Happily,
Lydia and I make a great team, and
where my will or energy flagged, she picked me up. We planned
carefully, chose our professionals wisely, stuck to our guns, and as a
result the Farm House is now structurally complete, with the finish
phase now begun in earnest.
At the same time, I must keep up
with the needs of my
foreman and his
workers to have the various pieces of finish lumber primed before they
are applied to the house. It is now common practice to prime the back
of most exterior finish wood pieces to protect them from moisture
coming out from the inside of the house and creeping into exterior
joints. Now, one cannot just prime the back, because then the lumber
will tend to cup towards the unprimed side. This means that pretty much
all that siding and trim going onto the new construction has to be
primed on all sides. That has proven to be a huge job, but a great
exercise for getting my painting chops up. I just found the largest
brush I could, loaded it up with paint, and started flailing away. Note
the brush pictured to the left. That's
the ticket, a brush with short, stiff bristles stacked an inch thick.
Later, I
found an even bigger brush with shorter bristles. I've gotten so I can
do one side of a 20-foot section of shiplap in 2 minutes flat. Who
needs a sprayer? Note also in the picture the standard giveaway with
purchase at
paint stores, a handy-dandy opener for paint cans and beer bottles—a
humanitarian gesture, that.
A
closer look, however, reveals some interesting
differences. The joints are mostly pegged through-mortises. The peg
serves to draw the tenon fully into the mortise, then keep it there
even if the glue fails. We saw a
lot of pegged mortises in the timber-framed colonial houses of Concord
and Lexington on our honeymoon. Well, we saw it in Salem too, in the
House of the Seven Gables. Come to think of it, the Farm House has
seven gables as well, No, wait, we added one over the new rear
entrance. So we’re one better! The pegged mortise is a quaint
thing
today, but it’s undoubtedly contributed to the windows’
longevity;
after all, those Colonial houses were older than the Farm House is
today when the Farm House was built. The sash (the moving parts that
hold the glass) are quite narrow in profile compared to more modern
windows, giving them an elegantly sleek appearance and allowing in more
light. The sash pulleys are cast iron, not pressed steel.
Curiously, in the upstairs windows, on the upper rail of
the inner sash, the glass is carried not in a rabbet (L-shaped notch),
as is nearly universal, but in a narrow dado (U-shaped slot). This will
be a challenge to glaze.
Most significantly for our situation, the window casings
(the wood frames surrounding the window openings inside and out) are an
integral part of the window’s structure—not mere trim pieces covering
an internal frame, as became the norm by the turn of the century—so
that if one were to remove the casings, the window would simply fall
out, frame and all. This feature is proving to be quite a complication,
for some of the frames are loose, and a few are even cracked, and to
tighten these frames back up and bring everything back into proper
alignment without being able to remove the casing boards can be a bit
tricky, especially considering that some of the exterior boards are
heavily weathered, dry and brittle.
Having said this, some of the sash on
the second floor
(again, the moving parts that hold the glass) are unsalvageable. The
wood, while not rotten, is so weathered in many c
ases that the lignin,
the stuff that binds the wood fibers together, seems completely gone.
As a result, the wood will not bear working. It turns to splinters and
dust under the pressure of a scraper. For these windows, we are having
new sash custom-built to replicate the original, which will go into the
existing frames. A few of these frames are in such bad repair that it
will take more than mere epoxy and screws to repair them; it will take
the kind of carpentry skills that only our able foreman can provide.
But the rest of the
window-salvation task is mine. Happily, this is a task at which I have
some solid experience; I like windows that work, and I’ve lived in
enough places with windows that didn’t to
have had ample opportunity to
learn how to fix them. Of course, I’ve never had to deal with cracked
and loose frames, but our foreman has given me some simple but
invaluable guidance on this front. I would have undoubtedly arrived at
some Rube Goldbergesque, over-engineered solution, but he advised me
that the most effective method was to epoxy the cracks, clamp
everything into alignment, drive screws through the outside casings
into solid framing members, then let the epoxy cure. As has proven
consistently true with the Farm House, the simplest, most elegant
solution is the best. It’s the Victorian way.
Yes, it’s quite a blessing to
have a guy like our foreman around. He loves his work, he’s good at it,
and he cares just as much about doing right by the Farm House as we do
Best of all, we communicate very well. For example, the subject came up
one day at the house of how to treat the casing around the medicine
cabinet in the new bathroom. All I had to tell him was, “Case it like a
window,” and the next morning, he had built it to match the precise
mental picture in my head. I didn’t have to mention scaling down the
proportions or the fact that the stool should be flush with the bottom
of the cabinet opening. This he knew. Anyone who’s ever dealt with a
contractor knows how precious this level of communication (to say
nothing of this level of knowledge, skill or speed) is.
In other news, Lydia and I are caught up with the
priming for now, thanks to another weekend session with the trim
boards. We learned an interesting phenomenon: 1-by-4-inch trim boards
take as long to paint as 9-inch wide shiplap per foot of length. It’s
because one must use a smaller brush. Here, a disbelieving Lydia learns
this for herself while I take surveillance photos.
We caught up just in time, for the primed boards are
being put to use. The garage and addition are now getting their skin,
and the transformation is amazing. The structures have been up for
months now, and I’m in and around them most every day, but while I’ve
appreciated them on an intellectual level, in my mind they’ve been mere
shells of plywood to me, nothing more than the sum of their various
parts. Now that they’re getting their cladding, although they are not
yet complete, suddenly my mind perceives them as something quite
different—as organic, unitary entities. Andrew Jackson Downing would
understand completely [see Vol. 1].
The tile in the downstairs bathroom is done, and I
couldn’t be happier. I'm very picky
about
tile, but I can't find one tile out of place, one grout joint out
of line. Simply put, the job is perfect. It'’s a sublime feeling to
carry a mental image around for years, then see it made real before
your eyes.
After years at the effort, I’ve finally
gotten the grass in the median strip (between the sidewalk and the
curb) looking like a lawn, weed-free and as green as any lawn on the
block. I’ve even got the plumbing cuts pretty much filled in. There
remain a few stubborn bare and brown spots, but they’re slowly
yielding. I’ve done this as sort of a token of good faith to the
neighborhood, an indication of things to come, but until we got water
on the property my efforts were confined to rear-guard actions against
the seasonal onslaughts of weeds. Once we got water, I was able to put
down some pre-emergent herbicide, and this gave the Bermuda grass a leg
up. This is all Bermuda grass needs, that and some water and a little
fertilizer. Bermuda grass has a bad rap, because it is so invasive, but
where it is wanted and can be contained, for my money there is no
better warm-season grass. It is wear-resistant, fine-textured, and mown
high (2 ½ inches, not the ½ inch usually prescribed) it
looks better than anything one can grow well here in full sun. Now, my
brother Jon in North Carolina works wonders with Kentucky bluegrass,
getting it so green that in fact does start to head a bit towards blue,
but that species does not do well in LA inland of the coastal regions.
I do plan to use creeping red fescue elsewhere in the yard, because it
has a wonderful meadow-like look, and is far more tolerant than the
constant shade under the tall trees. One does not even really need to
mow it. One does have to mow Bermuda very frequently when it is in full
growth, which is a definite consideration here, considering that the
area of just this median strip is the same as the entire front lawn at
our Culver City house.
Speaking of neighbors, I just last week made friends
with a particularly delightful neighbor to the rear of the lot. I think
we’ll get along famously, but I can’t speak for everyone in the family.
The
first step in application is to apply a release agent to the part to be
molded, a silicone-based liquid that, once dry, would prevent the
moldmaking compound from sticking to the tub.
Then,
make an initial application of the compound using a brush in order to
ensure that it fills in every contour completely. The directions
specify a “stiff brush,” and I should point out that the
brush pictured here did not quite fit the bill, so I had to take great
care to ensure that the compound got everywhere it needed to be.
Probably the best solution here would have been to cut the bristles of
the inexpensive polyester brush I used somewhat shorter to achieve the
ideal stiffness for the task.
The
second step is to build up the compound so that it completely encases
the part to be cast (1/4 inch minimum), using a flexible spatula.
Again, the tool I used here was not quite up to spec, so more caution
was necessary; from this experience I would say that the most
appropriate tool would be a standard Rubbermaid rubber spatula.
Here
is the completed mold, after building up the compound in, around, and
over each contour to a thickness of at least a quarter-inch all over.
This is left to cure overnight (it’s best not to be in a hurry
when moldmaking).
Because
the compound is flexible, the mold is not rigid enough on its own to
retain an accurate contour of the tub exterior during casting. It needs
a hard shell to provide the necessary rigidity. Ideal for this purpose
is Abatron’s WoodEpox, a two-part epoxy putty. After mixing it
together thoroughly, make a pancake of it and press it firmly around
the cured mold (I applied a bit more release agent around the
perimeter, to keep the WoodEpox from sticking to the tub).
After
allowing the epoxy to cure overnight, carefully pry the mold with its
shell off the form, and you will then hold in your hand the mold for
your casting. In retrospect, my mold was actually not quite complete,
for I had neglected to take into account the need to build up
additional thickness in the casting. I had chosen gypsum for my casting
compound, for it is inexpensive and easy to work with. It needs no
release agent, it’s easy to mix, and it cures quickly. Gypsum is
like plaster, but harder and more break-resistant. Even so, it needs to
be at least a half-inch thick to be strong enough for normal handling.
The
simplest answer would have been to build a rim out of modeling clay,
but I did not discover my error until I had mixed up the gypsum and
began pouring it in. Happily, I had some aluminum foil handy, so I made
a makeshift bowl out of this, and it worked well enough.
When
the gypsum hardens after a few hours, it will pop right out of the
mold, as mine did. The result: an exact copy of the tub foot mounting,
suitable for carrying around to local salvage yards. Neato.October
4,
2004—Big doin’s, Mouseketeers. They say that a picture is
worth a thousand words, and I can prove it. A cursory glance at the
Farm House Cam shot at the top reveals big changes to the Farm House; a
click over to the full-size picture will show that the exterior skin is
just about complete. Yes, those are the original turned posts; seven of
the ten corbels (the triangular, gracefully-curved pieces at the top of
the posts) are original as well.
Our foreman did a brilliant job of
recreating the original veranda; once the house is all painted, it will
take a skilled and schooled eye to detect that it is not the original.
This was by no means a simple matter. For one thing, the original
veranda was so thoroughly thrashed by the elements that nothing was in
its original position. For another, the structural elements of
the new
veranda are considerably beefier than those of the old, yielding less
space between the floor and the bottom of the roof structure. Thus,
getting the new veranda to match the old one took a great deal of
skill, knowledge and attention to detail.
He built the upper and lower railing
sections on the workbench, and our finish carpenters put them in place.
Now, the fruits of all their scrupulous work are on display for the
neighborhood to enjoy. It's like a huge piece of fine furniture,
and to me it’s simply beautiful. Even without paint and windows, the
Farm House is really beginning to shine.
Things are happening inside as well.
The upstairs closets are all built, and they look very nice. They
really dress up the rooms. Curiously, although in a literal sense the
rooms all have less open floor space than before, the closets make them
look bigger somehow. I think it's because they raise the apparent
height of the ceiling by excluding from view the parts where it slopes
down to two feet high. The cabinet design is mine, patterned
after the pantry under the stairs, but it is the finish carpenters'
execution of that design that makes them look so good.
The oak plank floor is installed in the
addition, but it won't be sanded and finished until the kitchen is
complete. The kitchen cabinets have begun to materialize, and again,
it's amazing to me how much bigger the kitchen looks with the base
cabinets in. The
interior woodwork is nearly complete, the gas is hooked up, and the
water heater is in service. The furnaces are installed and waiting for
winter.
Back to the outside. The grading
is done, and soon the driveway will be in. It will be a bit narrow, but
wide enough for our minivan,
and that's plenty wide for us. Moreover,
if it were any wider, we'd have to take out another tree, and that's
something we just don't have the heart to do.
I've been busy working on my projects
as well—rehabilitating the windows, painting, and restoring the finish
on the woodwork—but I'll talk about that later.