3/12/11 - Jamb Extenstions

Now that the insulation is complete the next step is to install jamb extensions on all windows and doors. Jambs are the part of the window or door that extend from the actual window out to intersect with the finishwall material (drywall, wood, ect). Windows and doors typically come from the factory with jambs that are made for 2x4 or 2x6 framed walls. Our walls are 7.25" deep so this requires custom jamb extensions. I am building ours out of 5/8" clear (no knots) pine and using pocket screws and glue to attach them.

Backside of jamb extension with pocket screw visible

Finished side of jamb extention

Using the pocket hole jig

In this video I have a horizontal component of a window jamb extension. I am using the jig to drill a series of angled pilot holes in the backside of the extension. I will then attach this piece to 2 vertical jamb extensions and another horizontal piece (using pocket screws). This will result in a 'picture frame' box that has the exact dimensions of the window. This box will be aligned with the existing factory jamb, glue is applied between the two, and pocket screws are inserted in the pre-drilled holes on the back side of the extensions and screwed in.

3/12/11 - Insulation inspection complete

We had our insulation inspection a couple weeks ago and passed after 1 minor correction.

2/9/11 - Side wall insulation

I took the day off work today. Our friend Andy, Kristin, and I worked on insulation for the entire day. Now that the rough plumbing and electrical are complete and all the insulation mesh is up (nice work Kristin) we can get serious about the insulation. Its dusty and dirty but fairly rewarding. Each stud bay is injected with cellulose until it feels like a firm mattress.

Andy filling the insulation blowerGrey filling the stud bays

2/6/11 - Rough Plumbing complete

The rough plumbing is finally done. All waste piping and supply piping is complete (even though we don't have a well yet). Now its full-on side wall insulation time. The blue and red pipes are supply lines. They are a material called PEX (cross linked polyethylene). It bends so no elbows or soldering are required. Great for a novice plumbing like me.

Bath sink plumbing.

Shower Plumbing

1/3/10 - Side Wall Insulation

We will be using dense pack cellulose for the wall insulation. Although the R value per inch is lower (R=3.5) then spray foam (R=6) it is much more environmentally friendly. It is 85% recycled newspaper (the average house will contain about 40 years worth or newspapers) and 15% Borate (a naturally occurring chemical that imparts mold, insect, and fire resistance/retardant properties).

We have borrowed an insulation blower (for the cellulose) from a friend. I can be seen here reaching into the hopper. Eli, Asa, and Grandpa Jim are collecting some cellulose that will be placed in the hopper.

Once the hopper is full it is turned on and 2 spinning mixers break up the cellulose. Asa can be seen here monitoring the hopper. A blower motor at the bottom of the mixer blows the cellulose through a tube and into the wall. Eli is operating the blower switch. We experimented with several methods. In the method above we screwed ply wood to the stud bays, drilled a hole in it, snaked a tube behind the plywood and filled the bay with insulation. The insulation packs so tight that you can remove the plywood and the insulation will remain. We decided that this method would require too much setup and too much wasted plywood. We opted for the method below.

This method requires stapling a special netting material very tightly across the studs. Then the insulation is blown between the netting and the exterior sheathing. This will allow us better visibility to ensure we achieve the proper insulation density. Eli operating the stapler, hey where's that kids ear protection. This process has just started and the upstairs is almost complete. Insulation won't happen for another couple weeks.

1/3/10 - Plumbing Rough-In

The plumbing rough-in is currently in progress. I have completed the waste piping and venting, which had to get done before the spray foam insulation. I have started the supply lines and should have those done in the next week or so. Sorry no pics right now.

1/3/10 - Roof Deck Insulation

In early December we had closed cell spray foam insulation applied to the roof, under the entry and bedroom bump-out which over hang the foundation, and on the rim joist. Although not the most environmentally friendly insulation it was a good choice for this roof. It not only provides high R value per inch, but creates an effective moisture barrier for our un-vented roof with big sky lights (always a leak potential).

Asa testing the foam with his new hammer

Ceiling of the great room