Things have been slow on the house building front as life got in the way for the last few months. Plus it was winter so when I went up to my site in the mountains to camp in my monolithic steel house it was about minus three degrees (inside and outside) and not very pleasant for doing anything that involved having to leave my down sleeping bag.
Instead I have been plodding away at my desk on paperwork and planning in my spare time.
However, spring is sprunging as you can see in the photo above, you have to wade through camellias and rhodos to get to my house, so the build is back on the top of my list. There is a lot to do.
First up I had a problem with water coming into the house, where the three containers meet up. I don’t know if there is a bit of sag happening, a not-quite-level-bit or if it was just condensation/dew from the top container running down the wall and pooling, but it took a few goes to fix. I can’t say I did a stunningly professional job of it but there will be decking and cladding on the outside and insulation and plasterboard on the inside so all I needed was an effective fix, not a pretty one.
There was a pretty big vertical gap of about 50mm between the top and bottom containers, and about 25mm horizontal between the two bottom ones. There is a big strip weld holding the bottom two containers together at the roof. Anyway, I started with foam flashing strips to plug the vertical gap between top and bottom containers on the inside, and added waterproof byute foil flashing over that on the outside which was wide enough to be mostly touching steel (not the foam).
I waited for rain and it still leaked, and it turned out to be mostly around the weld strip as I could see drip marks on the inside below that section. So I wandered through Bunnings and found some bitumen waterproofing putty and lathered that all along the joins. That fixed the main living room section, but a few weeks later after waiting for more rain I still had leaks back over one bedroom so I went nuts with more putty to seal the lower edges of the flashing as well and now there are no more drips. It hasn’t rained for a very long time but there was enough to form a small pool of water over the putty a few weeks back and nothing ran inside. We’ll sort out the waterflow/pooling problem when the deck is added on. There are other gaps between the containers where there are no water issues and I have sealed those from the inside with spray foam for now which should do until the cladding goes on.
The place where the three containers meet and water was coming in, on one side of what will be a deck. You can see the flashing and putty in the pic on the right, the putty runs either side of the strip of raw steel that was welded on to join the bottom two containers. The bit of carpet tile is there to block the flu penetration for my wood stove.
The other tricky thing was ordering a front entry door. Just go to a door shop and buy one I hear you say. I wish, not for a Flame Zone I’m afraid. The first company I found had some nice door choices in sexy aluminium (my door has to be metal framed), but the door would come from New Zealand and they wouldn’t supply a door frame for some reason. That sounded all too hard. The next two companies would do both door and frame but when it came to the final quote it took many weeks and calls for one of them and then an order time of eight weeks, and the quote never arrived from the other one. They were both very expensive and delivery fees even more so, and pickup was not an option.
To meet my fire regulations the door seals have to be silicon and that made it a BAL 40 rated door, and it turned out both companies would have ordered the door via Stegbar. So I contacted Stegbar, who quoted within days, I saved about $700 and have a door arriving around the 20th September, with frame. It’s mostly frosted glass to let in some more light, 6mm toughened of course as that’s the only glass I can have, and double glazed for cosiness.
Other things that I’m working on at the moment include:
1. Sydney water sewer and water connections – this has to be done through a water services coordinator and is a long and involved process, but it is well underway and I’m waiting on quotes from Sydney Water approved sewer constructors. I have to put in a low-pressure pump which is not cheap, and I chose the process where Sydney Water would own the pump and therefore have to fix it if it breaks, which involves more paperwork but saves a bit of money (they pay for the pump) and also saves me having to deal with any future sewer problems.
2. To get the inside fit-out happening, I need to finish my electrical plan, get the interior wired up and then I can insulate with spray foam and start to plasterboard. Most of the wiring and plumbing will be coming up through the floor due to the steel stud-work in the walls, but there is plenty of crawl space under the house due to the slope of the block so that shouldn’t be a problem. The electrical plan is taking some work as I had to work out where everything will go, including kitchen and bathroom design and cabinet sizes, power points and USB points, lighting, fans etc. So I’ve been a busy bee with SketchUp plans, trawling through Pinterest for ideas and crawling the net for various electrical and plumbing fittings. I’m finishing the plan this weekend so I can start to get quotes.
Basic kitchen cabinet layout, or half of it. The inspector-looking fellow is actually standing in the bathroom. The big grey block in front won’t be there, it will be stairs and cabinetry I’m just not clever enough to do stairs with quarter turns in SketchUp yet. The hole in the wall is a window over the kitchen sink. The splashback might be copper or bright orange, I’m not sure yet if I’ll go for classy or loud. The benchtop will either be timber or white.
3. I also need to get some quotes for plastering, including squaring up the walls as nearly everything that Port Shipping Containers did is crooked. I’m a bit sick of writing about them and finding more mess ups, so I think I’ll call them “They Who Should Not Be Named” to maintain a degree of distance. The wobbly bits include windows and wall stud work. I knew they couldn’t use a tape measure very well but it turns out apparently no-one there has a spirit level either. I have totally changed my expectations and I now assume nothing is quite where it should be, and nothing is level, and that has kept me much happier. I think my attitude might be called pessimism but I’ve put a cheery hat on it and I walk in ready to make a plan to adapt and fix stuff instead of having steam coming out my ears. I’m keeping tabs on things and the cost of fixing stuff, in case it’s worth suing them later on. Or finding the Elder Wand to sort them out.
The newly discovered level of crookedness slowed down the electrical planning as none of the dimensions on the drawings by They Who Should Not Be Named were correct, apart from the window sizes and the windows were made by someone else. So I had to go up to my site and physically measure all the internal walls to see where they ended up. Then I could work out where to place the power points.
4. I have finished the kitchen and bathroom design. I’m still looking into the pros and cons of Ikea versus Bunnings flatpack (overhead cupboards are the concern with Ikea apparently) but I have the basic design and cabinetry layout done, plus the colours of course as that’s the fun bit. It still includes my copper walled shower recess and I’m looking into the best way to achieve that. I’ve ordered a small piece of copper sheet to try hammering it, oxidising it and gluing it. I was planning on pressed tin with copper paint but all the tin sites say you should use powdercoat not enamel paint on the tin for wet areas, and the powdercoat copper colour is just a murky, dull, dark brown.
The mood board for my bathroom, including the copper shower recess and my fancy floor tiles. It’s a slightly dodgy cut and paste effort I did in Gimp (the poor woman’s Photoshop) and the bathroom should look much better in terms of finish than this! I’m still not sure if I should risk black tapware (hard to keep clean I’d say, and more expensive even on ebay) or stay with chrome.
5. An ongoing task has been removing the rest of the masking tape from the windows. This can be fun if the weather is nice and you approach it with a mental state of Zen, or it can be as annoying as a mosquito in your ear at 2am if you think about the fact it should not be this hard. True to form, They Who Should Not Be Named did not use window tape when they taped up all the glass for transport, they used the cheapest, nastiest masking tape you can imagine and put it everywhere. It crumbles into teeny pieces when you try to remove it, it won’t peel off. I tried solvent, WD40, window scrapers and just about everything else and it’s a torturous job to remove each strip of it millimetre by millimetre. I’ve had help from a bunch of people so it’s been several days of effort already. I eventually worked out that a heat gun was the best solution, it melts the glue behind it so the tape comes off in strips not atoms. Some of the tape is still left on the high windows and hard to reach places and will probably stay there until stairs and decks are on, or until I find a very tall volunteer because me plus my ladder is not enough.
Masking tape masking tape everywhere, on both sides of the glazing.
6. I’m chatting with a talented local carpenter for my interior stairs, which also form part of the kitchen as there will be cabinetry underneath them. I think they are going to be pretty special and I will share designs and photos when the plans are finalised. I just have to get the electrics, insulation and wall linings done before they can be installed – which is not a bad thing as deadlines are always a good motivation for me.