30 June 2010

Roof deck

Now that the roof is pretty rain tight the weather is turning nice!  I have a roll of heavy plastic up on top of Caratello just in case rain threatens.  I'm not sure when the roofers will be putting the lid on so we want to be ready if the sky turn nasty again.  We installed the facia around the perimeter of the roof and attached beams support the roof deck.   The deck beams had to be cut to fit the curved roof deck, we used a 4x12 fir beam.  Man is it cool having access to machines that can build a large wooden ship!  Still have to install the hatch to access the roof deck and the sheathing on the overhangs.  I found some really beautiful vertical grain fir plywood for the overhangs, it will carry the look through from the inside ceiling.

Right now access to the roof is by way of a ladder to the dock.  I'm really comfortable running up and down the ladder, but I don't think I will get Barbara up on the roof until the access is a little more solid.  I guess she doesn't have the advantage of working on ladders for the past 40 years.

While up on the roof I use a jack line (steel cable) that I attach my safety harness to.  I kind of feel like a dog on a leash, but that is better than ending up over the side in the lake or on the dock.  Safety is pretty important to the Lake Union Dry Dock folks so they remind me if I forget.

Next up is getting the windows ordered tomorrow, getting the rest of the roof sheathed and the access hatch installed, and the siding guys are going to start doing their thing.  Pretty soon it won't look like a box on a barge, I'm really looking forward to that.  Once we get Caratello sealed up I'm going to take a few days off, I think I have been on site for 10 to 15 hours every day for about a month now.

28 June 2010

More roofing, framing, and general clean up.

Roof deck is just about ready for the roofers to install the insulation and roof membrane.  We have been getting the decking down and installing the facia around the top of the house.  The siding guy came out to measure for metal and the window guy came out to take measurements on the openings.  I had to make a few adjustments on framing to get the door and window rough openings the correct size.  There have been a few glitches that I had to have help from the tin bender shop here at Lake Union Dry Dock, but they are easy to work with.

There isn't a lot going on in the yard right now.  The Coast Guard is still in Dry Dock #8 and they will be leaving in about a week.  Another ocean going tug is suppose to be here sometime after the 4th, but other than that it is the normal slow season.

It was pretty interesting getting these 2x12 facia boards into place.  Two of them were about 16 foot long and pretty heavy.  We used temporary blocking to set them, glued the mitered corners and secured them with nails, screws, and Hilti gun fasteners.  Here is the detail of the roof edge, the lip is 4 1/4 inches above the roof deck on the left side of the picture and about 5 1/2 inces on the right side where the house is wider.   Spent some time trying to figure out how to attach the roof deck and how to finish off the ends of roof where the overhang is.
Gene, the architect, came by today and made a few corrections to what I was thinking but overall he was very pleased with how Caratello is coming together.   The general concensus is that she is going to be a very nice place for Barbara to spend time on.  It is amazing how many people come by to look.  Barbara came by for a few minutes on Saturday, while I was cleaning up construction debris, and allowed that it looked good.  I wish she could be as enthused as I am, maybe once it is completed she will fall in love with the red boat too.

23 June 2010

Attack of the Puddle Pirates!!!

Our neighbor to the west moved out yesterday morning headed up to the fishing grounds in Alaska.  She was replaced by the very finest in 1960's technology the Coast Guard has to offer, the Cutter Monroe.  Built at the end of the '60s the 378 footer is still the bestest and goodest that the USA has to defend the homeland!
This is the younger sister ship of the Rush where I spent my two years before the mast (well actually aft of the mast most of the time because my shop and my berthing area was aft).  Kind of odd to think that other than the Commanding Officer and XO the entire crew's parents were probably in grade school when this old gal was shiny new. 

 Back to Caratello

Started getting the roof on just as summer seems to be here.  The 1x4 flooring makes for a very strong roof decking and looks great from down below.  The tongue and groove boards are bending pretty easily and fitting together nicely.  What ever Blackstock lumber is getting these from is doing a really good job, every piece fits together perfectly.

19 June 2010

The Summer Solstice - and it is still cold and rainy.

I have been remiss in keeping this blog up to date and I have heard about it from several of you.  Between working on Caratello and other things...  Well as Bluto so aptly put it in Animal House "sorry (shrug)".

Got more of the exterior walls up and placed the roof beams this week.  The beams took a full day of planning and a couple more days to install.  The first thing to do was make a jig so that each of the beams would fit nice and tight.  Each of the beams was cut to the exact length and then the jig was used to drill holes for the bolts and a pilot hole for the slot that needed to be cut into each end of he beam.  The slot was cut using a sawsall, not a tool known for it's fine finish tool.  The slot was very carefully cut and then dressed out to make room for the weld at each beam tab on the steel arches.  The final step was to set the beam, pound it into place, and lock it into place with two stainless steel carriage bolts on each end.

Barbara decided that she didn't really want an aft deck on the second level since that faced I-5.  Not the view you would enjoy with a bottle of wine and a cheese plate.  The aft stateroom/office will have a large window instead.

The HVAC system was set and I have been working on the plumbing for that and the bilge pumps.  I put the water and waste tanks in the hold.  I'm really glad that we made one of the frames removable because I wouldn't have been able to get the tanks in otherwise.  It is amazing how much junk ended up in the bilges, but between the shop vacuum and brushes I got things cleaned up.  Two days later I need to get the shop vac back down there, gravity still seems to work.

The plans called for 3/4" tongue and groove plywood to sheath the roof, but I found that didn't work very well on a barrel roof.  It is really hard to bend T&G plywood.  So I set off on a quest for a better product.  After many hours I found that 1x4 T&G fir flooring would work out nicely.  It bends, it is really strong, and it will look great since you will see it from below.  These are just some test pieces, the real ones won't be so weathered.

The next jobs to tackle are the roof and getting the windows in then getting the siding put on.  Things have been slowed down a bit due to the weather, I don't work as quickly when I'm cold and wet.  There have also been a few changes to the design.  The center beams had to be reworked because they didn't fit a expected so the steel guys did some cutting and welding.  The nice thing about steel is that you can lop off chunks and, unlike wood, you can add to it.

I'm going to put the jigs and other tools in the bow rake (front of the hull under the deck) with some spare parts and instructions.  With any luck who ever has to replace things in 50 years won't have to do as much trial and error as I have gone through.  Everybody that comes by seems to think that it will still be a home on Lake Union in a hundred years, kind of a nice thought.