Sep 222018

Today (and a bit from yesterday), we resumed the assembly of our Skylight framework, working along the front, then along the back side, both towards the right hand end and finally finishing off the whole framework with the five way coming together of rafters. All was successfully glued and screwed into place.

Skylight Framework Fully Assembled and Installed on Roof


Skylight Framework Fully Assembled and Installed on Roof


Now we have started on the next phase of putting on the rubber membrane and gaskets all over the white surfaces, with the completion of a “skirt” strip around the whole outer edge. This skirt is 100mm wide and it was glued and stapled right on the outside top edge of the frame, just below the slot and it falls down on the outside towards the kerb. Eventually, the breathable roofing membrane will come up the roof slope and tuck under this rubber skirt to seal the skylight to the roof, it also provide protection against the rays from the Sun for the membrane and ensures that it will last for years to come.
Skylight Framework Fully Assembled and Installed on Roof


Skylight Framework Fully Assembled and Installed on Roof


Finally, we brought into our workshop all the aluminium glazing bars and other bits and pieces, ready to cut them into their assigned lengths. We chopped some sample pieces so we can get a handle on how they feel and how they fit together.
On Monday, we will start on the Ridge and sort out the stainless steel bolts (three of them), slice up the glazing bars and start stapling on the rubber gaskets.

 Posted by at 6:05 pm
Sep 202018

Today, this afternoon, we resumed the job of assembling the bits and pieces to build our Skylight module. We went around the left end of the skylight and along the front, doing another seven rafters, two diagonal rafters and three sections of the rims.

Half of Skylight is Assembled


Half of Skylight is Assembled


Everything got the same treatment as yesterday, all glued and screwed and all holes were filled and sealed against water.

Tomorrow, we will carry on along the front and around the right end and proceed along the back side to complete the whole thing. Also our polycarbonate glazing sheets are expected to arrive tomorrow – Good Stuff!

 Posted by at 6:04 pm
Sep 202018

Yesterday morning and this morning, we continued with the calculations for the Slates and all the accessories to cover our roof. A 18 page spreadsheet was used to quantify the number of tiles, the number of rows and what sort of angled adjustments is needed for the various hips and valleys ends, depending on which roof section is under the spotlight. We are getting close to a final set of numbers, just need to run through the calculations again to verify the results before we start the process of ordering everything. The quantities are as follows:

  • 17200 300mm x 200mm “normal” slates
  • 700 300mm x 300mm “wide” slates
  • 3550 metres of 50mm x 25mm tiling battens
  • 700 metres of 38mm x 25mm counter battens
  • 300 metres of 1.5 metre wide Breathable water barrier membrane
  • 90 metres of valley drainage channel

We just need to double check these figures, plus any other material we would need, like for example, for the guttering and anything else for our roof!

 Posted by at 1:19 pm
Sep 192018

Yesterday we started on the task of installing and assembling our Skylight framework for real, right on top of our roof – at last!
The first job was to finish off putting on the wooden platform on the second scaffolding tower and get that ready for action. Then, using strips of foam, tied down with a lifting rope, we hauled up all the very long pieces, six of them individually and laid them resting on the steel cross tie bars. The shorter pieces of the outer rim parts, we carried up in pairs by hand, around and up the sloping roof to place these six items in their rightful places.
Then we concentrated on getting the ridge beam up on the nine central steel posts. We temporarily installing the two end rafters (inline with the ridge beam), so we could verify that the beam was in the correct position. Then we went to each of the nine points to glue and screw down tight the beam, including putting white PU sealant all over the middle kink joint too.

Assembly of Skylight Starts ..


Today, in the afternoon, we resumed the task, this time getting the outer rim edge (we decided to work on the back of the skylight first) positioned in the correct place, using a couple of rafters and were made to be as right angled as possible. Then we proceeded to get six rafters glued and screwed into place, plus also screwing and gluing this section of the rim too. Plenty of the white PU sealant was used to cover up all the joints and the head of the screws to provide a waterproof seal against rain water.
Assembly of Skylight Starts ..


 Posted by at 6:21 pm
Sep 172018

This morning, we used our new tool for the first time (a power file – a spinning little belt sander) to clean out the slots in all the various framework pieces that had dribbles of the resin stuff. This was the final stage of the preparation task before we could start installing and assembling the skylight up on the roof.
To this aim, this afternoon, we sorted out our scaffolding towers, putting a fresh new one up and getting it ready with the working platform etc. We had to do a quick repair job on one of the nut clamping point because the bolt had got really stuck and it sheared off. So we had to cut off the old nut and weld on a new one!
The other tower needed one more layer of the scaffold elements, so the second tower would be high enough to reach the Skylight region at the top of the building (We were lucky! the scaffold only just clears the steel skylight framework) !

Final Bit of Preparation on Skylight Joints and Scaffolding Towers Sorted


Final Bit of Preparation on Skylight Joints and Scaffolding Towers Sorted


Tomorrow, we will just quickly install the other working platform and safety kick boards and hand rails and we will be all ready to start the task of bringing up all the pieces of the Skylight module.

 Posted by at 6:29 pm
Sep 152018

Yesterday and today, we got down to the task of preparing our Skylight framework and all its individual pieces, to get them ready to be installed up on the top of the roof. The first job was to clean the bottom surface of all the items, to remove all the dribbles etc. and produce a clean surface, ready for gluing.
Then, we drilled out the fixing holes in all the rafters (all 33 of them) and countersunk them too so that the head of the screws will disappear down below the surface and be covered up with PU sealant. More holes were drilled in all our outer Rim pieces, so we now got three fixing points in every “window” section around the whole skylight (there are 33 “windows” in total) so this means a total of 99 screws to secure our framework to the Kerb.
The last job on these framework pieces was to cut a 3mm wide slot down the middle of the Rim items, this to allow the rubber gasket to be secured and held into place.

Two Days of Skylight and Kerb Preparations


Two Days of Skylight and Kerb Preparations


Finally, the Kerb needed to be “cleaned” to remove the 18months of weathering. We used our power planer and went around the whole 36metres length of the Kerb, trimming any plywood or OSB edging that turned out to be a little high and also levelled off any steps at transitions points between lengths of timber in the construction of the Kerb.

On Monday, we will use our latest tool, a power file (a narrow belt sander – 13mm wide) to clean an remove the last of the dribbles of the white polyester resin from all the wide slots in the Rim edging pieces (where the rafters will go). Then get the scaffolding towers sorted out and then we can really truly get the whole framework installed! Hurray!

 Posted by at 5:58 pm
Sep 132018

Yesterday and today, we continued with the task of coating the white top coat of the polyester resin on the wooden framework of the Skylight. We finally finished it today mid-afternoon.

Day 2 and 3 of Covering Framework With White Layer


Day 2 and 3 of Covering Framework With White Layer


Tomorrow, we will check all the surfaces for any defects, rub down any spiky bits and sand clean the bottom edge (this never had any treatment with the various resins) and drill fixing holes so it is ready for gluing and screwing down to the Kerb. The visible interior portions (like the bottom of the rafters) can be painted in the traditional manner later on when we decorate the interior.
Then it would be the big job of hauling all the pieces up to the roof and the Skylight to install the whole framework into place.

 Posted by at 4:30 pm
Sep 112018

Today, we rubbed down the second layer on all the pieces to get rid of a small number of drips and dribbles, plus also doing this coat of transparent base layer, revealed more knot hole problems so we dealt with them (by chiselling deeper into the knots themselves and then filling them with our 2-part wood filler) and finally the surface was washed down with acetone chemical to prepare it for the next resin coating.
Then we started on the white final finishing coating, by carefully painting just one side of each timber piece (rather than having to twist the piece around to the other surfaces and waste time – As the resin is continuously curing and hardening). We did the 12 pieces outside and a further 19 pieces in our workshop before the day came to a close.

First White Coat Starts Today


First White Coat Starts Today


Tomorrow, we will continue with this white layer on the other two edges and hopefully by the end of the day, we will have it all done, bar any tidy up and other repairs.

 Posted by at 6:18 pm
Sep 102018

Today, we rubbed down all the pieces of our Skylight framework, making sure that any dribbles, drips and sags were removed. It was a slow process and it took most of the day to process 43 individual pieces, and we also applied more wood filler, especially on knots as these were upsetting the curing process of the polyester resin coatings.
We managed to apply a second undercoat layer to all the critical areas where the triple glazing will be fitted, to ensure a good air tight seal on the surfaces.
Tomorrow, in the afternoon, we will check this second coat, do any further rubbing and then start applying the final white glossy layer.

 Posted by at 6:33 pm
Sep 082018

Yesterday, we started the process of painting the framework of the Skylight. We first removed all the tarpaulins we had covering things against any possible rain showers, and then unscrewed and dismantled the whole thing. All 33 rafters came into the workshop and the longer ridge beams and rim parts were left outside in the house but grouped together and much further away from any chance of being showered upon.
The first job was to coat these longer pieces with an undercoat layer of the polyester resin paint (this is a two part mixture) and leave it to cure hard. We almost did all 12 of the longer pieces.
Today, we finished off the last 3 pieces we couldn’t do yesterday and then returned back to the workshop to continue with the undercoat process on the 33 rafters. A filled some holes, sanded and then painted them with the resin.

Day 1 & 2 of Painting Skylight Framework


We finished with a little time to spare so we started sanding the first dry layer on the longest pieces outside to get rid of the spikey bits and get it smooth ready for the second coat, on Monday, when it will be the white coloured covering.

 Posted by at 5:22 pm