I figure I should post when I’m happy, and for some reason, today I’m feeling this level of happiness. There are plenty of days which are positive, but today, must be exceptional. Why must this be? Many reasons, but one of those reasons I think is that a project we started back in May of 2011 is coming to a close.

replacing our old troubled sewer line

So our new, old house had problems with waste water disposal, so we took advantage of some city programs and replaced the entire service, but we were planning for the future too….

opening up street to main sewer line

The property is a downward slop towards the back, meaning the high end is at the street. So we are at a disadvantage in getting water to the sewer main, but after measurements and calculations and placement of new line, we figured that if we achieved about a ~5 foot depth for the sewer lateral, we just may avoid the need for a sewage pump for the construction project.

sewer trench

So the trench was made as deep as possible and about as near as it could be to the current home. The old lateral was abandoned, house tied into the new line and a small stub was in place at the roughly 5 feet depth at the house.
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the final result in 2011

So now that the structure is built and the path is clear, we asked Dave to come back and finish the work he started almost a year earlier.

trench to the garage

Dually:"What the hell did you do to the dog yard?"

So we just squeaked by with the needed amount of fall from the new construction. So when the toilet flushes in the office, you can bet, that poop be gone!

new structure tied into sewer main!

Anyone that thinks being your own general contractor would be an easy addition to your already adult life is living in a fantasy. In the last month I’ve added more wrinkles, grey hair, and dispute to my life than I care to remember. At this stage in the project, as the framing is rapped up and additional trades begin to enter their small additions, the new challenges present themselves.

Challenge one(1): As a home owner built project, you’re last on the priority list for the sub contractors. As this may likely be your only project, the interest is to satisfy other contracts with professional general contractors. If you pick quality sub contractors, they likely have other jobs. If you pick less than quality contractors, you likely need to watch their work more closely.

Challenge two(2): Coordination of trades within the job. In the beginning, scheduling is rather easy since the work to be done is by one trade and for several weeks. So the coordination is nothing more than figuring out when the trade is complete allowing the next trade to commence. With the walls up, now you have the plumber, the electrician, the roofer, the finish carpentry, and on and on… and each trade may be waiting for next, or in the way, something is happening that requires your constant attention. The electrician, plumber, heating/venting trades need to make roof penetrations prior to the roofer doing the roof. Forget one detail and you end up having to undo something a trade did for another trade to do his work that should have been done in advance. One trade’s work may get boxed in by another trade’s and corrective action may be too costly.

Challenge three(3): Once the frame is in place, the detail work begins and change orders commence. Change orders will destroy a budget. Sub-contractors can recoup lost profits from a low bid as the sub has the advantage in a change order. Going into a project, the more details shown in the plans help to prevent this. When details are lacking and left to be resolved at the moment they are reached, the advantage for the owner is lost. For example the deck details were lacking in this project and will likely account for over $6000 in unbudgeted costs. (I actually don’t know what the final cost will be since we are not done yet)

Challenge four(4): More supervision required. As the final touches get implemented, you practically need to be the monkey on the sub contractors back to get things done “correctly”. Either they will do something wrong or they will do it differently than you assumed they would.

Since my last post, we have had two inspections on the framing, siding has gone up, some painting has occurred, some plumbing, some electrical, and some decking. Costs are now over the original budget. Cash reserve is low. Some things have been done “not perfect” and its too late to make corrections without incurring additional costs.

The construction crew is finishing up the siding and deck railing, to likely get refused the opportunity to do the garage metal siding as a cost saving move. The plumber is dragging his feet to complete his scope (which is good since the cash isn’t easily available to pay his costs). The electrician has completed the install of electrical panels but some follow up needs to happen to resolve issues.
Additional to be done:

• rerouting of water lines in fire wall
• install of metal siding
• install of deck railing
• painting of stuff
• swing PG&E meter
• swing phone/cable
• interior electrical
• interior low voltage
• finish plumbing
• I’m sure a lot more

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Last week we began the process of installing our doors and discovered that the updated door schedule was never placed into the plans… so the framer built door openings that were too big! A lesson learned once again; check, double check, and measure the work that is done by the contractors. The contractor didn’t do anything wrong, but this mistake could have been caught before the whole structure was built.

So last week we only got one door installed, but this week we had some time to prepare as well as get some metal flashing replaced that was custom made for the wrong size openings. Today we installed two standard doors and two sliding glass doors.

To install a door, it is helpful to remove the door from the frame (easier to man handle). Position the frame into the opening and check for level, make adjustments as needed. Before you secure the door frame with the first screw, insert shims from the front and rear at the location of the screw to keep the frame in its place. As you place each screw, verify the door frame width is maintained for the entire height of the door. Verify squareness. Verify level. Verify flush to outer plywood. Make adjustments as you see fit. Don’t be afraid to remove previous screws to fix frame level if needed.

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anchor bolt into concrete for last door (garage door)
flashing for sliding glass doors
adjust lock for lower sliding glass door
secure bottom of 1st floor slider
install nice knobs or temp knobs during construction
paint doors

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End of day before the storm

We have been very lucky with the weather. The rains led us to a late start in 2011 as the summer never seemed to appear, but the in the fall, the rains went on vacation. We had a nice shower just before we poured the foundation (positive). We had some small showers before framing started. Once framing started, we had some showers, but it was basic lumber getting wet, so no big deal. Once the OSB and sheets of plywood started getting installed, we didn’t have much but one or two small showers. Nothing that would slow down progress, so framing just kept hammering away. Now we are into January of 2012 and weather is coming back home. We have been very lucky to get some good responses from contractors to do their work and now, before the next storm, we have the structure fully wrapped, fully installed windows, a roof, and a sealing base coat  on the deck above the garage. Other than some doors not installed, we are weather tight. So welcome back weather, I invite you to do your worst and show me the cracks in the workmanship of those that have spent their hours here. Show me the pinholes that would slowly leak into the structure and cause troubles in the future. Show me the flaws before I cover them up with drywall… so I can fix them before the next years seasonal change. I am ready.
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WeatherUnderground radar as I write this post

Installing the windows was mostly done by an experienced friend. We provided assistance as we learned. Learned to respect the spring loaded windows – don’t unlatch the window when you are holding it upside down!

Cut into the “paper” (water barrier) at the location of the window framing. Fold inward the barrier and stable. The top section of the paper should be folded back and tacked  for the last step. Create a window pan. Verify the window fits into the framing, check how much shimming is needed, add shimming,  and remove window. Caulk the sides and the top – best to get nearest to the edge of the framing. Carefully insert window, check it for level, verify squareness, fasten about two screws to hold window in place. Check level, check for any bowing, make adjustments for correction. Open the window just a 1/4-in and eyeball that the window is aligned with the window frame. Fasten the window down. Repeat level, bowing, etc checks. If all checks out, place all the fasteners.

About 24 hours the caulk will have dried and you can then add the window flashing. Measure the length needed to run about 2-3 inches from the top of the window down to the bottom and a few inches more. Measure the length needed for the top of the window, overlapping the side by an inch or more. Make sure the flashing fits under the paper which you earlier folded back. Cut paper as needed to make this happen. Apply the sides first, then the top. Fold the paper over the top siding and use the appropriate tape to cover the cuts in the paper at the top.

Easy… all done.

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Windows on the second floor, make sure you are comfortable on a tall ladder. Luckily Michael had a clever method to do the window install from the comfort of the interior. So that was easy, where is my Staples red button? Though, I did get the pleasure of installing the window flashing which had to be done from the outside. And it wasn’t that bad. Perhaps a small, red easy button.

The last window had to wait for metal flashing to arrive and be installed due to the distance of the window to a lower roof. Once done, Amy and I installed that window as if we knew what we were doing…. lets wait and see what the first set of storms do to the windows…