Stephen

Feb 272018
 

This morning, our 75 sheets of pretty plywood arrived. The lorry managed to get down our Loke, and we placed our flat bed trolley alongside. We then pulled off the plywood, sheet by sheet. This allowed the delivery bloke to get off to his next port of call.

Pretty Plywood Arrives and Five More Rafters Created

Plywood-unloaded-onto-the-trolley

We then moved half the pile by taking 3 sheets at a time and walked about 15 metres to our new storage tent. Eventually, we were able to move the trolley itself, with much slipping and sliding on the snow, and got the remaining sheets unloaded.

Pretty Plywood Arrives and Five More Rafters Created

Plywood-stored-away

This plywood is much nicer than the last lot (well we bought it as pretty)

Pretty Plywood Arrives and Five More Rafters Created

Plywood-has-a-decent-numer-of-plys

Pretty Plywood Arrives and Five More Rafters Created

Nice-grain-on-Plywood


After lunch, we resumed in the lovely and warm workshop and created five more rafters.

Pretty Plywood Arrives and Five More Rafters Created

N-O-Rafters-made-so-far

That’s was enough for Shaun’s back so tomorrow we will finish off the last two rafters and get ready for doing the “K” section by measuring the final set of rafters! Hurray!

Oct 172017
 

This morning, we tackled the next rafter, the A4, to slice the bevel on the end of it, analysing the results. It was still inclining to curve outwards during the sawing and we surmised that the saw blade was ever so slightly off line. So we attached a thin 1mm plastic spacer on the sled at the bottom left corner to try and offset this skewness. And yes it did seems to do the trick. We then did the next rafter, A5, and repeated the bevel slice and this time we got a much better cut first time. We are a little bit more confident of the machine now. The proof came when we took these two rafters outside to get them up and installed. We decided to try and man handle them up ourselves as we had a great advantage with these rafters as the wall ends fits like a glove and actually anchors the whole rafter into place. We only needed to hold the top end to relieve the strain and make sure we don’t accidentally break the Bird’s mouth joints.

Roof-Section-A-Completed

Roof-Section-A-Completed

We fixed them the same by screwing a 8mm coach screws, one in the bottom and one in the top of each rafter and also glued of course too! It went very well and flat against the PA diagonal beam which further enhanced our confidence that the Bevel Slicing Machine is performing better.

Then after lunch, we went around measuring the other similar sections of the roof, namely the “M”, “I” and “E” sections by moving the tall scaffolding tower around, as all are having the same 32degrees slopes. During this task, we were concerned that we were getting spurious misleading measurements along the top flange distances because our template was not going flat against the Kerb of the Skylight and this was proven when we placed the spirit level on the template and the position of the Kerb was slightly proud of the steel webbing underneath. This caused us to reconsider and switch over to measuring the bottom flange distances instead as we realised that this aspect of the rafter element is much more “stable” and the main structural load points is on the bottom flange at the top and the shape of the wall end (the top-plate and legs) are much more accurate to where the Bird’s Mouth goes. So we took down a series of distances to then enter into our spreadsheet, ready for preparing the elements of the rafters in our workshop tomorrow. There are 10 more long rafters to make and a heap of the bevelled rafters to fill in those corners of the roof sections.

Aug 262017
 

The metal splice plates for the O ridge have been welded together.  More care was taken to weld them in short stages and swapping from one plate to the other resulting in almost no warping of the plate.

Ridge-O-Splice-plates-welded

Ridge-O-Splice-plates-welded

Now we have to make the wooden parts of these beams…

Aug 242017
 

The parts of the metal work for the K ridge were welded together, after they were finished it was noticed that the big metal plate had been distorted by the heat of the welding. We will have to investigate how to reduce this for the O ridge plates!

Ridge-K-Splice-plate-welded

Ridge-K-Splice-plate-welded

Tomorrow we will make the parts for the O ridge and maybe start welding them.

 

Aug 232017
 

After finishing the construction drawings, fabrication of the metal work started with drilling 64 holes in the flange reinforcement strips.

Flange-reinforcement-drilled

Flange-reinforcement-drilled

Then the two side plates were cut out and drilled for bolts.

Splice-plates-cut-and-drilled

Splice-plates-cut-and-drilled

Tomorrow the sockets for the adjoining  rafters will be welded on.

Jun 052017
 

While half the workforce is disabled, Stephen was busy designing and building several new pieces of equipment and tools to help with various future jobs that will be needed to be done as part of building the rafters and walls.
The tools were created approximately in the following order:

Polystyrene Foam Board Hot Wire Slicer

Insulation-slicing-Triple-hot-wire-cutter

Insulation-slicing-Triple-hot-wire-cutter

Hot-wire-power-supply

Hot-wire-power-supply



We needed a tool to slice our pile of 8 foot by 4 foot 120 mm thick boards into much thinner sheets (38mm thick) and a few different heights (between 248mm and 265mm). We couldn’t buy the correct thickness of sheet (only 35mm or 40mm) and 120mm thick boards were much less than 3 times the price of the the thinner sheets so we decided to slice the thick sheets down.
Using high resistance wire to form the basis of the machine, we can have 1, 2 or 3 wires, fully adjustable to different heights and separations, and connected to a high powered electrical generator to heat up the wires to melt the polystyrene foam.

Router Jig to Cut Rafter Slots in Cement Boards

Rafter-end-slot-cutting-template-1

Rafter-end-slot-cutting-template-1

Rafter-end-slot-cutting-template-2

Rafter-end-slot-cutting-template-2

Rafter-end-slot-cutting-template-3

Rafter-end-slot-cutting-template-3



This template slots on top of the wall, at each rafter and leg position, to guide a router to slice out a vertical slot in the wall cement boards. These slots allows the top flange of the rafters to pass through the wall and stick out to form the eaves.
It is adjustable to accommodate the different angles of the rafters.

Laser Guide for Wall to Steel Framework Alignment

Laser-Rafter-alignment-jig-1

Laser-Rafter-alignment-jig-1

Laser-Rafter-alignment-jig-2

Laser-Rafter-alignment-jig-2



We needed to transfer the position of the Wall Legs where each Rafter sits on, up to the Steel framework so the rafters will be exactly in the correct orientation and be locked into place. The steel framework will have planks of timber glued and screwed against the webbing and flanges of the steel i-beams, but also these timber pieces will have a series of 10mm deep slots sliced in, at the regular 612mm spacing. We need to make sure these slots are perpendicular in relation to the wall legs that the rafter will be joining onto. The laser is aligned to a leg and projects a line at right angles up to the steel beam.

Glue Spreader

Glue-Spreader-MK1-2

Glue-Spreader-MK1-2

Glue-Spreader-MK1-1

Glue-Spreader-MK1-1



Using our 3D printer, we designed a glue spreader to help us lay down a thin film of the glue on to the timber and stick down other materials like plywood etc. The glue is pumped into a the open space via small tubes, the chamber has a notched side to allow a controlled amount of glue to be spread as the tool is dragged along. The first version was drawn on the computer and then converted into a multi-layered object for the plastic extrusion printer to build, layer by layer, into a solid object.

May 242017
 

In the afternoon we started to cut and fix the short pieces of timber which fit between the lintels over windows and doors and the top of the wall. These short studs will provide places to attach some of the roof rafters (rafters will be attached to nearly all legs). We completed 5 of the openings before stopping early for other commitments.

Short-studs-between-lintels-and-top-plates

Short-studs-between-lintels-and-top-plates

Further commitments will mean no further work outside until Saturday but we will be ordering the LVL beams.

May 242017
 

We started the day by measuring the distance from the steel frame to the walls at all hip and valley beam positions as well as selected other points. We wanted to confirm these distances so that we can order the LVL beams to make the hip & valley rafters at these points.

To measure the distance we placed our very long ladder against the steel frame and stretched a tape from the steel to the outside of the walls top plate.

Long-ladder-for-measuring-steel-frame

Long-ladder-for-measuring-steel-frame

We made 15 measurements  and we a pleased to say they correspond to the drawing within 50mm (mostly within 30mm).

Nov 012016
 

After getting the Mag Drill we finished off cutting the angled ends of the beam ties.

Beam-ties-all-angles-sawn

Beam-ties-all-angles-sawn

Then we started marking and drill holes in the beams outside. The beams will have hundreds of holes in them, but only about 50 of larger holes need to accurately positioned. After marking out the position of the holes which will be used to attach the beam ties, we stated drilling them with the mag drill. We finished 20 of them before it got dark (at 5pm!).

First-holes-in-a-beam

First-holes-in-a-beam

We have ordered 2 powerful floodlights to help illuminate the house whilst we work on it.

Nov 012016
 

We collected the rented Magnetic drill this morning. The drill has an electromagnet in the base so once you position the drill you turn on the magnet and the drill is fixed in position so you can drive the cutter into the work. The cutter is hollow and has a retractable center pin which allows the accurate positioning of the drill, cutting fluid also flows down this hollow from the bottle above the drill.

The-Mag-Drill

The-Mag-Drill

Mag-drill-cutter-and-center-guide

Mag-drill-cutter-and-center-guide