Bob points out that Victorian cottages had camp-style exposed framing in the old days and Ryley is attempting to recreate this look with modern attributes. They are using straight grain fir for the framing as it is a higher grade than most framing materials and will hold paint better. Next step is bead board sheeting to look like Victorian paneling. On the outside where in Victorian days builders would have attached the shingles Bob is installing rigid insulation. He puts on two layers perpendicular to cover the seams. Then Ryley and Bob nail a layer of plywood sheathing to the outside.
Bob looks over the plans for the project with GC Charlie Tomaszewski. The carriage house (once the dairy building) and the main house will be joined by a breezeway. The side porch of the house will be expanded into the kitchen space. The porch addition will incorporate two of the existing porch posts into the interior of the space. Creating one big kitchen and family space will require the removal of a lot of the existing structural walls.
Walking behind the house, Bob makes a few observations about the design. He points out that the house and old barn were not exactly parallel to each other creating some issues fo the breezeway addition. Th architect chose to build the breezeway parallel with the barn, but as the roof is right onto the house, when you look at the roof overhang right on the corner of the addition it subtly increases in width in one direction. Another interesting feature of the architect's design is a 4 ft. wide and t10 ft. long "gang plank"-like balcony coming out from the second floor masterbath.
In this segment, Bob tours the exterior of the completed farmhouse, pointing out the contemporary green color scheme and breezeway connecting the old barn and the main house. The barn now houses an artist's studio and features refinished wide-plank floors. In front of the house Bob meets homeowner Rikk Larsen, too discuss more exterior features such as the side deck with trellises and the center bay with it's third floor Romeo & Juliet balcony.
Bob Fulmer from Harraseeket Restoration, Inc. joins Bob on the roof of the breezeway to install a double-lock standing seam copper roof. Before installing the copper, a plywood deck is applied, followed by a layer of bituthene for moisture resistance and then a resin paper slip sheet. The resin paper helps absorb the condensation generated on the back side of the copper panels by temperature changes. Additionally it insulates the copper from touching asphalt-based underlayment or bituthene on which standing water creates a diluted form of sulphuric acid which will degrade the copper. The copper panels are brake-formed at the shop and brought on site ready to install. The panels are joined in a double-lock standing seam in a two-step process. First the male edge is locked over the top of the female seam. Then a second seamer completes the second lock producing a one inch high profile double-locked at the top which is rolled over into the finished standing seam using hand crimpers.. This 16-oz. standing seam copper roof should have a 75 year life expectancy. Proper application is critical. Lack of provisions for thermal expansion such as permanently attaching the copper to the roof will create stress in the panel and eventually cause material failure. Also fasteners should be from the copper family or electrolysis will set up.
Bob meets with Bob Fulmer, Sr. of Harraseeket Restoration, Inc. to see how the gutters are installed on the copper roofed breezeway. The gutters are a single bead half-round copper gutter that attach by circle-type fascia hangers. First Bob, Sr. installs the outlet for the downspout. To cut the hole he punches out a hole in the gutter and, using aviation snips (called clinks), cuts a circle in a spiral till it's large enough. Next he solders the outlet into the bottom of the half-round gutter to achieve a watertight connection. It's important to get it hot enough to melt the solder but to sweat it underneath the lap joint. Once it's sweated underneath, he makes a second pass to build up the layer of solder and then solders a "lock" on the back for extra strength. Then he slips the gutter into the hangers and adds one more soldering joint. The gutter is secured inside the circle-type hanger with a brass clip which allows for contraction, expansion, or movement in the gutter.
Bob meets Tim Woods from the Internet Home Alliance at the Home Director network connection center in the basement. It's where all the structured wiring comes in and where the main controls happen: 2 +2 (cat-5 and RJ), cable broadband, security link-up, telephone, etc. Because the homeowners are a dual career couple they need to be connected to each other (home office to the studio) and to the outside world in a broadband environment. In the kitchen Larry Hicks of Home Director is installing some cable for a universal 2 + 2 outlet for TV, telephone or data near the breakfast nook providing flexibility for use of a phone, screen, etc. Looking at the Alliance's wiring plan, Tim points out the security camera at the front door and the ADT iCenter security system. The study/screening room will be a real media center with speakers for dolby stereo running through the ceiling, cable broadband, and a Panasonic high definition TV. There willl be speakers throughout the house allowing different music to play in diffferent rooms all controlled from the audio center in the kitchen. The Cisco Aironet system is a wireless network for the home allowing the homeowner to put a wireless card into his laptop and wirelessly port the web anywhere in the house. Because this is an old house in which they are trying to preserve the original plaster and lath walls, the installation of the structured wiring has required different tools and is a much slower process than in new construction, but it can be done.
With the first floor deck framing underway, Bob orients viewers to the home's layout and provides a progress report on the construction so far. Engineered wood products feature heavily in the framing process, and Bob makes special note of the engineered I-joists, fabricated from laminated veneer lumber (LVL) and oriented strand board (OSB), which provide span capabilities far greater than could be achieved with dimensional lumber.