Sunday, November 27, 2016

Workshop Remediation Completed

Ugh. Back in January, this tale had been started and left "to be continued". Well, blog posting being relatively low on my task priorities, the tale continues. The shed- topic of the last post- was a major detour. It did help clear the shop area out so the work there could proceed. The ceiling was the first task. I don't like drywall and wanted to maximize ceiling height, thus exposing the joists and using  rigid foam insulation with panels between the joist was the initial plan. Cost of solid foam panels to achieve required R value vs high density roll insulation changed the plan to a lower height of the panels between the joists. A visit to my local salvage yard gave to solution to the panels in some corrugated steel panels that required minimal cutting to fit as needed. The last photos on the 5/22/15 post show that part of the job in progress. Here are the finished ceiling photos. I would have loved 10 foot ceilings, but at least I can stand a sheet of plywood up straight.
The next step was taken care of by Dale, a general contractor who also does as much- or as little- as is requested. I had framed the rough openings for the new windows and gutted enough of the existing interior walls that he could re-wire and place a glue-lam beam to support the portion of the load bearing wall that was being removed to improve the workspace.

Here is the area (studs only) where the glue-lam was installed.

Next was removing the vinyl coated tile (VCT). The floor covering was there  when I purchased the property, so I was not sure if it was made/installed in the post-asbestos era. A Home Depot purchased asbestos testing kit confirmed that the tiles and glue were not a health hazard to remove. It was a chore to remove with some portions of the floor much more adherent than others. A concrete floor refinisher had given a reasonable quote on prepping and placing a epoxy finish on the old concrete. That was accomplished with an adventure component (he had to come back and re-apply the finish), but in time for Dale to do his work as scheduled.

I had taken some vacation time to finish the ceiling, and do the interior walls in the late summer. Vacation times can be difficult to re-schedule at my clinic, so there was some anxiety around the floor and interior structural work timing. I was able to install drywall and the wood wainscoting during the time I had scheduled to be off work.
Having tables and machines on rollers and being able to vary the height on my two modified festool tables made the next part of the task much more manageable
Here is drywall stage.

Once the interior was sufficient far along that I could start moving stuff back in, I could address storage. In my younger days, I would have built the cabinets but sometimes bought rather than built is the way to go. I wanted this time to store shop stuff in as portable and space-efficient manner as practically possible and metal tool chests with their thin metal drawers, caster wheels and large load bearing capacity could do a better job than anything I could make. Lowe's had roller cabinets on special, but by the time I had returned to buy them, they were back at regular prices and reading reviews dissuaded me from buying at that price.  As I still had plenty of work to do, I decided to monitor Craigslist for used SnapOn boxes as, other than price, that seemed to be the toolbox of choice. After 3 wks of searching, I found a box at a good price and not too far. Great box, except for weighing 400+ lbs, but that's why it's sturdy.

SnapOn would have been overkill for the remainder of our storage needs, but Gladiator cabinets were a good value on special when purchased.

Harbor Freight boxes are a mixed bag. Their glossy red stuff is well-built if the color is tolerable, but their black boxes were purchases I would not do again.

The last of the boxes was a Kennedy, which I found on Craigslist and is a good value if purchased used.

It seems that most woodworking shops have tools on the walls rather than in cabinets. I went with the latter approach as it is easier to keep clean. Drawers still need to be labeled and organization completed. As of the time I'm getting around to this post, still a work in progress.

Once the shop was functional, It was time to build stuff for the house again. The first project in the new and improved shop was a combination bench that could serve both as a reading reclined couch and a sitting bench as well as provide more book storage. Next post or else I'll fall hopelessly behind in keeping up with this blog.

Saturday, January 16, 2016

Storage Shed

Much has happened since the last post. As with all home improvement projects, the battle plan does not survive encounter with the task itself and this years work turned into a conflict with two fronts; military buffs know how that usually goes. This was in addition to deciding I wanted to read 50 books in 2015. Thus blog writing ceased for the remainder of the year. At the time of the last post, we were figuring out where to store the contents of the gutted space. Our TV room  and an adjunt storage space were able to accommodate some of the displaced stuff. There was still a great deal of construction material which needed storage. This brings us to a major change in the original plan.
The property as purchased came with a small shed which was used mostly to store leftovers from previous projects, yard stuff and other basically detritus. Walls were concrete brick but only 4 feet high and the roof was a simple low angle gable 7 feet at the peak.

While it remained watertight, the plywood door and plexiglass window made it at times a shelter for various neighborhood critters. As I was clearing junk out to make room, it became very clear that the storage shed needed major work; much more than my workshop needed additional space.
Thus the plan for bumping out the east wall by 6 feet was abandoned in favor of rehabbing the shed.
One thing that had been stored there that was both valuable and useful was about 200 linear feet of treated 2x6's. They were put to use as wall framing and trusses so the shed could have 8 feet high walls and a more PNW appropriate roof pitch. I preformed the wall portions and cut the angles for the trusses over a three day weekend. I thought I could tear the old roof down and get the structure to frame and roof stage over the following week. The battle plan went drastically awry when removing the old roof showed one wall about ready to fall over and another wall needing work as well.
The last time I had done any masonry work was 16 years ago. A wall that needed replacement and a proper foundation together with a slab and another wall that needed repairs as well were well beyond my minimal masonry level and free time. Fortunately Dale came to the rescue. He's the contractor who was going to do the shop extension. While he is a licensed general contractor, he mostly works on one man jobs and is sort of a neighborhood treasure as he does not advertise and relies solely on word of mouth for projects. He came the day after receiving my frantic call, looked at it and agreed to squeeze the job in that week. As it turns out, while he does masonry and concrete infrequently, he's pretty good at it.
So I was back in business. Dale helped me put in the roof beam and trusses and plywood sheathing and even helped me finish off that part of the task on the fourth of July. Like I said, he's a gem; the photo below is us working on 7/4.  As we were putting up the roof, I got nostalgic. One of my favorite photos is of our sunroom at frame stage. It was taken with B&W film.

Twenty years later, the color and digital version

The rest was pretty straight forward but time consuming and at times physically demanding. It was a fun little project; kinda like making a tiny house- minus the plumbing and electricity. I was able to incorporate a couple of old colored glass windows that were previously in the shop area and would not work in the revised shop area.
The shed once completed was able to store much of the materials to be used in the shop remodel. Once those materials were installed and detritus removed, DW would have plenty of space for a potting area. As the project progressed it became clear that rehabbing the shed was a better use of time and money than adding on to the workshop.

The interior now

Now it's back to the shop area.

Friday, May 22, 2015

Workshop Remedial

Le Corbusier, is famous for proclaiming "the house is a machine for living in".  Our ranch home has certainly influenced my life. As I addressed it's shortcomings, the house helped me develop values, learn skills and even played a role in finding my spouse.  How all this took place would not have been possible without a space that I could use as a workshop. Thing is, though, that while it led to a home that we're very happy with and which provides a great setting to pursue our interests and loves, the shop itself has been a bit of an ugly duckling. I hate low ceilings, lack of good ambient light and particle board all of which my shop possessed in abundance. This is the space back in 1995 when it was in escrow.

The shop/storage area is under a second story addition. It is 24 x 24 and divided into 4 sections. The photo shows the main section; two doors allow access to 8x12 ft and an 10x12 rooms. The first was used as a small work area and the other as storage (below)

 The main initially was a man-cave sort of area; the owners from whom I purchased the property used it as storage. The main area had two small windows. There is an additional area 6 x12 which was used as a garden shed. That purpose makes sense as it opens directly to the back yard. However, it wastes it's exposure to sunlight.

The floors had vinyl tile floors, particle board paneling, dropped acoustic ceilings, aluminum windows and particle board cabinets. Ouch.
The initial remedial interventions were to get rid of the acoustic ceiling in the main area and replace the aluminum windows with vinyl windows. The window on the long wall was covered over with a pair of stained glass wood windows as (my idea of a) window treatment and for insulation. It and the adjacent 8x12 area served as my shop for the next 18 years or so. The other two areas served to accumulate stuff, some needed, most eventually categorized as junk, during this time.

DW being a PNW native noticed a small wet spot on the upstairs south wall three years ago. I foolishly ignored it as it was not increasing in size. The reason it was not increasing was that it was traveling further down and eventually created a leaky shop ceiling. Good news: led to replacing a noisy and leaky skylight upstairs with one twice as large which made for much better headroom with a much larger ceiling opening. 

Getting back to the shop project; the above space is relevant because the shop's drywall ceiling had significant water damage. While getting rid of the acoustic ceiling in the mid 90's improved the shop ceiling height, I recurrently ideated ways of improving this further and rather than repair the drywall, going to an exposed joist beam would improve the "lacking headroom" issue.  As most of the shop area is under a second story, options are pretty limited. There is a 5ft area that has a flat roof only facing East that I thought about, but was dissuaded from consultants as practically implausible due to joist orientation. I settled in tearing down the drywall which I installed 16 years ago. That would let me put recessed LED 1x4 panels between the joists and raised the ceiling areas b/w the joists.  For insulation my initial plan to use solid panel insulation was changed to fiberglass rolls after learning the price difference. I was going to use plywood sheets between the joists, but found some steel panels at my local salvage that I used instead- no painting, sealing or dealing with seams. The price was reasonable as well.
DW had developed an interest in my shop after I began to share the area with our latest addition to the cat census. Like our prior addition, this was a cat squatter.

DW agreed that, given the known belligerence of our # One Son (Ernie) and the new kid, it was best for Andy to stay out of the house.  The cat still needed shelter from bad weather and other meaner, bigger critters, thus I have a new shopmate. DW also  developed an interest in dust management (see 4/18/14 post) and the general livability of the space. Given my hatred of particle board, it was ironic that it covered the walls of the shop and the cabinetry was made of the stuff. 

So, before we could even think about what then new was going to look like, emptying the shop and storage area and gutting the interior needed to take place. Storage space is valuable and necessary, but it also the case that it's a coffin for stuff. Between drywall removed from the ceiling, removing everything that's particle board (bears repeating that I despise particle board), and applying the rule that if something has not been used in more than a year, it needs to go,  Below is a pile waiting to go to the dump- multiply by six - and counting.

The exception to this is wood left over from prior projects; most woodworkers seems to need to keep a varying amount of supply on hand. 
Another challenge is that the shop still needs to be functional in order to do the work needed to rehab it. When moving tools and supplies, keeping things organized and accessible is proving to be a challenge. Fortunately, yet another small accessory area has come in handy. By getting rid of 3/4 of what was being stored, re-using some of the shelving and cabinets from gutting the shop area, I was able to make a temporary home for materials and tools.
Once gutted, DW was able to see what I could not adequately verbalize. Lack of good ambient light was my workspace's most significant problem. The space where my mitre saw and band saw were previously stationed could not be used without artificial light. It also served as a kitty litter area and bike storage (see above). The main area needed artificial light except if it was a sunny day and even then only from morning to mid-afternoon. I thought that by opening the previously closed off garden tool shed area to the shop and adding windows to the East wall would solve the lack of daylight problem. DW further suggested to bump out the East portion to add to the area that has the most sun exposure. Once the area was gutted, it was evident that it was quite spacious. So, why add square footage? Well, the low ceiling height would limit the height of the windows I could use and it would likely still be hard to get in daylight. This is the South view presently with morning ambient lighting-still kinda dark. I also had begun looking at internet sites for ideas for layout and found that most of the shops seemed to have even more workspace area than mine.

The hope is that by bumping out the South wall 6 feet and raising the ceiling height in that addition, we'll be able to, by taller windows and possibly skylights, introduce more light into the workshop area. The other areas below will be storage, bike garage and kitty bathroom and feeding areas as there are no windows there.  Here are before photos of the two rooms

And at the present stage

To be continued...

Saturday, October 11, 2014

Home Office Declutter

Most projects I read about or see are before, after and done. My office area often seems, like many areas in our home, a perpetual work in progress. We recently put in hardwood floors in DW's office, which provided the opportunity to unclog her chronically overloaded office and closet (yes, it's a nontraditional ranch house but mostly works for us). We were both really pleased with how her office looked and functioned afterwards.
Now that I couldn't get on her case about her office, imagine my consternation when looking at my space and realizing- Damn, that's cluttered. Perception is a funny thing- one thinks one can see, but it's often a funhouse mirror when looking at ourselves. I do find taking photos to be helpful with the vision thing.

In my own defense, I'll present what I started with. The house as purchased did have a dedicated office space. As a work area I wanted to keep it separate from other parts of the house.

It was also an alcove in a very large room (the good part) that needed a lot of work (the bad part). The alcove is behind the partition in the center of the photo.

Digital technology progressed in a Moore's way such that this room evolved into a great space for digital printing and for matting and framing photos. Thus I was back to my previous MO of requiring two desk areas (another story). Once married, I made room for DW's family heirlooms, one of them being a small secretary desk which I modified to fit where the original desk stood (I had removed it to make room for my desk) but kept the built-in bookshelf.  My need for storage expanded with digital printing. Thus along with wanting a standing work area for working on prints (vestige from chemical darkroom days) led to the standing desk area and the configuration shown above. Oh- and the wallwart heater and cord cover happened when we changed from baseboard electric heaters to heat pump. This location was the least obnoxious place for the heater- a necessary eyesore.
Of course to use the chemistry analogy of going over reaction hill to get to happy products valley, there was going to be some entropy and work involved in cleaning up this mess.

A new desktop and drawers made up for some of the storage area lost in simplifying the area, but making said items prolonged the task. The effort was worth it though as it cleaned up the area visually and provided the needed storage for the needed accoutrements for what the space was used for.

The final result (for now) a place for everything and everything in it's place. The wall-wart was minimized to the best of my ability

Here's the evolution from picture#3

PS- DW little desk from her GM dad's side was refinished, reassembled and has a new location in our spare bedroom.

Sunday, September 21, 2014

Tijuana Termites

Recycling and reclaimed are a couple of terms I've seen when referring to the practice of using not-new materials in home construction. Nowadays, or certainly post 2007, it has a very positive connotation and will be a noteworthy feature if used in a project. If done in a higher end project, the re-used material will be obtained from a Deconstructionist  (as DFW would say- those who refer to themselves as such understand themselves as capitalized).
This preamble is used to give context to the post's title.  The term originated with West Los Angeles construction crews  in the late 70's. It was noted that stuff was disappearing from tear-down sites of perfectly good structures before being hauled off by the disposal crews. It became known that the perpetrators were Hispanic and the construction materials and appliances were being used to build houses in Mexico. Thus came the label.  It most assuredly was not a complimentary description but it was also not regarded as illegal; the material was of no value to anyone in WLA and was destined for landfill. Being a Spanish ESL guy and from a modest SE background, I found the practice downright admirable even then. Which is why I remember it 35 years later; I tried researching the term in the LA Times to no avail.

DW's office and the guest bedroom needed new carpets in a bad way (cats...). But we had just finished a partial kitchen remodel, so I did not feel up to another significant cash outlay. I had been looking at Craigslist in the hope of finding flooring at a less than retail price for a few months. Don't ask why I was doing this while at the same time looking forward to a break from home improvement.
I found what I had been searching for and at lower price than I had hoped for, but packaged in an unanticipated way. Which is when Tijuana Termites came out of hard disk storage.
Not Deconstructionist condition, but not at Deconstructionist prices either. After a further price adjustment and the seller's son helping us bring the material to our home, I set to pulling nails. I had done hardwood floors before but with new material. Thus, there was concern about how well boards with less than pristine tongue and grooves would fit together and how significant the variation in thickness would be. The project developed into an economics exercise with the variables being cost, time and risk. Risk was the most worrisome aspect of the project as there was the possibility that end result would not be acceptable. I installed the guest bedroom floor first and was relieved that the boards had a tight fit in 95% of the floor surface. I had been hoping that the depth variation would allow me to use the boards in a "poor man's prefinished" fashion, but there was indeed too much of a thickness variation to allow for this (not to mention DW's veto).
The next risky part was sanding and finishing. I had successfully used an orbital sander previously along with a polyurethane finish. The polyurethane was DIY friendly but not very durable and gave the floor an undesirable yellowish tint with aging. We had decided on Rubio Monocoat as it has a flat finish and is nontoxic.  This would spare the need for a week of lodging expense for two adults and two cats. The supplier for the Rubio strongly recommended using a belt sander along with a buffer to apply the product. I had heard horror stories about novice screw-ups using belt sanders, so risk re-entered the project. As I was considering my options, one of my patients came in with prepatellar bursitis. I knew he was a carpet installer, When I asked him if he knew anybody who did hardwood floors, my floor finishing dilemma was solved (with the stipulation that I didn't want to see him on his knees).
The next leg of the project was over Labor Day weekend. It was warm and sunny and missing out on lazy mornings, bike rides and parties reminded me of another cost in doing projects- missed alternatives.

Installing the floor in DW's office was faster as she measured and cut the ends while I was nailing them down and the following day Don (my floor installer patient) and his friend Mark set to work on sanding the floors. We finished that leg early Labor Day morning. My plan was to use the buffer and apply the finish. Don asked- have you used a buffer before?- with my reply being no. He noted that there was a learning curve to using one and suggested that I begin in the middle of the room in case it got away from me. He probably would have been more forceful in his admonition if he had known that a step prior to applying the finish was to use a sanding pad with the buffer.
This was the end result after an hour playing mechanical bull with the (expletive) buffer. Or as the Germans say- no battle plan survives contact with the enemy.

So I called Don and his friend Mark who are doing what sensible people do on a holiday- hanging out with their family and drinking beer- to ask for their help. When I pick them up, Mark mirthfully says, "normally this would call for triple time, but we like working with you". The cavalry was here; unfortunately, Don also had a learning curve with Mr. buffer with a sanding pad attached.

Thankfully, Mark got the hang of how to use the buffer and, between the three of us, were able to apply the finish in a couple of hours. Even though there was monetary compensation involved, it felt more like working with friends and colleagues.
The trim was a bit of an adventure as well. I looked at my usual places for stock door and floor moulding with the retail options being either expensive or boring and cheap (in every sense of the word). So I went to a local salvage place that has a nice balance between the Deconstruction approach and the complete "as is" condition. The Saab that I drive used to be my DW's and she continues to be dismayed by how it's used at times:
Here are the finished rooms after DW painted and I sanded, stained and installed the trim. I lost track of the hours we spent on the project, but the monetary output didn't strain our finances and the risks were successfully managed. And we have a story to tell.

Monday, September 15, 2014

Back to School

As our kitchen update neared completion to the extent that the space could be used again, DW began to anticipate returning to work for the new school year. She had been looking at teacher easels and asked me if I could fix the remnant of an old easel that had been used by her mom

Once I saw what she wanted to use it with- a Walmart 2x3ft dry erase magnet board, it was apparent that the little easel would not be up to the task no matter how much I re-habilitated it.

I was tired of working on the house and had been thinking that it would be fun to make an artist's easel and this would be a good training exercise. I had enough leftover material from the kitchen update that no trips to the hardwood suppliers were needed. I was all set for the easel to be ready for her birthday as well as the first day of school.

DW then thought it would be great if it could hold chart paper as well. We looked for the loops at the local office supply places; the needed hardware was only available online. Thus ordered and the project placed on hold. Shortly after, I came across what would occupy both of us for the next 4 weeks and what will be the topic for the next post. I had been looking in Craigslist for hardwood flooring as the carpet in two rooms was waay overdue for removal. There it was in Woodburn in packaging and condition a little different than retail.
That project was finally completed last weekend which is why I'm on the keyboard now  In the meantime, last week the rings came in and today the easel is ready to go to school.