Sep 142019
 

The start of the week was a bit damp with a very light rain falling almost all day Monday. We resumed work on our roof by nailing and gluing the layers of plywood strips to make up the flashing structure for the Hips and Ridge that goes up the Side Porch and up to the Skylight on the E-H corner. We had to saw several lengths of plywood strips from our left-over pile (to make the 175mm wide pieces) and cut three more 100mm 15mm thick strips. But that is all done now and that also see the completion of this job of putting up these flashing strips as there is no more to do!!

Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

Hips-and-ridges-for-EFG-H-1

Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

Hips-and-ridges-for-EFG-H-2



So for the following day, Tuesday, we were able to get on with the job of installing the gutters, using our pile of Oak timber pieces, ready in their two styles. But we discovered that we are running out of pieces! We had only five and half lengths (2metres each) of our base boards and seven lengths of the front vertical pieces. This only allowed us to complete the remainder of the ‘E’ section and around the corner onto the ‘F’ (the Side Porch). We did have enough to continue around again to the ‘G’ section which is very short and has a downpipe channel located at the end but no more than that to enable us to complete the last section ‘H’ which needed three more base boards. So we decided to stop short on the ‘F’ section and make more Oak pieces in our workshop when it rains next time.
So we glued the base boards in and then got the front vertical pieces push on, glued and clamped, all the way to just short of completing the ‘F’ section, which now enables us to get the valley in the D-E corner to be prepared and get the Front Porch covered in slates.
Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

E-Gutter-wood-glued-in

Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

Half-of-F-gutter-done



Wednesday started a bit damp so we couldn’t get on doing the fibre-glass and resin process to seal the E-F outside corner so instead we got on with putting up the breathable membrane and half the tile battens on the ‘C’ roof section. It was very interesting as this roof is very steep at 60°!! We had more showers at noon so we came in for a discussion on slate tiling patterns and then had lunch.
Thursday was a lovely day and we got on with the task of putting up more battens on the ‘C’ and ‘B’ roof sections and they are now both complete and ready for slates.
Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

B-battens-finished

Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

C-battens-installed



During the day, after lunch, after waiting for the wood surfaces to be dry enough (after the rain we had yesterday), we proceeded to fibre-glass and resin the outer corner of the guttering, where the E-F sections intersects. With this done, we can now insert the rubber liner.
Finally, on Saturday (Friday?s work was lost due to other commitments), we indeed got our rubber liner inserted into the gutter running along the ‘E’ section of the roof. That was the morning’s task and after lunch, we then ran up a strip of membrane up the valley and nailed six lines of 38mm wide counter battens that supports the valley trough. And finally, we started putting up the breathable membrane bands across horizontally the ‘D’ and ‘E’ sections of the roof. We only managed to get one line up as our usual nail gun was playing up and misfiring the nails. We swopped over to our alternative gun that uses full headed nails held together in a strip by a plastic material moulded around the nails.
But then we tackled the first tile batten and the nail gun was doing funny things to the nail strips, this time they were the 50mm long nails. We had no problems with the 64mm ones! So we are having a jinx on our tools at the moment. Phew!
Finally, to finish off the day, we applied black mastic sealant to the ends of the rubber liner to make sure that water cannot creep in.
Preparation of Hips and Ridges All Completed, Gutters Installed and Rubber Liners Inserted In Gutters

E-Gutter-done-and-start-of-battens


Next week, we will get on putting up the breathable and battens to get both ‘D’ and ‘E’ sections water tight and ready for the next load of slates to go on.

 Posted by at 6:00 pm
Sep 072019
 

Monday, we had a little quick job of making some extra shelving for our living quarters, made out of pieces of plywood lying around

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

New-shelves-for-Mum


Then we got on with installing the last two metal aluminium legs for the Front Porch and its roof. We managed to hoist up the beam running underneath the roof edge, using our car hydraulic jack to lift it up 10mm on the outer corner and then a more distance (30mm) in the middle. All three legs are now bolted down into the concrete foundation pads and the plain steel concrete bolts were covered in bitumen sealant to protect them from damp sand in the long run. The top of the legs were screwed into the wooden beam using stainless steel coach screws.
Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

3-metal-poch-legs

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Porch-leg-concrete-bolts-masticed



The final job of Monday was to clean out the man-hole chamber that got damaged several months ago by a delivery van driver. We used our vacuum cleaner to suck up the sand and then wrapped a strip of rubber membrane around the top of the chamber to cover up the broken edge to stop further sand and soil to leak in. we will do a proper repair later on when we get the driveway laid.
Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Manhole-repaired-2

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Manhole-repaired-1



Tuesday morning was spent going around the eves cleaning the excess brown glue away from the rafters coming down to the back of the fascia, doing about half of the circuit before lunch.
After lunch, we resumed our task of moving the platform modules to their new position.
Wednesday was spent all day adjusting the platform modules including moving the lift shaft into its final position (where it will serve us right to the end of completing the whole roof).
Thursday was another half workforce day, so the second set of the aluminium bracing support were made, this time for the Side Porch. These arms are angled at 53° from the wall surface about 6 feet off the ground and reaches out all the way to the corner of the framework beam.

We wanted to avoid having straight vertical posts supporting the porch so we can move vehicles around on our driveway without the fear of bumping into a leg and causing complicated damage to the overhanging porch and the roof. The angle was derived by calculation the stress and strain numbers on the 50mm square tube and the 53° position turned out to be the surprising optimum angle! Late afternoon, we installed one of the new arms on the E-F corner, all screwed using four stainless steel 80mm by 6mm hex head coach screws at each mounting plate.

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Angled-porch-support-EF


Friday, we put up the second arm, similar to the first arm and it was screwed with more stainless steel hex head coach screws.
Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Angled-porch-support-FG

We had designed the porch with just two supports but discovered that we hadn’t fully appreciated in how flexible a 6metre beam would be and not having a third middle support point meant that we are likely to have a dip in our gutters especially after we have loaded the slates on to the roof! So we spent the day installing a middle horizontal additional support beam. We had to cut out a rectangular hole in the middle of the existing beam to allow a 89mm CLS timber to be inserted and a similar hole in the wall in between the Utility room’s window and door. That was the middle layer so two lengths were glued and clamped on top and underneath to stiffen it up. Behind the wall, we also put in a third layer underneath the two existing layers (of the top plate) and that was glued and clamped as well.

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

New-midspan-top-brace-on-F-porch


The last piece of structural piece of work to be executed was to provide a vertical post behind the cement board so we could screw the metal arm into place later on. This post forms the third side of the triangle that forms a combined structural element to hold up the middle of the Side Porch roof and gutters. The post is made up of three 95mm by 45mm regularised timber pieces, two of them glued together to produce a square core element and the third piece glued and screwed overlapping the front surfaces including the top and bottom timber layers of the original wall.
Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

New-wall-post

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Top-new-wall-post



On Saturday, we repaired the temporary Loke fence where some sections had torn the plastic webbing. One of the wooden posts proved to be fragile and rotten at ground level so we replaced that post with a new round post. Then using the left-over length of the fencing, replaced the torn sections and threaded a rope weaving in and out of the top line of the webbing to provide a stronger support for the plastic fence against strong winds.
Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Loke-edge-fence-renewed


The excess glue was cleared away off our new middle support beam and sanded it down hard to reduce the blobs of bubbled glue along the joins.

Finally, we finished setting up the platform modules with all the safety side strips and installing the motor into the lift shaft.

Metal Posts Installed, Platform Modules Rearranged and Guttering Completed for E

Scaffold-platforms-and-Lift-moved


We are ready to resume work next week on the roof now and get the Side Porch prepared for tiling and allow us to complete the Front Porch, at last!

 Posted by at 6:00 pm
Aug 242019
 

Another week is complete, with lots of Slates being mounted plus some little bit of work on the window’s octagon pillars. The hip flashing was first to be done, with the bull-nose shaped fibre-glass covered in the dark grey resin, going up the P-A intersection of the roof. Then we went to work on the […]

 Posted by at 6:00 pm
Aug 172019
 

This report is for the last two weeks of work, we had some of the days on other commitments, but we mostly worked on our roof with some in our workshop processing more oak during the wet days. The first task was to put in our Rubber liner into the gutters, in section “A”, “B”, […]

 Posted by at 6:00 pm
Jul 202019
 

For the last three days of this week’s work, we were in the workshop processing the pile of Oak timber that makes up the vertical elements of the window frames. It is ironic because the weather forecast said rain on all three days but actually the second day (Friday) didn’t have any rain what so […]

 Posted by at 5:30 pm