Posts from January 2011
the loft ladder: process
Most of our undertakings here at chezerbey follow a typical design process. First we brainstorm ideas and sketch things out on paper. Then we test out those ideas in SketchUp. When we’re happy with the design, we detail it out in AutoCad (not always necessary, but it was for a detailed assembly like the loft ladder).
Since we started out sending the design to local steel shops, the drawings were very detailed. After we decided to DIY, Kyle used the shop drawings to accurately measure and cut the various pieces (the design also changed a little bit in between). Unfortunately, I didn’t capture the total construction process. For one, cameras and molten steel don’t really go together. Second, while Kyle was welding, I was holed up in the basement trying to bring order back to the space. After six months as a storage unit and studio apartment it was stuffed to the gills. And then, it threw up on itself. Or at least that’s what it looked like. But that’s another post, back to the ladder!
Kyle started off by cutting the various pieces to size. In the photo above, he’s using a metal cutting saw to cut the steel rods for the lower and upper portion of the ladder.
Next, he used a grinder to bevel the edges of the rods and his drill press to slightly pre-drill the side rails, that way when he clamped it all up for welding it stayed in position.
Once the pieces were cut, the basic frame was welded together. We ended up swapping out tube steel for channels for the side rails. This lightened the overall weight and well, channels are just sexy and cast more interesting shadows. Don’t you think? Next, the rods and treads were installed. The treads had to be a precise angle so when the ladder is in place they would be level with the floor. This was probably the trickiest part of the process.
Kyle also pre-drilled and pre-counter sunk holes in the steel plates so he could later screw the wood treads into place.
I knew the carport would come in handy someday! Here, Kyle is grinding his welds to get a smooth joint.
After the ladder frame was complete, he moved on to the handrail assembly, comprised of 3/8″ diameter rods and 3/4″ square tube steel.
More grinding!
But it really did make a difference…the above shows a good “after” and “before”.
After the ladder and handrail assembly were complete and welded together, it was time to paint. Originally, we were going to have the steel powder-coated. However, we decided that since it’s not exposed to the elements and the steel portions won’t be regularly touched, a simple and durable paint was more than sufficient(and it would save us a considerable amount of money). After trying a half-dozen paints we settled on a dark grey paint used in the auto industry for painting motors. It sprays like a fan instead of a cone (like typical spray paint) so it goes on much more even.
After the paint was dry, Kyle applied a clear coat in a satin finish for a little extra protection.
For the wood treads, Kyle cut 2′-2″ lengths from 5/4×6 vertical grain fir boards (actual size is 1″x 5 1/2″). He then beveled the outboard edge and notched the underside to fit over the steel treads (detailed photo below). Where needed, he chiseled out the underside of the board to fit snuggly over the welds at the joint between the steel channel and plate.
For the handrail, he ran 2×2 fir pieces through the table saw to create the notch. At the bottom of the handrail where the steel ends, he used a chisel and hammer to complete the notch.
Where the tube steel turns 90 degrees and connects back to the channel, he used a small saw and chisel to notch out the wood.
(The photo below shows the completed handrail detail.)
After the clear coat was dry, we moved the steel portion inside and secured it in place with lag screws at the bottom angle and top flat plate (both sets of screws go into structural members so this thing is solid). The angle at the base also covers the exposed edge of the cork flooring. The gap between the ladder and the wall meets code requirements while providing enough space for the future barn door to slide past.
Bailey still doesn’t get it.
All in all, the ladder took about 6 full days of work but we saved a ton of money (even after you factor in the cost of the welding machine). This weekend we’ll apply the finish to the wood. We’re planning on doing a hardwax oil floor finish for the treads and a thinner polyurethane application on the handrails. At the same time, we’ll put the finish on the basement treads and risers (which are partially installed).
The big 2010 project is definitely stretching into 2011, but that’s ok.
the loft ladder
We’ll show the process photos later this week, but for now – the mostly finished loft ladder! (The wood pieces are just dry fitted now, they’ll be removed and taken down to the basement to get finished this week.) It took three of us (thanks Audrey!) to get the steel portion inside and into place, but it’s in. It was dark by the time we finished up today, so I turned on all the lights and tried to get a few decent shots.
Not a bad way to climb up 9 feet to a 200 sf space, huh? That’s 200 sf of unfinished space too. I’m still boycotting paint.
As the handrail extends up the ladder it straightens out and becomes a guardrail to the light well below. It’s also a good place to grab onto as you climb in or out of the space.
The handrails and treads are wood so that they’re warmer to the touch. The underside of the treads are notched to fit snugly over the steel treads (sub treads?) and will be fastened through pre-drilled holes in the steel plate. The handrails are also notched to fit around the tube steel handrail frame. We chose the inside face as the exposed side, not just because it looks awesome but because as you’re climbing the stairs your hand is more likely to wrap around the outside three edges, so it made sense for those to be wood.
The intermediate rods at the lower half of the ladder are there to meet residential code requirements.
We didn’t think we could have such feelings for a loft ladder, but we’re totally in love.
Steel and wood, you are hereby BFF at chezerbey.
welding time!
A month ago, we showed you our design for the loft ladder. Because welding was an unknown territory for us and we didn’t own the equipment, Kyle put together shop drawings and we sent them to a handful of local steel fabricators. Even though we were introduced to a couple great companies in the process, the estimates unfortunately came back at $3500-$3800 (and that didn’t include the wood work or powder coating). So…yeah. Time to DIY!
So Kyle took a 5-hr beginner welding class, found a great Craigslist deal on a welding machine (it even came with gloves and a helmet!), and got busy. (Even with the cost of the equipment, it was still way cheaper to do it ourselves.) We’re also lucky to have a steel supplier in our neighborhood.
But before he could build the loft ladder, he had to build a welding table. Or rather…weld a welding table. (His instructor recommended this as a good first project.) So right after we got back from the holidays, Kyle cleared out the carport (which is where we’ve been storing lumber, sheet goods, and well…junk), so he could have a protected place to weld. Since our concrete slab slopes, he set-up temporary supports to ensure that the table frame would be plumb and level. The design for the table was adapted from various welding tables that Kyle had googled. The main objective was a simple frame that had a flat work surface with numerous areas to attach clamps to. Kyle then created a 3D model in SketchUp and referenced dimensioned print-outs during construction.
The table frame is made of tube steel, with adjustable casters/legs attached to flat plates welded to the tube steel. I love this photo. I call the green suit his welding onesie.
The tabletop is a series of steel channels welded to the deeper tube steel members below. This allows the pieces that are being welded to be clamped to the table so nothing moves during the process. (Kyle also used a grinder on some of the finished welds, hence the shiny spots.)
(Even though we bought adjustable casters, our slab was sloped enough that we needed to use some steel scraps as shims to get it perfectly level.)
Not bad for a day and a half of work, huh? I know, my husband is a badass. He is also IN LOVE with welding now. He is literally looking around the house for things to weld, which is probably a good thing, considering we already have a lot of wood. But it’s all about the loft ladder now. Oh, and the sliding barn doors? You know we’re redesigning those!
living + dining reveal
Ok, disclaimer – the living and dining room are not 100% done. From a construction standpoint they are finished, but we still have lots of smaller things to complete. For the dining room, this means new chairs (we now have our hearts set on Eames fiberglass shell chairs in mustard with maple dowel and chrome legs – I’m sure we could find that on Craigslist…) and possibly a new DIY table. For the living room, we’re hunting for a large rug to go under the new couch and coffee table and one (or two!) Eames LCW chairs. Then there’s the media cabinet that needs to be built and art to be put on the wall (some we own, some we have ideas about). Of course the barn doors and loft ladder are still MIA, but one of those projects is in progress and the other is next in line.
Point being, it’s going to be a while before the spaces are truly done, but we figured we’d at least show you where we’re at now and then continue to update photos as things progress. (I’ve also been trying out my new camera lens. It’s a huge improvement over the old one, but I still have a ton to learn.)
We designed the dining room and pendant location so the table could work in its long position (as shown) or be shortened or turned 90 degrees. In the event that we have a big dinner party, we can scoot the couch down and add our fancy card table extension (hey, nobody knows when there’s a tablecloth on top!).
The couch and coffee table are from BoConcept. It was our first time purchasing something from them and we had a really great experience. Both the sales team and delivery crew were fantastic. The reason we went with a BoConcept couch is that they are highly customizable but not as expensive as other options we looked at. For our piece, we chose the configuration, size, fabric, legs and arm rest width (there is a lead time, for us it was about 3 months). We chose a sectional to provide a bit more seating space and help define the living area from the dining area. The fabric is a dark brown felt. We are trying to teach Bailey to stay off the new couch and while he is good about it when we’re at home, simple forensics show that he’s not so innocent when we’re not at home.
We still have our old dining chairs. Blah. I looked into buying new gray slip covers as a temporary fix a while back, but IKEA has changed the seat size of this chair so the new covers were too big. Oh well, the slip covers were also $40 a piece so I was glad not to spend $160 for a temporary solution.
By varying the ceiling shapes, we provided definition between the different spaces. The vaulted ceiling and skylights create a more open-feeling, brighter space, while the lower ceiling and exposed dark joists in the living room lend a cozier feeling to the living space.
After demo, we found the word “Carkeek” written on one of the living room joists. After a little research we discovered that there used to be a Carkeek lumber mill north of our neighborhood. Fun fact.
Our new coffee table is also from BoConcept. This is actually the first coffee table we’ve owned so we’re pretty excited about it, let alone its magical properties. Behold!
Extra storage plus couch-dining capabilities (which I think is funny considering the dining table is a few feet away). It’s still mostly empty but we’re planning on stashing magazines, coasters, and other odds and ends in its cubbies. It would also be an excellent place for remotes…if the TV was in this room. Instead, the pile of remotes sit on a chair in the flex room. Oh well.
Bailey kept forcing his way into shots, such a prima donna.
The flex room/bedroom is serving as a TV room for the time being. We moved our old couch in there and did our best to hide the college-era TV stand. Actually, of all the places we’ve lived this is the first time we’ve ever had a second bedroom and it’s a luxury we’re still getting used to.
Lots to do still but it feels great to finally be at a point where we can think about the little details and finishing touches. You never know…I might even get crafty.
