Roselea

Category: Roof

  • Rest of Oak Timber Glued

    This morning, we finished gluing the last fifteen sets of Oak timber, only using 5 set of clamps (as our new ones haven’t arrived yet). We had to wait for the 30 minutes for the PU glue to reach first hardening stage but it wasn’t too bad as we were able to keep a cycle going with new freshly glued ones and be able to unclamp the oldest glued set which was just about at the 30 minute point.
    Then after lunch, the five we had glued yesterday, we scraped off the excess glue and then put them through the planer to slice off a fraction of a millimetre to clean off the stain of the glue and any slight imperfections.

    Spot-the-glue-joint-1

    Spot-the-glue-joint-1

    Spot-the-glue-joint-2

    Spot-the-glue-joint-2



    You cannot see the actual joint itself, but only by the fact that the two Oak strips have a very slight different in colour and of course the grain do not match up either.
    But it is looking good and tomorrow, when we have done the same to today’s fifteen glued planks, we then will be ready to pass all of these twenty glued planks, plus the other twenty single Oak pieces, through the planer in its thickener section and achieve, hopefully, a set of forty Fascia boards with all the same thickness. We will see!

  • First Set of Oak Timber Joined

    This afternoon, after lunch, we finished off planing the various pieces of the Oak Timber so they are ready for the job of gluing them together to form wide enough Fascia strips (needs to be greater than 150mm wide). Then using our biscuit jointer tool to help align the pieces, we proceeded to glue and join together five planks.

    First-5-Glued-up-Facia-boards

    First-5-Glued-up-Facia-boards

    We used a fast acting PU glue so we don’t have to wait eight hours to get maximum strength, this glue will reach working strength after only 30 minutes. We are planning to be able to clamp nine set of pieces together in a session and by the time we have done the last one, the first one will be ready to be unclamped and we can carry on with the tenth set and so on. Hopefully the new clamps will come tomorrow in the post! – or else!
    After the twenty sets are glued and cured, we will very slightly plane the finished surface again to remove any trace of glue and any very slight misalignment’s, and then all forty pieces will be put through the thicknesser part of the planer machine (this planes wood to a fixed thickness) to get a final set of finished Fascia boards – at last!

  • Oak Timber Still Continues to be Processed

    These last few days have been somewhat disrupted with various external meetings and other commitments and the work on sorting out, planing and processing the Oak Timber have been patchy. So far, after today’s full day, we have selected  32 narrow pieces and sawn them to 95 mm wide, then selected 11 pieces just over 180 mm wide. These pieces have now been put away back on the Oak Storage rack outside for later in the project.
    The rest are the 40 mm thick oak is being processed into more than 75 meters of Fascia boards, we need 40 pieces of oak  which are 150 mm high, we have enough planks to make 20 pieces from whole wood and parts to make another 20 from two narrower pieces glued together.

    Oak sawn to size, 32 pieces@90mm and 20 pieces @155mm

    Oak sawn to size, 32 pieces@90mm and 20 pieces @155mm

    Oak-for-garage-window-sills-11pieces-@-180mm

    Oak-for-garage-window-sills-11pieces-@-180mm

    Oak-for-gluing-together-to-make-another-20-@-155mm

    Oak-for-gluing-together-to-make-another-20-@-155mm


    All of the pieces have now had one flat surface planed (60 pieces in total). Now we are planing the narrow edges to ensure that they are right angles to the processed face. On Monday, we will finish that task off and then start gluing and joining together strips.

  • Oak Timber Sorted and Being Processed

    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.

    Sorted-oak-ready-for-slicing-to-size

    Sorted-oak-ready-for-slicing-to-size


    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.
    Table-saw-with-new-Fence

    Table-saw-with-new-Fence

    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!!

  • Oak Timber Work Continues

    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

    Width-Measuring-tool-1

    Width-Measuring-tool-1

    Width-Measuring-tool-2

    Width-Measuring-tool-2



    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.

  • Oak Timber Continues Being regularised

    The task continues today of processing each Oak timber piece to regularised them into flat and straight consistent planks of wood.
    The smaller widths are now done.

    Stack-of-Edged-40mm-Oak

    Stack-of-Edged-40mm-Oak


    But the wider set is proving more difficult to handle as the weight of these 2metre long planks can be quite heavy (upto 20Kg!) and we discovered that this is causing a slight distortion within the planer machine itself (like the little castor wheels were bending, and the latest, the metal flat input and output tables are also being deflected slightly too). So we are finding solutions to handle these oak planks, including buying more rollers on legs and putting the machine on blocks of wood.
    Trying-to-get-planer-to-work-on-larger-pieces

    Trying-to-get-planer-to-work-on-larger-pieces


    There are hundreds of Oak pieces we have bought for all sorts of jobs around the house, which we will need to plane and regularise so we are going to invest some time and thought to build a sturdy framework, possibly extending the input and output tables to help support the heavier Oak timber and create a factory like setup to consistently and accurately do this job properly.

  • Some of the Oak Timber Planed on One Edge

    Today was the day where our Oak Timber started the process of being regularised. The first process is to plane one edge straight, there are 90 pieces to process and 35 of them have been done.

    Oak-facias-Day-1-of-edge-planing

    Oak-facias-Day-1-of-edge-planing


    It was a case of learning the technique and making sure the finish edge is flat and straight.
    Once this edge is made flat, we can set aside the 32 planks to slice in the circular saw to achieve the desired width of 90mm which are for the four pillars to form the corners of the Conservatory and 11 planks of 175mm wide to make sills for the garage windows.
    The rest is for the Fascia which needs to be 150mm wide and some of them will need two pieces glued together, in order to get up to this width.

  • The 40mm Thick Oak Timber Being Processed To Generate the Fascia Boards

    Yesterday and a little bit late this afternoon, we have started processing a some of our Oak Timber to create the Fascia Boards for our Roof.
    We brought (yesterday’s shorter work day) into our workshop all the planks of the 40mm thick Oak and have it all laid out on the floor. It adds up to about a ton of timber!

    Pile-of-40mm-Oak-planks

    Pile-of-40mm-Oak-planks


    Then, today, we started the task to plane all the planks, using our big planer machine, on one edge to establish a flat straight edge. We noticed that the width of the rough sawn timber is not parallel and there is some variation. We didn’t have time to do many so we will learn more tomorrow to how this variability will reveal itself in the bigger picture and change our calculations of which planks of Oak will be put aside for other part of the building etc. We need about 80 metres of 150mm wide boards to do the Fascia and the rest will form parts of the conservatory and Garage Windows.

  • Conservatory Dormer Roof Framework Now Complete

    Taking advantage of the better weather today, we went to finish off the task of installing a couple of sheets of cement boards to complete the gable triangular section of the wall.

    Cement-boards-on-Q-Gable

    Cement-boards-on-Q-Gable


    Then we tidied away the remaining spare cement sheets and stored them in our sheet material storage tent. We have six sheets left for future jobs like the rain filtration unit.
    After lunch, we sliced and cut two long diagonal 95mm by 45mm thick timber rafters to conclude the framework for this dormer roof structure that will connect to our Conservatory (which will be built in a couple of years). There was quite a complex joint to make to connect to the sloping valley rafters sticking out of the building(as the picture reveals below)
    Joint-on-end-of-Q-facia

    Joint-on-end-of-Q-facia


    Then these two final pieces were carefully fitted, making slight adjustments until all was good and tight, at which point, they were glued and screwed together. The excess valley beams were sliced flushed afterwards.
    Q-Framing-complete

    Q-Framing-complete


    This concludes the building of the framework of the whole roof and the next job is to produce the Oak Facia boards that goes all the way around the edge of the roof.

  • Framework All Completed for Conservatory Roof Interface Dormer

    Today, we proceeded to cut six rafters to fill in the sloping sides of the dormer roof structure, and then four vertical posts to fill in the gable flat extension of the wall going up.

    Q-Roof-framing-complete-1

    Q-Roof-framing-complete-1

    Q-Roof-framing-complete-2

    Q-Roof-framing-complete-2



    On Monday, we will put up two cement boards on the gable wall to get that covered up and then we will need to add the last rafters on the front which will be the actual interface to the conservatory

    The we can start looking at the Facia boards and the guttering.