Tag Archives: bugs

Kitchen Countertop Adventures

So I had left off previously talking about the new counter-top we were working on for the trailer. I can’t say that it is all complete, but we have made some progress.

We decided to put an epoxy finish over the wood to give it a nice shiny, protective coating. This has turned out to be a little tricky. I am, however, getting ahead of myself.

We started off with the prep work. I took the counter out to our truck shelter which is acting as our work shop. Out there, Kat applied the stain and varnish to it.

Once that was done, I propped it up to it was all as level as I could get it. I taped all of the edges to prevent spill-over and I also prepared a sheet to cover it after we finished the pour.

If you’re wondering what the big log in the middle is for, that’s to hold up the cover sheet so it doesn’t touch the counter.

So, let the pouring begin!

We learned quite a few things doing this. First, epoxy likes it to be warm. The warmer, the quicker it will cure. Secondly, humidity is bad. This will encourage bubbles in your epoxy and that’s not a good thing.

Kat and I did this together because the epoxy starts to setup pretty quickly after you mix it. We managed to complete the pouring in short order. Fortunately, the counter-top isn’t that big.

Once the pour was completed, I spent some time trying to get rid of some of the bubbles, but that didn’t go so well. According to the instructions, gently exhaling on them should make them burst as it supposedly reacts with the CO2 from your breath. Well, I did a lot of blowing and the bubbles didn’t pop at all.

I also couldn’t spend forever working on this because it was starting to set, and also bugs kept falling in it. We did fish some big ones out and eventually I just covered it.

I used an old shower curtain for the cover, which worked really well. After that we let it sit for a long time, over a week.

When we finally went in to look at it, it was all nice and shiny, but there were a few bugs sticking out of it and lots of bubbles. Also, the tape didn’t work quite as well as we had hoped and there were a lot of drips down the sides that we had to shave off.

Here you can see Kat in her bug hat removing the tape.

I took some time and dug out the bugs I could find, as well as many of the bubbles. Then I did a filler coat on top of that. It has since dried, but I plan to do one more final thin coat as that last one came out a bit rough.

I did some searching online and found one website that said the most ideal setup for doing epoxy is in a vacuum. Not having a vacuum chamber readily available, we went with what we had. Hopefully, after this third coat, it will look nice. I’ll let you know how it goes after we get that done.

Soggy spring

I would love to say that we have accomplished a whole lot in the last month since I posted, but unfortunately we haven’t. This is largely due to the weather. I think this past May has been the soggiest one on record. Rain is pretty common in May, but it has been rather severe this year.

Our area was pretty lucky in that the worst we had were a few basements where the sub-pump broke and they wet basement floors. Other parts of Ontario and Quebec had full blown evacuations and states of emergency. When you come back to your house after it all resides and find that the water was up to the level of your counter-top in your kitchen, you could say that we had a lot of rain.

My last post was on May 2nd and it wasn’t long after that when things started to get crazy. We had two days of severe rain, then this happened on the 7th.

Yeah, that’s right. It started snowing. This has been known to happen in May, so it wasn’t so much of a big deal, except for the fact that it didn’t stop. I bet you can guess when I took the following picture?

That wasn’t the end of it either. It just kept snowing, right through until the 9th.

You can see that there wasn’t a whole lot of accumulation, but still, three days of snow in May?

Someone needs to turn up the outdoor thermostat.

That wasn’t the end of it either. I think we had a day or two break and then we had two more solid days of rain. When I say solid, I mean around 60mm (2.5 inches) of rain. That number may seem small, but if I put that in equivalent snow terms that would be 60cm (2 feet) of snow. It rained A LOT!

Those were the two heaviest days, but we’ve had quite a few days where it rained since then. Not nearly as bad. On May 14th we had a severe thunder storm which included hail. I had just done my weekly trip to the dump and it started on my way back. I was pulling into the driveway when the hail started so I sat in the truck for a bit and snapped this picture of the hail building up on the windshield wipers.

Not only has it been wet, it hasn’t been particularly warm either. We’ve had a few days above 20C (68F) but not many. And on those days when it isn’t cold and raining, the bugs are bad enough to pick you up and carry you off if you aren’t careful. The black flies especially are having a bumper year. We’re hoping the dragon flies will show up soon and we have seen one or two, but the big swarms of them have yet to arrive. They help a lot with reducing the biting insects.

All of this wetness has put a big damper on our firewood harvest this year. Going out in the pouring rain to cut down a tree isn’t a great thing to do. It’s even more inadvisable if there is high wind. Don’t try cutting down a tree in high wind and expect it to drop where you want it. I avoid that at all costs.

In addition to this, because of all of the rain, there were times we couldn’t even get the truck up the hill for fear of burying it out of sight just because the ground was so saturated with water. We still can’t drive to the top of our hill because a lot of water is draining down the road and it’s very squishy.

Of course there is the bug factor as well. Once you do get a decent day to go cut wood, you have to deal with the bugs. So, needless to say, we are behind in our firewood harvesting.

Fortunately, we haven’t been completely idle. We did get started on installing a new sink and finishing the counter-top around it. Here you can see the cutting of the hole where the sink is going to go.

Slightly closer so you can see the sink outline in pencil.

There we have it, a hole for a sink.

We even have a sink to put in that hole too! We bought it at the Re-store which I have to say, is kind of a hit or miss in terms of whether it’s really worth it or not. The sink we bought didn’t have holes for faucets, nor did it have a strainer basket. We weren’t too concerned about the faucet holes as we aren’t likely to have any faucet for a while. A new strainer basket cost $20 for the cheap one. The sink cost us $45. I could have bought a brand new sink for $100 that included holes for the faucet and strainer basket. Add some tax in there and you start to wonder if it was really worth the savings. Things to think about if you ever go to the Re-store for building materials.

Now for the counter-top we decided to use a 19mm (3/4 inch) piece of plywood with red oak veneer. One sheet of that will set you back $85 so you don’t want to mess it up. I cut out the piece to size for the counter first.

I scribed the hole for the sink from underneath and then cut out the hole for the sink as well.

Voila! New counter-top. Well, almost. The counter then went out to the staining and finishing department. I can say that it has been stained and had two coats of varnish put on it. The next step is to put a thick coat of epoxy on it to make it durable and waterproof. We have the epoxy, but it is sensitive to temperature and humidity so that part has been put on hold until things dry up and warm up a bit.

So it’s been a slow start to the year. We haven’t planted anything in the garden yet either because it’s been so cold. Last night we had a low of 2C (36F). Yes, we had a fire. They say we should be safe for planting after the full moon in June, which is this Friday. We can only wait and see at this point.

Kitchen cabinet saga, part 1

Take a deep breath and prepare yourself, this one is going to be lengthy.

So we mentioned a while back that we would be working on rebuilding the kitchen cabinets now that we have our appliances. We have not been idle in this, but there have been many other things to work on as well. There is also the budget factor as well, but I’ll get into details about that later.

Considering that I have never built cabinetry from scratch before, this has been quite the learning experience. Where do you start? Well, I started in the tools department.

SkillSaw01

That is a brand new Makita skill saw I picked up back at the beginning of May. I had been wanting to replace the really old one I had and after doing some internet searching, I chose this one. I have mentioned before I have a bunch of Dewalt stuff that I become fond of, and I did consider the Dewalt saw, but the Makita won this round due to this nice little feature:

SkillSaw02

There is a handy guide on the back that indicates what your cutting depth is set at. Not many saws have that, but boy is it nice. It’s not super accurate, but if you are cutting a piece of wood that is 1″ (2.5cm), it makes it easy and quick for you to set the cutting depth.

As you can see, I did put a Dewalt finishing blade on it. That was mainly due to the fact that when I got around to buying the blade, the place I was buying it from (Canadian Tire) didn’t have much in the way of quality choice. Most of what they had was Master-crap. I was really happy with this blade though. More on that in a minute.

Another tool I used, which you wouldn’t think of, is this little baby.

Planer

That, my friends, is a planer. I didn’t buy this, my Dad gave it to me as he didn’t need it any more. I have to say, this is one of my favorite tools. This thing can make crappy, old wood look like new again. It can also turn rough cut lumber into pristine looking wood.

Interestingly, I didn’t use the planer for any of the pieces that went into the cabinet. What I did use it for is to create some really nice spacer guides for setting up my new skill saw for an accurate cut. I have two spacers, one for each side of the blade, depending on which side I need to cut from. I draw my cut line, put the spacer down along it and then clamp my cutting guide against the spacer and I know that I have the saw positioned properly to accurately cut along the line. That was the basic idea, anyway.

Here you can see a pile of other tools that I have been using during this process:

PileOTools

Various clamps, speed square, tape measure, pencil and gloves. Can’t forget the gloves.

There is also a 2×4 there that I planed the edges of to give me a nice straight cutting guide. Here is a closer look at it.

FenceGuide

So, now that we have a bunch of tools, we need materials. For this project I decided to go with plywood that has one finished side for the structural parts. For the face parts of the drawers and cabinet doors, I bought a sheet of particle board with red oak veneer on both sides. None of this was cheap. I bought six 4’x8′ (122x244cm) sheets: three were 3/4″ (19mm), two were 5/8″ (16mm) and the red oak veneer was 11/16 (17.5mm). That was $400.

Oh, hey, what about hardware? You know, drawer rails and cupboard door hinges. We ended up going to Lee Valley for those and we got some really nice ones, but they weren’t cheap either. That was another $400, though we did get more than we needed for just this one cabinet as there will be other areas where we will need to make cabinetry.

After spending a crap tonne of money and finally being finished with firewood processing, we embarked on our cabinet making journey.

Here you can see Kat is all set to help with the first cut.

KatHelpingWithFirstCut

We were using the picnic table I built last year as the working surface. To help reduce bugs, we put one of our screen tents over it, but it does make moving materials in and out of it rather complicated. We did persevere, however.

I setup the cutting guide, double checked everything and was all ready to go. Here I am, with new saw in hand.

AllPreparedToCut

The first cut was made, and I have to say, that new saw, with the new blade went through that 3/4″ plywood like it was a hot knife through hot butter. There was almost no resistance at all. That first cut was supposed to be at 6′ (182.9cm) exactly. Here is a picture of the measurement after we did the cut.

ExactMeasurement

Yes, the piece I am measuring is the one to the left of the 6′ mark on the tape. Not bad, if I do say so myself.

That being said, we did have a few glitches. The off-cut side was only supported by Kat; it didn’t have any table under it. As a result, when I got to the end of the cut, the blade got squeezed and the saw kicked. It’s difficult to hold the off-cut side so you don’t squeeze the blade at the end of the cut as there are multiple directions this can happen.

I should also mention, while talking about mistakes, that my first cut was pretty perfect, but my second one I screwed up due to the fact that I didn’t double check my guide positioning. Fortunately, it wasn’t a huge screw up and we were able to live with the result.

I think I did one more cut inside the tent and then decided to move it outside, as I just couldn’t get it setup well enough to avoid the blade squeeze I mentioned above. I ended up just putting down some boards on our driveway and cutting on top of those. It worked well, but it was harder on the back with all that bending over.

Anyway, after doing a few more cuts, I took the big pieces into the trailer to see how they fit.

Size&SpaceTesting

Just try to ignore the bag of avocados hanging down from the top.

You can probably see in that picture that the big vertical pieces are against the back wall at the top, but not the bottom. It’s really difficult to fit wood that is more or less square into a space that is not. I futzed with this for quite a while until I managed to get the pieces positioned in a way that was level and square. That did mean leaving gaps or putting in shims in certain spots to account for the non-square space.

Once I had that solved, I went back out and finished cutting the pieces for the cabinet frame. This also involved making my first attempt at making a dado cut, which would have been much easier if we had a table saw, but we didn’t. I only have the skill saw, so that’s what I used.

DadoCut01

That picture was taken after I had made three passes with the saw. The two cuts frame the section of wood that was being removed. The depth of that cut was 5/16″ (8mm) on the 3/4″ plywood. I did several more passes to remove the rest of the channel and then cleaned it up using a chisel.

This is what it ended up looking like.

DadoCut02

I was pretty happy with the results. I was even happier that it was pretty accurate too. The mid-way shelves fit into those dado cuts nice and snug. Not too tight, but no wiggle space either.

After all this cutting and prep work, we then needed somewhere nice and flat to try and put the frame together. The only real option for this was the interior of the shipping container.

KitchenCupboardAssembly01

I took that picture after I had fit everything together, but not fastened anything yet. For that, I glued the edges, put them together, clamped them and then drilled counter-sunk pilot holes which I then put screws in. This worked okay, except in one case the screw decided to separate the plys of the wood, instead of cutting it. I’m thinking nails might have been better to use in this case, but I won’t know for certain until I need to do it again.

Here is a blurry picture of the frame completely assembled and standing up in the shipping container.

KitchenCupboardAssembly02

As is pretty obvious, the cabinet will have three sections: the bottom will have drawers, the middle will have shelves on rails that can be pulled out and the top shelf is just static.

It was around this point I got fed up working on the ground, or trying to use the picnic table, so I decided to build a work table. It was a really basic design using 4×8 sheets of plywood and some 2x4s and it should have only take about two hours to complete, but the bugs had other things in mind.

I was working on it out on the driveway and the black flies were out in force. I had just enough time to take one measurement, or do one cut before I just couldn’t take it any more and needed to take a walk to shake off the bugs. I got the bottom layer of the table completed with the legs, but I just couldn’t take it any more that day, so I left it. I got up extra early the next day (like 6am) when the temperature was skill cool and I was able to finish the table with only a few mosquitoes buzzing around. Black flies don’t come out until it warms up.

This is what I ended up with.

WorkTable

I have to say, having the table makes work projects way easier, though you do still have to deal with the bugs.

With the cabinet frame all put together, Kat sprang into action and put some stain on the finished sides. She used a fairly light stain so it didn’t darken the wood a whole lot. After that, the only thing to do, was install it.

So we did.

Size&SpaceTesting02

Again, another while was spent leveling it and making sure it was in the best position we could make it. In the end, it turned out pretty good. Now we need to move on to drawer making.

I had made plans for three drawers in the bottom section: two deep ones and a shallow one on top of those. I have to say, making drawers isn’t the easiest thing to do.

Originally, I thought I would get really fancy and dado cut every joint. Here is an example of that on the vertical drawer walls.

Drawer02

For the bottom of the drawer, I did a trench dado cut like I did in the cabinet frame for the shelves. I then had to make the joining cut around all four edges of the bottom of the drawer. That may be difficult for you to get without a picture, so here is one.

DrawerDadoCut01

With the front side removed, you can see how the bottom of the drawer is notched into the vertical walls. I have another picture here where I took out the bottom of the drawer so you can see all of the dado cuts.

DrawerDadoCut02

That, as you can probably imagine, is a lot of dado cuts. Using only a skill saw means this is a very long process.

The other problem is that for plywood, doing the L shaped dado cuts right on the edge means you have a really good chance of getting a ragged edge. The trench or grooved dado cuts work fine, but the edge ones have a tendency to be messy. In the end, I only did dado cuts on the vertical drawer walls on one of the drawers. The other two, I only did the groove for the bottom of the drawer.

As luck would have it, we had a planned trip to Ottawa to visit family and my Dad happens to have a table saw. I brought all of my drawer pieces with me and we used his table saw to do all of the dado cuts. We did all of the cuts for all of the pieces in about two hours which is a lot less time than it would have taken me using the skill saw. Thanks Dad, that was really helpful.

After all that, here is the first drawer where I did all of the dado cuts for all joints clamped together.

Drawer01

And here is a picture of it all put together.

Drawer03

I glued all of the joints and then I broke out my compressor and brad nailer to finish the job. That’s another story unto itself: the compressor.

I got this compressor from my Step-Father and I hadn’t really used it much. I finally decided that I really wanted to use the brad nailer so, I had to get it up and running. It’s not that complicated a device, but it has given me some issues.

The first one is that the hose connections leaked. I thought maybe the hose was old, so I bought a new one and new joiners as well. I used that fancy teflon tape to seal the threads and tightened everything down. I fired it up and it still leaked.

On top of that, I am running this plugged into my generator. When I first turn on the compressor, it runs until it reaches full pressure and then the motor shuts off. After you use the nailer for a bit, the pressure will drop and the motor will start up again to repressurize it. Well, after the first run of the motor to pressurize the tank, any time the motor started after that, it put my generator into overload, which basically means all power was cut off. The only way I found to reset the overload was to stop and restart the generator.

This is no small generator either. It’s a Honda 3000 and it has never balked at anything I have plugged into it previously. Not sure what was up with that.

In the end, I managed to get enough pressure to nail together one drawer. Then I had to shut everything down and start it all up again to do the next one. I’ll need to spend some time figuring the compressor out.

Anyway, here is a picture of the small drawer all put together.

Drawer04

See how handy that work table is? Yeah, that was totally worth the bug bites.

I finished putting the drawers together and then Kat put some stain on them. Then, the ultimate test came: trying to install one.

You don’t have much leeway if you want a proper fit with the drawer rails. When I first tried fitting the drawer in the frame, it seemed like I had a bit of extra space, so I thought I might need to shim the rail on one side. I tried that, twice. The first shim was about 1/8″ (3mm) and it was too thick. I tried a second shim that was about 3/32″ (2mm) and that was too thick as well. Hmmmm.

It turned out that either my cabinet frame, the drawer, or both weren’t perfectly square as the rear of the cabinet was narrower than the front. In the end I didn’t use the shim at all and the drawer seemed to fit just fine. Here it is.

Drawer05

I also have a picture of it extended out.

Drawer06

The rails we bought are full extension and will support up to 100lbs (45.45kg). That’s good because I weighed the drawer and it weighs 23lbs (10.45kg) already. I haven’t put on the front face either, so that number will go up again once that is done.

That’s all we have done so far. There will be more staining and drawer installing and then I’ll get to work on the upper shelves and the front facing. It’s going slow, but this is uncharted territory for us, so it’s largely a learning experience.

I’ll post again when we have made more progress.

Colorado Earthship Build: Day 10 (Packout and concrete)

This day started super extra earlier. Well the story for it does, anyway. Around 1am last night I had been sleeping on my side and I rolled over onto my back and felt something hard squiggling under my back. No sooner had I felt that when it decided to take a big chomp on my back. I immediately reached behind my back and crushed the offending beast. However, he had left a lasting mark.

This was no small creature either.

ColoradoBuild_Day10_001

Not sure how he made it into the tent, but it was the last mistake he ever made. After that interruption to my slumber, I went back to sleep until the alarm went off.

There always seems to be something interesting and beautiful when we get up in the morning. This time it was a mist that was coming off the river. Not sure how well you can see it in the picture, but it was quite lovely.

ColoradoBuild_Day10_002

Anyway, we did our morning things and headed out to the build site. The main section looked something like this when we arrived.

ColoradoBuild_Day10_003

Rob and Helena were busy at work on the stairs again. This picture is partway through the day. They ended the day with four steps done, instead of just the first one they had yesterday.

ColoradoBuild_Day10_004

At one point Kat was put on bottle hunting and cleaning duty. Where do you hunt for bottles? In a bottle jungle. Something like this.

ColoradoBuild_Day10_004b

Depending on how picky you are about your bottles, this can take some time.

We both got to do more concrete and mortar work today. First I had to drill some holes in a concrete block that was previously poured, but didn’t have any vertical rebar in it to connect it to the next pour on top of it. You’d think finding a drill with a masonry bit would be simple on a construction site, but that didn’t prove to be the case. We wanted to use a powered drill to avoid draining the batteries of a cordless one. The first one we found was impossible to change the bit as it was rusted together and it didn’t take a chuck key so we couldn’t loosen the bit holder. The second one we found did take a chuck key, but we didn’t have the key so we had to resort to using large wrenches to loosen the bit so we could change it. On top of that, the masonry bit they gave me was really dull.

Meanwhile, while we were trying to sort all of that out, Mike R shows up with his cordless DeWalt drill with a nice masonry bit on it and I had four of the five holes drilled before the powered drill was ready. Go figure.

After that, I shoveled the concrete into the spot and Kat pushed it around and leveled it. You can see the aftermath of our pour on the far right of this picture, where the rebar is sticking out of the lath.

ColoradoBuild_Day10_005

As usual, everyone else was busy too and here you can see they have installed some door boxes on top of the footing for the vertical green house wall. More in the foreground you can see them prepping a piece of Trex for use as a nailing plate. They always use Trex for the first layer that sits against the concrete.

ColoradoBuild_Day10_006

Around lunch time, the big concrete pump truck arrived. We were down the hill filling our faces so I got this shot from afar. You can also see the big pile of logs that will be put in this house, eventually.

ColoradoBuild_Day10_007

Kat talked yesterday on her blog about the installation of some large beams. These beams are the support structure for the concrete arches at both entrances to the drive-through garage. Here you can see a picture of some extra supports put up in the middle to make sure they don’t give way when the concrete is poured.

ColoradoBuild_Day10_008

And concrete pouring they did. Well, for a little while. Unfortunately, they had some technical issues, which resulted in a big spill. So I came up with this parody.
(Sung to the tune of Wheel In The Sky by Journey)

Oh, the concrete in the sky it ain’t pourin’
Don’t know where the blockage is
Oh, the concrete in the sky it ain’t pourin’
Maybe we’ll get some tomorrow

ColoradoBuild_Day10_009

This is what the setup looked like, with the pump truck up front and the cement trucks backing up to it. There was a blockage or something in the line and a whole whack of concrete got dumped on the ground between the two. That was no fun at all. I’m just wondering how that will affect the structure.

ColoradoBuild_Day10_012

After the failure of the big pour, the truck departed and we were left doing what we were doing without the noise of a huge engine going right beside our ears. Kat and I were doing more packout in the afternoon. We’re getting close to finishing that wall near the stairs.

When the day ends I usually try to walk around and see what else is new. I found that they had put in the rebar for the dome that will be going over the entrance to the garage on the west side. We will have the same thing on the east side entrance as well, but ours isn’t in place yet.

ColoradoBuild_Day10_015

Remember that bottle work beside the door that goes from the house to the garage? Well, it’s done. I have a picture of it, and all of the new can work they did today for the bond beam form.

ColoradoBuild_Day10_016

I mentioned yesterday that they had put the can wall form on top of sheets of lath, but I wasn’t quite sure why. Well my guess, it turns out, was correct. I asked Phil this morning when I got there about it and he confirmed that it was just a timing thing. They didn’t have time to packout and let set all of the the tires that needed to be done to get ready to lay the form, so they just used the lath.

Hurray for correct guesses 🙂