Thursday, January 17, 2008
New doorstep and staircase opening
Two main jobs this week, increasing the size of the opening for the staircase and building a door step.
As I mentioned before I've got two pieces of granite from a broken mantlepiece. I did consider using them as external door steps but neither piece was really long enough. The sill of the side door from the lounge is about 20cm about finished floor height, so why not use the granite inside. It should tie together the stone walls and complete the picture. Each piece of granite had to be cut to length. I used an angle grinder with a diamond blade to cut around all four sides then a couple of whacks with a coal chisel and lump hammer saw the two pieces part company.
The idea here is to remove the broken ends of each piece then butt up the clean original outside edges in the center of a new step. The cut ends will be pointed in.
In order to get the levels right it did require some excavation under the door. A bit of hard core, sand, plastic membrane, then mortar to lay the granite blocks on. Positioning the blocks was really really difficult. We couldn't get our hands round the blocks and anyway they were just too heavy. After quite a bit of shuffling the blocks were in and positioned and level, but too low! The mortar shifted around, squeezed out and mucked everything up.
It was a tough decision, but it would have annoyed me every night, so out came the whole lot. The mortar dug out, more hard core and packing and second attempt. This time it went much smoother. We used a technique of aligning the blocks on a plank then rolling them onto the bed of mortar. It worked much better than trying to lift and shuffle.
The new opening for the stairs was necessary in order to fit a standard 'off-the-peg' hardwood two quarter turn staircase. I've choosen the staircase I like and it required a 180cm square opening. The current opening was too narrow. I could have had a staircase made to measure but that doubles the price of the stairs, so a bit of elbow grease was required.
The cross beam (the one with the ladder on it) needed removing and moving back about 30cm to ensure the hole was large enough. Because the cross beam was buried about 40cm into the wall the only option I really had was to cut off the tenons to remove the old beam. With the other beams supported by acro-props the cross beams could be wiggled free. The existing beams cut where short and new tenons made at the beam ends to fit into the cross beam mortices which where then pegged with new oak pegs. These seasoned oak beams are like cutting concrete and I've completely trashed a couple of panel saws hacking away.
Re-using the existing cross beam meant I didn't have the extra length to remake the tenon and I certainly didn't fancy cutting a new mortice so I cheated and got some 14mm steel bar and just drilled right though the beam and into the end grain of the cross beam. A couple of 'pegs' and it's rock solid.
You can just see above the blue clamp some shuttering where the hole has been filled from the old cross beam position. The horizontal acro-prop is just there to ensure the cross beam was pushed up tight.
| 8:03:09 PM
New doorstep and staircase opening
