Bob and the mason discuss the chimney. Pointing out that we have two flues, one for the boiler in the basement and one for the wood stove. By code, the ceramic flue liners need to be surround by at least four inches of solid masonry (the chimney). The mason tells Bob how they are going to attach the pipe from the wood stove to the flue. Then the mason shows how easy it is to cut a four-inch cement block with a hydraulic jack. The mason and Bob then discuss the supports for the hearth, including a concrete table and a blue stone finishing floor.

John Martin from WarmZone is on hand to show Bob how the medium density fiberboard (MDF) faced with reflective aluminum shielding and precut channels for the Pex hot-water tubing comes together to create a layout for the in-floor radiant heat system. One key advantage to radiant heat is the comfort level, since it is steady heat that is evenly distributed and free from the blowing, particulate matter that can come with forced-air systems. Martin explains how the WarmZone system comes ready-to-install with complete layout diagrams and directions that make it simple for do-it-yourselfers. The panels are set in adhesive, with spacers to temporarily align them and line up the tube channels until the panels are nailed in place. The heat panels then become the substrate for finish floor coverings. Unlike gypcrete, which is a skim-coat concrete application, these panels add very little weight to the floor. Since it is a 5/8-inch product, there is also no need to alter existing door openings. WarmZone specifies a 3/8-inch Pex tubing to deliver the heated water. Martin fits and taps the tubes in place in the channels to complete the installation. Bob then looks at the heat distribution system with supply and return pipes that come directly from the boiler room below. WarmZone has specified three short runs and circuits, which will give steady even heat throughout the space even with the heat loss calculations they have figured. Michael Willburn from WarmZone shows Bob the preassembled boiler-room manifold board and radiant-zone board that are created match the application and arrive ready-to-install from WarmZone. WarmZone takes the information directly from the homeowner, creates the system to fit the job, and then ships it to the site. The homeowner or installer can do all the work without the aid of a plumber until the system is connected to the boiler, at which point a professional installer should verify the connections and operation of the system before firing it up. Initial costs are about double the cost of a traditional baseboard-heat installation, but the operational savings are approximately 30 percent annually.

Wood floor expert Howard Brickman is on the job site installing White Oak hardwood floors from Carlisle Restoration Lumber. Instead of blind nailing the floors to conceal the fasteners, Brickman is using a screw-and-plug method. After locating the joists beneath the subfloor, the floorboards are pre-drilled about halfway through their thickness. Flooring screws are then driven into the pre-drilled holes in the floor, passing through the subfloor and into the joists. The result is a very secure installation. Finally, plugs, which were made from scrap flooring pieces, are inserted into the holes to conceal the screw heads. The plugs are tapped into place with a hammer, and then cut flush with the finish floor using a Japanese-style pull saw.

Bob joins Steve Shelowitz from Williamsburg Parquet Flooring to observe the installation of the hardwood floors in the penthouse apartment. Before the floor is secured, a red rosin paper is laid over the subfloor. The underlayment prevents dust from traveling between the subfloor and the finished floor, and prevents wood-to-wood contact to reduce the possibility of squeaking. The Ash hardwood floors are first roughed into place to determine the layout. Joints are staggered for an attractive layout, and longer boards are placed in the room's most visible areas. The floor's finish is factory applied, and is guaranteed for 50 years of normal residential use.

Bob checks out the Shaw's Chateau wood flooring that David LaFossse and his crew are about to install in the great room. It's solid rock maple from Canada pre-finished with a clear, water-based finish. David starts the layout at the hearth as it's the room's focal point and to ensure he'll have full boards and full width around it. He makes a double border around the fireplace with a squared joint on the first row and a mitered one on the second. The first board of the field is placed up against the hearth border. The boards are picked at random based on their length creating a continuous piece from one end of the room to the other. Adding a spline gives the first board a tongue on both sides making it possible to lay boards in either direction. The crew lays out 100 boards at a time making sure that the joints are staggered before they begin nailing. One of the advantages of a factory pre-finished floor is that it is very resistant to abrasion and requires less maintenance than a traditional hardwood floor finished on site.

Bob meets with Michael Shiels from Shiels Builders who is the local on-site contractor for the Modular Mountain Retreat project. Shiels insures all hook-ups from plumbing to electrical are ready and meet code in the area. He also arranges for the building inspections and insures the grounds and foundation are prepared for the delivery and installation of a house. In this case, Superior Walls foundation system cannot be backfilled until the house is set upon it as it depends on the weight of the house to prevent it from toppling in from the pressure of the dirt. The modular concept saved the builder about 50 percent in time and 25 percent in cost in the overall construction of this house.

Bob talks with Howard Brickman of Brickman Consulting about how to fix squeaky floors. Brickman first he checks the moisture level in the joists to make sure it is in a normal range. Changes in moisture content cause wood to shrink and swell, which contributes to making floors squeak. Brickman reviews some of the cross-bracing that has been put in place to help make the floor stiffer. Having floorboards that run at an angle rather than perpendicular to the joists gives the floor more strength. Brickman explains how to fix a squeak, by first determining where the squeak is located, either between the sub-floor and the top of the joist or between the wood floor and the top of the subfloor. Brickman thinks the problem is between the wood floor and the sub-loor based on the sound of the noise. Screws are driven from the basement into the the sub-floor, pulling the wood floor and sub-floor above down and pressing them close together. A 2x4 is drilled into the top of the joist and the bottom of the subfloor to reduce the squeak by pulling the subfloor down tight to the joist. Brickman then discusses the use of shim shingles and construction adhesive to reduce squeaky floor noise when they are driven home between the joist and the subfloor.

Bob is in the basement talking with Erling Andersen from A.I.M. Radiant Heating. A.I.M.'s "Boiler Room In A Box" has been installed and the baseboard tubing is being run throughout the house. Made of a cross-linked polyethylene material, the pipe is routed behind A.I.M.'s decorative baseboards. The baseboard itself has been trimmed out to fit the Colonial's design scheme. Technician Dave DuVerger is on location installing the last few stretches of tubing. Once the tubing is connected to the boiler system, hot water will run throughout the house to create radiant heat that maintains a consistent temperature in each room.

House four of the Elmwood project. Kitchen and bath remodel at the home of Mark and Christina Macheska. An overview of the problems and solutions, demolition and installation of reclaimed pine floors.

Bob Vila takes an early interior tour of the modular home. Bob is in a 15-foot-wide-by-48-foot long section. The flooring and walls are almost complete and much of the molding and cabinetry is laid out and ready to be installed. Bob points out an archway between the kitchen and breakfast nook�one of the pleasant design surprises that can be added to a custom modular home. The floors are Bellawood�s Northern Red Oak with a gunstock finish. The darker finish gives a more sophisticated and formal look to the room. The hardwood floors are installed in the modular home just as they wood be in a site built home. Mike Snyder from Mike�s Flooring, a flooring sub contractor in the Simplex plant, points out the quality of the Bellawood noting it has very few flaws and a durable finish. The flooring is left incomplete where two pieces of the modular home are to be attached. On site, quick work will be made of the few details left when the large modular sections are joined.