Roselea

Category: Phase 1

  • Light Chamber Complete

    The full Light Chamber is now complete, all 20metres of it, going right around the three sides of the garage room, starting from the front left corner, down the left side to the middle wall then across to the right side and back towards the front right corner. It has reflectors inside the Light Chamber which will provide two functions, the primary function of reflecting as much light out to the room and the secondary function of providing an electrical Earthing point which is required for the fluorescent tubes circuits.

    Light Channels - Installed

    Light Channels – Installed

    Light Channels - Installed

    Light Channels – Installed

    Light Channels - Installed

    Light Channels – Installed

    The flange is covered with an additional layer of the Fermacell to make it blend into the whole structure of the finishing surface.

    Now the boring job of filling in the staple holes and the joints!!

  • Building the Lights

    Today and yesterday, we have been slicing up leftovers to create our light chamber around the edge of the main garage room. We bought two rolls of aluminium foil to serve as reflectors to make sure as much of the light is deflected into the garage itself shining across the ceiling.

    Light Channel foiled boards

    Light Channel foiled boards

    Light channel ceiling reflecters

    Light channel ceiling reflecters

    Light channel ceiling reflecters

    Light channel ceiling reflecters

    The “Chamber” will be 200mm (8inches) wide sticking out from the wall and 80mm (3inches) down from the ceiling. This narrow slot contains the fluorescent lighting units, a collection of T5 (5/8inches diameter) 4foot tubes controlled by high efficiency electronic ballast. We will have 3 tubes down each side and 4 tubes across. We are trying out the latest digital dimmable controllers to try them out and learn what they are like and how difficult they might be to use.

  • All Shelving Uprights are Up!

    Today we finished putting up the metal shelving uprights. The extra ones we needed came today in the post so all the four walls now have some shelves on them. We have re-cycled most of them from the refit of our old shop, thus the multi colours! We will paint over them when we paint the walls…

    Garage Shelving Uprights Installed

    Garage Shelving Uprights Installed

    Garage Shelving Uprights Installed

    Garage Shelving Uprights Installed

    Garage Shelving Uprights Installed

    Garage Shelving Uprights Installed

    We also put on the correct bolts and washers to fix and hold the covers to the counter weight chambers inside the walls.

  • Fully Slotted!

    We have finished slicing the walls up! All the slots for all the metal upright brackets are now done and ready for them. There are in total 64 individual uprights to screw up spread all over the three main walls and two smaller sections on the front wall. A rough calculation shows that we could have well over 120metres linear distance of shelving! That hopefully will be enough!

  • Slicing the Walls Up!

    We have been slicing up the walls in the last three days! We have cut out the windows (again) to let in the daylight, trimmed around the counter weight panels coverings

    We are slicing vertical slots to recess the upright shelving brackets (this reduces that annoying gap at the back).

    The garage is the place where all sorts of things will be dumped and we are making sure we have plenty of shelves to store the “Junk”!

    Just one more day of slicing slots into the last side wall and front wall then we can mount the metalwork!

  • Fermacell Mounted!

    We have spent the last three days putting up the Fermacell sheets on the walls of the garage. Virtually all four walls of the front half of the garage is covered now.

    Garage Fermacell on walls LF

    Garage Fermacell on walls LF

    Garage Fermacell on walls ML

    Garage Fermacell on walls ML

    Garage Fermacell on walls MR

    Garage Fermacell on walls MR

    Garage Fermacell on walls RF

    Garage Fermacell on walls RF

    We started using 38mm staples but decided to switch to the shorter 25mm staples as they seem to be holding just as well and the majority of the thickness (made of 18mm OSB and 10mm Fermacell) is only slightly deeper than 25mm! it is working very well so far.

    Next we will have to fill in the staples holes and the joints between panels, we did a small test today and we are wondering if the filler supplied by the Fermacell people is the same as Polyfilla. We are planning to do further tests to find out.

    The technique of snapping the boards at the cut line seems to be working ok as long as the “waste” piece is large enough to bend in one piece without breaking into smaller pieces. Just a quick wipe with the Surform to smooth off the slightly ragged edge and that is it. No flying dust from a circular saw! Thank goodness!

    The boards are very flat and very regular in thickness and are joining together very well. It is looking good! Can’t wait for the finished article!

  • Day 2 – Fermacell All Up!

    At last! All the Fermacell boards are now up on the ceiling in the front half of the garage! It was a long day and we didn’t finished until just before 8pm!!

    Garage Ceiling Day 2

    Garage Ceiling Day 2

    Garage Ceiling Day 2

    Garage Ceiling Day 2

    Thank goodness for the lifter!

  • Day 1 Fermacell panels going up

    We have started the task of sticking up the Fermacell sheets on to the ceiling of the garage. It is quite hard, working above one’s head and each Fermacell sheet weighs over 35kg! fortunately we have a “lifter” specially designed to lift sheets up and allow us to position the sheet in the correct place.

    We have completed 2 rows out of the 5. We are speeding up as we learn techniques and developing a procedure so we should get the final 3 rows finished tomorrow.

    Garage Ceiling Day 1

    Garage Ceiling Day 1

    Garage Ceiling Day 1

    Garage Ceiling Day 1

  • Glass Wool!

    O boy! The Glass Wool is up, up and away in the roof space! The 170mm thick wool is nasty stuff and we wore our one piece dust suits and dust masks!

    The rolls split into three segments at their pre-cut points and mostly they fitted ok except for the middle segment where there was another pre-cut point on the original roll with caused the wool strips to start falling apart! We had to resort to stapling up strips of plastic sheets to hold up these awkward pieces!

    Insulation in garage celing

    Insulation in garage celing

    Insulation in garage celing

    Insulation in garage celing

    We finally, for extra insurance against any strip falling out, we criss crossed the ceiling a hazard white and red tape we had lying around!

    We are glad that it is all done, very tiring working above your head! Tomorrow it is the Fermacell turn to be put up! O boy!

  • First stage of interior wall completed

    The first stage of the interior assembly of the walls is completed, well at least the front part of the garage is!

    OSB Lining complete

    OSB Lining complete

    OSB Lining complete

    OSB Lining complete

    OSB Lining complete

    OSB Lining complete

    OSB Lining complete

    OSB Lining complete

    As you can see, there is a slot half way up the wall, called the The Utility Rail, open and ready for the electrical cables etc. It is a 100mm (4inches) high cavity all the way around the garage. This will allow us to have sockets anywhere we want as well as compressed air outlets, data network connections, vacuum ports and anything else we might think of in years to come!

    Drift of sawdust

    Drift of sawdust

    It was a pretty dusty environment we were working in but we had dust masks and thank goodness we had especially when we were sweeping the sawdust up!

    The Fermacell will go up on the ceiling first tomorrow and then on the walls themselves in a few days time. This will create almost the final finishing surface! Just nice brilliant white emulsion paint as the finishing touch!

    P.S. The light splotches on the photos are air born dust reflecting the flash.