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mid-january progress
January is tough. It’s rainy and gray and unfortunately, home remodeling doesn’t really kick the winter blues like a trip to Hawaii would. But we’ve pulled on our work pants once again, making a little progress and crossing things off the list.
The barn door track is painted and installed! We contemplated keeping the galvanized finish (which Kyle had actually cleaned up a bit), but decided instead to paint it with the same automotive primer that was used on the loft ladder. We chose stainless steel lag screws for the fasteners and left them unpainted since the paint would be scratched if we ever needed to undo or adjust them. (The shiny orb above is our door bell.)
It only took four months after painting the main floor to muster the motivation, but I finally did it. Two coats, six hours of painting. I know, but there are a lot of corners, weird angles, and compromised head clearance (not to mention the challenges of white-on-white). It was not fun. Even you crazy people who like to paint would not like this.
Here’s a view looking the opposite direction showing the loft ladder in place. And no, the centerline of the ladder/light is not the same as the roof ridge. Even though we typically try to force our house into submission, when you’re working within an existing structure there is only so much wiggle room.
Hello down there! (The ladder treads are off and in the basement waiting to be finished.)
For the loft lighting, we chose a single wall sconce with a solid shade that would primarily provide light for people going up and down the ladder in the middle of the night (that’s why the switch is near the floor). This light is similar to the kitchen wall lights, although Resolute changed the design of the escutcheon plate and I now love this fixture even more. For the rest of the space, we’ll probably have a small table lamp on the opposite wall.
In addition to some finish electrical work, our last step is to select and install the flooring. Although we’re generally anti-carpet, it makes a lot of sense for this space. 1) It’s a dog-free (therefore, dog hair-free) zone. 2) The plywood subfloor isn’t smooth enough for a glue-down material and we really don’t want to mess with self-leveling compound again. 3) It’s supposed to be a cozy space and carpet is a good solution for that.
Our first thought was to go with Flor carpet tiles. Flor is a great company that makes attractive and responsible products and we’ve been happy with the tiles in our mudroom. So we ordered a bunch of samples and then narrowed it down to these three:
The two on the left are both from the “Love Ewe” line and are super soft. The one on the right is “Well Suited” and also comes in the gray color. You know I can’t get too crazy with color, so I thought it would be best to steer towards the neutral options and then do bolder colors for less permanent things. The first one is $7.43/SF while the latter is $4.46/SF. Of course I liked the more expensive one the best, but talked myself into the herringbone-esque pattern (which is pretty soft to the touch too).
So I took some measurements of the space, drafted it up in cad and laid out a grid of tiles (roughly 19″x19″ each) to see how many we would need. Then I did the math. Then I rechecked my math. Even with the cheaper tile and a 20% “designer” discount, it would still cost about $700 to carpet the space. That’s really way more than we wanted to spend for a room that we just kinda “threw in” after we started this project. I mean, $700 is a weekend in Palm Springs (always dangerous to compare remodeling costs to travel costs, but that’s where my mind is these days!). So we’re back to the drawing board in a sense and are now looking at getting a remnant from a roll of carpet, trying to spend about half of the Flor price. We’ll see.
When we finished the mudroom almost a year ago, we installed two Bach coat hooks to the left of the door. Not wanting the space to feel too cluttered, we thought we could get by with one double hook per person. Well, that didn’t work out. So we finally got around to ordering and installing two more hooks on the opposite side of the door. Much better!
Our big plans to build a custom storage bench were derailed by the Big Project of 2010. So we moved our IKEA Molger bench in as a temporary solution (it was originally bought for our old bathroom). But now, we kinda like it. Except for that basket. I know, it’s very un-Zerbey. We inherited it from somewhere and oddly enough it’s the only container we have that fits in the space (we use it to hold gloves, scarves, etc.). I’ve been on the hunt for something to replace it but no luck yet. So I don’t know…maybe the Molger bench could get tweaked? Did you see what Dan did with his?
So there’s a glimpse of what we’ve been up to. Kyle’s also been working on a steel and wood handrail for the basement stair and the first frame for the barn doors. Bang, bang bang…weld, weld, weld.
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.
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.
2010 year in review
It seems like this week is all about year in review posts, so we’re jumping on the bandwagon too. This was a big year for us – we took on our largest project to date and lived to tell the tale. Here’s how it all went down…
In January we started collecting samples and finalizing the design for the kitchen/dining/living room. We also made a crazy Excel spreadsheet to help establish a budget. I’m pretty sure we don’t want to go back and compare it to how much was actually spent. Yes, it ALWAYS costs more and takes more time than you initially think. Still, we saved tons of money by doing the work ourselves and carefully choosing products and materials.
2009 was the year of the exterior, but by the time we were done painting we didn’t have the energy to finish the mudroom. So we gave ourselves an ultimatum to finish the space before we started demo in the house. Such a small space, but surprisingly a lot of work!
During March, we made final preparations for demo day and begrudgingly finished the mudroom (though we’re really happy with how it turned out, even if it’s still not 100% done).
In April, we DEMOED! We invited a bunch of our friends over to help and were blown away by their enthusiasm and destruction skills.
One of my favorite memories was watching the guys stomp out the ceiling from up in the attic. Lath and plaster dust for all! Sawing out the kitchen ceiling was not as poetic, especially when one chunk swung into the bedroom wall on its way down.
At the end of the day we had transformed our tired old house into…well, a barn.
We spent the latter part of April and most of May in framing mode, which included sanding and refinishing our 100 year-old joists and installing the painted MDO above to serve as a subfloor for the new loft. (FYI – the loft was not part of the original plan, but after demo we decided to just “throw it in”. This probably explains why it’s still not finished.)
Of course we couldn’t do something easy like flat ceilings…
In June, we focused on installing skylights, tension rods and rigid insulation in the vaulted ceiling.
Our friend Dustin spent several Saturdays helping us out and we were sad when he (and my sister) moved to Texas. So much for the “Everyone move to Seattle!” campaign.
July brought electrical rough-in, which is probably the most boring thing to blog about.
See what I mean? At the beginning of August it didn’t look too different. But this month was different, we were on charrette to meet our (revised) September deadline (charretting is architecture-speak for work like crazy and get little sleep until it’s done).
With the electrical work finally done, it was time to wrap our house in furry blue insulation.
We also installed the plywood vaulted ceiling and then the drywallers came to work their magic. Besides the Silestone countertops (which we couldn’t install ourselves), this was the one thing we hired out and it was worth every penny. (On a side note, the room seems especially narrow in the picture below. Weird.)
The first two weeks in September were spent priming, painting and installing the cabinet boxes, counters, lighting and appliances. We had planned a big party at the house for my 30th birthday and even though it wasn’t done, it was close (if you kinda squinted).
We kept working on the kitchen, but the big project for October was the cork flooring.
In November we focused on finishing the kitchen – custom shelving, plywood wraps, and a quick break for Thanksgiving (though thankfully, not at our house!).
It should be noted that Bailey was, for the most part, a real trooper and put up with all the craziness of this year. In the end, we learned that he didn’t really care what we were doing as long as he had a place to sleep and got fed twice a day (whether it was via two plastic bowls on the floor or a custom dog bowl holder).
And in December we finished the kitchen!
We also finished up the stair cabinet and decorated our house for Christmas. (Our new couch and coffee table were also delivered!)
As this year comes to an end, we’re finding more time to relax but also chipping away at the things that are unfinished. We’re hoping to wrap up the loft, loft ladder and barn doors in the next month or so.
So what will 2011 bring? We don’t have any more walls to knock down so we’ll be focusing on smaller projects. And really, we’re excited about that. We also have tentative plans to do some landscaping this summer. 2011 will also be about refilling our remodel penny bank so we’ll have to wait a bit to tackle the basement or the eyesore of a garage in our backyard.
Finally, a big thanks to everyone who reads this blog. Your comments and encouragement go a long way in motivating us to keep pushing forward. Seriously, how did people remodel their homes before the internet? Were there local support groups? Y’know…places where you could throw around words like Expedit and Akurum and people would know exactly what you were talking about? Regardless, we’re glad you all are out there and that we have this great forum for exchanging information and sharing ideas. Here’s to 2011 and all the projects it will bring!
