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Posts by milton

The steel inside

Posted on 2 May 2017

Overkill is our strong suite, but in the case of the newel posts on an outside stair, I think our approach is pretty justifiable.  The connection between the post and the stair stringer is often the first point of failure on a deck.  Typically a 4×4 gets bolted (or, mercy!, nailed) to the side of the stair stringer, and as people pull on the post going up or down the stair, the short grain of the stringer starts to fail and the post gets wobbly.

 

We’ve developed a system where we fabricate a steel sub-post on a thick plate, and then we bolt the plate to the concrete pad at the bottom of the stair.  The finished newel box gets installed over the steel with big-assed tek screws.  On a recent job, the geometry of the steel post was a little more complicated because we were using 3½” thick engineered beams for the outside stringers, but the general idea is the same.  We also had intermediate newel posts on this stair because of the long run.

Rubin deck stair-8154

 

Rubin deck stair-8158

 

Rubin deck stair-8132

 

Rubin deck stair-8134

 

And some images of the finished newel posts:

Rubin deck newels-8550

 

Rubin deck newels-8551

 

Rubin deck newels-8553

 

Rubin deck newels-8558
Categories: Details, Structural work, trade secrets

Tagged: deck, engineered beam, newel post, Stair, steel, stringer, welding

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Overkill

Posted on 5 August 2015

The quirky little projects we get are some of my favorites.  They fall outside the typical reach of woodworking, and most folks wouldn’t want to be bothered.  And while they are rarely lucrative, there are other kinds of compensation.   Two years ago (I couldn’t believe it when I checked the email thread!), a regular client asked if we could fabricate the missing wooden handle for an heirloom pistol he had. I of course said yes, before even seeing the project.  I know nothing of guns or gunsmithing, but weird old stuff excites me, and the transgressive allure of a firearm made the project irresistible.  Up close, the pistol was even more interesting than I had imagined, unlike anything I had ever seen.  …

Categories: History, trade secrets

Tagged: boot pistol, machinist, pistol, Rikert Engineering, Steve Reichert, underhammer percussion pistol, walnut

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Practice

Posted on 6 July 2015

We rebuild a lot of porches, but our current project is more rewarding than most.  Though the house was built in 1880, and the front porch had adopted a pronounced rightward lean, the important bits were still there.  Benign neglect is often our ally, and in this case enough of the original architectural details were still present that we’ll be able to recreate this porch almost exactly.

 

The deck and floor framing had rotted to almost nothing, so we removed them, along with the masonry steps, to leave us with the parts we planned to restore.

Front porch, partly disassembled

Front porch, partly disassembled

Closer view of carving

Closer view of carving

The carved panels, in particular, were pretty well preserved, even though the framing inside the half wall was almost non-existent.  We disassembled the panels and the columns above so we could re-support the roof, with the intention of repairing and reusing the decorative pieces.

Carved panels with Luc for scale

Carved panels with Luc for scale

The plain panel is from the back of the half-wall.  The bonus came when Dan checked the other side of the plain panel:

Visible and hidden carvings, with Musti

Visible and hidden carvings, with Musti

It seems that someone on the original work crew had done some practice carving.  Over lunch, we were imagining a scene where the young apprentice proudly shows the work to his boss.  The boss pats him on the head and assures him that his scroll will find its way into the finished porch…

Closer view of hidden carving

Closer view of hidden carving

 

Categories: Found, trade secrets, victorian

Tagged: Canton, carving, front porch, hidden work, Massachusetts, restoration

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Ain’t no window big enough

Posted on 18 March 2015

We are working on a master suite renovation, and one of the key features of the project is a large (really large) soaking tub.  About halfway through the planning for the project, someone raised the issue of actually getting the tub into the house and up to the second floor.  Tape measures came out, and we quickly determined that a tight turn on the main stair would not allow passage of the tub in any orientation.  And though the house is large, the second floor windows are rather petite.

 

When the clients confirmed that the tub was indeed very important to them, we offered that we could always cut a hole in the side of the house and hire a crane. With some clients, this would lead back to a conversation about smaller tubs, but in this case, we got the thumbs-up.

 

The morning of the move became slightly complicated when we realized that the geometry of the crane wouldn’t work, but an off-road forklift (with a very skilled operator!) came to the rescue.

 

Before we made the hole

Before we made the hole

The hole

The hole

Moving the forks into place under the tub

Moving the forks into place under the tub

Starting to lift

Starting to lift

Clearing the garage

Clearing the garage

Getting closer

Getting closer

Lined up with opening

Lined up with opening

Coming through the opening

Coming through the opening

And in (whew)

And in (whew)

And the tub's temporary home until we're ready to install it

And the tub’s temporary home until we’re ready to install it

Categories: Structural work, victorian

Tagged: bathtub, flying bathtub, forklift, Jacuzzi, Lull, victorian

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Just part of the job, Ma’am

Posted on 3 September 2014

No one warned me about cats.  There was nothing in the curriculum at North Bennett, and none of my early employers mentioned anything.  But it turns out that cats play a crucial role in our daily work:  keeping the indoor cats in, the outdoor cats out, making sure there’s litter box access for everyone who needs it.  And sometimes it gets more interesting.

 

Our current job is in a very feline-friendly neighborhood, so we didn’t pay much attention to the persistent meowing coming from the front of the house.  But around mid day, our client realized that her very shy cat Mika was not merely hiding but actually missing.  Then we looked up:

 

Cat stuck on rooflet

 

It seems that she made her way out of a (barred) window in the attic, across two window hoods, and onto the roof return.  Dan and Ralph saved the day.

 

Carpenters rescuing cat from rooflet
Categories: Found

Tagged: cat, Mika, rescue, roof

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Proof of principle

Posted on 17 May 2014

I think most working carpenters are familiar with copper’s ability to discourage fungal growth.  It’s the main additive to pressure treated lumber, imbuing the fast-grown southern pine with the ability to resist wood rot, i.e. fungal attack.  A smaller subset of tradespeople are probably familiar with copper’s use to keep roofs from turning green.  Roofs in damp locations, especially if they’re facing north, tend to develop a covering of algae, lichen, or even moss.  I believe there’s some legitimate difference of opinion about whether the green growths can actually damage the underlying roofing material, but many homeowner’s object to nature’s intrusion on their building.  An old roofer’s trick is to install a course of copper flashing high up on a susceptible roof; rainwater washes…

Categories: Building science

Tagged: algicide, copper, fungicide, gravestone, marble, Mt. Hope Cemetery

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Five out of ten

Posted on 30 April 2014

It was a fairly common call.  A repeat client wanted me to look at a section of his barn where the corner board was showing signs of rot.  When we went to look at the job, it was clear that the corner board, and everything behind it, had decayed considerably.

 

Carpenter burying his pry bar into a rotten corner post

Greg’s flat bar is buried all the way into the 4×6 corner post; there was indeed a problem.

 

Concrete shed behind barn

The barn was built in about 1915 to house the limousine for the estate, and the concrete shed attached to the back of the barn held a (coal?) stove to keep the limousine warm.  The current owner’s sense is that the shed was built at the same time as the barn.

 

The shed was almost certainly the cause of the rotting corner — the intersection of the shed’s roof with the sidewall of the barn was poorly flashed, allowing water into the wall assembly from the shed down, and the concrete against the wood was keeping the barn wall from drying to the outside.  The shed was also dramatically complicating the repair, as it was covering much of the area that needed attention.  In consultation with the client, we decided that the only reasonable way forward was to remove the shed.

 

As readers of this weblog know, we are wood guys, and the demolition of a 99-year-old concrete building is well outside our competency.  In situations like this, I call Steve Sullivan of Celtic Landscaping, an uncommonly careful guy with lots of big machines.

 

The first steps were to take down the chimney and create some temporary supports.

Disassembling brick chimney

 

Temporary shoring post for a rotten corner post

 

Deck temporarily supported by ropes

 

 

Steve was a bit concerned about how to safely demolish the small shed.  The roof seemed like it was made up of 8 inches of solid concrete, and the strength of the terra-cotta block walls was uncertain.  Further complicating things, we needed to leave the stair to the second floor in place while we were taking down the shed.  He decided that the best approach was to temporarily support the roof with an off-road fork-lift while taking down the walls, to eliminate the possibility of the roof coming down unexpectedly.  This is the sort of solution that would never occur to me, and a good example of why I like to work with Steve.

 

The first step was to make access holes for the forks in the face of the shed.

Man using concrete-cutting saw to make access hole in concrete wall

 

 

Man using sledgehammer to make access hole in concrete wall

 

 

And then time to set the machine.

▶

Followed by demolition of the upper portion of the walls.

Demolishing concrete and terra-cotta block wall

 

 

Demolishing concrete and terra-cotta block wall

 

 

And then, (gently) bringing down the roof.

▶

 

The rest of the walls came down easily, and the final step was to break and remove the shed’s foundation.

Using a hydraulic hammer to break apart concrete slab and foundation

 

 

Steve is typically a very cool character, desirable, I suppose, in someone operating heavy machinery.  As the shed demolition proceeded, and especially as the heavy roof was balancing on the forks, he seemed edgier than I’d noticed before.  Once the structure was down and he was more at ease, I asked him how hairy this project was compared to others he’d done.  “Oh, about a five.”

Categories: Structural work, trade secrets

Tagged: barn, Celtic Landscaping, Concrete shed, demolition, Lull, Steve Sullivan, structural repair

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Trying to stay out of the picture

Posted on 4 April 2014

For almost 25 years I’ve been drawn to photography.  I had resisted it before that, out of some prescient suspicion that it would take over my life,* but during a trip to Europe in 1990, a friend put an ancient Nikon (maybe an F Photomic, though I don’t remember for sure) in my hands, and my fate was sealed.  Making photographs has not led me to spend time in jail, nor yet to bankruptcy, but it has been a steady, sometimes-overtaking presence in my life since that summer trip.  I made some effort early on to earn a living through photographs, but discovered that I didn’t have the creativity for fine-art photography, the nerve to shoot weddings, or the intestinal fortitude for commercial work.…

Categories: Architectural photography

Tagged: architectural photography, bathroom, custom cabinetry, Horst-Buchanan Architects, modern, vanity cabinet

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Rescue!

Posted on 13 February 2014

Unless something goes terribly wrong,* carpentry is not usually not about adrenaline rush.  Firefighters burst into burning buildings to save puppies, while we shave another few thousands off a piece of crown miolding to make a perfectly coped joint.  Slow and steady tends to suit my constitution, but a bit of urgency now and then can be nice, too.  So I was excited to get the call from Lex, a repeat client of ours:  “There’s an oak library in a house in JP, and they’re about to gut the building.  We can have it if we can pull it out tomorrow; otherwise, it’s landfill-bound.”  We jumped into action, though our shop is not equipped with any slidey fire-poles.     The house was substantial…

Categories: History, Seen, victorian, vintage

Tagged: Jamaica Plain, library, oak, salvage, victorian

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Luc on beam

Posted on 17 January 2014

We were at Longleaf Lumber in Cambridge this afternoon picking up some engineered cork flooring for a project.  Longleaf’s primary business is finding, milling, and selling old-growth wood of the sort that can no longer be harvested in the wild (though they also sell new cork and bamboo flooring).  They typically find material in old barns or mill buildings that are being torn down, but they are open to any and all sources of old, interesting wood.  I’ve seen live oak timbers in their yard salvaged from the maintenance facility of the Constitution.  Most of the old wood they salvage gets milled into flooring, like the pumpkin pine we used a recent project.  But one of the great joys of visiting their yard is seeing the weird, random stuff they bring in.  Today’s discovery was a pair of giant pine beams (with full-grown border collie for scale) from an mill they were involved in dismantling.

 

Border collie sitting on large old-growth heart-pine beam

 

Border collie sitting on large old-growth heart-pine beam
Categories: Seen, vintage

Tagged: border collie, heart pine, Longleaf Lumber, longleaf pine, Luc, old-growth lumber, reclaimed lumber, southern yellow pine

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