Apr 242018

Today, the all the timber pieces were sorted, measured and recorded in a new spreadsheet. We now have a realistic list of timber pieces with known minimum widths and we can now more accurately sort and set aside the planks we will need for other part of the house construction.

Oak Timber Sorted and Being Processed


The saw bench is now set up ready for the task of slicing down all the timber so we get a complete collection of pieces that has both edges that are parallel to each other, cut to almost the desired width (the final adjustments will be done on either the planer or other cutting tools, depending on the target requirements).
We got out our old fence guide (from a previous work table [you know we never throw things away!]) and passed that through our planer machine and we now have a straight flat guide (accurate to 0.2mm maximum deviations down the whole 8feet length). We wanted to use this guide instead of our other fence because we found that one single fence without any joins or transitions will give us an uninterrupted consistent movement of our work pieces going through the circular saw.
Oak Timber Sorted and Being Processed


Tomorrow, we will begin the next stage of processing the Oak Timber, and then glue together some of the pieces to make wider version to make up the required numbers we will need (some 40 planks for the fascia) all being at least 155mm wide.
It is taking the time but again, we are setting up the “factory” so we can get repeatable and consistent results each time and give us satisfaction and a nice looking house!!

 Posted by at 7:07 pm
Apr 242018

Today, we finished off creating the new Covered Storage Area while it was raining gentle showers all day. A chest high line of “arms”, six of them, are now mounted and braced so we can load it up with miscellaneous lengths of timber. The three sleepers on concrete blocks underneath will take all the remaining 63mm CLS timber lengths we have got.

New Timber Storage Created and Tidied Up Old Pile of Timber


The old storage tent that was situated out near our Loke, has been taken down and tidied up.
New Timber Storage Created and Tidied Up Old Pile of Timber


The tarpaulin will have to be sorted out and where it has ripped, we will throw those bits away but any decent pieces we will keep. In fact, we will use several pieces to cover up the windows in our new Storage area to keep off driving rain blowing in a window!!
Tomorrow, we will dismantle and move the pallet of the 63mm CLS timber from outside the house, to inside the house and that will clear up access for our scaffolding tower when we are working on the roof, plus also make more room for more deliveries like the slate tiles and timber cladding when we get them.

 Posted by at 6:24 pm
Apr 232018

Today, in the morning, we did some odd jobs that were left over from the weekend, tidied up the workshop, repaired a puncture in one of our tyres for our medium flatbed trolley and service our air pump that provides oxygen to our septic processing unit.
In the afternoon, we decided that we would make a new protected storage area for our CLS timber which is now badly located outside our house and is in the way of us working on our Fascia and the roof. So using the left over piece of our white tarpaulin sheet, we fixed it to the corner of our Great Room, using the internal legs and horizontal strut and rope to secure it.

Odd Jobs and New Timber Protected Storage Area


Tomorrow, we will build two layers of shelving, the lower one sitting on the concrete floor that will take the large number of the 63mm CLS timber lengths and a second cantilever shelf about shoulder height which will take the odd dozen or so remaining timber pieces we have left over and will be needed to for future jobs.

 Posted by at 6:11 pm
Apr 232018

This afternoon, the task of passing our Oak Timber through our Planer Machine to produce one straight flat edge continues. The remaining pieces (about 20 lengths) were completed.
Then the next task is to slice each plank to a set of required widths. But before we can do that, we need to know what the minimum size each Oak piece is. We built a measuring gadget

Oak Timber Work Continues


Oak Timber Work Continues


This is slid along the new flat edge of the Oak and the two arms are pushed against the opposite edge, but the second arm (underneath)is left behind when ever the width increases again. this means that the second arm will measure the smallest or minimum width and this value is recorded, ready for the actual rip sawing task later on.

 Posted by at 6:11 pm
Apr 202018

This afternoon, we decided that it was finally time to do a good sweep of the concrete surface inside our building. There is quite a lot of saw dust, wood shavings and other rubbish lying around and this is the first time this year that it is all dry and easy to sweep with the lovely hot weather we have been having.

A Spring Clean inside Building


We filled up two large trugs of sand, saw dust, pieces of cement boards and loads of empty glue tubes! It all was put into two large rubble sacks and dumped with the rest of our building waste, all waiting for a skip when we have enough to justify having one.

 Posted by at 6:17 pm
Apr 202018

Yesterday and today, we did the job of covering our long skylight running down the whole width and length of our Corridor in our temporary living quarters. Each year, we have to put up a sheet of tarpaulin plastic to cut down on the huge amount of sunlight energy pouring into our home! This year, we bought a thick heavy duty white tarpaulin and then cut it up to create one long strip of 10 metres (30feet) by 2.1metres (7feet) strip. We used our domestic sewing machine to join the two strips together and then sew the folded over edges to provide a sleeve for the thick rope.

Sun Shield Over Corridor Created and Mounted


Sun Shield Over Corridor Created and Mounted


It is now mounted up on our roof and it will stay up until around September or October depending on how far the hot weather reaches into the Autumn season (assuming the stitching holds).

 Posted by at 3:20 pm
Apr 192018

Yesterday and today, the planer machine was serviced, and some repairs were performed. We had been having trouble with the power supply while using the machine and occasionally, we would trip the circuit breakers and a popping sound would be heard. So we took the opportunity to give our planer a good looking over, doing a redesign of the main power safety switch and power cord inlet (which is a large sticking out mess) and also replaced the electric motor starter capacitor. The popping sounds was the capacitor having a breakdown moment inside the can (hence the popping sound).

Planer Machine Serviced and Repaired


Planer Machine Serviced and Repaired


The new layout for the start button and the emergency stop button are now flush fitted to the metal cabinet itself and the power cord now comes in behind the machine instead. All the safety cut-off switches (thermal overload on the motor and several absent of equipment sensors) were re-joined into the circuit behind the new buttons. Finally, we replaced the capacitor that arrived in the post and all seems to be ok .. so far!!

 Posted by at 6:19 pm
Apr 162018

The last task of the day was to adapt our template that we have been using to trim the top of our cement boards on our walls so we can trim the five remaining inside corners. It was a bit fiddly as any inside corners are awkward places to get a ladder into and to make it more complicated, there are sticking out eves as well to get in the way too!!
It took longer to go around to each of the five corners and it was quite late before it was all done! Phew!
Anyway, that concludes the trimming of the cement boards (both the top of the walls and the vertical edges for the nine outside corners) and when we get there, the roof boards now can be laid flat on the rafters and go all the way to the Fascia smoothly without hitting anything!

 Posted by at 7:10 pm
Apr 162018

Today we finished off the task of building two extension tables for our Planer Machine. On Saturday, we had our double thickness OSB boards all set from the gluing and it was sliced down to required size. Then a clearance hole was made in one of these OSB platform for the large knob sticking out the end of the metal table platform (this knob adjusts the depth of cut the planer does) and also we made four wooden legs with an extra plastic cabinet adjustable foot fitted and glued up inside the end of each leg. Today, we mounted these legs to each extension table, bolted on two metal arms and assembled the table to the end of the planer. While we were adjusting the height and level of the new extended table, using our 6 foot spirit level, we noticed that the wooden surface wasn’t quite flat and had a bulge here and there. So we spent the next hour or so sanding the high ridges until it was all flat all over. We did the same with the second extension platform and then proceeded to set each one into place, using glue and screws to fix the wooden bases to the metal arms (plus using several clamps to hold it together while the glue dries).

Planer Machine Has Been Extended


We now have a 3.4metres (11feet) long platform (1.7 metres, a bit over 5½ feet, on each side of the planer blades) and this will, We Hope, Fingers Crossed(!!), bring a much better and more consistent results of achieving a straight and flat edges and surfaces on our Oak Timber!! Tomorrow will reveal all! Grin!

 Posted by at 4:53 pm
Apr 132018

Today, we settled down to analyse the planer machine to learn what is happening when we try to plane larger pieces of Oak timber and why it is coming out with a slight dip in the middle. We wondered whether the heavier pieces was causing a slight ‘bending’ of the metal platforms that guides the timber in and out of the machine but carefully putting a series dumbbell weights and watching the surface against a steel rule (using a bright LED torch to shine through any gaps opening up) but nothing happened even after we put 17½ kg load on the very end of the table. The machine has 500mm long input and output tables and reading more about these types of machines on the web, we were concluding that the long pieces of timber is too long for the machine. The cylindrical rollers don’t give enough support because they only hold up at one point and as soon as the timber slide pass, it loses support and ‘moves’ which is part of the problem.
This means we needed to extend the flat tables to provide a much longer surface to keep the timber on the straight and narrow and the planer then can do it job on removing the excess material that is causing the bow or dip.
So this afternoon, we created two thick wooden platform made from two layers of 18mm OSB board, measuring 300mm wide by a metre long and these were sanded smooth and then glued together. Next we got out of our metal supply two lengths of 50mm wide by 3mm thick steel strips, both being more than 2metres long. These were cut to form four 1metre pieces. Then a triple set of 8mm holes were drilled in both the steel strips and also into the sides of the metal (aluminium) tables. Finally, we drilled a series of 5mm holes down the other end which will allow us to screw our thick wooden platform pieces into place. We will slightly enlarge the steel holes (the set of three holes) so we can wiggle up and down the whole extended platform so it becomes dead level and aligned up with the rest of the machine. Finally, we will put on two legs underneath to help support these extended guides as the whole machine will suffer and tilt over when it tries to handle heavy and long Oak timber pieces.
This is taking quite a while to analyse, design and implement this necessary modification to our planer machine but we want something that will be solid and long lasting so we can deal with all our Oak timber for the whole building project. So just a couple of days of work here will save many, many days of frustration and problems later on!

 Posted by at 6:10 pm