Tag Archives: pre-mixed floor compound

2015/08/29 (S) Up and Down

When we arrived at the South Lyon Senate Coney Island just before 8 AM there were only five other SLAARC members there but we had 16 by the time the last two people showed up.  Linda (K8LMF) got to sit next to Linda (NF8C) for the first time in quite a while and they had a long chat.  All but one person stayed until 9:45 when we got up to leave and everyone else followed suit.

We were back home by 10:15 AM, changed into our work clothes, and got back to work on the bus remodeling project.  It was a very overcast and cloudy day with a high probability of rain that was forecast to be an all-day event.  That altered our plans a little in that we did not want the pieces of underlayment to get wet and our air-compressor could not be out in the rain as it has an electric motor.

Yesterday we marked and cut the underlayment panels in the driveway, laying them across 2x4s to create space for the circular saw blade.  In order to keep the project moving forward we decided to use the temporary “workbench” in the garage for this work.  Since the workbench was covered with drawer fronts that had to be moved we decided to take a little time to put the new handles on them and reattach them to the drawer boxes.  Sometimes it’s true that “there’s no time like the present” to get something done.

Linda has worked hard on cleaning and waxing the walnut drawer fronts and fixed cabinetry in our motorcoach.  The results so far are amazing and we are feeling like all of our work will be worthwhile as the interior of the coach is going to look very nice when we are done with this project.

We had cut the piece of underlayment for part of the hallway last night but needed to trim it to get it to fit correctly.  I think we took it out of, and back into, the bus at least four times, each trip requiring us to go up and down the seven steps in the entryway/cockpit plus the stool outside the door.  I do not know how many times we went up and down those steps today but it was a quite a few.  To add to our enjoyment and bus conversion physical fitness program we were usually carrying something and it was often heavy and/or large.

The next pieces of underlayment to be cut would fill out most of the living room.  I had planned to cut them a certain way but changed my mind after talking it through with Linda.  We took measurements and I made drawings that were close to scale.  We ended up using the full 48″ width of a 4’x8′ sheet and about 86″ of its length for the piece that fills the alcove where the built-in sofa and storage base will go.  It had two large corner cutouts, one to make it fit with two other installed pieces and the other to go around the base of the media cabinet that doubles as an end table for the forward end of the sofa.  After test fitting it we had to trim a couple inches off of a back corner because of a wire bundle and create a notch for several wires that ran through the floor just in front of the driver’s side HVAC chase.  We waited for a lull in the rain and took it back into the coach.

It fit just right but unfortunately there were defects in the subfloor, such as small gouges and depressed screw heads, that needed to be repaired.  Since we could not use the air-stapler today I did not have a good excuse for not patching the floor correctly so I worked on that while Linda resumed working on the woodwork.  The quart of “ready to use” floor patch was not as ready to use as I would have liked.  The directions said to stir thoroughly and when I opened the container there was a half inch of milky white liquid on top of somewhat drier and stiffer material with the consistency of fine wet sand.  The directions also said the open (working) time was about 15 minutes.

I set the timer on the microwave for 20 minutes, spent five of those trying to stir and mix the floor patch ingredients, and then tried to patch everything that really needed it in the allotted time.  I did not care for this material and wish I had used the Universal Patch and Skimcoat that I used everywhere else.  It was gritty and did not feather out or finish as smoothly as I wanted, but there was nothing to do now but wait for it to dry which would take three hours.

Linda decided to work in the house and eventually fix dinner while I worked in the bedroom (of the bus) trying to remove very old masking tape from the subfloor using a 1.25″ putty knife.  After an hour I had about half of it off but called it quits as my hands were sore.

For dinner Linda cooked a couple of ears of corn-on-the-cob, heated some vegetarian (vegan) baked beans, and cooked two vegan “burgers” topped with vegan cheese.  Mustard, ketchup, pickle relish, and four large leaves of romaine lettuce made for a tasty sandwich.  We each had a glass of the Cupcake Black Forest Decadent Red wine with the meal.  Dessert was fresh sliced strawberries with non-dairy (vegan) peach mango “yogurt.”  It was a tasty summertime meal.

After dinner I tried sanding the floor patches even though the directions said not to sand the dried material.  I used a very old piece of 120 grit sandpaper in my orbital sander and went over the entire area.  I vacuumed the whole area but I could still feel a residual grit on the floor.  I got Linda’s vacuum from the house and tried that.  I then got the Revel wet/dry mop and tried wet moping the area, but it was still gritty.  I was preparing to go over the entire area with the new 80 grit sandpaper but Linda managed to get it clean using the brush attachment on the house vacuum cleaner.

With the area cleaned up we put the piece of underlayment for the sofa nook in place and it fit very nicely but we did not staple it.  We redid our measurements for the passenger side front piece and made some minor adjustments to the dimensions on the drawing.  What I have tried to do wherever possible is to keep at least two factory edges with a common vertex (corner) and use that point and those sides as the basis for my measurements.

It looked like heavy rain was going to hit us from the west but must have tracked north of us.  We continued to get rain, off and on, but nothing heavy every materialized.  Working in the garage we measured and cut the last piece for today.  We made extensive use of the circular saw running it along a saw guide.  By the time we had the sheet cut there was a lull in the rain so we took it to the bus to test fit it.  The fit was close but needed minor trimming in the front outside corner.  By now it was 8:30 PM and we did not want to haul the sheet back out of the bus and into the garage to work on it.  That will be our first task tomorrow followed by stapling the three pieces that we cut today, weather permitting.

We turned in at 10 PM.  There wasn’t anything on TV that interested us, so Linda read for few minutes before falling asleep and I wrote until 11:30.

 

2015/08/25 (T) Turning The Corner

It got pleasantly cool overnight and with the bedroom doorwall open it made for nice sleeping conditions.  Between being up a bit late last night and not wanting to get out from under the warm covers we slept in a few minutes longer than usual.  I put on my sweats, which I find very comfortable on a cool (or cold) morning, and made a pot of Costa Rican decaf coffee.  We had our usual granola for breakfast, took a few minutes to enjoy our coffee in the living room without our cats, who were off somewhere and probably up to no good, and then got to work.

In order to install the new seats in September we need to have the desk installed and in order to install the desk we need to have the floor installed and in order to install the floor we need to have the underlayment installed and in order to install the underlayment we need to have several things done.  First and foremost was finishing the patching and leveling of the subfloor, so that was my first task today.  While I pursued that Linda continued working on cleaning and waxing the walnut drawer fronts.  Given the limited work surface in the garage Linda can only work on three to six drawer fronts at a time depending on their size.  When she reached a stopping point with those and started working on the woodwork in the bedroom.

I have spent the last week patching, skimcoating, and sanding the entire area where the old tile was installed which I estimate to be about 80 square feet.  I went over it one more time this morning with 80 grit sandpaper on the orbital sander.  The sander has an integral dust collection bag so it did not get the coach too dusty.  I was satisfied with most of the job but still had some unevenness along the edges by the walls and especially in the toe kick spaces extending out about three inches from the cabinet bases.  That is because I did not get the last skimcoat as smooth as I needed to in those areas and the orbital sander cannot reach them.

 

I figured I would need to do one more application of floor leveling compound but did not want to open the second bag of mix for such a small job.  I decided to go the Lowe’s and buy a small pail of pre-mixed floor patching compound and the 3/4″ #8-32 machine screws we needed to install the new handles.  While I was there I noticed that they had 50 grit hook and loop sandpaper triangles designed to fit our Porter-Cable oscillating saw.  I was aware that we had a sanding pad attachment for the tool but had not considered using it until I saw the 50 grit paper.  I bought a pack and picked up some 120 grit as well.  I would also have bought 80 grit but they were out.  I had to go to The Home Depot for the machine screws as I wanted the same brass ones we had already purchased.

Back at the bus I decided to try sanding out the imperfections rather than filling them in with another round of patching and sanding.  I was, admittedly, tired of this phase of the work and anxious to be done with it so I could move on to next step.  August is slipping away and I am very aware of the date.  I was also not keen on creating more sanding dust inside the coach.

I don’t know why I did not try this tool sooner.  The design of the tool and shape of the sanding pad allowed me to work in the all of the areas the orbital sander could not reach and it worked very well with the 50 grit sandpaper.  The circular air sander can also reach these areas, and was the right tool for grinding down the old thinset and mastic, but the oscillating tool was the right one for this final smoothing.

When I thought I was done I vacuumed the floor and used the Revel Damp Mop to pick up any residual dust.  We then went inside to have lunch while the floor dried.  Linda heated up a can of Amy’s vegetable soup, made roll-up sandwiches, and served fresh black grapes and plums.  It beats fast food hands down.

After lunch I inspected the floor carefully and decided that the patching and leveling was done.  Although it was one task out of many, and there was no fanfare attached to the moment, I was very much aware that we had finally turned the corner.  We still have some minor disassembly to do, but from this point forward most of our tasks will involve putting the interior back together and installing new things.  All things being equal (which they never are) the building work should be more fun than the deconstruction work.

The major exception is the wallpaper.  We still need to remove the old paper, much of which is stained from old water leaks, and install the new paper, which Linda will be ordering tomorrow from Delux Drapery and Shades in Ann Arbor.  The critical pieces are the ones that go behind the desk and the built-in sofa.  Most of the rest of it can be finished later but we would prefer to have it all done by September 12th if possible.  The more stuff that gets installed the more awkward it will be to work on the walls.

With the floor leveling done the next impediment to installing the underlayment was getting the refrigerator out of the living room and into its alcove.  That, however, required three other things to be done.  First I needed to replace the electrical outlet with a recessed one.  Second, we needed to build up the base of the alcove and finally, we needed to install the pantry as we cannot get to the slides to mount them to the side of the alcove with the refrigerator in place.

The electrical outlet only took a few minutes to change.  With Linda’s help I used the template I made last Thursday to cut the base pieces from the 4′ x 8′ sheet of 3/4″ plywood we bought on Tuesday.  The bottom piece was the full width of the refrigerator alcove (34″ wide at the front and 33.75″ wide at the back) and 25.75″ deep.  We set it in place, checked the front setback, and screwed it to the subfloor.  The next piece was the same width as the first but 1/2″ deeper (26.25″).  We set it in place on top of the first piece and made sure the front edges were flush with the back edge extending 1/2″ farther back.  I used longer screws to go all the way through both pieces into the subfloor.

I was not happy with the way my circular saw blade was cutting and a few raindrops gave us an excuse to take a break.  We were working just outside the small garage bay and moved everything into the garage to keep it from getting wet.  I went to Lowe’s and bought a new 7.25″ blade with 60 teeth, which should give a very clean cut through plywood but still work on 2x4s and trim boards.  While I was there I checked their selection of driver bits again.  I was looking for a 3″ long No. 1 SR (square recessed) bit but they did not have any that long.  I found a 2″ bit for $2.48 but then I spotted a pack of seven 2″ long bits for under $4.  It had two #1, three #2 (the most common size), and two #3 bits from the same manufacturer as the single bit.  Can someone explain that pricing structure to me?  Apparently most of the cost is retail packaging.

Linda prepared large, wonderful salads for dinner.  She made her own dressing using balsamic vinegar, walnuts, raisins, garlic, and seasonings, and it was very good.  We finished the Pinot Grigio with the meal and then resumed our work.

I changed the blade on my saw and then we moved the wood and 2×4 supports back out into the driveway.  The new blade made very clean cuts confirming that changing it was long overdue.  The third piece of the alcove base was not as wide as the first two, measuring 28.25″ across the front and 28″ across the back.  (The alcove tapers in 1/4″ from front to rear along the right side.)  The depth was 26.75″ to match the refrigerator base depth, and a half inch deeper than the second piece.  I set it in place, snug to the right side of the alcove and flush with the front edge of the other two pieces, and checked for an even reveal along the left side of 5.75″.  Everything looked good so I screwed it down.

There are several reasons for this design/construction.  First, there is a large bundle of wires and two air lines that run across the floor of the alcove at the rear wall.  Using three layers of plywood allowed the top layer to be high enough for the base of the refrigerator to extend over the wire bundle and have its back about 1″ from the back wall (thus the reason for the recessed electrical outlet).  It will also leave about 1″ of clearance above the fridge, which is enough.  The second reason is that the 5.75″ width at the left, with only two pieces of plywood under it, is where the pull-out pantry will go.  But third, I will install a 24″ long 2″ x 2″ angle (steel or aluminum) on the middle sheet against the left edge of the top sheet to prevent the refrigerator from shifting to the left.  The front edges of the plywood base pieces will be covered (eventually) by a something, probably a piece of 3/4″ thick walnut hardwood, that will stick up above the top surface of the top piece just enough to keep the fridge from rolling out.  That piece, however, will have to be removable so I am still thinking about just how I want to secure the refrigerator case in the alcove.

Linda does her Vanna White impersonation, highlighting how the new pull-out pantry will look when it is installed.  The pantry is in its extended position revealing the slides sections that will mount on the cabinet wall.  The refrigerator is out so we can work in the alcove.

Linda does her Vanna White impersonation, highlighting how the new pull-out pantry will look when it is installed. The pantry is in its extended position revealing the slides sections that will mount on the cabinet wall. The refrigerator is out so we can work in the alcove.

We still had some light but with the heavy cloud cover it was darker than usual in the coach for this time of day (6:30 PM).  We rigged up a piece of twine to hang the work light and turned on as many interior lights as we could.  We then carried the pull-out pantry from the library (in the house) to the bus.  We brought all of the slides in as well, along with two pieces of 3/4″ plywood and a 4′ length of 2×4.

We set the two pieces of 3/4″ plywood in front of the left edge of the alcove flush with the two bottom base pieces.  We then set the 2×4 on flat (3.5″ side down) spanning the plywood inside and outside the alcove.  We installed the cabinet halves of the nine slides onto the pieces attached to the pantry and then set the unit in place with the bottom resting on the 2×4.  We moved the pantry in and out checking its position and considering where the slides needed to be attached to the alcove wall and exactly how we would do that so the front has an even reveal relative to the vertical front trim of the left alcove wall.

By this point it was after 8 PM, it was getting dark, and we were too tired to start something as critical as attaching the slides to the alcove wall.  We are behind schedule, but had enough sense to not push beyond our limits.  We closed up the bus, relaxed on the couch for a bit with our kitty cats, took some Advil PM, and went to bed at 9 PM.