Monday, September 3, 2018

BYO Furniture: Sofa Table

Recently we had been looking for a sofa table for quiet some time, but could not find the one we wanted. So we started looking at buffet tables, but the same result - the ones we found were expensive or not what we wanted.  After weeks and days of going from store to store and searching countless websites and ads we were to the point of giving up on our search. One day while picking up supplies at our local builders supply warehouse I said to my wife, why don't we just make our own.  She looked at me with bewilderment - you know the look of doubt with a side-eye.  The conversation went a little something like this.
    Me: well I can just build the table.
    Her:  hmmmm
    Me:  what? you don't think I can do it?
    Her: I didn't say that?
    Me: I just need to know how long you want it, what color any particular style
    Her: ..........
    Me:  You still on building the table aren't you?
    Her: well ...
That evening, I looked online for design ideas and came across a few that I liked and some that I didn't like. I showed my her the ones I thought were great, but we still couldn't agree on the one that suited our home. She asked a good question though: what will the table legs look like?  Hmmm, i don't have a lathe so I couldn't turn any wood to fashion legs. How about we go to Lowes or Home Depot to see what prefab legs are available? Off we went, we looked at the stores and some other surplus stores, but ultimately came back empty handed.

That night while lying in bed it occurred to me why not look at some some cast iron table legs?  I woke the next day and started searching for cast iron legs.  I ran across some nice antique 1885 Singer Sewing Machine legs. Perfect!!!   So I ordered the legs ($85) from EBay with free shipping and they were delivered in about  three days.

Okay so it has been a few decades since I had to fashion a table from two pieces of wood, but thank God my dad who was a shop teacher taught me well during my childhood. Thanks pops!!!  Anyway,  the choice of wood is poplar. I went to a local building discount store and picked up two planks of poplar at $6.00 a piece.  When building a table and selecting wood you must make sure that they are straight or have very little curves.  After about 1.2 hours of going through the lumber they had I found two that have very little warp to them.  Since dealing with natural growing materials they will not be completely straight/level that's why they make planers. However, I don't own one of these machines - hence the time at the store, but I digress.

The wood came in 8'x8"x1.5" planks - not necessarily wide enough for a table so I had to combine two boards to get the size I wanted.  Joining two pieces of wood together is not a hard thing to accomplish here  are the items you will need:

  • Biscuits
  • Saw Horse
  • Sander
  • Router / jigsaw
  • Wood glue
  • Clamps 
  • Rubber mallet
  • Drill
You don't really need the biscuits or a biscuit joining too.  Instead take a 1/4 dowel or 5/16  dowel and cut it into 4 inch sections. Measure and mark the holes for the dowels to be inset into the board. Measure and wrap a piece of tape at the two inch mark on the bit this will ensure you have the appropriate depth needed. Please make sure the drill bit is the same diameter of the dowel or you will have trouble inserting the dowel.  Fill each of the holes with wood glue and tap the dowel into place until it stops (2 inches) with the mallet repeat for each hole. Once you have the holes and pegs (biscuits) in place you will need to drill matching holes in the second material that you want to join. 

Tip: to make the correct placement of the holes, place each board on a flat surface, using a daub of paint on the end of each dowel, push the two pieces together - causing the paint to transfer from the dowel to the second board.

On the second piece of material drill the matching holes also at a depth of two inches.  Remove any excess dust or debris from the holes and fill with wood glue.   Run a bead of wood glue along the edge of both pieces of wood this will ensure it is held together securely. Squeeze the boards togethers tightly and clamp together. I do not recommend the clamps with triggers as they cannot give the amount of pressure needed to bond the two pieces of wood.  The excess glue will be forced out of the seams. Immediately wipe off any excess glue with a damp cloth.   After 24 - 48 hours hours the table top can be unclamped and prepared for sanding. 

If you want to get creative or add a decorative edge or flare to your table, you can use a router or simply draw our the design and cut it out using a jigsaw. Using a palm sander or a belt sander with 250 - 600 grain sandpaper sand all sides of the table.  The higher the number in sandpaper the smoother the surface, lower number sand paper used to remove material.  The next step is to make what they call cleats, these are actually braces that spand across the underside of the table to provide strength and support.  You can make these cleats out of scrap wood, but they should be equal in size and length. The two end cleats will act as leg supports.  After a couple of passes with the sander and wiping off the table it is ready for a couple coats of stain.   But not so fast young whipper snapper.. I still have to set the spacing for the legs.  This is where the cleats come in to play.

There are three cleats on this table, one on each end and one in the middle. The two end cleats are placed nine inches from the ends of the table for the leg placement. The top of the cast iron legs have two bolt holes  from the original sewing table so there was no need to try and fabricate them. However, I had to bore out the bolt holes in the cleats.  To do this, simply place the cleat on top of the table leg and using a Sharpie, mark or color in the hole position on the cleat.  Bore out the hole  and make a counter sink so that the head of the bolt is even with the surface of the cleat. The bolt should fit snuggly if done right. 

Flip the table top upside down and mark the positions of the cleats, for this the edge of the cleat is nine inches from each edge of the table.  Insert the bolts (screws) if not already done  run a bead of glue the length of the cleat on the underside table and also on the cleat and fasten with three 1-1/4 inch screws. Repeat for the next leg and middle cleat. Once the cleats are set and the glue has dried the legs can be attached using washers and nuts.  Remember to do a test fitting to determine the bolt length.  The bolts I used are hex bolts because I wanted to make the bolt flat inside the cleat and to have it anchored inside the cleat.

After determining the placement of the cleats and table legs, the table needs to be braced.  The legs are not not strong enough on their own to prevent the table from wobbling. These Singer Sewing legs come with pre-drilled holes. two on the left and right and on bottom center. These are great places to add bracing in order to add stability to the table. You will need to find a place that can fabricate two metal rods with screw ends. Luckily for me the place I chose (Brownsville Welding) did an awesome job. I went to them on a Friday  even though  they were closed the owner met with me and took the material and by Wednesday I had my support bars.

Viola the table is complete. 







Wednesday, June 27, 2018

fireplace and mantels

In this episode of DIY Adventures we are going to take a look at installing a mantel. But not just any mantel, one the size of a railroad tie.    If you dont know what a railroad tie is, it is the wood slats that lay under the steel rails - don't use a railroad tie as they are carcenoginic and flammable.This was actually done in November of 2017, but I am just getting a moment to post... actually I have several more to post. 

In most parts of the country homes have Fireplaces, those in climates that do not get really cool in the winter usually are not equiped with these little features.  It the focal point of many homes, but ours just seemed blah.   Take a look.---->


When we purchased the house some years ago we had all these ideas to make this our home.  The fireplace was something we wanted to do, but didn't know quite what it was that it needed.  The flipper painted it white using some cheap paint which bubbled up and flaked off after a while causing the red brick to show.  We still have to get a chimney sweeper out to inspect the chimney but that will be later- cause im not climbing up in there and ending up in the 6 o'clock news.

From here on out when I use the word we there it was only I doing the work - the Mrs. was doing Mrs' things and occassionally shaking her head.  So weekend project number 45 ( I really don't know the number just sounded good) update the fireplace.

We thought about doing a full surround with the decorative column and the mantel, but it would look out of place with our current decore and home design. So I suggested a railroad tie.  Now I  have seen them done in other homes and they looked really nice. I did some research on them and found a place that was selling them for about 15.00. That was great, however, I kept reading.  Why did I think that I could just use something that came from outside and looked good for being over 60 years?  Ya' can't.  Why?  as stated at the start of this railroad ties are carcenogenic, soaked with creosote  and other chemicals to protect them from insects and rot, also they are highly flammable - so that's out.  The next best thing was to find timber that would resemble a railroad tie.  I found a 6"x 6"x 8' timber beam at a local surplus and salvage store for about 10.23 with tax.  Always check your salvage yards, they usually have some good stuff at cheap prices. The beam weighed in at about 105lbs  yup a two man (woman / woman & man / man & teen ) job. You will need a couple of saw-horses...I got mine from Harbor Frieght for 8.99 + a 20% off coupon. Coupons are always a good thing!!!

There are a few steps that I did not take pictures of and that is the distressing and staining of the beam. If you want the mantel to have knicks, dings, scratches, you can achieve these by using a heave rock, chains, screw drivers basically anything that will scar the surface. Once you have it distressed as you like choose the color stain.   I did not paint this beam,  but used stain, as stain penetrates the layers of the wood. This will take a few days... so do something in between coats (3-4), make sure you protect the beam incase of rain.   While that was being done, we needed to get the flaking paint off.  Nothing better to remove paint than a paint scraper. I have no idea what type of cheap paint this was, but I grabbed a corner and about two foot section came right off - hmm. After the fireplace was scraped and the residue removed with a damp cloth, we painted the entire fireplace with paint designed to be used for masonry/brick.

Now since all the touchup has been done, it's time to prep the mantel for mounting. You will need the following:

  • Hammer drill,
    Install of Lag Bolts
  • Masonry Bit
  • 10" inch lag bolts 
  • Sleeves
  • Masking tape
  • Measuring tape
  • Steel ruler
  • Level
  • Construction adhesive
  • Ratchet 
  • Angle grinder w/ cutting wheel
  • Heat resistant caulk up to 700 degrees
  • Rubber mallet.
Measure (starting from the hearth of the fireplace) to find the desired height placement of the mantel.  You will want the first mark to be the bottom of the mantel and then measure again to top of the mantel to find the center. Once you have the center  marked - draw a line from edge to edge. On this line measure about 6 - 7 inches  along the line and mark - these will be your drill points. To secure my mantel I used 5 lag bolts and sleeves positioned at every 10 inches to equally disperse the wieght.  


heads removed from lag bolts
Make sure your drill bit is larger than the lag bolt to adjust for the sleeve insert that needs to be placed in each hole. Make sure you keep the holes level, if you are off higher or lower it will affect the end project.  Drill each hole, blow out the debris and dust (oh yeah it will be messy) from the holes and insert the sleeves. The sleeves should fit pretty snug if  loose thread the lag nut in the sleeve slightly and then place it in the hole.  Using your level, place it on the lag nuts to verify if it is level. Tighten each lag bolt with the ratchet until it is firmly set ( DO NOT OVER TIGHTEN).  

Once the lag bolts are secured and tightend, using your angle grinder, cut off the head of each lag bolt.  If there are any shards left from the cut, gently grind them out. Measure the length of the proturding lag bolt you will need this to determine your drill depth on the mantel.

Here is a cheat and a great way to get the hole placement right on the back of the mantel.  Find a piece of scrap lumber the same width and length of the mantel. Place a daub of paint on the end of each bolt.  Grab your friend/wife/neighbor/kid someone to help you with this and the next few steps. With help from your partner, place the board against the lag bolts to mark the positions of the holes.  Using the same board clamp it to the back of the mantel, ensure its placement is even on all sides.


mantel secured view 2Mantel securedWrap a piece of masking tape around the drill bit according to the measurment take of the extruding lag bolt - this will be your depth gauge.  Once you have all the holes drilled, turn the beam over and give it a few whacks to dislodge any shavings in the holes. Now is a good time to stretch those muscles, hope you been hitting the gym some. With the help of your assistant, do a test fit of the mantel on the lag bolts. Do not attach it all the way - you are just making sure the holes are aligned correctly. Remove the mantel and using the heat resistant caulk, place a liberal amount on either the lag bolt or in the hole in the mantle. The caulk will act as an insulator and protect the mantel from heat when using the fireplace. Take the construction adhesive and  place a liberal amount on the backside of the mantel (make a zig-zag pattern).  Reposition the mantel on the lag bolts and push it into position.  you may need to whack it a few times to get it fully in place.  I know I said use a rubber mallet, but for ours we used a 8lbs sledge hammer to knock it in place. Once it is in place, caulk around the sides of the mantle to fill seal any gaps. After about  a few hours the construction adhesive should be cured and the mantel firmly fixed in place.
Finished mantel and hearth
Viola, you have a new decorative mantel  that only cost you about $40.00 to do yourself.   We continued to improve our fireplace by adding slate tile (Home Depot - $25.00) to our hearth. We have already covered tiling so I won't go back through the steps.  The tiling only took an hour to complete and our fireplace project is done. Add some stuff like pictures candles  or a clock to cozy up the area. 






Friday, June 3, 2016

Last of the flooring: Floors No More

Hallway
What's with the title you wonder: I have completed removing all the carpet from the home and replaced with laminate flooring, Yippie.  I know I am the only one celebrating.

There is already a post about how to do laminate flooring, but I thought I would add to that post with some recent photos and some added tricks to help you along the way.

First, if you don't have this app you should: Handyman Calculator.  It is available on Google App Store and is totally free. Sure you can buy the premium version, however the free version gives you so much stuff.  Whether you are doing floors or laying brick you need this tool: it calculates everything including total project price, square yards, square feet and cubic feet, and air volume. Yes, air volume for those who need HVAC calculations.   It does a lot, lot, more and you will not regret the download at all.
Second, put down the measuring tape.  That's right, you don't need a measuring tape to lay laminate, tile, nor hardwood floor.  But what you do need is a Sharpie to mark the boards.  Only use the measuring tape for hard areas that are hard to get around such as closets.  Instead of using the measure twice cut once rule, line up your next cut by laying the board next to the area to be cut and mark it.  You will have to flip the board the opposite direction, but by marking instead of measuring you will get the most accurate cuts and save you some material and frustration.


Additionally, do not throw away all the cardboard boxes from the flooring.  One or two of these will come in handy as templates for entry ways, door jambs and closet opening. By creating a template you will save yourself time, material and money.   To use the box as a template, unseal the edges (top, bottom) of the box and unfold them.  Lay the box under the door jamb and trace it onto the box using your Sharpie, then transfer that to the flooring.   Please Note: the stud  of the door frame is usually about 2 inches away from the sides doorjamb and about 3 inches in the front.  To check the space under you doorjambs use a straight ruler, not a tape measure, and mark it on the ruler.  This will help ensure you have the right depth of cut so that there will be less chance of filling gaps.


Get a Good Underlayment: do not go with the cheap roll of underlayment they will be more trouble then they are worth.  I went with an underlayment that was a little more pricey, but less the hassle. I went back to my store (Lowes) and found this easy cut underlayment that comes in 100 Sq. Ft sheets.  (39.99 pk).   The first floor (see earlier posts) I used the roll type underlayment and I quickly grew frustrated with having to weigh it down so I could cut the next piece to size and tape it down.  This goes on flat and you can cut it with scissors or a knife. Definitely worth the money.  In my pictures you will see 3M Aluminum HVAC Tape securing the underlayment.  Well the reason for this is because aluminum tape is recommended for this type underlayment I purchased.  However, when looking at the price of the tape ($10.00 for a small roll), I looked at the HVAC tape at 8.00 for a large roll, this tape will always come in handy.  You never know when you may find yourself doing some HVAC repair. 

Next ONLY REMOVE the base boards you need to remove:
I have seen and heard of people removing all the baseboards in the room before laying the floor, however, I found it easier and beneficial to only remove those that need to be removed.  These usually tend to be the front of the room and the wall the last row falls.  Why do I say this, the first row of flooring is always going to give you issues and when you are laying it down by yourself  the baseboard will give you that extra hand that you need in keeping the floor from shifting and even.  But how do you know which baseboards to remove?  Once you have decided on which direction the floor will flow (usually determined by light source) the two (3) baseboards will be easy to determine.  In addition, when laying laminate or hardwood flooring you want to ensure you leave at least 1/4" gap from the wall and the floor for expansion.  Leaving some of the baseboards down will ensure you have this safety buffer. You can tap the edges of the flooring under the lip of the baseboards to hold the flooring down, but DO NOT tap them to the base of the wall.

Speaking of Gaps: you will have some gaps around the doorjambs and closets, these are unavoidable but can be easily fixed by using caulk  or adjusting the door casing.  The latter is time consuming and can be tricky so I suggest taking a piece of the flooring with you to your local Flooring store or hardware store and see if you can match the caulk to the floor.  It may not be 100% matching off the shelf but will be close. You can also mix colors to try to get it to an exact match if you like (Art classes pay off ).

Transitions, smansitions why not go transitionless?  Transition-less floors are a thing of beauty and are not hard to accomplish.  There are only (will only be ) two transitions on this floor: bathroom entry and from tile to laminate transition.   Many say don't go transitions-less as buckling can occur but buckling in the floor is only caused by the expansion and contraction of the house or a water leak. This is why they tell
you to keep 1/4" of space from the wall and the floor.  Transition-less flooring allows the  lines of the floor to continue from one room to the next without being interrupted.  It does take some planning and I scratched my head for a moment before I solved my own problem.  See I laid the floor in the main bedroom first and ended it at the doorway before I ripped up the carpet of the hallway.  The floor is measured out so the locking side is placed toward the hallway. As you can see in the pictures there are no transitions from the closets to the hall nor the bedrooms to the hall.  The first room took some time to complete but this is where that template will come in handy.

Closets:  people complain of the doorjambs well my arch enemy was the closets. I have three closets in just the hallway alone not to mention the ones in the bedroom. Each closet was the same but yet each was challenging.  The very first one was at the right of the hallway and I had to start on the right side of the hallway as I had already finished the master bedroom floor and was doing transition-less flooring.  This one closet took me at least 2 hours to do,  UGH!!  The closet was no bigger than 3 or 4 sq. feet, but I managed to get it done and continue into the hallway. There is one good thing about lock and snap flooring, they pretty much go together in any direction as was the case with this first closet.  The closet floor actually is laid horizontally as opposed to the vertical lines in the hallway.  Again, I am no Pro if I did it over I probably would have figured out the best way to lay the boards in this closet. But I redeemed myself with the other closets in the hallway.

My last two tips for you guys is to invest in a multi-tool and glue.  Doorjamb cutters are way expensive and the handsaw trick will make your life miserable.  The multi-tools come with vibrating/rotating saw blades and make quick work of cutting the baseboards. They do cause a lot of dust so make sure you have a vacuum around which will help with the cleanup.


Why Glue? when you are doing hardwood or laminate you will eventually end up having to butt two pieces together for longer runs of flooring or for those pieces that require only 1-2 inch strips of flooring. Using glue is a process the pros use and is simple to master in order to join two pieces together (big or small).  Remove the locking trim from the edges of the boards to be joined.  If this is a fresh cut and no locking edges you can still use this method.  Using your glue, preferably wood glue, but white (school) glue works well if you don't have any wood glue around; run a bead of glue on both boards and then tap the planks in place until they are joined. Use a damp cloth to remove the excess glue.  You can see this technique on YouTube.


Only thing left to do is re-caulk the baseboards that you removed and install the 1/4 round trim around the base of the floor.  I hope these tricks will prove useful to you. there are some videos on YouTube that may explain the transition-less floor better and help you measure without a tape measure.

Friday, January 29, 2016

Ugh its a Broken Valve!!! Laundry Room Remodel

Well it happened yup the dreaded washing machine died so out it goes, but before I disconnect the machine I shut off the water to the house.  I know its not a necessary step because there are valves that can be closed, however, I didn't trust the valves as they were old.  I turned off the cold water valve pretty easily with a little force, but the hot water would not budge an inch.  I twisted it to open, still would not budge, then twisted it to close still nothing.  I added more pressure on the valve and it gave, I thought thank you Lord, and so I turned it some more and the stem broke off in my hand. It was stuck to the open position and thus couldn't turn the water back on. What a way to end a Saturday afternoon. 


There are many things I am but a plumber is not one of them.  After trying unsuccessfully to try to get a plumber to come out (earliest was Friday of the week), I decided to try it myself.  I used  enlarged the hole around the valve to try and unthread it from the pipe, unfortunately they were braised on, yes the threaded pipe was braised on.  I tried melting the solder using a propane torch. I held it on the valve for 5 minutes and using pliers (pipe wrench) tried to unseat it, but it would not budge. Only thing left to do is to cut the pipe.  


Had to make a 2' x 3' hole in the wall to access the pipes enough to remove the old valves (faucets).  What moron decided it was good to build the wall using two pieces of sheet rock?  After I sawed through both sheets of sheet rock I used my $3.95 pipe cutter to cut the pipes and used steel wool to clean the copper.  I removed the burs caused by the cut and even file the cut to make sure there are no sharp edges. 


Now the trouble starts:  I used Mueller ProLine Push Fittings (female coupler)  that I purchased from Lowes.  I purchased 4 (@ 8.57ea) just in case one or two were bad.  I also purchased a Washing Machine Box (34.95).   The push fittings are supposed to be quick and simple to use and require no glue or sweating the pipes together (this is why I purchased them as I am not good a sweating pipes).  I place the first one on the cold water line and screw in the new valve (test fitting) I then do the same to the hot water line and go outside and turn the water to check for leaks.  Well it didn't take long before I noticed that there was definitely a leak but not from the threaded valve but the push fitting that was said not to leak: FAIL!  It was not just a leak but a steady stream of water pouring from the bottom of the fitting.  So I try again seeing as how the cold water line is holding (has a small drip) compared to the hot water line.  I remove the fitting and try the next three.  I polish the pipe with the steel wool and made sure there was indeed no sharp edges that may break the seal.  All three push fittings FAILED.  

I called a guy I knew and he came over ( a simple job turns into hours) he attempted the same thing (he knew what he was doing as compared to myself)  however, the fittings all leaked. He said "well looks like we gonna have to solder them on I guess."   Solder kit 15.99 at Lowes and 12.00 at Home Depot.  I took the push fittings back to Lowes got my 32.00 back and went to Home Depot.  On the isle I saw the SharkBite push fittings.   I remembered reading online about SharkBite fitting and people using them so I decided to buy both the fittings and the solder kit.  But the guy had to leave so my brother was on his way to sweat the pipes.  He's much better at welding and soldering than I so it should be rather simple for him. 

But I wanted to try these fittings just one more time. So I got home and pushed the fittings on each line and re-tapped the threads of the valves with plumbers tape to do a test fit.  I turn the water on and Viola!!! no leaks.  So apparently the Push Fittings at Lowes (Mueller ProLine) are cheap, worthless imitations:  I guess I shouldn't say cheap at $8.57 each.  The SharkBite fittings were $5.67 each. 

Since the test fit worked and at this time its 7:45 in the evening and I am tired I undo the valves and place the washing machine box in the hole to make it semi presentable and screw everything back in place and turn the water on and check for leaks. Praise God no leaks.  So I secure the box to the wall for now until I can decide if I want to re-sheet rock the area or do a patch job.


All this because of a broken Valve.  Time+$$+Energy x Frustration = experience I guess.  But onto the next phase Tiling. 

The laundry room had linoleum tile in it and it was crumbling (another poor install job) and since we are getting new machines and have to take the old ones out I might as well get started. 


First, if you have a store called Dirt Cheap in your area check them out. They have great prices on tile and other things: you can even buy a pair of jeans for $2.00.  Yup $2.00 you just have to look through the racks of clothes - hopefully they have your size.

But they pretty much carry everything, tools, clothes, shelving, tile and flooring.  After spending 67.00 in supplies that includes a 50lbs bag of white mortar and 5 boxes of 20 x20 tile  we are all set to tile.

I still have not grouted that patio yet as the weather has been freezing lately so why not just start this and grout the other during weekend when it's supposed to be in the 70s.  I did not take a before picture of the laundry room, but trust me it was a mess.  But the tile turned out nicely.  It was a bare making the cuts for the legs of  the water heater stand, but I got that done.  The tiling of the laundry room only took two evenings a total of 8 hours.  Grouting will commence as soon as I can get the moment after work.

 


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Thursday, January 21, 2016

Talk of the block: Patio Makeover:

When we moved into our house some 11 years ago we didn't think much about the backyard.  Yes we hosted bar-b-q's throughout the year and had numerous dinner parties. However, while we hosted these events we didn't pay much attention to the patio, until a few years ago.  See the previous owners  decided to paint the patio, first it was green and then a light gray.  The paint in areas started to crack and separate so every time one would step it would sound like a bowl of Rice Krispies.

So we decided that it must be dealt with, but that was not the main concern.  As stated in previous topics we live in Florida the Sunshine state that received an average 59.21" of rain per year, and with this rain, we noticed after each rain there stood about 3" of water in right corner of the patio.  Whomever, laid the slab of the patio did a poor job and thus the right slab of the patio developed a 25 degree slope that ended up being 1.5" below the foundation and causing the patio not to be level.  The picture above is the patio in question it is a total of 367sqft  as you can see by looking at the brick line the left of the patio is slightly below the right slab so this had to be fixed.  Standing water can cause a lot of damage even to concrete.  


Two years prior I had the wild idea of what to do with this space, why not tile it.  Sounded like a good idea, but how to accomplish this feat?  Research!  yes I asked a few friends and asked a builder and did some searching online and viola I figured out what exactly I needed.  

Material List:

Tile (16x16)
Cement
Type S Mortar
Rubber mallet
RedGard Waterproofing and Isolation Membrane
Paint rollers (2)
Backer Rods
Grout
Caulk
Float
Bull-float
Level
3/8' spacers
cement
Trowel
Sponge
Bucket
Wet tile saw
Angle grinder
Knee Pads




First Choosing Tile:
First things, first  the area to be tiled is 367SqFt. and finding the correct tile is a chore.  Since this is an outdoor uncovered patio the tile needs to be slip resistant.  The tile should also be made for outdoors,  however, you can use ceramic and porcelain tile outdoors. It is not recommended that you use these type tiles as they can crack in very cold conditions. With that being said we found a pattern of tile that we really liked the only problem was that it did not say it could be used outdoors.  The tile we choose had a slip resistant surface and a striking pattern. Since we found the tile we wanted it was just the matter of purchasing it: $375.00 on sale.


Because we had chosen a tile that was ceramic and not designated for outdoors we had to make sure that the tile would hold up under weight, stress, and external conditions.  


Prepping the Patio:
Remember I said the patio was painted by the previous owners?  It had two layers of paint plus a primer.  The paint and primer has to be removed as the top coat of paint was flaking off.  I did not want to use any harsh chemical solvents  which is costly, time consuming and dangerous to animals and children so I opted to use a pressure washer with a turbo nozzle.   Equipping the turbo nozzle to my 1900psi pressure washer made quick work of stripping off the layers of paint.  Some came off in large sections while others took many times to remove. In all it took me a day to do the entire patio. 

Leveling:
Once the patio dried out (1 day) it was time to address the leveling of the patio and mend any surface cracks.  Using a level and a string I determined that the right side of the patio was in fact level so I needed to raise the left side up to become level.  Using a the level, tape measure and chalk line, I marked the brick to where I needed to level the patio.   If you need to level a floor they do sell a self-leveling mixture that you can use to save time. 

However, I did not buy the mixture as I needed to ensure that water drained off the patio correctly.  Instead I used three 80lb bags of cement  and added more water than what  was prescribed.  The mixture needed to be more fluid to ensure that it covered the area needed. 

Starting with the lowest side I poured the concrete mixture and spread it out using a trowel  ensuring that I was the height required.   After establishing the desired (leveling) height, I made a 45 degree slope away from the house to make sure that water drained away from the house.   I brought the cement all the way to the end of the patio using a bull-float.  As the slope became thinner I mixed in  Type S mortar to feather out the end of the patio.
 
Tip: if you don't have a bull-float you can rent one from Home Depot for 4 hours at about $13.50 total.

There was no need to slope the right side of the patio just yet, I can do this later  when creating the mortar bed for the tile.

Expansion Joints:

Expansion joints are essential in slabs that are more than 16'. The joints allow the concrete to expand and contract, absorb vibration and allow movement due to ground settlement. These joints minimize any cracking that may occur during ground movement. You must take note where these expansion joints exists as you do not want to cover them in cement or mortar doing so will cause your tile to crack when /if  the ground moves. 

Note: You must take these joints into consideration when laying out the design for your patio.  Use caulk to fill in these joints DO NOT USE MORTAR OR CEMENT.


Crack Membrane:
RedGard  Waterproofing & Isolation Membrane
It's important that when laying tile over a concrete slab that you fill in any cracks, divots or holes in the concrete. Mending these existing cracks now will ensure your that your tile will last longer and that the cracks will not carry through to your tile.  If you notice any large cracks in your slab you will need asses whether these cracks have grown or remained about the same.  Cracks have  a tendency to expand and contract during the seasons, if the cracks continue to expand I suggest you look into having them fixed professionally before proceeding to tile.  You can fixe these cracks yourself, but there could be an underlying problem that is causing the cracks to expand.

To prevent cracks from carrying through to the tile, you will need to lay down a crack resistant membrane.  There are several on the market that you can choose from, I used RedGard because it was cost effective ($139.00 for 3 gallons) and after research was the best choice.  Ditra Isolation Membrane is also very good, but is expensive ($84.98 a roll) and covers only 54SqFt. per roll. 

RedGard is a liquid rubberized plastic material that can be applied either using a paint sprayer, a paint brush or paint roller.  It's drying time is about an hour and an half, but should only be applied when temperatures are about 40 degrees for 72 hours.   When it dries it will change from bright pink to a dark red as seen in the photo above.  Apply the RedGard to a thickness of .38mm for optimum protection. RedGard is great for tiling in wet areas such as bathrooms, kitchens and even to cover basement walls.

Once  the membrane is dry you should begin placing the mortar and tile down immediately.  If you cannot do so, cover the area in plastic or protective material to keep from damaging the membrane.  Do not wear the spiked cleats used when doing concrete as they will puncture the membrane.

Laying Tile:
Before you begin to lay the tile make sure you do a dry pattern first. This will allow you to choose how you want to lay the pattern of your tile. It will also allow you to make any adjustments and pre-cuts that are needed before you commit the tile to the patio.

It is important to use the right mortar. Since this is an outdoor patio you will need to use Type S mortar formulated to be used in outdoor environments. Mix the mortar according to the ratio on the bag and apply to the patio and back of tile.  

Depending on the area you are tiling this will not be completed within a day so do not rush. If you are unable to finish the area remove any excess mortar using a damp sponge and clean water.  In case of inclement weather cover with plastic to protect the mortar bed.   Again, this will take more than one day to accomplish depending on the area of tile to be covered.

Once the tile is down please remain off the tile until it sets (3 days).


Because of the are of the patio I wanted to cover left a slight lip from the old slab to the new tile I laid additional mortar at the edges to prevent tripping.  In these pictures you will notice the two half walls.  I did not want to leave these walls as they existed so I decided to tile them.  This presented a slight challenge as whomever constructed the walls left them free-standing anchored with tie bolts.  These needed to be removed (cut) prior to tiling.  Also on the far wall (left) is an outlet which power is ran under a wooden plank secured to the wall by these tie bolts. 
Using and angle grinder and cutoff wheel I cut the tie bolts flus with the block. I also carved out a notch in the top of the block to house the Molex wire that provides power to the outlet.  Make sure you turn off the power before attempting.

Tiling Walls:
You will also notice in the above picture the same person that built the wall incorrectly built the right wall and cut off the facing blocks leaving it hollow only covered up by a board also anchored with the tie bolts and a few nails.   These boards had to be removed in order to tile the walls. Again using the cutoff wheel on the angle grinder I removed these bolts (two at the top on in the facing block).  

half walls tiled and facing covered and repaired
 Since the wall on the left  has an open face I had to build a footing to support the first face tile.  I did this by using a scrap piece of wood that was square and poured mortar  into the open bottom face.  Once is hardened I wet the edges of the block wall and the prepared the mortar, however, this time I used a little more water than needed to make it a little stickier than when laying the tiles.  I applied tile to the outer edges of the cut blocks and also to the back of the tile.  I placed the tile and tapped it in securely with the rubber mallet. I then attached the second face tile repeating the same as the first. I then rigged a support for the facing tile using scrap wood.   I left an open tile on the top of the wall and proceeded to mix another bucket of mortar and poured the mortar into the opening thus filling up the hollow cavity.  The wall is now repaired and ready to be grouted along with the patio.  I had left over mortar so I took the liberty of finishing feathering out the edge of the patio with the mortar that was left over again this prevents a trip hazard.   I chose this picture as you can see the shed from the last project in the corner, but also it was a good angle showing the entire patio before it is grouted.




Grouting:
Grouting is the easiest part of tiling, though the hardest part is trying to match the color grout with the tile, but after you found the color it is pretty simple.   To save a step I suggest you purchase an additive that will both seal and protect the grout.  The additive is used in place of water, however, if you need to you can add more cold potable water into the mix without affecting the protection.  When grouting outside please make sure you follow the manufacturer's directions.  Do not grout when temperatures will be below 40 degrees or if you are expecting lots of rainfall in the area.  Tile should not be walked on for at least 3 days and it should not freeze for at least 10 days.


Enjoy your new patio!!!!


Now onto the next phase....


Monday, November 16, 2015

DIY Garden Shed Project

I don't know about you, but over time I accumulate stuff and that stuff was cluttering my utility room. It was stuff not junk. So much s that my wife started complaining about this stuff.   See my house doesn't have a garage and didn't come with a storage shed, so when we needed to buy shovels and tools we just placed them in the utility room where our freezer and washer and dryer resided.  However this was not optimal so I said why not just get a shed. 

I looked and searched and priced, and was going to spend over  $500.00 either way for a shed, so in my creative voice I said I will just build one.   I looked on the net for shed ideas and found one that I liked on Pintrest.  So I studied the picture over a few days and jotted down some notes.   But never really drew up any plans.  Yes you read that correctly. This shed was built without a single plan only an image.  The total cost of the shed was

But this shed was going to be slightly different after all I live in windy Florida place of hurricanes and sporadic storm fronts.  What does living in Florida have to do with building a shed?  Well there are some things you have to consider.  With winds reaching up to 60mph during a spring or summer storm you don't want to see your shed tumbling through the neighborhood.  So it has to be sturdy and secured. 

Most sheds you see on Pinterest are your basic garden shed, not really secured, but just relying on the weight to keep it in place.  Not so with this.  

THIS IS NOT A WEEKEND PROJECT  expect to spend some time on this project to get it right.

Tools & Hardware - Let's start with the tools you may need to build your shed
Circular Saw Corner Brackets
Miter Saw or table saw Wedge Anchors (tapCon Screws)
Drill 4" Deck Screws
Level(s) 3" Deck screws
Hammer 1 1/2" Deck Screw
Tape Measure1" Deck Screws
Speed SquareRafter ties  
Palm SanderStud Braces
ClampsGate Hinges
Socket WrenchLock/Latch
Rubber MalletShingles/felt/plywood

As I stated anchoring your shed should be first thought when building your shed. Some places require you to pull permits or submit plans when building a structure on your property so you may want to check with your city before deciding on a location for your shed.  But Permits are for suckers, who needs a piece of paper after all it your property right?!  

I am not going to put how many of each item you will need to complete the project because it totally depends on the size of your shed. 

I chose to use treated pine for my shed as it was easier to find and cheaper material than cedar ( 1.20 vs 3.94).  As long as you get pressure treated lumber your shed will last a long time.  The total number of screws used in my shed are 353.

I used the following wood sizes depending on your project:
1x4x10 ,  2x4x12 , 1x6x16 

Pouring the Foundation

I chose to place my shed off the utility room (just  in case I ever wanted to run power to it). Once I had the location now I needed to both raise it to prevent water from entering and to secure the shed.  Using left over wood from a pergola I tore down, I framed out my new foundation.  Pouring a foundation is relatively simple, all you will need is about 5 - 15 60-80LBS bags of cement depending on the thickness  and square foot of the foundation.  You will also need a wire mesh (not rebar) that can be found at Lowes or Home Deport for under $10.00.  Cement can be pricey so watch for sales at your local hardware store.
$8.95 at Lowes.
Once you have framed your foundation lay the wire mesh in the frame covering as much of the area as possible. The wire mesh will give your foundation some added strength and flexibility to prevent it from cracking as the ground shifts.  Follow the directions on your cement for the appropriate water to mix ratio.  Using another board (skrim) and person smooth out the top of the foundation ensuring the cement settles into the corners well. 

Before the foundation hardens insert  the wedge anchors.  This will prevent you from having to down drill into the foundation to insert Tapcon Screws.  Threaded end pointing skyward. The wedge anchors will be used to secure the walls to the foundation.  The anchors should be spaced about 18" - 20" apart to ensure that there are away from any studs when framing the walls.

Cover the foundation in a plastic sheeting this will help the curing process and also protect your newly poured foundation incase of any inclement weather.  The foundation may seem difficult but if you have ever mixed cement you can do the foundation.  Please wear gloves when working with cement as it can eat your hands raw.  The foundation took me 2 hours to mix and set using a wheel barrow and shovel. Depending on the weather it may take up to 3 days for your foundation to fully cure.

Framing Walls

While the foundation is curing, you have time to frame out the walls of your shed.  There are three main walls: the two sides and the back.  If you need to sketch them out before starting now is your chance.  Unlike most, I prefer to use screws when working with wood. The main reason is for durability. Screws do not work themselves out unlike nails will over time as the wood expands and contracts.  Secondly if you mis-measure or have to undo your connections you can easily unscrew them instead of risking damaging the wood with a hammer or mallet.

In this picture you can see the side walls are actually framed.  The shed will having a sloping room. The roof is sloped toward the back to help with drainage from rain.  It is important to take the slope / pitch of your roof into account.  Depending on where you decided to locate the shed rain water runoff can harm the area around the shed.  It is also important when framing the walls as you want to ensure that the walls sit flush.   The studs on the walls are 16" on center.  You can do walls 24" on center if you wish, but 16" is the norm meaning that every 16 inches you should run into a stud.  

The back wall (not shown) will be shorter in height than the other two walls.  Please make sure that the walls are even and flush at the corners.

Siding

Lap Siding stained and secured using screws
Choosing your siding for the shed in itself is a chore. You can choose lap siding (as I did) or you can go with solid plywood walls and stucco, or brick.  The least expensive is the lap siding or paneling.  After the walls are framed this is the next step into building your shed.  I chose pine dog ear fence boards in 10' lengths. Cut off the dog ears and stain or waterproof the fence boards.  Staining will take some time but will give you various options in colors to choose from. Staining and weatherproofing the wood will guarantee long lasting use.   Which ever siding you choose please make sure you take the time to prep the area by sanding if necessary and/or staining and painting.  It will be easier to do so now than when the shed is completed.

Lap Siding is easy to achieve.  Measure the length of the wall and transcribe that to the planks. The bottom plank should cover the base of the frame fully. Using your table saw/miter/circular saw cut the boards down to size. If your wall is square, you can make continuous cuts until you get to the taper at the top.   Make sure the first plank is level across the frame and using the 1 1/2" deck screws screw the board down.  Take the next plank and overlap the board just enough to cover the screws in the previous board.  Use your level and make sure that it is straight and secure this board to the frame as well. Make sure the plank is secured to each stud on the wall. Hint: Predrill all the holes in the planks  before screwing to prevent splintering or cracking.

Repeat these steps for the two side walls and the back supporting wall. 

Putting it together

At this point in the project you will need a partner. After the siding is placed onto the exterior walls they will weigh significantly more.  Ask a friend or neighbor, a son, wife daughter but don't try to do it yourself.  Unfortunately, I been working out some and the weight wasn't the problem it was supporting the walls while you ratchet them into place. But I managed to do it alone.. How did I accomplish this?, prayer helped, but also two 1x4x10 posts (which is what you will need later)  1 placed on the outside of the wall the other placed on the inside to hold the wall in place.   The wedge anchors come with hex nuts and washers for fast easy installations.  If you remember from previously your anchors should be placed 18" - 20" apart. transpose the locations of the wedge anchors and drill a hole through the base of the walls (bottom plate)  3/8" hole in this case. You may want to make the hole larger than the bolt so the wall will fit easily into place.  Once all the holes are drilled (make sure you double check the placement.   Hint: take white out or paint and place a dob of it on top of the anchor lift the wall and set it down on top of the anchors (these will place a mark on the bottom plate) and drill the hole.

Set the walls in place, have your friend hold the wall while you ratchet the wall into position.  Check to make sure everything lines up smoothly and secure the walls.  The wedge anchors will support the walls as each one is rated for over 250lbs of force.   Join the walls together in the corner. you can use a 3" deck screw to joint the side wall to the back wall.  Here again you may want to predrill the hole.  Wood is natural and since it is natural there are some knots that you can't see.  Predrilling these will save you time and heartache trying to force the screw through this hard section of wood.   I placed 6  of these 3" screws on each wall.  Once all three walls are together place an L brace on the bottom of each of the studs.  This will give it an added layer of reinforcement to prevent sway another step is to brace each section of the wall with a cross brace, more on this later.
You will notice a mistake I made in prepping the wall.  OH SNAP!  I forgot a wedge anchor.  Oh well not to worry. Get a hammer drill and an TapCon Screw and drill through the baseplate and foundation, insert the TapCon and viola fixed.   Remember place the "L" braces along the studs of the wall 1 per side.

Top-plates and Rafters

By now your shed should have all 3 walls in place
and is free standing (well with the help of a brace). The next step you can skip if you are just building a simple garden shed. But I don't know what simple is so here is the next step adding top plates.  What is a top plate? It is an upper wall plate which is fastened along the top of the wall studs as pictured here.  By the time you finish building this shed you will be ranked as an intermediate framer, meaning that the techniques used to frame this shed is the same as framing out rooms and walls in houses and buildings.

The top plate is going to be used to secure the rafters for the roof as well as secure the three walls together.  But first we need to put another board across the front of the shed.  This board will be used to frame your doors as well as support the roof and rafter system.  This beam will provide lateral support for your shed as well and contain a top plate.  Measure the distance from wall to wall and cut the beam (2x6x10) and knock it into place using the rubber mallet. Again its time to call a friend or call in a favor.  You will need more than one person for this section of the project.  If you have a drill to make pocket holes here is when you need to do so.  

If you do not have a pocket hole joiner (Kreg Tool) simply predrill the holes in at a 45 or 35 degree angle into the adjoining boards.  Then screw the beams together with the appropriate length screw.  Do this for both sides of the beam.  Next measure the length for the top plate.  The top plate should extend from one side wall to the other and across the door frame.  Secure this top plate with screws or nails your choice but screws are better.
Top plate over door and back wall.



Because my shed is angled and not square I had to do some additional cuts to place the top plates across the sides of the two walls.  What do I mean by additional cuts? Well as  you can imagine since the walls are slope
d the space at the end of the walls are slightly off,  though the height is not the issue since we will be adding rafters  to the shed for the roof.  Not necessary if you are going to do a flat roof ( just frame it out as you would a wall).   But remember I said I am not simple so I don't take the easy way nor many short cuts.
So how did I overcome the issue with the height of the side walls vs the height of the back wall?  Simply I ripped the 2x4x6 the same angle of the wall  using a circular saw and notching out a section to secure the top plate.  This would be easier using a table saw but I did not have one handy at the time of this build.  Mental note buy a table saw.
  
The top plates can clearly be seen in these photos. The gap at the top plate is easily solved by adding shims or cutting scrap wood and hammering it into the position of the gap, once in screw down the top plates, you can also caulk this area if you want. 

Adding top plates to the shed will add strength and stability  to the structure as well as give the rafters an area to be secured down.

Determine the length of your rafters (they should all be the same length).  Here is where you will need to use a speed square to determine the pitch of the roof and to make the notches in the rater over the top plates on both ends of the rater.  I suggest using scrap wood before making the initial cuts on your wood so you can get the angle just right.  The two outer rafters I had to rip in half as they would have been higher than the rest of the roof.  When you find the right angles for the notches use each board as pattern for the remaining rafters.  You may need to make some slight adjustments for each rafter as wood is not perfectly straight.  With the use of your friend ( you may have to bribe them with some beer or food) lift the rafters into position.  Like I said I did this portion alone as well, after all I was still working out regularly, lol. 

Back of rafter with 3 rafter ties
Use the 4" deck screws to secure the back ends of the rafter.  Predrill as much as you can as these longer screws can bend easily if you hit a knot.  The screw should go through the rafter and the top plate.  Remember rafters are usually made up of 2x4x10s  (the actual height of a 2x4 is between 2.75" and 3.5"  its not really 4" so long screws are needed. The head of the screw should penetrate the wood as well (do not leave them flush)  which will indeed reach the top plate.  The rafters are secured by 2 of these long screws. Repeat the process for
Front of rafter secured with 2 ties
each rafter front and back. Make sure you check the spacing before securing the front of each rafter;  you want to at least maintain 16" between each rafter.  Add the bracing (rafter ties) to each rafter, 1 on each side of the rafter front and back. Also, for additional support add rafter ties to using the inner bracing as seen in the picture.  There should be 5 rafter ties per inner rafter and three for the exterior rafters.

Repeat the process for each rafter securing both the back and the front of the rafters to the shed.  these rafter ties are normally used with nails however, I always use screws even though they are  more expensive it just means you don't have to worry about the boards coming undone.  The rafter ties are secured with 1 to 1 5/8" screws. You will need to make sure that there is a screw in every hole. If you pulled a permit the inspector will be looking that each hole is used.

The holes are there for a reason so make sure you use them.  Rafter ties will securely hold the roof system in place and will also hold up in winds in excess of 100mph.  Here is a

closer look at the rafter ties used.  You can pick them up from Lowes for as low as $.59 each, yes fifty-nine cents. Do Not  over look these.

Now that the rafters are basically installed, we need to add cross bracing to the roof system. Cross bracing adds stability and durability as well as allowing the roof decking a place to be anchored too. Measure the space between each rafter and using the scrap wood that  you is left from the 2x4x8s  cut them to fit in between each rafter.  Make sure you stagger them in a step pattern.  Secure the cross bracing with 2" deck screws or nails.   Once you have finished bracing the rafters do the same thing to the interior walls of the shed. the cross bracing here will prevent the twisting and swaying of the walls and add strength.  These cross bracing in the walls can double as storage space or shelves for your tools.

Now it's time to add the roof decking.  Roof decking is nothing more than sheets of 5/8" or  3/4" plywood. Hoist the roof decking in place and secure using either screws or nails; you already know which I chose, yup 1 1/2" screws.  Place hurricane clips between the decking sheets. the hurricane clips provide strength to the decking where there is a two pieces being joined.   Tack down the roof felt (about 24.00 a roll at your local hardware store), you will have a lot of felt left over, using roofing tacks.

Building the Doors

The doors of the shed can be done last as well as the added trim. To build the doors you will need to frame them using 1x4x10s and fence planks or plywood.  The fence planks look more decorative.  Once you have measured the inside frame for the doors transfer those measurements to your lumber.  Frame the door as you would the walls, first the outer walls beams first, followed by the cross bracing then secure the planks to the door frame. Remember to leave room from the edges of the door for the hinges and the closing of the door.  You will need to add a door stop to the door frame and you want to make sure that the edge of the door fits properly.  You will need to use your large clamps here as well as a bottle of wood glue and the same friend you called upon before.  These are large doors and are considerably heavy between 50 - 80lbs each.  Depending on the size of your door you may need three gate hinges to attach the door.  Have your friend hoist the door in place while you attach the gate hinges start at the top, proceed to the bottom hinge and then the center hinge this will make sure the door is even.  Open the door  and close it to make sure it is landing where you desire especially at the door stop.  Repeat this process for the second door if there is one.  I chose not to stain the doors as the natural wood grain on these planks look great.

You are almost done,  just a few more touches and your shed will be ready to store your items.  Choose your shingles, mostly likely use the same type as is on the roof of your home. I chose

architectural shingles, cost a little more but I only needed two bundles (29.00 each).  I left the overlap of the shingles at the front.  The reason for this is that I wanted the shed to be able to breath.  Sure the lap siding provides some airflow but the I purposely left the portion between the roof and the top plate open so air could pass through freely alleviating the danger of fumes from gas or any other chemicals that may be stored in the shed.  I did, however, put a screen (not shown) in these gaps to keeps wasps and insects out of the shed.  I also took an added measure of preventing spiders and other unwanted insects by spraying pesticide around the top and bottom of the shed. This is to be repeated every 6 - 9 months.

Enjoy your new shed.