Entries Tagged 'Carpentry' ↓

Often times I am struck by the amount of folks who treat home maintenance as crisis management. I encounter this in all types of homes and all types of homeowners. It is not restricted to one socioeconomic class or another, nor is it restricted by geographic boundaries. I have seen this in mansions, and I have seen in in railroad shacks. What is always the most striking about this is the reaction I get when I ask the homeowner about their “maintenance plan” and am greeted by a glassy-eyed stare complete with rapid blinking of the eyes. The oft repeated statement that follows is usually something like- “Maintenance plan?” “What do you mean?”

When one buys a car, it is generally accepted by the buyer that the vehicle will require some regular maintenance and upkeep to run properly and have a long lifespan (this is not true of some friends of mine who think that cars are self-healing and require only gasoline). Anyway, most automobile owners know that if they do not keep up with their car’s maintenance and treat it well, it is likely that the car will not treat the owner well either. Due to the potential expense, loss of investment, and general inconvenience experienced when a car suddenly breaks down, most people try to at least achieve the minimum level of required maintenance on their vehicle, some people like my father-in-law even take pride in this and are downright militant about it.

But this is much less often the case with homes. Your home is a machine. It keeps you dry, provides a comfortable temperature and living space, and protects you from the elements. Your home is a machine because it works 24 hours a day, without ever stopping or getting a break. It is punished by a constant battle against ground movement, sun and weather, seasons, hot/cold air, wind, and usage by inhabitants. Don’t take that last part personally. Being inhabited is hard on any structure, no matter who the inhabitants are.

- At this point I am curious, is this boring to you? If so, you can confidently disregard the rest of this post if you can promptly and affirmatively answer ALL of the following questions:

1. When was the last time you replaced your furnace filters? Was it within the last 90 days for regular filters and/or 12 months for pleated HEPA fiters?
2. When is the last time you replaced your humidifier filter on your furnace? Do you even have a humidifier on your furnace? Do you know where your furnace is? If you have a gas-fired furnace, have you had the flu cleaned and the burners adjusted recently? Ever?
3. Have you cleaned and purged your water heater recently (annual job)?
4. Have  you cleaned your dryer vent (interior) and any pest screen (exterior) in the last 6 months?
5. Do you have a water filter on the home line or the water dispenser on the fridge and if so have you replaced that in the last 12 months?
6. Have you tested your smoke and carbon-monoxide detectors in the last 12 months? Did you know that the NFPA recommends testing monthly?
7. Do you have a fire extinguisher (you should have at least one in the kitchen and one near the cloths dryer) and is it current with a full charge?
8. Have you done a visual inspection of exterior masonry and/or siding to see if any tuckpointing or caulking/painting (respectively) is needed?
9. Have you performed or had a tradesperson perform an annual inspection of your roof, foundation, and visible structural members?
10. Are you experiencing any water pressure or drainage issues?
11. Have you noticed any new cracks or movement in the drywall/plaster on the interior of the home?
12. Have you performed a test of all GFCI breakers and receptacles in the home in the last 30 days (NEC recommended)? If not, have you done so in the last year?
13. Have you had your boiler (if applicable) flushed and filled and all air bled this year?
14. Is your A/C system properly charged- with no leaks –  and are the components of the system operating properly?

This is the short list. And just in case you are curious- YES these are serious things to be checking. Roofs only leak when things have gotten BAD. Bad spots in masonry joints can quickly transform into water intrusion spots and structural weak-points. Missing caulk and paint on cement/wood siding invites water and weather in which means higher energy bills and possible mold formation along with ruined drywall and trim. Clogged dryer vents mean decreased dryer efficiency, higher operating costs, and a VERY REAL threat of fire. A slow drain can usually by handled with a drain auger, a stopped drain may be able to be augered but can translate into sewage backups and piping replacement. Defective smoke detectors and GFCI receptacles are defective life-safety devices and don’t protect anyone if they don’t work. These devices have saved countless lives and must be maintained to protect you.  Clogged furnace filters decrease efficiency by a tremendous amount, lower the ability of the furnace and A/C to make the home comfortable, shorten the lifespan of the equipment, and will wreak havoc on allergies. Dirty humidifier filters render the humidifier useless and can grow mold and mildew which is then pumped throughout the home in the ductwork.

A technician can inspect these items inexpensively and perform routine maintenance quickly in the vast majority of cases. This can save tens of thousands of dollars in replacement work, hundreds if not thousands of dollars in energy costs per year, and provide peace of mind. It can even save lives!

If you have done these things, I applaud you on your technical knowledge and diligence in the upkeep of your home. If you have not, consider doing so either yourself or by hiring a professional. A professional can show you how to perform the bulk of this upkeep yourself and can handle the ladder and technical inspections.

Protect your family. Protect yourself. Protect your investment. Inspect and maintain your home.

As we move into 2012, we wish you a VERY HAPPY NEW YEAR!

Note: Scarlett Construction Company employs several professional tradespeople who are more than adept at inspecting and maintaining homes. Please contact us if you have any questions or would like to set up an appointment.

So, we decided to trace and build them in-house. That is how we did the majority of the fabricating on this project although we had help from Burkart’s Millworks and a few others.

Making the corbel templates

First we made a cutout sample of a corbel still in place and used that to trace our templates. Second, we cut the two outer pieces for all 32 corbels from 1×16 Miratec trim boards. To achieve matched pieces, we clamped two pcs of the Miratec together, this method yielded book-end pairs.

A rescued original corbel with the bookend templates

Once all the outer pieces were cut, we began cutting the centerpieces. We  made a template for the centers because the centerpiece of each corbel was recessed 5/8″  on the lower face of the corbel. To make this piece we used treated 2×12.

The three pieces were then sanded using an oscillating spindle sander and a table sander to clean the profiles for assembly. They were then adhered together using OSI polyurethane adhesive and galvanized finish nails. The adhesive was over-applied at the seams and the pieces were tightly clamped with vise clamps to press some of the glue out. The excess was wiped away and acts as a sealant to prevent water from getting between the pieces.

Finally, the assembled corbels were given a fine-grit sanding and pocket holes – with plugs (drilled from like materials using a plug-cutter) were drilled for screws to attach the corbels. The pieces were the primed twice and painted twice. I do not recall the primer used but the paint was Sherwin-Williams Duration exterior paint. The paint has a lifetime warranty and does not require priming (although we usually do). Also, this paint is bombproof! I do not often tout painting products ( due to the risk of backing a product that turns out not to work 15 years later) but this is fantastic paint (and at fifty bucks a gallon it should be).

The pieces were then transported to the site and installed using DeckMate 3.5″ screws and the plugs were inserted. Then came the touch-up painting and standing back to admire…

The final product installed - a weather-resistant French Corbel

And the project result was…

The completed porch - Custom from top to bottom

How do you replicate 100+ yr old exterior items on a home with new items that look identical to the original ones and stand up to the weather? If you are lucky, there is already a matched piece made by one of the many manufacturers of synthetic architectural accents and trims (like Outwater or Fypon) that is worth its higher cost over traditional materials because of its projected lifespan. If budget is no concern, you can have a mold made of the original and new pieces cast in a resin or other synthetic material by a specialty manufacturer.

Or you can utilize the best available materials that will resist the weather and you can pay extra special attention to the assembly to promote the longest lifespan possible. That is the route most conscientious custom builders in historic districts will take – and for good reason.

Generally, if you buy precast synthetic trim and accent pieces you pay a premium and often the items are not an exact match. Another complication is that many construction  synthetics (and pretty much all plastics) don’t take paint well unless it is very light-colored paint and specifically formulated for that synthetic/plastic material. If you have the item custom-cast for the project, you will need to order a very large quantity or the cost will be 10 times (or more) than the precast cost and if the casting is done in synthetics you face the same problems posed by the precast.

Which brings me to the project where we faced this problem on virtually every item.

Original Post Corbels that disintegrated when touched

A truly enjoyable project, this porch offered challenges for every piece installed. I will discuss the decking, spandrels, spindles, handrails, newels, accents,  guttering with integrated crown and so on in a later post.

Note the shape and construction of the corbels. Everything had to match perfectly as the City Historical society oversees construction in historic preservation districts such as this one. Further, the need for painstaking accuracy was elevated as it was also reviewed by the Lafayette Square Restoration Committee who walked past and reviewed it daily. And as an added layer of project oversight, the many neighbors of this home in the Square would visit regularly and request that the porch be accurately rebuilt. At first (when we tore the old one down -basically we just hit it once with a hammer and swept it up), we thought some of them might run home and grab torches and axe handles, form a mob, and return to pummel us. But we reassured them that it was going back with looks exactly identical to what it was, and as it took shape they gradually became much more friendly. By the end they were as neighborly and welcoming as any neighborhood I have worked in.

So back to the corbels. The original pieces on the porch were 3-piece layered construction, and we decided that they had lasted this long, we’d do the same. See pt. 2