The first amendment

Two days after I posted ‘Hot Potato,’ I received this thinly-veiled threat:

This blog using my company name is completely inappropriate, inaccurate and defaming.
I formally ask that you remove it immediately.

This came from someone who manages to be involved in a lot of conflict, which I don’t really need, so I removed it, and we’re all poorer for it. It was my take on a very interesting recent chapter of my life. And what are blogs for?
If you want to read it, email me for the password.
  [password removed 5/15]

Good luck to you, Meryl. You deserve better.

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Hot Potato

Back in the summer, when the weather was nice, we’d sit out on the deck and watch the view. And one day, there was smoke coming from Johnson. We didn’t know what was burning, but something sure was. We saw it in the paper the next day, on TV soon after and, eventually, on the web and Facebook. I like that, in an age when information travels fast,  smoke signals, newspaper, and  TV, in that order, brought this fire to my attention.

It was Hot Tamale that burned to the ground.
Hot Tamale did Mexican take-out in a college town, straight out out of a Mexican lady’s kitchen. (Is that even legal?) We’d never eaten there,  and I filed it away under “That’s a shame” and moved on.

Well, Mary’s business is floors, and she keeps her ear to the ground. At some point, she heard that the old floors in a downtown restaurant project were beautiful, and she went to take a look. It was Hot Tamale, planning to rise from the ashes.
“Whoa, cool! Need some help? I’ve got some tables you can use.”
That’s the short version, of course, but it was enough to get Monet, the cook’s daughter, up to the Mill to take a look at some tabletops Mary’s got left over from a job in Boston.  And while she was visiting, Mary got the whole story.

It seems that Meryl’s friends loved her cooking, and encouraged her to try selling tamales at the Farmer’s market. So she made 50, and they sold out immediately. So she made 100, and they sold out immediately. So she made 1000, and they sold out immediately. All of this on a 2-burner stove in her home.
The next summer, she had a 4-burner stove and did 14 farmers markets, and they all sold out. Her customers were knocking on her door that winter, wanting tamales.
By the next year, she had an even bigger kitchen in a house on Rte 100 and she hung up a sign, “Hot Tamale,” and sold take-out.  Her customers started asking whether she had a place where they could sit and eat.
And then the whole place burned to the ground.

When I was in third grade, everyone in my class had to memorize and recite a poem.
Mine went (in part) like this:

I found a little beetle, so that  Beetle was his name
And I called him Alexander, and he answered just the same.
And I put him in a matchbox, and I kept him all the day.
And then Nanny let my beetle out.
Yes, Nanny let my beetle out.
She went and let my beetle out! 
And Beetle ran away.

She said she didn’t mean it
(and I never said she did)
She said she wanted matches
and she just took off the lid.
She said that she was sorry
(and I really mustn’t mind
as there’s lots and lots of beetles that she’s certain we could find)

I mention this because Monet didn’t mean to burn the place down.
It’s the difference between a watched pot and an un-watched fryolator, though, and she really is very sorry about it, and she’s working hard to put Hot Tamale back on the map. And that’s when Mary heard about the beautiful old floors in a restaurant project downtown.

Mary and I have a morning routine that usually includes some variant of: “What are we having for dinner?” And a week later, Mary started off the morning with: “What would you think about turning this place into a Mexican kitchen?” 
“Ole'”, I thought! “Mexican for dinner! Works for me!”
Except that that’s not what she meant.  Mary has a heart of gold and, if she could, she would save the world. Short of that, she wanted to help Meryl by giving her a place to cook enough tamales to sell, and maybe get back on her feet. After all, I’m over at the other house most of the day, and she’s at work, and the kitchen is idle, and who knows? Maybe Meryl will cook us dinner once in awhile.

A week later, Mary invited Meryl over to talk and look at our kitchen. Mary is a salesman, and she was selling the kitchen. “We have a 4 burner stovetop! We’ve got an oven you can use, and a sink, lots of counterspace, we’ll put some shelves over here for you, and you can freeze 50 dozen tamales in our freezer. We’ll put an ad in the Stowe Reporter, and people can pre-order their Holiday Hot Tamales.” Meryl is listening to all this, a little shell-shocked, and I’m taking it all in, thinking to myself: “This is crazy.” We had coffee and tea and continued to talk in the living room.
Put yourself in Meryl’s position. You’re jobless and broke. Your home and business have burned to the ground. Your husband’s been deported,  and you’re having tea with some strangers in an old house with tarps for ceilings, and they want to give you their kitchen. 
“What do you need to make tamales,” Mary asks?
“Crisco, masa, and monterey jack,” says Meryl.
“What the heck is masa,” thinks Reid?

Masa is corn meal, and you can get it at the International Market in Winooski. Mary called to find out what time they were open on Saturdays, but the guy didn’t speak English. We found it, though, and arrived just as the owner plunked down a bloody goat carcass on the scale. We bought 8 5# bags of masa and headed to Costco for Crisco. The next morning, we were missing some masa, because BZ got into the bag.

Mary busted her butt rearranging everything, making it easy for Meryl to cook. And tuesday morning, Meryl showed up with her tamale pot and a bunch of ingredients, and started cooking. Mary went off to work, while I stayed home, available but trying to stay out of the way, because I’m a pretty intimidating sight. Meryl cooked for several hours and left. And left behind rice, beans, salsa, chile rellenos, and sauce.
That night, Mary and I ate Mexican food. The rellenos were fabulous. The salsa was savory. The rice was moist and fluffy and delicious all by itself.
And the beans. The beans made you want more beans. I have never had beans like that before. This lady is the real deal. I think that the message she was sending to us that day was, first, “Thank you,” but also, “Taste it for yourself. This is what I can do.” This is someone I’d met exactly once. She showed up when she said she would, did what she said she was going to do, cleaned up after herself, and left. Good job.

Later that week, she did it again. She showed up on time, built 6 dozen tamales, froze them, cleaned up, and left, leaving some cooked ones in a pot for us. Best tamales I’d ever had.
Then she did it again, with a different kind of tamale.
Then she did it again, with chicken enchiladas.
And pretty soon, the freezer was full.
Nice job.

Somewhere along the line, Meryl showed us the space she and Monet were trying to turn into a restaurant. It’s right downtown, across from the movie theater, down the street from the high school, by the town offices and the post office. The River Arts building is a block away, and the Oxbow Park is 2 blocks down the hill. It’s in an old crooked building with a front room that will hold 50 people, a galley and a big back room for prep. An electrician has been working on the wiring, and commercial kitchen equipment and furnishings were scattered everywhere. There was a plan taped to the wall.  I watched and listened, but didn’t say much. Big lot of work.

The left side of my brain said: “I have a lot on my plate, trying to finish our new house and maybe get my life back on track. The last thing I need is to get involved in a Mexican restaurant.”
The right side of my brain said: “I am exactly what they need. Meryl wants to cook. Mary and Monet want it to look nice, but they need someone to put it all together – to make it physically function. And I happen to have all the skills, time, equipment, and know-how to get it done. Heck, I’ve even got a large stash of barn boards in the barn to use in the front room.”

But what a job! I met with the landlord and inspected the basement. The plumbing’s been altered a dozen times, and there is no hot water. In Monet’s plan, there are sinks in front of the electrical panel. The layout has foot traffic taking a left and then a right past the fryolator, and she wants to put the refrigeration unit thru a wall into space she isn’t renting. There is no financing, and the business plan estimates that at least $50k is needed to open.  
“Run,” said my left brain! “Run away!”

 

The back room at the restaurant, full of equipment.

I thought it through and decided that the best way to ease into the project would be to assemble the Walk-In Cooler. This is an 8’x16′ unit bought at auction for $500 and then disassembled and moved to the new space for another (un-planned) $2k. It’s the elephant in the room, and if you want a credible floorplan for the back room, you have to start with where the WIC goes. So I moved all the panels aside and built a planar base atop the crooked floor using 2-by’s and a chalk line. I started re-assembling the WIC’s floor, but quickly found that nothing lined up, because condensation in the cooler had caused the particle board in the floor  panels to swell and disintegrate. So I peeled off the sheet metal, removed the MDF, replaced it with plywood, and put the metal back on.  Basically, I was on-track to re-build the floor before moving on to the walls, doors, ceiling, and compressors. Once that was done, we could move sinks and equipment around.

2×4’s nailed to the crooked floor and chalk-lined flat to create a planar base for the WIC.

All this time, bits and pieces of information filtered in. Meryl had cooked at our house enough times that she was starting to trust and talk with me, and I looked hard at Monet’s business plan.  I’ve never seen a business plan before, and hers looked pretty thorough to me.  But it also seemed like a lot of it was boilerplate that could have applied to any restaurant.  They’d struck out with banks, municipal and state small business development agencies, venture capitalists and crowdfunding, and it wasn’t really clear why. Meryl and Monet have very different visions for the business: Meryl wants to cook. Monet wants to ‘develop the brand.’ Before the fire, Meryl invested in trailers and equipment. Monet spent on staff and fees. Meryl wants to do take-out. Monet wants people to linger. Monet was trying to manage the project from 3000 miles away. She claims she only wants what’s best for her mother, but it sure seemed to me that it was Monet’s own agenda that she was pushing. 
Monet emailed me an introduction, and I emailed back, offering a lot of help for an ownership stake. After one more exchange, I got a written ‘stop work’ order. So I stopped working on the cooler.

Meanwhile, Meryl had a gig lined up at the River Arts building, feeding 25-50 people at a swing band concert. She showed up to cook at our house the day before, and again the day of the gig. She spent all day in the River Arts kitchen, preparing the meal, and when we showed up, she was just about ready. Every oven and burner was warm, and a long row of serving trays were full.

The kitchen help

I’ve never done food service, and I was supposed to be cashier. You would think I’d be good at that, right? Well handling other peoples’ money made me nervous, and I traded cashier duty for taco assembly, where I excelled.  There were fresh-pressed tortillas, 3 kinds of tacos, 3 kinds of salsa, 4 kinds of tamales, rellenos, rice, beans, and a Mexican drink. Just about everyone who came to watch the band bought food. Everyone loved it, and nobody farted. I scrubbed pots and pans for 90 minutes. We took a lot of food home to freeze.
Meryl ran the show like a pro. She cooked way more food than they ate, but if she had been working out of her restaurant, it would all have been sold the next day. Monet’s stop-work email had shown up the day before, and Meryl was beside herself, but she still showed up, got it done, and even made a little money. Good job!

The next day, we heard nothing. Nor the next. No calls, no returned calls, no texts or emails, and nothing since. My guess is that Monet has Meryl under her thumb and told her to stay away from Reid and Mary, who are dangerous predators, trying to take advantage of her. Which is odd, because that’s what people say about Monet.

It was over so suddenly that it’s a little unsettling.
The right side of my brain wants to stay involved, but I cannot do business with Monet, and I don’t want to be messing with their mother-daughter bond. Even without Mexican food, my plate is plenty full. 

So the left side wins, for now.
Good luck, Meryl. You deserve better. 
 

 

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Setting up the new shop

Remember Frank and his dresser which inspired the look and feel of the doors I’m building? Frank’s done a lot of cool things in his life, and a few years ago, he built some big crazy tables. One thing led to another, and at one point, Mary was going to build the tables that Frank would design, and everyone would die old, rich, and happy. That hasn’t happened, but Mary gave it her best shot. She owns a really nice set of tools and, between her and Bill, managed to get some very nice projects built. But Bill is gone, and the projects dried up with the economy, so her tools started gathering a lot of dust and a little rust.

Along comes Reid.
My own power tools are 30 years old and, when we sold Westford, I tried (halfheartedly) to get rid of them, because Mary was going to give me hers. I got no takers on Craigslist, so I put mine in Chuck. But the day after they spray-foamed the basement, the new shop was mine to move into, and I got started.

The day we took the beams down, we also moved my big bench into the new basement. This baby is 10 feet long, 42″ wide, and 2 1/2″ thick, solid maple, and as flat as the bowling lane it used to be. It weighs 300# and I used to just lift it up and put it on my car.
No more. Chris and I moved it to the new house, and we set it up in the northeast corner of the basement, away from the walls, so I could work at it from all sides.

I went to the Mill and took apart Mary’s table saw, loaded it in the truck, and carted it home. It’s a Jet cabinet saw with a big motor, nice iron, and a big table and fence. Some assembly was required and, after so many months without a shop, I went at it with a level and a micrometer. I forget what was the first thing I cut with it, but it felt really good.

Most of Mary’s power tools

That weekend, I took the trailer over and loaded most of the rest of Mary’s tools. Jointer, planer, 2 sanders, a band saw, drill press, mortiser, compound, dust collector … I pretty much cleaned her out, and it’s all first-rate stuff.
Thanks, Mary, you’re a peach. I promise I will make you proud.

 

 

This is why I put a double door in the basement

Getting all this heavy stuff on the trailer was a project, but it was really just a question of ramps, grunts, and a dolly, and I got it all loaded and tied down in a couple hours. Nothing fell off on the way home and no cops stopped me. There were still a couple hours of daylight left to unload and, with chains and the tractor, it wasn’t hard. It’s times like these that I’m glad to have that double door in the basement.

 

Stu, the storage unit, has been full of my big metal tools since April. When we moved from Westford, it took 3 trips and 5 days of work to move them into Stu. To get them into the basement, I’d planned to use the beams and the A-frame hoist to move them from Stu onto the trailer, and then use Bernie’s excavator to get them from the trailer onto the beams, and then roll them into the basement. I was gung-ho when I got started, but I lost interest when I realized it was going to be at least as much work as it was the first time.
I’m too old for this.

Lifting the bandsaw out of Stu

So I had Morrisville Lumber’s big delivery truck meet me at Stu on a Wednesday morning. I’d queued everything up the day before and got there early to move the beams into place so we could roll the heavy equipment onto them. From there, the truck’s hoist could take over.  With Ashton’s help, everything went smoothly. We put the beams on the truck with the equipment, strapped it all down, and headed home.

Have a safe trip

This is waaaay easier than last time

Off the truck and onto the driveway

The ground at the house was muck, so we decided not to drive the big truck down to the basement entrance. Instead, we unloaded the equipment onto the driveway and used the tractor to move the safe and the bandsaw into the basement. We put the beams in front of the double door and moved the mill onto the beams with the excavator. By now, I have a pretty deft touch about moving these tools and, with a nice collection of pipe diameters at hand, we transferred the weight from the beams to the basement without messing up the threshold, and then took a breather. We moved the lathe the same way and there were handshakes all around.

Moving the safe to the cellar

Moving the lathe to the cellar

With enough careful planning, it all went smoothly, but the truth is that I was amped on adrenaline the whole time. Somewhere along the line, I noticed that my hands were a bloody mess, with 6 badly scraped knuckles that started hurting as soon as the excitement wore off.

Mounting the J-head on the mill

Over the next couple of days, I rolled the lathe and mill to their permanent locations and winched the J-head up to mount it on the mill. I converted all the plugs to the ‘correct’ NEMA types for 3-phase, but when I turned on the breaker, the basement lit up, and I followed my nose to the smoking short.  Finally, with a temporary 3-phase connection in place, I used the mill to fabricate a box cover to mount the male receptacle where the rotary converter feeds 3-phase power to the wall.
(Thus proving that the chicken-and-egg problem is much easier than the chicken-or-egg problem)

 

 

It feels great to be able to make a mess in a real shop again.

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The doors. Part I

There are barns and there are barn doors.  And then there are doors made from barns.

In Westford, I remember making the first set of downstairs doors on the day the carpet installer was there. I made them out of cedar left over from the living room ceiling.  A few years later, I made cherry raised panel and louvered doors for the upstairs. Later still, when I built the Cave in the basement, Mary and Bill gifted me a set of doors made out of reclaimed oak. Custom doors can be a woodworker’s way to make a house personal, and nothing says “Not from Lowes” like the click you get when you close a heavy, solid, hand-made door. When we moved, Mary insisted that we bring the Cave’s oak doors with us, and I replaced them with cheap pre-hung doors from Home Depot. What a difference: 5/8″ jambs, screws in masonite, and that cheap, hollow sound. Ugh! In the new house, we’ll be making our own doors. Out of wood reclaimed from the chicken wing of the barn.

A few years ago,  we went to visit Frank in Garnerville, and he had an Art installation in his studio. It was presented as the desk of a working artisan in medieval Europe, and it was really good. The handles and drawer slides all looked more worn than the rest, and the cracks and wobbly fits and the patina of the pieces made it look convincingly old. I came away believing the signage that claimed it was a 400 year old desk. Frank is good.

 

 

And that’s how I want our doors to look when they’re done. With the same depth of old, old color, so the knots look like muscles flexing within the wood and the parts you touch glistening from years of dirty hands.  And if there’s anyone who can make this happen, it’s Mary. I gave her 56 sanded door timbers for pre-finishing and there’s about that many more 9-footers prepped for jambs.

All this prep work was done in the shop-in-a-barn I set up last summer, but with winter setting in, I’ve got to get a shop set up in the new basement before I can work on the doors, and I’d really like to be able to lock the (store-bought exterior) doors before I move my tools over. So when the doors and windows went in, I figured it was a no-brainer that we would go to Home Depot and buy some doorknobs. Well that idea fell flat with the Missus, who claimed that sheetrock dust would scratch them up. We decided to go cheap.

But even cheap ain’t cheap when you’ve got 7 doors to lock. I bought an ugly lockset for the basement, some deadbolts for the back doors and an $8 keyed knob from Family Dollar, but that still left 6 pre-drilled holes to fill.

My tools were stored in Chuck, which is across the lawn from the barn, and I strung a couple extension cords (taut) between the barn and Chuck, and bandsawed some tapered bungs out of 2×4’s to seal off the rest of the holes. They’re crude but they keep the cold air out, and my craftsmanship has no place to go but up.

Doorknob #1

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Big visible progress

When you get up every morning and look out the window and the new house looks a lot like it did yesterday, it’s easy to wonder if this is EVER going to end. (It is Week 22, if you are counting.) Framing went on and on and on. Never seen so many 2-by’s or so much OSB in my life. But in a short timespan, big changes started happening.

The ‘next big thing’ was going to be getting the radiant slabs poured, but the concrete guy was backed up, so we waited. And for the longest time, the sleepers and PEX tubing fastened to the floor turned walking across the room into a game of hopscotch. Finally, on Friday morning (10/19 ??) the concrete crew showed up. These guys are hard working, friendly and good at what they do, but really scruffy. It had been raining for a couple days, and they were glad to be working inside for once.  The truck backed right up to the front door, filled off wheelbarrows, and they rolled them throughout the house. These slabs are going to be covered with flooring, so I wasn’t expecting a finely trowelled finish, but really, all they did was level them off with 1 pass with a 2×4. It’s good enough for what they’re for, but there will be no bare feet until we get some flooring in.

Handprints to commemorate the date

Whenever we pour concrete, we try to put our handprint somewhere. We didn’t do this on the footings or the walls or the slabs, so this was our last chance. I made a frame with some 2-by’s and wire mesh, and when one of the crew got wind of our plan, he put some serious effort into trowelling it smooth for us.

 

 

Concrete truck stuck in the mud

The ground was pretty soft from the rain, and although the first 2 cement trucks got in and out OK, they chewed up the front yard pretty good. When the 3rd load came, the truck sank up to its hubcaps. If you line up half a dozen guys and push on the rear bumper of a stuck cement truck, it’s still stuck. They called in a dump truck to pull it out. The whole crew took a break to watch before heading off to their next pour of the day.

Pulling out the concrete truck

 

 

With a smooth floor in place, the insulation contractor moved in on Monday with his spraying rig. Cold air and mice go right through fiberglass batts: they’re really more of a filter than an insulator.  In Westford, after freezing for years, I tore out the batts and nests in the basement walls and sprayed them with foam. It sealed all the air leaks and made a huge difference, but it outgassed for about a month. This time, we used a soy-based foam, and there was no smell to speak of the next day. They sprayed an inch or 2 near the eaves to seal the leaks near the cellulose, 4″ between studs, and about 2″ on the concrete walls in the basement, behind the 2×4 frame-out. It took them 3 solid days of spraying to get it all done, and gave the place an erie greenish-blue glow.  I was supposed to stay out of the house while they sprayed, but I found and fixed a couple of blocking errors which would have been cold spots, and had them re-spray them. I’m really happy with the way this came out.

A sprayed wall. 3-5″ of blue-green rigid foam.

A problem with sprayed foam is that, when you spray, your boxes, pipes and wires in the wall get encased in a rigid, plasticky mass, so you’d better get your wiring done right before you spray. I was pretty confident I had it right, but Shawn pointed out that I had a round light box poking thru the basement wall with no wire in it. So I spent 2 hours prying thru the foam with a putty knife, locating the boxes and running the missing wire. No doubt I’ll come across more like it.

At this point, the front of the house had a big-ass ugly expanse of  blank wall above the windows. A neighbor had actually asked why we hadn’t put any windows in the 2nd floor.
The plan was to have a front porch with a shed roof complementing that of the garage, and taking advantage of the views and the afternoon shade. The details of the roofline kept eluding us to the very end. As Bernie says: “The solution will present itself when it comes time to build it.” And he’s right. With the grading done and the windows and garage roof in place, it was pretty clear where to run the outline and the roof. And since we’re kicked out of the house while the spraying happened, Now’s the time.

 

With cold weather on its way, we needed to get the heating system running soon, and we bought a 1000 gallon propane tank. Owning the tank means we aren’t married to a particular fuel dealer. With such a tight house, we expect to fill up just once per year and we can get a good price when we shop around for one big fuel buy.  Bernie has a small excavator and buried the tank and the line and Bournes, the local dealer, hooked it up.

There is a new local fuel coop where we could get a good price on propane. The plan was to get the tank installed, plus a small delivery from the dealer to get started, and then buy a shitload of propane thru the coop. Well the coop took our entry fee and did nothing. I don’t think it is a scam, but the coop is just getting off the ground and they’re not ready for prime time. Meanwhile, they turned on the furnace using the 25 gallons or so that a new ’empty’ tank comes with and after running continuously to heat the slabs for a day or so, we ran out of gas.

Purging the tank with an open flame

So we ordered another 200 gallons from Bournes. The driver pumped 900. Mary got right on the phone and negotiated a really good price for it. But it turns out that the gauge on the tank is broken, stuck at 90%, and it’s almost like the driver wanted it to ‘read right’ once in its life, and kept pumping until it did. But we can’t be having a propane tank with a broken gauge, so they sent out a tanker and a technician, whose first attempt involved banging on the gauge. Still reading 90%. They replaced the dial. Still 90%. They pumped out 200 gallons. Still 90%. They pumped it dry and then purged it by burning the dregs in an open flame. Still reading 90%. They replaced the lever arm that floats on the liquid and then pumped in 200 gallons. Now it’s reading 91%. They did all this stuff again and now the dial is stuck at 0%. They pumped 200 gallons back in and went home stumped. With the furnace running, we really have no idea how much fuel is in the tank.

That night, I dreamed about propane gauges, replaying in my mind everything I’d seen that day. I woke up convinced that the lever assembly within the tank was built for an above-ground tank, and the 2′ riser tube which allows the tank to be buried was interfering with its operation.  I drove down to Bournes to speak with the maintenance honcho, who said “no way.” So what’s the problem, I asked? What do we do next? “We don’t know, ” he said. “Maybe we’ll exhume the tank. Next year.”
It is my fond hope that the next time someone googles “Bournes Propane”, they’ll get this post. Buncha fuckin’ jackasses, if ya ask me.

Right about this time, Mary and I went to California. There were sheetrockers and roofers lined up to get started, and since the papered roof has a few leaks, Bernie was nailing a couple of tarps to the roof to protect the sheetrock in case it rains. Hurricane Sandy was heading our way, so we left 2 days early. I had a bad feeling about this.

The hurricane came and went. Vermont got off easy. We came back.

The garage doors had been installed. Wrong. Mary had spelled out, in writing, exactly how to order the panels: glass goes 2nd-from-the-top. They put the glass 4th-from-the-top.
And the North door won’t go up and down.
Mary was bound and determined to get the garage door trim painted to match the windows, and used the tail ends of 2 nice days to prime and paint them red.

The sheetrockers had done all the ceilings and some of the walls by the time we got back, and then moved on to a different job. The main thing was that the ceilings were in place, so the blown-in attic insulation guys could get started. And since this was about the time when the furnace was running out of propane, the place was too cold to mud anyway, so they put us on hold.
I wandered around, admiring their work, and noticed that a light switch was missing. And another. And a couple plugs. Sheetrocked right over, and nary a bulge in the walls. I’ve got all kinds of photos of what’s in the walls, and I located all 4 boxes with a hole saw. The guy said it had never happened before. By now, they are on the 2nd coat of mud, and it is already smoother than I’m usually able to get it after 4 coats.

When we left for California, the plan was to move full speed ahead on everything but the attic insulation. I wanted this to wait because I was going to use lag bolts thru blocking to cinch the antique beams into place against the living room ceiling, once it was mudded and primed. Well they decided that they can’t mud the ceiling until it was insulated, in case of a cold spell. And they’re probably right. So the morning we got back, the insulation truck was backed up to the garage,  blowing cellulose into the attic at about a bale a minute. WTF !?! Since the front porch had gone up pretty much the day before we left, I’d held off on wiring the porch and flood lights, and suddenly I had a crisis on my hands. So I’m up in the attic with a flashlight and some tools, asking the masked man with the big hose to please ‘point that thing somewhere else’ while I run a few wires. That part was easy, but by the time I was ready to cut the hole to mount the box for the flood light, there was a sea of cellulose, 16″ deep, as far as the eye could see.

The hole I had to cut was 9′ up, and about 30′ away from the crawl-hole thru the ceiling, so my plan was to wade over there, screw a 2×4 to a truss brace, climb up onto it, and do the work.  All with a flashlight in one hand. I got up into the crawl hole and gently put my 2×4 down on the insulation. It silently sank out of sight, leaving no scar on the surface. Did you ever drop a screw on a sawdusty floor and spend 15 minutes on your hands and knees looking for it? If I ever kill someone, I am going to haul the body up into the attic and leave it there. No one will ever find it. I did find the 2×4, and I eventually got the floodlight box mounted, but it was a bitch, and there is no way I’m going to be able to secure the beams from up there.  In a way, this is good, because it means that cleaning and straightening the beams is no longer a crisis.

The siding has been going up for 2 weeks and they’re about as far as they can get without the roof being done. It is mostly “rustic channel” – sort of like vertical clapboards – and stained a dark grey called “dragon’s breath,” which we used on the garage in Westford. The gables and the south porch are red cedar shakes which Mary has been treating at the mill with her finish. It looks pretty good. The soffits are not going to get stained this year, but there’s still some discussion about what colors to use anyway.

Sheet steel is bent and extruded onto outfeed tables

The roof is finally done. It’s a standing seam metal roof, and they did a fabulous job. A 3-man crew from East Coast Copper put it on, and they got there early and worked until dark for 6 days. It is 7000 pounds of coated steel and everything about it is perfectly straight and true. It’s a work of art, and I couldn’t be happier about it. I had never seen standing seam get installed before. They spend a lot of time prepping the edges and once they get going on a flat expanse, it goes pretty fast. They haul a trailer housing a forming machine with a 1000# roll of stock on one end and an outfeed on the other, and it bends a continuous sheet into a 6-sided profile onto an outfeed table. The longest sections were about 32′, over the garage.

Formed piece is carried to the roof

They walk the formed sheet up onto the roof, lay it flat overlapping the last piece, and crimp the first couple feet by hand. Then they put a power-crimper on a sled at the top and let it gravity feed down the roof. At the soffit end, there is a fair amount of hand work, but it all boils down to careful cutting and folding with snippers and pliers.

A problem with standing seam roofs is that there isn’t much friction to hold the snow in place, so once it starts moving, it goes, taking anything in its path with it, including antennas, plumbing vents, and chimneys. We moved the chimney placement at the last minute because the original spot was 6′ down from the peak of the roof, and they said that sooner or later, a heavy storm would shear it off. 

Seam crimper feeds itself downhill

For the plumbing vents, which are located near the peaks, I had expected that that they would poke the PVC  pipes through a stock boot, but they promised that this would fail too. They soldered together a stainless steel assembly to enclose the pipe, crimp/joined it into a normal section of steel and then spiral-rolled the top of it over the PVC for an extremely sturdy and weatherproof housing. Very impressive. As it turns out, these guys do a lot of high-end commercial sinks, countertops, and decorative sheet metal work during the winter months. They know what they’re doing, and it shows.

So we’re getting there. Here is how part of it looks now.

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Up Up and Away

Up up and away in my beautiful balloon
Way up in the air in my beautiful balloon
We could float among the stars together, you and I
For we can fly!
                                   The 5th dimension

If you’ve watched television lately, you’ve seen ads for impotence, irregularity, hemorrhoids, athelete’s foot, and worse, and you probably didn’t bother to change the channel. So when I tell you that today’s tale is a little disgusting, I know I’ve got your attention, and you’re leaning forward in your chair.

#1: Sometimes, when I drink beer, wine, or burned coffee, I turn into a human fire hose.
#2: Sometimes, when I eat something that disagrees with me, I just have to sit down.

The reason I mention this is that we just got back from a vacation in California, where we did a bunch of good stuff: A finishing workshop, visits with family, a few shop projects, a few tours, some sight seeing, and the like. And on Sunday, we took a balloon ride!

We spent Saturday with Ella and Travis, and that means Beer.  We toured Padre Stadium in the morning and then headed to the Stone Brewery for lunch and a tour. Stone Brewery is known far and wide for its strong beers. Not just high alcohol content, but a double dose of ingredients, giving their beers lots of flavor. So if there’s something in beer that’s going to make me pee, the Stone Brewery is the place to find out. We each had a beer with lunch and then Travis went to the bar and came back with an armful of samples. “One of each.”

Now I am nothing if not a good sport, but after I’d weighed in on each of them, my kidneys had a good spurt. The floodgates opened and I barely had time to sit down after a visit to the rest room before I had to go again. Shake, rinse and repeat. How embarrassing.

There are times when this cycle takes days to wind down, and if I’m going to be stuck in a balloon basket the next day, then I had to get this under control. So after the brewery tour, I gave my free (beer) sample to Travis and peed yet again before getting into the car. I stuck to water and coke for the rest of the day, though I tempted fate with a chinese beer and sushi for dinner. I was ‘only’ up 3 times that night and had just 1 cup of coffee with breakfast on Sunday. It looked like I had this beat.

On Sunday, we drove out to the balloon rendezvous point and then decided to grab a quick lunch before the ride. Plan A was pizza at a local bar and grill known for it’s selection of – what else? – Stone beers. It looked too crowded, though, and we ended up next door at a dive specializing in Bud Lite. We ordered sandwiches and waited. And waited. Apparently, they don’t serve a lot of food there, and when it finally came, it was pretty bad. We bolted it down and headed back to meet the balloon guy. On the van ride to the launch pad, my stomach started rumbling, which usually means I’ve got to either binge or purge.

Shit. I gotta take a shit. And there’s not going to be a rest room in the balloon.
I started to panic. Maybe I could sneak away during inflation and shit in the woods? Imagine the stories they’d tell: “We went on a balloon ride and Reid shit in his pants!”
This is not good. Please, God, help me out here.

My prayers were answered. The pilot sent us all across the road for a final pit stop before liftoff, and I locked myself in the Rite-Aid men’s room for so long that they sent Mary back in to find me. Problem solved.

The balloon ride itself was great. Very tranquil, and not scary at all. We rode the wind for about an hour at 15 mph, and the pilot had good control over rotation and altitude. It’s a pretty affluent area, and I was astonished at the complexity of the rooflines. The winds are apparently pretty predictable, and the chase vehicle was waiting for us in a clearing about the size of a city block between a development and a freeway. We landed 20 yards from the van.

That was a lot of fun.

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Save the Beams part III

If you read Save the Beams or Save the Beams part II, you know we’re reclaiming a bunch of the wood from the Green house for use in the new one. Normal wood lovers just go to the reclaimed wood store and buy what they need, want, or can afford. Not me. My goal is to spend close to zero dollars on wood for this house. The Green house is the mother lode of old wood, and whatever comes out of it is what’s going into the new place. This is a lot like I used to work wood before I got carried away with other things. Instead of planing a pile of 4/4 boards down to 3/4″, I always plane them down just as far as I have to to get a uniform pile, and then I tweak the design to work with the thickness of the planed boards. Instead of “how much wood do I need to build this?”, the question becomes: “This is how much wood I’ve got. What can I make with it?”

Well, when we took down the old barn, we left the rafters in a pile on the lawn, and there they sat for half a dozen Vermont years. They’re just 2×6’s, but they come from an era when a 2×6 was 2″x6″, which makes them older than me.  Rough cut, and not very uniform, they aged pretty well while the barn was up, and after a few years in the Pile, they are cracked, split, mildewed, punky, and rotten. Add to that all the bark, the beetle borings, nail holes and knots, and you just can’t ask for more from a pile of wood. I de-nailed and stickered them earlier this summer and decided to make doors out of them. Heavy plank doors with big-ass steel hinges. And since the boards were >16′ long, why cut them down to 80″? So they are roughed out to 7’6 and they’ll be a little shorter when we’re they’re done.  And since I don’t really know how tall they’re going to wind up, we decided to run the jambs right up to the ceiling and put a transom over each door. When it comes time to sell, we’ll market the place to retired NBA players. We’re going to need about 90 decent boards to make all this happen, and there’s not quite double that in the pile, so by the time you reject the rotten ones, we’ve got about enough to get it done.

When we took down the chicken wing of the barn, there was a lot of weathered barn siding left over, and Mary had it stickered and stored in the 2 back rooms in the barn. Right under where the roof leaked. So these boards too have plenty of character. The plan is to use them to make kitchen cabinets, but we’ve got waaaay more than we need for that.

Square nails from the floor

For a week in August, I worked on removing the old flooring from upstairs in the house. It’s all gone smoothly, but it was a lot of work to get the boards up intact. There was still a random smattering of square nails holding them down that I missed back in April, and it’s tough to work while dodging under the turnbuckle chains. The floor boards had been painted many times, but the undersides are basically perfect. We are going to use them for the master bedroom floor and, if there’s enough, for the corner office.

Beneath the floor boards was the under-layer. These are the boards that were visible behind the 2 layers of sheetrock in the living room ceiling. They are about 1/2″ thick and up to 20″ wide by 10′ long, and perfectly flat, because they’ve been the meat of a wood sandwich for 2 centuries.  They aren’t thick enough to support my weight, so I had to move in 4′ steps from  beam to beam while I worked.

Under-layer boards: big wide thin & flat

Sedimentary layers of dust

In geology, sedimentary rock is created when years of dust and sediment pile up, oldest on the bottom, and harden. You can see the same thing happening in this 2-layer floor. With 1 layer gone, there was a pattern in the accumulated crud. First, there was a lot of straw and grain throughout. I don’t know if, in the old days, people slept on straw mattresses that leaked, or maybe the upstairs was a hayloft at one time, but I’m thinking that the old time builders might have sprinkled straw between the 2 layers of floor to keep the squeaking down.  Beyond the straw, there were distinct ribbons of grey dust and white dust diffusing from the gaps between the top boards. It looks as though whenever someone spilled ale or bodily fluids on the floor, it mixed with the dust in the gaps and hardened off into long brittle wads of sealant between the boards. Most of this is still stuck to the boards of the under-layer, and getting them clean is sure to be an adventure.

I moved the boards to where there was no tarp in the ceiling

It took 3 long days to pull up the floorboards. That was mostly brute force, and in some ways, it was a more interesting job getting them out of the house. It took another long day to move them to Chuck and the barn. The easiest way to do it seemed to be to hand them down at the far end of the living room, where there was no tarp on the ceiling, and then walk them out through the whole length of the house and across the yard. I started off carrying 4 boards at a time, but by the end of the job, I was down to half that. This was a bitch, but it gave me an excuse to clean off my TV.

… and then lifted them down by the TV and walked them out through the house.

All this happened back in August, before I got involved doing wiring, so the beams had to wait. But now they’re talking about doing sheetrock, and it’s time to either take out the beams or stop talking about it. So we took them out. Chris volunteered to help. He’s Celia’s room mate and an easy-going, big, strong guy. He might even be smart, for all I know, but that day, all I cared about was big and strong.

       

I attached 2-by’s underneath to hold them up after they were cut

I need 6 beams for the new house, and  there are 10 in the ceiling. #1 is an integral part of the outside wall, and #10 holds up Celia’s old room. So I tagged #’s 2-4, 6, 8 & 9 for removal, leaving  5 and 7 (plus the turnbuckles) to hold up the house. I screwed 2×4’s to the undersides of the ones I’m leaving behind so that, as I cut off each beam, it would be supported by the 2-by’s and not go crashing to the floor.

 

We started at the far end and chainsawed 1 beam at a time, scooted it across the rest of them, eased it out the window, and then down a ladder to the driveway. I was sweating, and exertion was only the half of it. Everything went exactly according to plan, and nobody got hurt.

We started with 10 beams

We scooted each beam toward the window

… and then lifted one end out the window

The mastermind is pleased with his work.

Six old beams, safe in the new basement

These beams are hand-hewn, 19′ long, and bowed an inch or 2 from carrying the weight of the upstairs for 2 centuries. 

That evening, as Mary relaxed with ‘the usual’ Jack Daniels, I thought it might be a good night for some Jim Beam instead. Either way, I’m pleased to report that we “saved the beams.”

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