Duct tape, drywall and a driveway
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What's been happening? So many things that I've had a hard time remembering them all, but I think we're finally getting to the point where we can start to think about a move in date. Drywalling has commenced after finally getting the electrical finished. Wiring took so long that I can't even remember when it started. Part of this included us running all the RG 6, phone lines and other assorted media-specific items and wiring all five of the thermostats for the radiant zones. UPDATE: Before I could get this post up, the drywallers finished and taping has commenced as of today. This is costing us a small fortune because of all the detail work with the window jambs, trimless doors and visible top of wall edges in the areas of exposed ceiling, but I think it's going to look amazing when it's done. Here's a look:
Installing the air exchanger and bath fans. May we never see a piece of ductwork again. The only high point here is that I can now claim to have used duct tape for it's intended purpose instead of only as an artistic medium.
Our stairs arrived. Amazing what not having to climb up and down a ladder from floor to floor does for making this project actually feel like a house. After tons of searching and a lot of frustration, I found a great welding and fabrication shop to make the stairs, railing uprights and handrail. Getting the stair in place was a major feat. After ignoring my advice to try and gain access to the house via the south sliding doors and getting truck, trailer and 3000lb.+ chunk of steel throuroughly stuck in the mud, the stair was brought in through the west door, rolled into position on pipes, and then chain-hoisted from the roof joists into it's spot. It looks really cool.
The most labor intensive portion of that adventure for me was jackhammering and saw cutting a 4'x2' opening in the balcony floor. A mess to say the least.
I started with the jackhammer to get as much of the material out as possible, lest we be dropping a several hundred pound chunk of concrete onto the slab below. Then I went at it with the masonry saw to give the edges a clean cut and allow the fascia steel to be placed.
This not only covers the exposed edge of all of the upper floor concrete, it provides an attatchment and welding point for the stair to hang from. Ultimately, the stair hangs from this fascia, welded to it along the vertical edge of the stringers. The remaining fascia pieces have not been installed yet, but will go on when the railing uprights and top rail are installed in a few days, leaving me with a support structure for stringing and tensioning cable.
As soon as the stair was in place, we got to work framing the powder room below. Hopefully I'll never have to frame another slanted ceiling room as long as I live, because I think this tiny thing took as long to frame as our entire upper level. Figuring out how to deal with the slope of the stair, a bar joist, the fan soffit and the bike room wall all converging in the same place was quite a chore. I think it's going to look cool, however, and I've got a couple of interesting ideas for dealing with the odd angles it creates. That's the powder room tucked under the stairs in the second photo.
After a long wait that involved the payment for our heating equipment getting lost in the mail for two weeks, our boiler finally arrived and we're looking forward (or fearing) the challenge of getting it and all of the pumps, zone controllers and lines connnected and getting heat in the house.
UPDATE: After soliciting several bids to get our system up and running, and realizing these radiant heating "specialists" were significantly more clueless than we are AND wanted ~$6-$7K to do this, we've gotten going on doing DIYing this. The hydronic stuff has been Vern's project since the beginning, and he's done an amazing job of turning himself into a hydronic heating expert. We should have heat just in the nick of time, as winter is threatening as I type.
A driveway!
When we were originally planning this project, we had planned on an asphalt driveway, but because these prices have increased drastically and our concrete guy has done such great work for us already, we decided to go with concrete instead. It's something of a splurge, but also more durable and longer lasting. I'm thrilled to finally put and end to the muddy ruts we've had for the last year.
As you can see, we're still not finished siding. My galvalume just showed up a few days ago after a two week mistake/delay, in addition to the four week lead time. I can't wait to see what it looks like once it's up.
Perhaps the biggest development is the sale of our home. We put it on the market at the beginning of October, expecting it to take a month or two to sell. Or agent even warned up that the market was seeming a little "sluggish" and that we might have to be patient.
Well, four days later, we had a signed purchase agreement for cash, our full asking price and no contingencies. The kicker: the buyer wanted occupancy on October 27th.
We had always considered that selling and moving before the new house was completed was a definite possiblity, but moving in three weeks was a interesting plot twist.
We agreed to this quick close, and I had a POD delivered a day or two later to start packing things up into.
While I've spent the last year gradually purging and getting our stuff pile pared down, we still had no problem filling the container. While not exactly cheap, using these movable, modular storage containers is extremely conveneient. I'm really looking forward to being able to unpack from the POD on our schedule instead of lugging around box after box and then having to look at them for a month while we figure out where to put everything.
So we're staying with Vern's mom for the time being and trying to get as much done as we can from day to day. Lately that's meant 16-20 hour days at the new house for me and a regular work day followed by work on the house time for Vern.
We had a ton of details to wrap up in preparation for drywall, but now that that's behind us, we can refocus our energy before the real fun of finish work begins.
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Does Vern want a radiant heating project in TN?
Send him on down! Things are looking great in you house. What will the finished stairs look like? Are they all steel?
We are consulting with the Logix people about their product. They seem to have a great rep in our area and are very helpful by phone so far. Which thickness did you use? We are in a seismic zone and have been advised to use the 6" blocks (which means our walls are 11 3/4" thick!!!). I am considering using 6" on the first floor and 4" upstairs. In your photos it seems that you did not carry the blocks up to the parapet? Why? I found a parapet detail (specifically like the one with a concrete ceiling) on the LOGIX cad files that looks great. Wondering how well this works in the field. Since I am doing our architectural drawings, I am relying on these cad type details to learn how this material fits together.
If Minnisota was not so far away from us, I would love to come see your house! I am so impressed.
Good luck to the finish line!!!
raidant, logix, etc.
Too bad you guys are so far away, Sara. It would have been extrememly helpful to us to at least observe a radiant system being connected before jumping in ourselves.
I spec'd the stairs of plain steel. I'll probably clean them up a little bit and maybe experiment with waxing or oiling, but overall, I love how they turned out. Their rough, industrial character is exactly what I'm going for and I think it will be an interesting contrast to the more sleek modern elements we'll incorporate.
The engineering specs for our home dictated 8" block for all of the exterior walls, presumably due to the large number of openings and the concrete/steel roof structure they support. The two interior garage walls are 6" and the parapet 4". Just as with the upper level floor structure, the parapet walls sit on top of and contain the edges of the concrete roof slab. The ease of setting these courses depends a great deal on the accuracy of the concrete slab they rest on. A good level perimeter means they can just be set vs. having to shim or shave down to get the entire course leveled. Makes for great windowsills depending on where in the opening you decide to place the windows.
Looking back on your plans-
As we are working on the drawings for our house, I went back to some of your older blogs and reviewed the plans. Our house in form is similar to yours, modern, functional, boxy...we are hoping to get away with as much as possible- unfortunately or fortunately we live in a newly formed random historic distric. Very random area. Great lot, etc... Back to the plans. Where are your closets in the masterbedroom? Did you add them later? My husband and I do not have tons of junk, but we both have a decent amount of clothes and need good size closets. I am having difficulties getting hte closet space needed to work in our plan without adding on more and more square footage! I did not realize how hard it would be to control the square footage and still get good size rooms.
How did your bath turn out? Japanese soaking tub? Also dealing with desire of nice tub and walk in shower, but want to get as far away from those insane suburban baths as possible! Advice now that you are nearing completion????
Thanks!
closets
I don't recall how it's drawn on the plans, but I'm doing wardrobe closets along the 12ft of west wall of the master bedroom. It's just too hard to beat IKEA's PAX system for usability, price and looks. Regular, framed closets have always really bugged me. I dislike their typically deep returns, and that you lose so much good space needlessly to 2x4's and then pay to have them sheetrocked and finished to boot. And then you get to spend several hundred or thousand dollars making what's left of the space usable. Tres un-modern, IMO :) I guess I have no idea how this will work in real life and I'm sure the appraiser would dissaprove, since by definition, a bedroom has to have a closet. We have closets drawn in all our "bedrooms" but the only closet we actually built was in my studio, mostly to house the raidant manifolds. I think there's a fair chance I'll be cursing this decision in the future but hey, closets can be built any time, right?
I have the soaking tub form all ready to go. I had our concrete guy in to critique my formwork. He had some good advice and also convinced me I should use ready-mix instead of bagged. Since I'm going to be casting all of our countertops as well, I decided I'd wait to pour the tub until I had the forms built for the counters and could do everyting at once. (Vern is laughing at the idea of the concrete truck showing up and finding me standing there at the ready with my five gallon pail.) Since there's been so much talk on this subject on the board in the past, I intend to blog about it in detail once I've done the deed. I'm really excited to start the finish work in that bathroom...I have something SO cool worked up that I can't wait to show off!
Advice. Hmmmm. Stick to your guns and trust your gut. Don't let others infect you with their artificial, fear based limits on your ideas or goals. Be fearless, but do so with a sound knowledge base and lots of common sense. Consider any restrictions to your project opportunities for creative problem solving. I really believe this is what yeilds the most impressive results. Have as much cash avaliable as you possibly can manage, exclusive of your construction financing. I can't emphasize this enough if you're going the owner-builder route. You're about to be nickel and dimed to death and being able to pay for stuff out of pocket takes a lot of the pain out of trying to manage and coordinate draws.

Looks terrific
We should have flew Vern in to L.A. to hook our already installed system! We paid 2K just to have the system balanced and hooked up between modules. I understand what you mean about radiant specialists. In our case, most of the "specialists" we found were plumbers or heating contractors without any real experience with hydronic heating systems. I'm sure that you'll find that concrete will be great with the in-floor heat. We have cork throughout the house and when the system's on, the bathroom slate tiles feel warmer than the cork.
Congratulations on the sale of your house and all of your progress. You guys have done an incredible amount of work. And your driveway looks great.