Nov 202021

This week, we completed the task of inserting at least one layer of PU foam board up into the rafters that we can reach from the First Floor .. the other half of the building, along the back doing sections M, L, K, J and I.

The task we thought we ought to do next is to make a couple of unusual air duct channels, to take the hot air out of the Skylight. We used the rafter space itself to encapsulate the air duct tubing so it is hidden and does not intrude into our living space. We had one down near the Great Room and the second location is right down at the other end of the Skylight where it squeezes through a narrow opening just before the hip section of the glass.

We had to cut our way through the kerb and all its layers of material, removing everything down to the steel RSJ surface, making a rectangular shape hole but with a tapering top surface to guide the air downwards.
We used 6mm MDF sheet material to create the liner for the chute, to go over the steel RSJ beams and bend downwards to the bottom of the rafters, where the air is then transported down using more smooth insulation boards and this travels down before sweeping sideways to join into the main air duct that will be built to run around the whole house.
These MDF pieces were all glued in using our glue grade expanding PU spray foam, putting in lots of clamps to hold them in place while the glue sets.

Roof Rafters Accessible from First Floor Has Some Insulation Inserted


Roof Rafters Accessible from First Floor Has Some Insulation Inserted


Roof Rafters Accessible from First Floor Has Some Insulation Inserted


The size of the first chute near the Great Room is approximately 500mm wide by 100mm high, with a slight squeezing as it travels over the RSJ but having a 50,000 square millimetres capacity is about half the total capacity of our main air ducting that the fan is designed to work with. It is that size because the skylight and the Great Room will be collecting a great deal of sunshine energy during those sunny days and we need to make sure we have the capacity to remove this hot air easily without struggling. It is so much cheaper to design in a high capacity air ventilation system in the first place, combined with our super-insulated roof and walls, would mean that we don’t need to burn large amount of electricity to run refrigerated air conditioning units to cool the house down. Invest the money in the insulation at the beginning, a fixed cost and avoid the running costs later on especially if the world is facing large temperature rises.
Anyway, we did the second chute as well, with a similar design using MDF pieces but only 300mm wide by 100mm high, before spreading out to the full width of the rafter like before. We also put up more layers of foam boards up and down the rafters themselves.
Roof Rafters Accessible from First Floor Has Some Insulation Inserted


Roof Rafters Accessible from First Floor Has Some Insulation Inserted


Another job we did was to drilled a conduit hole through the kerb at our ‘chimney’, to allow a 40mm conduit to connect to the bottom of the metal arm and vertical pole. The vertical pole has a 40mm conduit going up the inside and poking out the top, ready for the electrical connections to all the devices that will be mounted into and on the chimney when that is built later on.
Roof Rafters Accessible from First Floor Has Some Insulation Inserted


That is about it for this week, we will finish off those two special ducts, plus one more that is needed for the upstairs toilet and shower room, which also has to come over the steel RSJ but we only need a simple 100mm round hole to let the flexible air ducting through. The other job to finish off is dealing with the last huge pile of PU foam boards which we will slice up and insert in places up in the roof rafters, just to get rid of them.

 Posted by at 6:00 pm
Nov 182021

Today, we took an opportunity to install a new strip of LEDs up on the under side of the steel RSJ part of the Skylight. We wanted to rearrange some of the 100W floodlamps that were previously positioned to shine down lighting up the ground floor but that was before we had built the First Floor structure. So we bought a 45m length mains rated LEDs strip, we actually ended up with only 28metres (we got the difference refunded!) and we started at the North end of the house (over the Bedroom Three and Utility rooms) and split the strip into two lengths of 14metres to go down both sides of the Skylight. We used the 12mm thick plywood that we got installed up inside our Skylight and drilled a series of little holes for cable ties to clamp the LEDs strip up on the edge. We just managed to reach the fat steel legs (number 1 and 7).

Lighting Installed Upstairs and Flood Lights over Great Room


Lighting Installed Upstairs and Flood Lights over Great Room


Then unconnected four 100W LED floodlamps from various places and got them installed over the Great Room to shine down over our work and saw benches. We used the Ground Floor lighting circuit to connect these lamps so we now have a very well lit work area in our Great Room and a pretty good illuminations upstairs too.
Lighting Installed Upstairs and Flood Lights over Great Room


Lighting Installed Upstairs and Flood Lights over Great Room


We may have to put in a couple more lamps in the last rooms downstairs like the Kitchen, Bedroom One and the Entertainment Room so we can continue to work in the dark evenings now.

 Posted by at 6:00 pm
Nov 132021

We had a week of slicing and pushing loads of PU insulation foam boards up into the rafters! We carried on with the task we started last week where we wanted to get rid of all the random collection of 2nd grade of expanded polyurethane foam boards we acquired very cheaply, slice it up and […]

 Posted by at 6:00 pm
Nov 062021

Among several interruptions during this week’s work, we got on with installing new framework for two sliding doors for our stand-alone Bathroom as well as for Ensuite Two. Both of these rooms are going to have two half¬†sliding doors, built into the body of the walls themselves (pocket), not exposed, mounted on the surface. It […]

 Posted by at 6:30 pm
Oct 192021

This week we finished cutting hatches into the hall floors on Monday and Tuesday. Then we needed a way of lifting the panels easily. So we drilled a hole 100mm diagonally in from each corner and inserted a ‘Pronged T Nut’ into each hole from below, then we could use a bolt with a T […]

Oct 162021

For this rather truncated week of work, we resumed the task of laying down the floorboards after a week of building the framework. One of the first things we did was to put in a load of insulation bits and pieces from our giant bag of “rubbish” we got outside into the area under the […]

 Posted by at 6:00 pm
Oct 092021

This week (apart from one day on Friday lost due to other commitments) was spent constructing the complicated framework for supporting the remaining Hallways, going up to the Great room, the crossroads and the bigger section under the stairs and up to the Front door. One of the tasks we had to do first before […]

 Posted by at 6:00 pm