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Tear It Down

As the spring arrived this year, the twins and I started to spend more time outside in the backyard. My parents got them an awesome water table for Christmas that they loved playing with. I set it up on our deck and we spent a lot of time out there. Although the twins were already walking, when they went used the stairs, on the deck, they needed to crawl up or down them. We also had a play date with other twin friends who were not walking yet and the failings of our deck quickly became apparent. The deck’s wood was in bad shape. There were splinters (or potential for splinters) everywhere. Some of the boards were popping out which made for prime tripping hazards. There were also some nails that no longer laid flat against the wood which was another safety issue.  Jim and I had already talked about how the deck needed to be replaced at some point but it now seemed like the right time to undertake this task.

The old deck - view from the yard

The old deck – view from the yard

 

Another view

Another view

 

Third view

Third view

 

The side stairs - you can see the stains on the deck and just the overall not good shape it is in

The side stairs – you can see the stains on the deck and just the overall bad quality

 

Look closely for the board sticking out

Look closely for boards sticking out

 

Close-up of the splinter maker

Close-up of the splinter maker

As you know from our previous projects, Jim and I normally do our big house projects together. Jim often is the mastermind behind the project (he makes the designs…with my input, researches the how-to, and plans out the steps) but I am there every step of the way to help and get my hands dirty. We knew that the deck project could not work out this way. Although we started talking about redoing the deck in the spring, the project did not get under way until the summer. In addition to having to watch the twins, I was already pregnant with baby number 3 before the project began. Therefore, I had zero energy to help when the twins were sleeping. Jim was going to do this project 100% solo.  Part of the reason it took so long to decide to undertake the deck remodel was because of the time commitment it required. Jim would only be able to work on the weekends and after the twins went to bed on the weeknights. I would also be watching the twins by myself almost 100% of the time.  It was a lot to consider but in the end, we decided it was better to do it now before the third baby came.

The original plan (or “pitch”) that Jim presented involved only replacing the decking boards and the railings.  We would keep the frame of the deck and therefore, it would not take very long to replace the decking board with new boards (we decided to use Trex boards). Jim also pitched expanding the deck and adding a built-in bench. I worried how much more time this would add to the project (a.k.a. how many more weekends will I be without him to help me with the twins). He designed the plans and figured it would only require him adding 2-3 new support posts which wouldn’t add much time to the project at all. I (hesitantly) agreed. As “d-day” (demo-day) started to approach, the plans started to shift. Jim looked at the current foundation of the deck and questioned whether it followed code. There was more overhang per post than there should be.  He also wasn’t even sure if the current posts were in cement. It may be a better idea to just demo the whole deck and start over…

This is a common theme in our DIY projects.  So many of them start with simple plans that won’t take long or cost too much.  Then Jim (who I love so much and appreciate all that he does) takes a closer look and changes the plan. He is a perfectionist and working off of someone’s else’s work doesn’t fly for him most of the time. It is better to blow it up and start over so it can be perfect from the bottom up. I know that every project we have done is quality because of this, but man does it take extra time.  Jim still framed the deck tear down in a way that it wouldn’t add too much time to the project. He could rent a two-person auger (fancy term for a hole digging machine) and get a friend to help him dig the holes for the posts. The two-person auger could create bigger holes which meant larger posts and therefore fewer posts would be needed.

Well, plans don’t always go as…planned.  D-day began Fourth of July weekend. Jim started taking down the deck on Friday. The hope was to have it completely demoed by the end of the day. He also needed to set up a bunch of strings to figure out the exact locations of the posts. He hoped to have the strings set up by the end of Friday as well.  Jim’s friend Andrew was coming to help out on Saturday, so they could get the two-person auger and dig the holes if everything was set in place by the time he got there.  By the end of Friday, the deck was not gone.  A lot of it was demoed, but nowhere near all of it. The nails on the boards were rusted and didn’t come up easily. Jim had to cut some of the boards with a saw just to take it apart. None of the deck just “came apart” easily.  Andrew came over on Saturday and helped Jim complete the demo of the deck.  They also moved the old stairs of the deck over to the back door, so we could still let our dog out in the back yard. Sunday, Jim started working on the strings.  There were no holes in sight.

Mid demo - Jim took this picture to show how rusted the nails were which made demo so much harder

Mid demo – Jim took this picture to show how rusted the nails were. This made demo so much harder. (Without me to take pictures…there are a lot fewer pictures than previous projects. I tried to stick my head out and remind him to take pictures every now and then but it wasn’t on the top of Jim’s to-do list)

 

Some of the demoed deck (there was more that couldn't fit in the dumpster bag)

Some of the demoed deck all packed up and ready to go (there was more that couldn’t fit in the dumpster bag)

 

The string set-up (and no more deck)

The string set-up (and no more deck)

Unfortunately, Jim was unable to recruit another person to help him dig the holes. That meant renting a one-person auger. A one-person auger meant smaller holes and smaller posts. This also meant more holes and posts were needed. I think the number of posts required went from 7 posts needed to 11 posts. The holes were not easy to dig. There were rocks and tree roots that the auger had to fight through. The auger could only go to deep and so wide, and Jim had to shovel the rest of the holes himself. Three of the holes had cement from the old posts (they were in cement) that Jim had to jackhammer through.  The holes needed to be 2 feet deep and about a foot wide. The depth of the holes was very important because it had to be below the point the earth would freeze in the winter. If the cement was above the freezing point, when the earth froze, the cement could shift. This could cause the posts to shift and therefore cause the deck to be unsteady. The cement needed to be deeper than the freezing point so that there was no risk in it shifting.

Holes

Holes

 

Close-up of how deep they were

Close-up of how deep they were

After a long time and a lot of hard work, Jim had all the holes dug. Jim then put all the strings up again so he could determine the extra location the posts should be secured in the holes.  He added the cement to the holes and placed screws in the exact locations determined by the strings. Once the cement dried, he screwed brackets into the screws.  He was finally ready to add some posts.

Some of the holes with cement finished

Some of the holes with cement finished

 

Cement in place!

Cement in place!

 

Ready for posts!

Ready for posts!

The holes being completed was something Jim had hoped to finish the first weekend. This took about two weeks to complete.  We were in for the long haul.

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Handle This

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As Jim worked vigilantly on bringing water to our kitchen, I decided to make myself useful by adding handles to our cabinets.  We ordered knobs for the cabinets doors and pulls for the drawers.  I needed to drill holes before I could screw the knobs and pulls into place.

In order for the placement of the knobs to look good,  I needed to find the center of the corner of the cabinet door (follow that?).  Luckily, all the cabinets’ corners are the same measurement, just either on the right or the left. So I made two templates for the hole to be drilled and just taped it up for each cabinet door.  It took me more time lining the template up perfectly than actually drilling the hole – being a perfectionist can be time-consuming.

Picture of my template

Nicely drilled hole

Knob!

The pulls were not so simple. To begin with, there were two holes that needed to be drilled for each pull. The holes needed to be exactly the same difference from the center of the drawer so the pull would be centered. We also have a variety of lengths and widths for each drawer. This meant I needed to remeasure for every pull. I made a template for the distance between the two holes so I would not need to measure that. This was surprisingly time-consuming. It also did not help that we do not have a regular ruler, so I was making templates with measuring tape and measuring tape does not like to go flat against paper. After all the holes were drilled, I went to start screwing in the pulls. Unfortunately, our drawers have a piece of wood that juts out inside of the drawer. This adds length and therefore the screws that came with the handle were too short!  I decided to pick up some longer machine screws the next day at Home Depot (seriously, Home Depot should be paying us for how often I mention them in this blog). I brought along my original screw. I used Home Depot’s screw block to figure out the thread I needed for my screw. I needed #8-32 and estimated about 2 inches for the length. After buying the screws, I tested them out on the pulls and they were just a little too long.  Shoot.  I quickly returned to Home Depot ready to buy the 1 3/4 inch screws and the 1 1/2 inch screws just in case. When I got to Home Depot, I saw only 1 1/2 inch screws. I was in a hurry so I decided that would have to do.  They didn’t.  They were just too short.  I needed 1 3/4’s.  Later in the evening, on my third trip to Home Depot, I found out that was an unusual length for machine screws and they didn’t carry them. Doh.  The man told me to try a hardware store – is Home Depot not a hardware store?  The next day I took a trip to Ace Hardware. After a lot of searching, they too confirmed they did not carry this type of machine screw. They ordered me a special box just to call me the next day to tell me they did have the screws, they just couldn’t find them the day before.

So it was Wednesday before all the pulls were done.  I needed to drill holes a little wider in order to accommodate the pulls – my template proved to not be fool-proof but it all worked out in the end.

I forgot to take pictures of the templates for the pulls – probably because I was so focused on the measuring.

These drawers were especially annoying to measure out - but they are so pretty now!

Knobs and pulls

In addition to completing the handles on the cabinets – Jim has been adding another finishing touch; the quarter molding!  This has taken a lot of time and patience. There is a lot of measuring and calculating angles on where the quarter molding will meet. He has also had to deal with the vent in the toe kick (which doesn’t allow for quarter molding) and also the toe kick itself (which comes out a little bit on the edges).  Jim decided to have the quarter molding go around the vent. He also decided to cut into the toe kick in order to allow the quarter molding to continue smoothly. It is hard to make sense of this with words – so I will let the pictures do the talking.

Cabinet before the quarter molding

With the quarter molding - so pretty!

Quarter molding around the vent - nice close up of the tile too!

View of the molding going into the toe kick - it is hard to tell that Jim cut into it so it would be smooth

Another view

Jim also added outside corner molding to the island. This really added a finished look to the island.  It is something you don’t realize is missing until it is there. Now the island looks great.

The outside corner molding - so professional looking!

The wine rack also had its finishing touches completed.  Jim added the toe kick to the wine rack.  Since he designed and created the wine rack, he had to also create the toe kick.  It fits seamlessly with the rest of the toe kick so you would never know it wasn’t part of the rest of the cabinet.  We also ordered wicker baskets for the shelf on the wine rack.  We are going to keep our wine openers, corks, and other knickknacks in these. Another productive week in the Mai Household!

Wine rack complete - now we just need to fill it with bottles!