The Biggest Stud

This is a cross section of a black birch log that John and Paul cut last Friday afternoon from the woods out back. It's a perfect candidate for the load bearing column we need in the main section of the house. The photographer was unavailable to document the actual felling, but, by all reports, it was as unconventional as it was challenging. The birch had to first be cut about nine feet in the air, and then cut again at ground level (which was frozen and snowy), to retain its character. The fact that it was growing over an unforseen rock also challenged the chainsaw. And then all nine plus feet of trunk had to be hauled about 100 feet to the house and then hoisted a few feet more to the first floor. This was accomplished by two sturdy Michiganders, a sled, and some rope.



John then proceeded to remove the aromatic bark with his draw knife. Black birch bark is used to make "Birch Beer". To me it smelled like wintergreen and the "kids paste" we had in grammer school.




Along with the bark, the cambium layer was removed to expose the light wood underneath.




It took a few hours and lots of muscle to finish the surface.




Another challenge was making the "butt" end perfectly square and flat. John discovered that the hand planer was an appropriate tool for this...



along with his level. Plane some... check it with the level... plane some more, and eventually it was flat and square.




Now it just needs to be vertical. John spent some time putting it in place...




And it fit! The temporary supports can now be removed.


The weekend's project is complete.

Double Studdin'

Before we begin, here's a shot of some birches through a 2nd floor window:



"Double Studding" is sometimes termed" super insulated". In our case the outside wall studs are doubled up with a strips of rigid foam insulation between them which serve as a thermal break to prevent heat from being conducted through the studs from interior to exterior. This also creates contained cavities for the cellulose insulation. Here's an example of how the second set of studs are installed. Notice the rigid foam strips along the edge of the studs:



Here, the second set of studs are erected:

The rim joists also need to be insulated. See the blue rigid insulating board at the top of the wall:

Spray foam is applied to the cracks around the rigid insulaion inside the rim joists. All spaces must be air sealed!

Upstairs, the rafters have extra insulation and framing added, too:

Full sheets of rigid foam board are installed over the rafter assemblies. The space behind the rigid foam will be filled with blown-in cellulose.

Meanwhile, John contemplates how to frame the skylights:

Interior walls are being framed too. The house has become a studding display:

(Builder's note: I once worked with a carpenter whose truck sported a bumper sticker that proclaimed "It Takes Studs to Build Houses" Sigh.)

Medium Bronze, Seal Brown

Even roofs have fun color names: Medium Bronze, Seal Brown, take your pick -- that's what the color sample called the color of our metal (aka brown) roof material.
Tim Luce (Luce Brothers Roofing), took measurements a few weeks ago. Then the pieces were fabricated at a nearby metal fabrication shop. Here's Matt prepping a piece:

This type of roofing is called "standing seam". In the photo below, the right edge is secured with screws. The left edge of the adjoining piece hooks over this edge covering the screw holes. This creates a water tight seam.


Andy and Tim install the first panel:


Here, the ridge vent is being installed.


Tom patiently poses in the frigid cold: (yes, he's standing on the ridge; and, yes, it's quite windy. Don't try this at home!)


After a few days, the roof is finished:


They will return to finish the last few pieces after the chimney is up.