you have to have a feel for materials and you have to like working with your hands. Your intuition also plays a big part and is an invaluable skill in and of itself. Don’t be afraid of it!

The next level is to take stock of the materials that you will be using. This generally takes two forms: (1) the actual material and, (2) the things you need to stick it together. For a wall, that will mean (1) lumber and drywall, and (2) nails, screws, tape, and drywall mud. For a masonry fence (what I happen to be building), that means (1) concrete block (i.e. concrete masonry units, or CMU’s) and caps, and reinforcing materials (rebar, anchors), and (2) concrete (for the footing), and mortar. Don’t forget the wire ties for the rebar and the rebar chairs to elevate your rebar assembly so it doesn’t bottom out  in the footing.

Understanding your materials is very important because you will be manipulating these materials to produce your DIY masterpiece. How do I cut it to size? How do I move it around and put it in place and how to keep it there? The answer to this second question is always very important to a DIY’er because, for the most part, you’re the only person there. In fact, the ability to do a job by yourself, without help, can be a crucial factor in deciding whether to go the DIY route, or to hire the job out. That is why I plan on hiring out my sidewalk concrete job.

Then there are the tools. Ah, tools! The MOST important tools that you have  (and everybody has) are your hands, your eyes, and your brain. That is why safety is SO important, because it becomes vastly more difficult, if not impossible, to do DIY projects if you are injured. See my previous post on safety. That being said, you just can’t cut wood or rebar with your hands. You need tools, which are basically extensions of your hands that perform a specific task. Tools can be segregated generally into the categories of measure, cut, beat, twist, or squeeze. The tools become more nuanced depending on the material you are working with, and generally can be grouped that way. Woodworking tools are different than metalworking tools, are different from masonry tools, etc.. You won’t use a hand saw to cut rebar, nor will you use a grinder to cut wood. So, to accomplish a project, you will likely have to get tooled up! And each new project can be viewed as an opportunity to add to the tool stable. If you’re just starting out, then obtaining the tools you need may be more expensive than the materials for the project. Fear not. Tools are an investment, and you can use them for the next project (and the next, and the next). Eventually, the ratio of tool to material expense goes way down, but NEVER to zero! There is ALWAYS room for one more tool. As an example, because I am taking on a masonry project for the first time, I had to invest in a number of tools, seen in these pictures.

Masonry Tools That I Bought

Masonry Tools That I Bought

 

Safety Equipment: Gloves, Safety Glasses, Hearing Protection, Breathing Protection. DON'T SKIMP!

Safety Equipment: Gloves, Safety Glasses, Hearing Protection, Breathing Protection. DON’T SKIMP!

Finally, to actually build, you have to apply your tools and your skills to the materials and start the creative process. But what if your skills fall short? Well, you have to self-educate. That means one of two things: learning by doing and making mistakes, and learning from others who have made their mistakes. This reminds me of one of my favorite sayings ever:

Good judgment comes from experience. Experience comes from poor judgment.

So, the BEST learning comes from your own experience (and mistakes) because you’ll remember them. However, that imposes a lot of risk and wasted time, so the BEST approach is to learn as much as you can from others with experience, and then go ahead and get some experience for yourself. That way, your mistakes, which you WILL make, will be less common and of less consequence. Before the Internet, I used to get all of the books and magazine articles I could on whatever subject I needed to study and spent a lot of time going through all of it. Now, the Internet has not only vastly more information on any given subject, but there are also VIDEOS which, for me, make all of the difference. To see a master craftsman with 30+ years of experience showing you how they do it, step-by-step, is almost like being in an apprenticeship program. Except that you don’t have the master yelling at you when you screw it up. That is left as an exercise for the you, the student.

For masonry work, I found a guy called Mike Haduck, who is a master mason in Pennsylvania. He has a YouTube channel  (here)  which is really good, and he covers every aspect of masonry that I could possibly imagine. He has great humility and in my mind is a great teacher, but why I really like him is because one of his tenants is that “there is no one right way”, meaning that his way is not necessarily the only way that you can produce a good result. It’s just his way. For a DIY’er, just getting insight on any way that works is better than nothing. However, because each job has its particulars and nuances, you have to remain flexible and, when necessary, do a riff on the basic techniques to make things work for you. And, as you get more experienced, you may develop your own ways which you can carry forward to other projects.

Here are some pictures of getting ready for the project:

Ready For The Footing

Ready For The Footing

Pouring the Footing

Pouring the Footing

Footing Completed!

Footing Completed!

Always sign your concrete work!

Always sign your concrete work!

Brick Delivery

Brick Delivery

Building Materials. Christmas in February!

Building Materials. Christmas in February!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

I also had to make a lintel, which is a piece of masonry that spans an opening. I followed Mike Haduck’s You Tube instructions (see here), and here are the pictures of the effort:

Making the Lintel. The 7" grinder is a new tool Santa gave me for Christmas!

Making the Lintel. The 7″ grinder is a new tool Santa gave me for Christmas!

Tools for rebar cutting: Measuring tape, 4" grinder, work stand (work-mate or equivalent) and a sharpie.

Tools for rebar cutting: Measuring tape, 4″ grinder, work stand (work-mate or equivalent) and a sharpie.

Bent rebar, cut blocks, and mortar, ready for assembly

Bent rebar, cut blocks, and mortar, ready for assembly

Finished lintel. I didn't pound it, like Mike did, so I hope it will be OK.

Finished lintel. I didn’t pound it, like Mike did, so I hope it will be OK.

Time for cleanup. Always keep your tools clean (especially masonry tools) and always clean up after a day's work. My dad taught me that.

Time for cleanup. Always keep your tools clean (especially masonry tools) and always clean up after a day’s work. My dad taught me that.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Now, I’m ready for the President’s Day long weekend, and I’m very much looking forward to it. This will be the culmination of a lot of work in that this will be the construction of something that will be actually be permanent and seen by all. Stay tuned…..

 

 

 

 

 

How To Be A Safety Pro

Yesterday, I set about digging (again!), this time for a foundation for a masonry fence. Because the excavation for the foundation was right next to the sidewalk, I knew I would have to provide some kind of barrier and visual key that there was a deep (2’+) and potentially dangerous trench next to where people would be walking. Seriously, if you ended up walking into this thing, you would almost certainly break your leg, or worse, and that’s a liability I’d rather not have to bear. More importantly, being safe and providing barriers and warnings to potentially hazardous areas of your work shows consideration for those around you, and is just plain common sense. That got me to thinking about safety, and when you’re doing any kind of handy work, safety needs to be an integral part of how you approach the job.

OPEN TRENCH BARRIER

OPEN TRENCH BARRIER

 

 

 

 

 

 

 

First, you have to protect yourself. That means things like gloves, safety glasses, proper footwear (steel-toed boots-yes, flip-flops-no), hearing protection, breathing protection, and hearing protection. Of course, you’re not going to necessarily use all of these at once, but this always has to be part of the thought process before you proceed with whatever the next step of the operation happens to be. Almost always — safety glasses. I’ve spent way too many times trying to get crap out of my eyes and I’m probably lucky I’m not blind by now.

Second, you have to be aware of the hazards around you. Is that wire or electrical box hot? Have you checked? Is that pipe under pressure? Is my ladder stable? Will something fall on top of me? Do I have a bunch of trip hazards I have to watch out for?

Third, be considerate of the people who may be around you. Cordon off public areas where there may be hazards. Clean up after yourself. Make sure that you have a clear path around your worksite so that people can go where they have to without stumbling around in your mess.

At any rate, I finished my digging and put up an effective barrier. Those traffic barriers sure come in handy! Here is a short video of the work.