Drawer Boxes

Big snowfall today

Cabinet drawers in process. The interconnecting joints are called box joints

Today was an effort to keep warm and work well. We're staying out of the house while the nasty fumes from the polyurethane on the floors dries. Tomorrow is the last coat.

Today I spent making the boxes for our cabinet drawers and it went quite well. The easy part is planing them down to thickness and then the slightly trickier part is cutting the box joints at the ends. This requires some careful set-up on the table saw with a dado blade and a lot of micro adjustments, but in the end I got it all to work neatly.

A box joint is what you'll often see on traditional or nicer cabinet drawers. I'm familiar with making box joints for our bee hive boxes. It it a very satisfying way to join wood.

Tomorrow I'll complete the drawers and think through mounting the doors and getting ready to install the drawers. Maybe I'll even get beyond the thinking part!

Progress...

The last few days have seen a few developments: the floor finishing crew has been here and given all the floor surfaces a thorough sanding and have now put down the first of three layers of polyurethane. The floors look great but the fumes are nearly unbearable, so consequently Nance and I are fully living back in the yurt for the week until the floor process is complete.

I installed the shower fixtures last Sunday before work on the floors began. They look great but we haven't had a chance to actually test the shower out yet since we were waiting for some caulk to dry. We'll get our chance this weekend once we can get back in the house.

I've been back at the cabinetry project and have put together most of the cabinet doors. Tomorrow I'll start building the drawers and drawer fronts.

Today I also made a run over the mountain for maple that we'll be using for the baseboard and door trim on the first floor.

Ready to finish floors

Jeremy setting nails last week

We've been busy preparing for the floor finishing crew that arrives tomorrow morning to sand and then polyurethane the pine floors we put down last week. The most time intensive aspect of getting ready has been setting the nails. It's just a lot of work and the kicker is that when the finishing guys showed up this morning to drop off some equipment they said we had to set them deeper then I thought we would, so we had to go back over it all this afternoon. Luckily for me Randy showed up to help out and made a long hard job manageable.

Otherwise, we are ready. I'll be back to working on the kitchen cabinets this week as access through the house will be pretty limited until the floors are done, which should be Thursday sometime. This means Nancy and I'll be living in the yurt again for the week.

Some Old Snapshots

I found an old box of photos that miraculously seem to show the day's events... a planning meeting with Nancy; a visit from Randy and Solveig, and the light coming in on the new floor.

Floors down

The pine floors installed. Notice also the woodstove is now set on the slate hearth. We'll get around to hooking it up soon. Oh yes, we also built a somewhat more expansive bottom step spilling out into the living space

Adam hard at work

The floor in process

Jake's tile work grouted and nearly done

Adam has been back up to help us out for the last two days and he and I managed to get the flooring down on the first floor. Due to some supply issues we went with 2" nails on the first floor instead of the 2 1/2" nails that Nancy and I used on the second floor. It was striking (no pun intended) how much easier the smaller nails were to nail in. Also, in a blessing from on high, the span of the main area of the living space on the first floor turns out to be just under sixteen feet wide and this allowed us to install our large stack of sixteen foot pine planking with no joints whatsoever on the first floor. I wish I could say I planned it, but I didn't -- it just worked out that way.

The next job for me is to set all the nails on both floors, which means hammering them with a tool called a nail set that submerges the nail heads roughly an eighth-inch below the finished the surface. This will make things good for next week when the floor sanding/finishing crew arrives to polish off the job.

Working alongside Adam and me today was Jake who is nearly done with the bathroom tiling project. The last remaining detail is to caulk the corner joints and then we are free to hook up the all the fixtures and call it a working bathroom. Maybe that'll happen this weekend?

Square Cut Nails

We are putting our pine floors down with square cut nails, which if you were to see them would probably look like what you think of as "old fashioned" nails. Cut nails were most commonly used from the seventeen-hundreds up through the early twentieth-century, and are made by shearing a small wedge from steel plate. This results in a nail that is parallel on two sides, and tapered on the other two. A head is then formed on the sheared nail and it is ready for use.

We're putting down wide plank pine floors and cut nails work well because there is a lot of width across each board to attach to the sub floor and using three cut nails each gives it a lot of hold. In the old days, this is how a floor would go down and you'd have the nail heads showing as a part of the process. We're pretty happy with the results.

More floor

This is a really cool wedge system to push the flooring planks together as you are installing them to achieve a tight fit

Nancy and I spent a long day yesterday and made a lot of progress on the second floor. We've calculated that it takes, on average, about an hour per course of flooring to put down. This includes rearranging, making special cuts, backing up when necessary, etc... We figure we're about two-thirds of the way done on the second floor and expect to finish it this weekend.

At the end of the day we each took a bath and then nodded off just after midnight.

Happy New Years!