Jan 252020

This week, we created a machine to slice up our pile of random insulation sheets (which can be up to 150 mm thick) and started putting them into the walls surrounding the Entertainment Room. We needed to do this job now as we require access to the “I” section of the wall in Bedroom 3 so a new window hole can be created and this is being blocked by the stack of insulation.
So our slicing machine is constructed using a full 8foot by 4foot sheet of 12mm plywood, framing the edges and putting it on legs and then mounting a sabre saw into a wooden bracket and screwing it to the under side of the table. The table had a square section measuring 300mm cut out so we could gain access to the saw clamp to change blades. We also put together a boom arm over the blade and mounted a pair of ball races that grips the saw blade to stop it flexing sideways.

Foam Board Slicer Created and Started Putting Insulation into Walls around Entertainment Room


Foam Board Slicer Created and Started Putting Insulation into Walls around Entertainment Room


We also made provision to have our large format vacuum machine to suck away the crumbs and dust of the insulation material as we push it through the slicing machine.
Finally, we got a mobile adjustable fence with two clamps so we can set up a regularised width to guide the foam sheets through the machine.
Foam Board Slicer Created and Started Putting Insulation into Walls around Entertainment Room


Then, first job was to slice some of the sheets from the random heap of thicknesses, widths and lengths to produce a regular 940mm size. This measure is the distance from the concrete floor and to the height of the concrete wall and its three lines of timber. This means that when the first section is filled in, then the upper section can be loaded with another set of regularly sized insulation boards.
So this is what we did and now the Entertainment Room has the lower section along the “d” and “c” of the wall all filled in, apart from the window section.
Foam Board Slicer Created and Started Putting Insulation into Walls around Entertainment Room


Then we realised that we could use up the left-over pieces of the polystyrene foam sheets (they came from when we were making the rafters) and we could use them to fill in the gap within the leg themselves, as they were already 38mm thick and this is exactly what we need here to block a potential cold bridge through the legs.
So all the pieces went through the slicing machine at 220mm wide and ready to be inserted when we need to.
Finally, we started the task of filling in the upper section of the walls and we decided that because of the random nature of the foam boards we got second hand, we would slice the pieces into a regular width and then stack them on top of each other and build it up layer by layer, with lots of PU spray foam to make sure that we don’t get any cold bridging. So we started right in the corner (the “C” – “D” corner) and sliced a set of 620mm wide pieces. We had found enough for two layers of 120mm thick boards and finished off the third layer using 100mm thick boards.
Foam Board Slicer Created and Started Putting Insulation into Walls around Entertainment Room


It was rather fiddly but we are learning and some of the pieces were quite tight so next time, we will make it a little looser and use more spray PU foam to seal all the edges and joints. This would mean using a lot more spray foam but it is a small extra cost against the total cost of the insulation and it would help us move quicker in doing this job too.
Next week, we resume filling the walls in around the Entertainment Room, the reason we are doing this area first is because we will be building the soundproofing concrete walls as one of the first jobs to do inside the house when we have finished all the exterior cladding and have installed the windows and we would lose access to get the insulation in!!

 Posted by at 6:00 pm
Jan 142020

After our Christmas and New Year celebrations, we resumed work this week with the outstanding task of sealing all the cement boards covering the walls of the house. We resumed the grinding operation and washing tasks to clean and smooth the joints. We completed the remaining segments, namely the J, K, L, M, N, O and P1.
Just before Monday’s lunch, we started rolling on the flashing tape, 3inch wide and extra heavy duty bitumen backed tape, to seal the bottom edge of the cement boards to the concrete blocks (to deflect any rain running down behind the cladding away from the joint). It was cold and the bitumen glue wouldn’t stick by itself so we got out our hot air gun and warmed it up and rolled it hard to the surfaces. We got this all done by the end of the day at 5pm in the dark!!

Sealing the Cement Boards on Walls


The following day, Tuesday, we then resumed the other half of the job of rolling on the shiny aluminium tape over all the joints of the cement boards, completing those last parts of the walls left undone since before Christmas.
We also used our new cut-down platform modules to help gain access to the two porches, the front door and the side door porches and got all the joints covered too.
Sealing the Cement Boards on Walls


Sealing the Cement Boards on Walls


Sealing the Cement Boards on Walls


Sealing the Cement Boards on Walls


Finally, to complete this job, we spent the last hour in filling in the window hole on the B wall (we decided that this window was no longer needed), this is the left hand four feet sticking out portion of the Front Door and Leisure Room structure of the house. We sliced off 30mm of the existing cement board around the window. This left room to put up two pieces of fresh cement boards cut down to fit which then we glued and nailed both bits into place. The final job was to cover these new joints with the aluminium tape to make sure it was air tight.
Sealing the Cement Boards on Walls


Sealing the Cement Boards on Walls


Oh yes, we decided to seal up the joins in our Conservatory as well so we were truly air tight as we won’t be able to work on the Conservatory when we got the internal rooms all done and we needed to perform the pressure test procedure.

 Posted by at 5:00 pm
Dec 142019

With Christmas fast approaching, with various interruptions occurring, we had only managed to do a couple of days of work. We got on with the task of sealing all the cement boards covering our walls around the whole house. The first part was to grind all the edges of each board because they were smeared […]

 Posted by at 5:00 pm
Dec 072019

After our conclusion of the slates on the roof (the front porch section) on Monday, we finished dismantling of all the remaining platform modules apart from two full height modules that we managed to move inside the house and a further three modules were cut down to provide a new lower working platforms. We then […]

 Posted by at 2:30 pm
Dec 022019

On this very chilly Monday morning, and a bit of the afternoon too, we finished off putting slates on the last section of roof, the “C” section which is our front porch roof facing our Loke. Another 100 slates went up, followed by about 80 slates for the flashing up the two hips. This concludes […]

 Posted by at 3:00 pm
Nov 212019

We start the week with the left-over task of moving the Larch Timber inside our house to get it under cover. It was two and a half tons of wood to shift!! See Larch Timber Arrives. But over the next couple of half day sessions, two afternoons (Monday and Tuesday) and one morning (Thursday) we […]

 Posted by at 1:00 pm
Nov 162019

We resumed work on our roof, continuing with the task of putting up the flashing slates up the “F” Porch roof section and then started doing the “G” little section on the side of the porch section. This narrow strip is very very fiddly, having to work on both the valley and the hip and […]

 Posted by at 5:00 pm