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Arches and lath

Wednesday, November 18th, 2009

One of the things we wanted to experiment with as we built the battery house is archways. We’ll have several archways in the houses, both inside as doorways and outside as an architectural element. The idea is to have indented archways around a few of the outside doors.

This kind of detail is added by putting Styrofoam on the outside of the house and then stucco’ing over it. Apparently, some people put this inch-thick Styrofoam over their whole house (for insulation value, we hear…that seems very odd to us), but we’re doing it just for looks where we want detail like this.

While I love the design (see below), I have been concerned about how we would do the arches.

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Brad has always said he’d just “freehand” it, and it would be fine. Today, we found out.

We began by looking at different shaped arches on the Internet. Then we talked about how we’d do it. Since Brad thought he could just draw it and this was only a test (we could always throw out the foam if it didn’t work; we have lots), I said go for it.

We planned to cut one half first and then use that as a guide for the other half so they’d be symmetrical. Brad started by showing me how this would work and that it would indeed result in the point at the top that I wanted.

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Then he drew out the design.

He cut the foam with a jigsaw and used a guide for the straight part.

Here’s the end result.

And on the actual battery house.

After we got the arch done, we mounted it on the wall of the battery house and started on lath. The lath we’re using is called stucco netting, and it looks pretty much like chicken wire (or what they call here “poultry netting;” that cracks me up). We were both dreading how difficult it would be to put up.

It has to be nailed down very tightly so that the stucco goes down smoothly. And the stucco goes on in a very thin coat, so you can’t really cheat it much. On the solid wall, we used a staple gun to nail it down. On the foam we had to use very long roofing screws, which was a lot harder. Overall, though, it really wasn’t bad to put up. More pictures here if you’re interested.

All in all, a very good day’s work.

Making doors: take 1

Tuesday, November 17th, 2009

So, we have begun to make our first door. Here are the steps.

First, we chose seven 2×6 boards that were reasonably straight, flat, and nice looking, a challenge given the quality of our lumber. Here the boards laid out on the slab to make sure they are flat.

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Then we used a table saw to cut about 1/2″ or so off each side to square them up and help ensure fit.

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Then we ran a router around the edge to give a beveled look. There are many shapes of router bits with various angles, etc. We chose one that would make a shallow, slightly rounded edge.

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Next, we laid out the boards on a series of four pipe clamps with cardboard underneath for gluing. We smeared the edges of each board with carpenter’s glue and then clamped then tightly together, trying to make sure the boards were all flat with no bowing.

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Here it is all clamped together….now to wait for 24 hours.

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After it came out of the clamps, everything looked great. It’s going to be a week or so before we get to town to get stain and varnish to finish it, so you’ll have to wait until then to see the final results.

Special delivery

Monday, November 16th, 2009

We are having many deliveries at the ranch this week. Today, the inverter arrived. This driver was really great.

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We had a productive building day today as well and got the whole battery house wrapped. We plan to start on lath tomorrow and hope to get it done before the paper begins ripping off. (The gale force winds are a real problem.) The battery house is looking really nice and solid. We’re going to stucco the outside, in part as practice for the “real” house. I am quite certain that are batteries are going to have one of the nicest houses ever.

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(This is the back. The inset is for the generator. Boy were the corners of this hard to nail down. The generator needs to be outside, but this will keep it covered and will shelter us from the noise. I don’t think it will be running much though.

The weather here has been freezing. Literally…mid 20s at night. This afternoon we finished work at about sunset, and we were both shivering despite our warm hats and coats. It seems only a couple days ago that it was so hot. The human body has an amazingly narrow comfort range!

The next installment

Thursday, November 12th, 2009

So this afternoon (as I’m walking out the door for work…impeccable timing again), I get a phone call.

“This is Joe from Accurate Freight. Is Brad there?”

“No. He’s at the Sunrise property expecting you.” Actually, he was expecting you three hours ago…but he’s still there.

“Well, I’m at the end of Noland Road, and it’s about to turn into a dirt road.” (This is the not-NM way to go…the dirt road way.) “I’m not sure whether to keep going this way or to go back to the interstate.”

OK…. My first thought is, Why are you asking me? My second thought is, Really? you have cell coverage there?  We’d been told earlier that he would be driving a truck that was licensed for NM *and* that had a liftgate and pallet mover. At this point, I decide not to about the latter. “Do you have the paperwork to drive through NM?” I say.

What ensues is a long, complicated story about how he has the appropriate paperwork for taking the batteries through NM but the truck isn’t multi-state licensed (or something like that…I really wasn’t clear), and his boss is worried and told him to take the dirt road.

Without hesitation, I say, “Take the dirt road. It isn’t bad at all. Trucks take it all the time.” At this point, I think that getting the batteries here is the most important thing.

He hesitates. I reassure. We go back and forth.

“Well, I don’t have directions to go that way.”

I give him directions. They are not difficult. He sounds unsure and says that he will probably call me halfway to get clarification. I tell him that he won’t have cell coverage and then instantly regret saying that for fear he’ll reconsider and go back to Tucson.

He agrees to try. I call Brad to convey the information and leave to go do some work.

When I get home, I am anxious to hear the rest of the story. Did the batteries actually arrive?

Well, the short answer is yes. The long answer involves Joe stopping in Portal (which wasn’t on the way according to my directions…he admitted to taking a right when I suggested a left) to call again to clarify where we were. It also involves Doug going out to search for him (he didn’t find him) and an incident in which the truck’s mud flap apparently fell off….and part of his hydraulics had been tied to that mud flap. A kind motorist (really? on the back dirt road?) stopped to help him tie up his hydraulics so he could continue on. The whole thing took several hours, and it is only a 30 minute drive. At any rate, he got there and had a liftgate and pallet mover to boot.

More good news is that with all day to work on it, Brad and Doug managed to construct and mount the shelves for the batteries.

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Busy!

Wednesday, November 11th, 2009

It’s a busy week at the ranch! First, we have a guest visitor this week — Brad’s long-lost (just kidding) brother Doug. He’s here all week, and you better believe we are putting him to work! I’m not sure he knew this was what he was signing up for. He has his own business, and it’s the first time he’s taken time off in a long time, so we are honored that he chose to spend it here.

Secondly, we’ve had all kinds of adventures related to the delivery of the various solar components. They were supposed to call ahead about deliveries so we’d be there, but you know that wasn’t going to happen! On Monday, I was home by myself (getting ready to go out to a school I’m working with here) and I got a phone call — 4,000 pounds of batteries are on their way here now (with no forklift), and they need directions. I give them directions, but there is a major problem — they don’t have paperwork to drive through NM….but that’s the only way to get here, on paved roads at least. So I tell them about the back road. Several phone calls ensue. Brad gets involved. The end result is that the batteries go back to Tucson.

In the meantime, we’ve got our very nice neighbor to drive his tractor with forklift attachments over. It’s sitting on our property now…waiting.

We got a call today from the freight company who says that they will be coming again tomorrow, this time with a truck that is licensed for NM and with a liftgate and pallet mover. Hallelujah! Let’s hope even half of that happens.

We’re also expecting the panels in the next couple days. Brad and Doug started assembling the supports for the panels today. It seemed to involve a lot of reading and re-reading of directions and a fair amount of unhappiness, so I mostly worked on finishing the battery house walls and moving some dirt while they did that.

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Other than that, with the whole battery thing, we’ve kicked the battery house construction into high gear. Yesterday, we put in blocking, insulated the walls, and put the inside OSB decking on. (Lots of hammering for me.) These will be the first walls to be completed. We didn’t have enough insulation to finish the whole thing, but three walls are up, which is enough to build the shelving for the batteries.

The weather here is glorious this week. It’s hot, sunny, and clear. Our garden continues to thrive, and we have more arugula and lettuce than we can eat. I’m hoping for one more batch of tomatoes this year as well.

We are celebrating

Monday, November 9th, 2009

…because the electrical work has commenced, and Brad has ordered the solar equipment!

Here’s the Mini after Brad’s trip to Lowe’s to get electrical supplies.

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Sisterhood of the building pants…or…Time to go shopping

Friday, October 30th, 2009

This building stuff is hard on the pants.

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For those interested, here are two local web sites we’re building: Portal Rescue (our local fire and rescue group) and San Simon USD (the section on San Simon under For Community has a lot of great info on the local area…kids wrote it all). These are both “in progress” but have been fun to work on.

Shocking

Wednesday, October 28th, 2009

Well, the weather forecast was right. It didn’t get out of the 40s today, and there is snow in the mountains. (None here…yet.) We just went and harvested a bunch of lettuce and covered the rest, since it’s supposed to freeze tonight.

We also put the tomato plant (which has a half dozen still-green tomatoes….it’s thriving on drip irrigation) into the house. Despite the cold, our house has remained toasty warm (and the fireplace is not hooked up yet). This bodes well for when we move in. The only bad thing from this weather is that the winds have been howling, and for the many-ith time, some of our house paper has ripped off. I’ll be very glad when we get some stucco on it.

Also, in our big driving adventure yesterday, we broke a strut on the truck….really broke it right in half. It is amazing that in 10 months of living here, this is the first car problem we’ve had. It’s something I’ve been kind of dreading, because of our lack of proximity to anywhere, but we found a repair place in Douglas that seemed pretty good, and thankfully the truck made it there.

360 on the doors

Tuesday, October 27th, 2009

In one afternoon, I have totally changed my thinking about interior doors.

Originally, I had been thinking about rustic wood plank doors. Then I looked at prices and decided that it wasn’t worth it.

Then I found some pretty nice and inexpensive wood doors at Lowe’s that I liked. They have a kind of arch in the top panel that I thought would look nice with our other arches.

This afternoon we went to visit someone’s house who has solar to see his setup. (We also heard he has a very nice adobe house, and I’m always eager to get new ideas on interiors.) We weren’t exactly sure where he lived and inadvertently ended up at someone else’s house. It was someone else we’d wanted to see though (they’re on the board of the local fire & rescue, for whom we are doing a web site, and they have done their own lovely cabinetry), and so we took a quick tour of their house. It was a very nice house, and they have done all the work themselves. As we were walking through, lo and behold, they had the Lowe’s doors I was thinking about. I really liked how they looked which helped confirm my plans to go with these doors.

Then we went on to the house we had actually intended to visit. Wow. Beautiful house. And all the interior doors were made by the owner out of plank wood. They were stunning. He said that all he did was laid 2×8’s on a table, glued the edges, and clamped them. When they dried, he nailed two planks crosswise at the top and bottom to add stability. Then he rough finished them with a wire wheel and distressed them a bit to add character. (He also hand forged his own cast iron handles, but I would be happy just buying those.) So that all seemed manageable and something we could do (which Brad confirmed on the way home).

We really only have one interior door in the main house, but we have several in Tumbleweed. I would like to try this there. My only real hesitation is that we have so much else to do, but I think we could leave this door project until after we move in.

Also on this drive, we found another old abandoned train car. I took pictures and am still working on my collection. Stay tuned.

By the way, it is windy and cold here. Yesterday, it was 36 when I left in the morning. They are talking about possible snow later in the week.

I put a lid on it

Saturday, October 17th, 2009

The battery house is progressing nicely. Yesterday, while I had some other work to do, Brad put up hangars for the i-joists. Then this morning, we cut and put in the i-joists. Then while Brad cut OSB for the decking for the roof, I nailed it all on. I didn’t count the nails, but it was a lot. A 9′ x 12′ space with i-joists every 16″ and nails every 6″ on every i-joist and every edge. Very satisfying work. Brad also got the back wall covered with decking which added quite a bit of stability to the whole structure. I do think that framing is one of my favorite parts of construction.

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Now, for an update on some of the everyday details of our life here and some of the things we worried about initially and how they’ve worked out. (Feel free to stop reading now.) The 50 mile distance to a grocery has been no issue at all. We go shopping  every couple weeks, though we sometimes go into town more often in need of construction supplies. I cook every day, and we eat better than we ever did in California.

We just ate our first salad with produce entirely grown ourselves. The compost…well…it’s about the same.

The guesthouse we are staying in continues to be a godsend in terms of easing the whole building process, though I am anxious to move into our own house. This will most likely not happen by the end of the year, but I am hoping for early next year. I keep thinking of ways we could move sooner, but always forget about that pesky occupancy certificate.

We have both lost weight and are in better physical shape than we’ve been in a long time. (Amazing for me, since I’m eating more than I’ve ever eaten. I’m worried that when we stop building, I’ll gain a ton of weight.) We are still running every week, but the yoga has fallen by the wayside for now. We’ll resume it again at some point. Brad found a new doctor that he really likes, and his  blood sugar, etc. is better than it’s ever been.  I have started taking the full recommended dose of Gucosamine/Chondroitin/MSM, and my hands are better.

Our Internet here is great (more reliable than the phones and/or power sometimes), and we don’t miss cell phone service. We have started using Google Voice which works well. We don’t miss much from “civilization” except for the occasional sushi (which we have in Tucson) and once or twice, a movie (Julie & Julia…, Star Trek, which we’ll catch on pay per view).

I love my new camera. (In case you don’t get enough of the photos here, you can always check out our Flickr page.)

My planned decrease in regular “work” work has gone well. I’ve been able to spend a good amount of time working on the house, while still maintaining enough business to pay the phone bill. :) I am doing projects with three local school districts now as well. I’ve managed to reduce my travel significantly. I have a couple projects that are ramping up now (one that involves no travel and one that could be a lot of travel but only for a few months) and am a little worried that will cut into construction, but we’ll see.

We love spending 24/7 together (but that’s not really a change). And I especially love working outside in the sun almost every day. Very good for the mental health.

All in all, we are loving it here. Come visit!