A tribute to one of my biggest fans

 

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My friend Nelton Maples

James Nelton Maples, 87, passed away on Tuesday, September 11, 2018 at Huntsville Hospital, here in Alabama, after a battle with pneumonia and intestinal cancer. He was a husband, father, veteran, and friend. This is the second really good friend I’ve lost to cancer. It is a devastating blow.

I met Nelton after my tractor had a slow leak in a tire back in April, 2016. I was still dragging logs out of the woods – hadn’t even started my foundation. I had met his children, and they kept saying, “you ought to talk to Dad- he’d love what you are doing.”

I found out why after I met him.  It’s rare to find a friend who is into “doing” as much as I am. Nelton’s nephew commented to me the other day, “boy, if you’d have met him about 10 years ago, you’d have trouble keeping up.” It’s too bad, but I’ll take the two years I was given with him.

The man knew a lot about everything, unlike me- I know a little about everything. Let’s see if I can list the things and occupations he was involved in:

  • Phone company lineman
  • city surveyor
  • Police chief
  • farmer
  • engine mechanic (diesel and gas)
  • engineer
    • built a road grader from an old grain harvester by turning it backwards and putting a plow on it
    • built a sawmill for sawing logs for his son’s cabin
  • certified welding instructor
  • carpenter
  • electrician
  • concrete expert
  • horse trainer
  • pig & chicken farmer
  • Truck driver
  • guitar player
  • Sunday school teacher

I was always impressed with his knowledge. He mostly blew it off and said, “You do what you have to do to survive.” He built his own house back in the 1950’s, when you hand-mixed the cement- they didn’t have cement trucks back then. His father used to own almost all the land on Maple road- over 100 acres. And his Grandfather owned even more before that. They are founding members of the city. They built a cabin up on the mountain (near Paint Rock) as a vacation home. He has tools galore- mostly old fashioned, many he made himself (log tongs, forks for his tractor, a plow, a grader, etc.). The garage is always in a state of 12 projects going at the same time.

He gave each of his kids 5 acre plots- all together on the same block. It is quite a legacy.

His son Danny built a cabin back in the 1980’s. They hauled the trees for it from down on Hobbs Island Road. He built a sawmill to process the trees- they milled two sides flat, and spiked them together. It has a gable roof, and was the talk of the town back then- there were articles written and a news crew came out to ask them about building your own home.  Nelton can now chalk up another cabin that is the talk of the town, 30 years later.

He started by offering to let me park my tractor at his place at night after my critter cam was stolen, and the friendship and my admiration for him and his wife grew. They are old-fashioned, tough, gritty, and funny, with hearts of gold. Surely God created people like the Maples to watch over foolish headstrong people like me. After watching me from across the road tip the tractor up in the air while skidding logs one day, he said, “you might want to chain that log lower on the bar- if you chain it higher than the axle, you’ll tip up.”

He had a pacemaker, so he taught me to weld from his porch- away from the EMF that could disrupt the pacemaker. He would listen to the torch and tell me, “too hot” or “too cold”, or even “are you hungry? you ain’t welding right today – sounds a little shakey.”

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the golf cart pulls up…

I’ll never forget the 5 mph golf cart pulling onto my property, with him and bunch of tools to give me some advice on surveying, or just to say hi, and offer us something from his garden.

He mowed his yard every week- right up until about 2 weeks ago. I saw him on his little John Deer riding mower, his straw hat, and boots, tooling around. He also has a 1950’s John Deer 3-wheel tractor in his barn that he keeps up. He had me weld a step on it so he could get up in the seat. I also put a new hitch mount on his firewood splitter.

I picked his brain on everything. He had had a stroke, so he couldn’t talk that well. But he was a master teacher. From my blog post “stuff breaks”, while working on my tractor lift arms:

I welded the right side with the neighbor’s supervision- well, he has a pacemaker and can’t get near high voltage devices, so he sat on his porch and listened to the welder. When I was done welding the first time, I drove by on the tractor and gave him the thumbs up. I got across the street, backed up to the log that broke it in the first place, and immediately broke the weld. Limping the tractor back across the street, and I see the neighbor in the chair grinning at me.

“What?” I said.

“I knew that was gonna happen- you were welding it too hot.”

“Too hot?” (I don’t know anything about welding….I guess you can ‘hear’ when someone is welding too hot?)

“Yeah- when you’re welding hardened steel to cast iron, you gotta turn the heat down on that thing – otherwise, you’re not really welding it,” says the former certified welding instructor.

Oh.

Turn down the heat. Weld it cooler very carefully. Grind off the slag. Weld again. Grind off some more slag, adjust the heat. Weld again. The neighbor comes over to eyeball it. Gives me a nod. Off I go.

Back at the log in question. Start to lift it- “clunk!” <a few choice curse words>. Turn around and look- my weld is holding ok. Look at other lift arm: now it’s broke. <smile>. Drive back across the street. Neighbor is a little concerned as he sees me coming up the driveway. Then I show him what happened. Now he’s grinning, too.

“I’ve done that same thing before, believe it or not,” he says, laughing. Luckily, I bought a universal screw pin from Tractor Supply, and what do you know? It fits. And the weld has held up since then, too. Third time’s a charm?

When we excavated, we also had the guy move the culvert for our driveway. Nelton watched from his driveway. He said, “you see that little built up area in your driveway? Many years ago, my uncle was riding through that field, and his horse had a heart attack and died right there. They couldn’t move it, so they dug a hole and buried it right there somewhere on your property.  I was just wondering if you noticed anything while you were digging.”  I guess we didn’t get down that far.

They asked me to go to church with them on New Years, but my daughter was sick, so we couldn’t go. They were Baptists, while I’m Mormon. With the historical animosity between our two religions, I was afraid to upset the apple cart. “I go to a church in Huntsvill,” I kept telling them. But Joyce kept asking, so I finally told them I was Mormon.

“And what do Mormons believe?” Joyce asked.

“We believe in God the Father and his Son Jesus Christ, and in the Holy Ghost.”

“Do you believe Christ died for your sins?”

“Yes, Ma’am.”

“Well, then, you’re alright by me.”

He knew everybody – “I know his daddy- do you want me to talk to him?” when I was having problems with the permit people.

He wasn’t well- heat, cold- all of it affected him. “But don’t worry about me- I’ll lay down for a while, but then I’ll crank up again.” The last time I talked to him, was out on his patio. We talked about the rafters I was making. I was getting close to having all 28 of them made. He nodded his approval. I always look to see if him and Joyce are sitting out there in the shade, enjoying the breeze when I pull up to my property. Two beeps from my horn, and I always get a friendly wave. Joyce told me a few weeks ago, “We’ve sure enjoyed watching your sunflowers grow.”  I said, “oh, you should take some tomatoes while you’re there.” “no- we’ve just been watching them from here- we can see your garden from this little corner in our yard. We can’t wait to see you get the roof on your cabin.”

That chair is empty now. But I think there’s one in Heaven that has now been claimed…. probably won’t get much use, though- I’m sure he has 12 projects going at the same time up there. A mighty tree has fallen in the forest.  I’ll miss you, Nelton. We only got this far with you and Joyce’s support.

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Cutting Rafters

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They are not easy to maneuver.

Background

I’m neck deep into using my sawmill. Back in February when it was raining and muddy, I welded up another 18 feet of track for it in the neighbor’s shed. I made dogs to hold the logs in place and squared it up very well. I thought I would be putting the roof on in June of this year. But, I’ve had several delays- the weather being the number one delay, but then my job sent me to Florida for a week of training, and then our LandCruiser needed a new headgasket. Finding, cutting, peeling, and installing the RPSL’s was another task that slowed us down. I also made a new trailer for hauling logs- works great for small ones, but I bet it would’ve collapsed under the wall logs. And then finding, etc., etc. the logs for the rafters was a major slowdown, but I’ll explain below.

A note on the headgasket- I was just raring to go on the rafters, and desperately wanted to pay someone else to do it- it was going to eat up two weeks of progress – one week to troubleshoot (I needed some help from my buddy, and our schedules didn’t line up), and another week to get it fixed. He diagnosed it (perfectly, I found out) as a broken headgasket between cylinders 5 & 6.  Knowing that I’m neck deep in the cabin and wanted to pay someone to do it, he called his Toyota buddy, who said “September, and probably $2,000  – $3,000”. Wow! I was thinking $1,000. Not $3,000. I’m not THAT desperate, I guess. So, I ordered the parts. My buddy got me hooked up with a bay in his old partner’s garage that they weren’t using (working on cars in the rain is a pain). I was very busy at work, but managed to get a couple half days, and a full day to “git-r-dun”. So that was a little set back.

Which brings us up to speed.

 

 

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Current status

I’ve got 23 rafters out of 28. I need to find about 5 or 6 more. The awesome neighbors keep offering more, even though I’ve already gotten about 20 from them so far. I cut them down, then walked off 30 feet on each log, and cut it at that point. I saved the tips, since many are 10″+ diameter and 20′ long- they will be used for the wrap around porch roof post supports (need 16 of them). I’ve got the milling process almost figured out to where it takes me about 2 hours to make a rafter- from pulling the log off the rack, to stacking the finished beam on the rack. I hope by the end of August, I’ll have them done and ready to go.

Problems and solutions

As usual, as I go from a total newbie on everything to a “pro” (I use “pro” very loosely, ha, ha), I’ve learned some tricks.

My engineer calculated that a beam with a minimum 10″ tip, and a 12″ middle and bottom has the same strength as a 4″x12″ beam. You would think that to make a rafter, you just lay the log on the track and cut one side to be 12″ thick, and the other 4″ thick, and you’re done. I wish. My logs are crooked and tapered, so I have to massage a 4×12 out of them. I’ve been able to, on some big logs, coax two 4×12’s out of them. But mostly, I only get one rafter, and a lot of nice 2×10’s or 2×12’s.

 

 

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I found early on that the taper of the logs makes it necessary to jack up the log on the track before cutting it. The track has a very hard time keeping up. But back to the tapered log problem. I found that if I jack up the narrow end to be level with the fat end, I can then run a flat cut with the sawmill down the entire log, ending up with at least one flat side. My idea is that the flat side will face up- that the roof T&G needs only one flat side on the rafter- the bottom only touches the house in two places- at the Ridge Pole, and at the cap logs. So I’m not wasting my time making the bottom flat.  Once I have one flat side, I turn the log on the side and begin milling it down to 5″. This may take several passes because the log might be crooked, and won’t initially sit flat on the track.

A few logs have been large enough to get two rafters. I jack up the small end as above, but then I just cut the friggin’ thing exactly in half. Then I work on each half to get it to the right size.

Don’t forget we’re talking about a 27.5′ x 12+” diameter log that probably weighs 2,500 lbs. It is very difficult to turn the log for each cut. I’ve even turned some of them with the tractor because they are too heavy. They can also roll off the track. I keep having the scary thought of getting my leg crushed inside the track when a log decides to roll, so I never ever put my legs or arms anywhere a log could roll and crush something.

Eventually, the rafter behaves, and I get a pretty good 4×10 -> 4×12 by 27.5′ long rafter.

 

 

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Here’s a video my wife took of me cutting a rafter.

Next steps

After I have 28 rafters, I’ll treat them with borate solution, then put on my math hat. The math hat is going to be tricky: To get the roof perfectly flat, I have to consider a few things:

  • Ridge Pole (RP): This log is what holds everything up. It is 56′ long, 29″ at the base, and about 15″ at the tip, so it has some taper. To make it level, I have to shorten the RPSL at the back of the house by 29″ – 15″ = 14″. This will make it level when it’s installed on the house. But then it’s not perfectly flat on top- it has some bumps and waves. I have to work this in when I place rafters on top of it. I may have to notch it to get everything perfect.
  • Rafters: They are not all exactly 4″x12″ on both ends. Most have a 4×12 butt. But the tips vary from 10″ to 12″. All of them are 5″ wide. I may put a 10″ on a part of the RP that is “high”, just so the rafters are all level.
  • Cap logs: This is where the other end of the rafters connect- these are the top wall logs. They are not perfectly level either. I have to consider this when placing the rafters on them.

With all this fitting and figuring, it seems like I should do it as I place the rafters and RP on the house, but that would mean measuring and fitting and chiseling while up 30 feet in the air. So, the plan is to do everything on the ground in advance:

  • Run a string line down the RP and level it on the ground.
  • Mark exactly where the rafters will go on the Ridge Pole. Note and mark the diameter of the Ridge Pole at each point the rafters will attach. Use the string line to get the height exact at each rafter attachment point.
  • Do the same thing on the Cap logs.
  • Use some really bright colored chalk or something to label the rafters, “AE or AW” through “IE or IW”: ‘A’ – ‘I’ designates the position, from back of the house to front of the house, of the rafter, while ‘E’ or ‘W’ designates whether it is on the (E)ast or (W)est side of the house. Each rafter on the East is paired with a rafter on the West- there are 14 pairs, spaced 4′ apart, so ‘A’ – ‘I’ makes sense.
  • Match the short rafters (less than 12″) with the tall part of the RP (where a bump or a bow sticks up). Match tall rafters (at least 12″) with the low parts of the RP (where it bows down).

When complete, I’ll have all the rafters laid out on racks in order, bolted together in pairs, next to the ridge pole, and all ready to lift by the crane when he shows up. If all goes well, the whole lift operation shouldn’t take more than about 5 hours. We are so excited for this part!

 

RPSL’s installed

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Another small milestone. Just two more logs so far, but wow, it was not easy.

Background

RPSL’s are Ridge Pole Support Logs- their job is to hold up the Ridge Pole (RP)- the largest, longest, straightest, heaviest log in the entire build. They are very important logs, and must have no defects and be very straight. I estimate the Ridge Pole I’m going to use to be about 5 tons (for comparison, the heaviest wall log was around 3 tons). Vertical compression strength for a 12″ log averages around 650,000 lbs (about 325 tons), whereas the horizontal strength of a 12″ log averages around 20,000 lbs (about 10 tons) over a certain span. Sorry for all the math, but what this means is you can have very skinny looking RPSL’s, and they will still be strong enough for any RP.

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For a 40×40, the three RPSL’s are installed on three specially sized piers- 2 RPSL’s at the walls, and one in the middle. Before I poured the concrete, the inspector came out and he didn’t like the pier size specified in the plans. He wanted them one foot deeper in the ground (meaning one foot taller). He also wanted the RPSL to stand completely on the pier with no overhang. I did one better- I made them 5.5′ square on the base, and 5.5′ tall, and almost 20″ of support for the RPSL. They are about 2 feet in the ground. I estimate the roof at about 80,000 lbs. The piers on the plans should hold about 50,000 lbs each. I estimate my beefy upgraded piers at about 70,000 lbs each.

Getting ready

We looked at all the logs we had left and didn’t like what we saw. Julie wanted me to cut some new logs for RPSL’s. She found a reasonably straight tree, but when I cut it down, it had an awful (awful for an RPSL, but really good for a wall log) bend in it. After looking at it over and over, we decided to use it anyway. I found another tree for the second RPSL and cut it down as well. We will put the third RPSL up after the RP is installed. I was able to cut each RPSL and peel it in one night.

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It went well, except when I tried to turn one of them with my ‘can’ hook- stupid thing was so slippery from being freshly peeled that it slipped when I was turning it- it sprung back to its resting position, catching the arm of my can hook, and slammed it into my collar bone, instantly dropping me to the ground. I laid there in a daze for a few minutes before I was able to move. When I thought I could move, I felt my collarbone, thinking I broke it, but it didn’t appear to be broken. But the pain was so intense, I was light headed and thought I might lose my cookies. Luckily, I recovered enough to drive home, and was back to work the next day- but with an awful looking bruise.

 

 

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Installing the RPSL’s on a 40×40 is interesting- since we are building a two-story home, the top of the wall is 20′, and our roof pitch makes the final height of the RPSL about 30′. You can easily slide a 30′ RPSL under the house, and then stand it up on the inside. I hung a pulley from the wall at 20′, and proceeded to lift the RPSL into place. But the darn thing was top-heavy somehow, and I found I needed two additional pulleys to stop it from spinning like a propeller.

Another thing was the rebar coming up out of the pier that attaches to the RPSL was in the wrong place. It was a guessing game from the beginning: The 3 oversized piers have double duty- the two on the perimeter hold up the wall logs and also hold the RPSL’s. The one in the middle holds an RPSL and a girder support log (for the second floor support). Unless you use logs that are uniform in size (like telephone poles I guess), there’s no way you can know ahead of time where the center of the RPSL will be, and so you can’t know where to place the rebar into the pier when you pour the concrete.

The solution was:

  1. Cut the rebar off from the pier
  2. set the RPSL in place temporarily onto the pier
  3. measure where the RPSL will sit (you want it exactly perpendicular to the wall, plumb, and as close to the wall logs as you can get
  4. lifting the RPSL back up off the pier
  5. drilling a hole in the pier with a hammer drill
  6. squeeze the structural epoxy into the hole
  7. put a stick of rebar in the hole so that 12″ sticks out the top, wait  5 minutes for it to set up
  8. drill a hole in the bottom center of the RPSL where you marked it in step 3
  9. re-install RPSL onto the rebar
  10. re-check that RPSL is centered and plumb and lines up with the other RPSL
  11. check again just to be sure
  12. bolt RPSL to wall on every other wall log

 

 

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Since our wall logs are so tapered and crooked, the RPSL doesn’t butt up against the wall next to every log. So instead of settling for the ugly look of all-thread between the RPSL and the wall logs, another nice idea from the LHBA forum was to install black pipe in between the gaps, giving it a nice uniform look. It was not easy, but it was worth it. I may counter sink the nuts and washers and put nice plugs over the holes, but I can do that any time.

New tools

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world’s My longest drill bit

Drilling a 5/8″ hole through a 24″ log, and then onto another 20″ log presents another challenge- I needed a longer bit- like 48″ long at the minimum. I went to the orange box people – $75 for one of those! wow! I went down the regular drill bit aisle and found a short one for $12. Then I went over to the neighbor’s and welded a 4′ stick of rebar to the drill bit. I ground down the chuck end so it would fit in my 1/2″ drill. It worked very well- just had to back it out of the hole 20 times (flutes were too short to get the shavings all the way out). No matter, it wasn’t too bad, and went pretty quick- after I got my scaffolding in place.

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Yeah- scaffolding. Even though I don’t have temporary flooring in place and moving the scaffolding right now is a pain, the ladder is just dangerous for trying to drill horizontal holes – it’s usually too far away, or too close because of the angle of the ladder. The 13 amp drill I use can break your wrist if you don’t hold it right. Scaffolding will be invaluable when we get to chinking and a thousand other tasks coming up. And I got the scaffolding from California for about $600, including shipping. I love Craigslist.

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Next steps

I was going to go right onto getting the RP installed, but from what I’ve discovered, I should get my rafters ready before I call the crane. Yes, I’m calling in the big boys. I wanted to do this all myself, but a couple of realities have surfaced in my mind:

#1: I don’t want to die installing a 5 ton log 30′ in the air, balancing it on 2 RPSL’s. This is seriously heavy stuff. Yes, the wall logs were heavy, but not this heavy. Lots of things could go wrong.

#2: I would have to spend $260 on 2 chain hoists (I need some 5 ton hoists for the RP), plus $160 on 2 new 13,000 lb chains. That’s over $400. The crane guys say $130/hr, 4 hour minimum. That’s just over $500. I think my life is worth at least $100.

#3: I can probably get the RP and all 28 rafters installed with a crane in about 4 hours. If I do it myself, I figure a couple weeks getting the RP supports in place, and about a month to get the rafters up. Saves me a month of work, for just a little extra $$$.

We are nearly out of trees that are straight enough for rafters, so I talked to one of my neighbors- she’s letting me have probably a dozen more trees from her 5 acres for my rafters, if I bring her a plate of stuffed lasagna shells my wife made.  I think there are probably a dozen (trees, not stuffed lasagna shells- stay with me) on my property, and probably about half a dozen on the next door property. I just have to cut them, move them, rack them, and then mill them into 4×12’s (work= yes, but I don’t have to peel them – yay!).

Stay tuned. I’m sure there will be a video of a crane and a 5-ton log flying over my house in the near future….

 

 

Cap Logs Installed!

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Our cap logs are installed- this means we are almost ready to enter a new phase of construction. It has been a long hard road. Some folks at LHBA claim we are moving at “one gear below breakneck speed” using our lifting poles, but it often doesn’t feel that way…

What are cap logs?

Cap logs are the final logs on the walls. In the photo above, they are the ones that stick way out on the front of the house. Paired with ‘double-butt logs’, they hold up the roof rafters, and give the roof enough overhang to protect the wall logs from rain. In a kit log home, they usually don’t stick out much, but for a butt & pass log home – with an expected lifespan of 350 – 450 years – they are a major part of that lifespan.

Notes on installation

Our plans are for a 40’x40′ cabin. The overhangs on the roof protrude out 7 feet past the walls on the gable ends, and about 4 feet out on the eave side. This means the cap logs have to be 7’+7’+40′ = 54′ long. Also, they need to hold up the roof rafters, so my goal was to make sure they were 12 inches minimum on both ends. With our tapered logs – this meant that the butt end would have to be absolutely huge to ensure at least 12 inches at the tip. This would also throw off our level layers (all 4 corners should be the same height).

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The solution I came up with was to take two normal sized logs, splice them together and put them up as one log together, and let the butts hang out over the ends.

Easier said than done. How do you lift half of a log when the lifting poles are in the corners? In other words, how do you hold up a log in the middle of the house where there are no lifting poles? Easy (not easy)- you chain both together and lift them at the same time.

Although I could have (maybe) installed a temporary center lifting pole- this would take a lot of energy and time- I would basically need a 30′ lifting pole (the size of an RPSL) installed. It would need to be chained to the wall, along with pulleys, etc. Lots of work for something I would use once. So I decided to try everything else before this idea.

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Using a cradle (suggested by Plumb Level), we were able to “safely” hold the logs in place while we pinned them. I won’t go into the details (unless someone is dying to know), but there were a lot of scary moments- like once I got the chained logs in place, I had to remove the unused portion of each log- this involves cutting the excess of the log, and hoping the desired portion just falls into place, with no way to chain it or support it until it was in place. The cradle helped a lot, but there were no guarantees.

Some unlucky (and funny) events from Course 13

First there was the “pinned boot” incident:

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There was a gap in the log I was working on. I was perched up on top pinning it into place, and my boot happened to be placed right where the pin was coming through. Once they go in, they don’t come out. It didn’t pinch my foot- just the edge of the boot- and tight enough that I couldn’t get my foot out. I was stuck. I called for Julie’s help. Now she is not normally one to climb ladders of any size, but she courageously started to climb. She was clinging to the ladder like she was a thousand feet off the ground. I kept encouraging her and she finally climbed up high enough to hand me my crowbar, and I was able to loosen the pin just enough to free my boot. LHBA folks suggested I just leave it there and chink around it, ha ha! ……No.

We had this log that was the right dimensions, but had a nasty hook in it at the tip. No matter how we rotated it, it wouldn’t lay flat. We decided to pin it anyway, and just deal with it later. It ended up being flat most of the way, until about 6′ from the end where it had this big bow in it. Since that corner (NE) has been historically low, we decided having the extra height in the corner would help get the height back up to where it needed to be. But since you can’t accurately measure the height on an odd row, we’d have to wait until layer 14 to find out if it was helping or not. And it is: before the cap logs, our heights worked out great- starting at the NE corner and going clockwise, we have 17’8″, 17’8″, 17’7″, 17’7″. For non-builder types- this means the East and West sides match each other exactly for height, while between the two sides, we are off by 1 inch. Remember- this is all using tapered crooked logs with knots and bends- a real testament to the Butt & Pass method.

And the burned out motor on the drill incident: It is a Black & Decker 1/2″ drill that didn’t really want to drill 300 holes, but it held up for the most part, and then just gave up with the drill bit lodged 12″ down in a log.  So I left it stuck up there; “sword in the stone”-like, for the weekend. I figured more power to the idiot who decides to try and steal it. There were no takers.

And five minutes later, the “what the heck happened to the jack hammer” problem: it just lost power in between pounding rebar. I took it home- I guess all the vibration and the weight on the cord from being up so high pulled its guts loose from the switch. I put a new clamp on the wire, taped it in place, and then put the handle back on. Then I taped the cord to the handle on the outside to alleviate some of the stress.

What’s next

The final height of our cap logs determines the final headroom height at the top of the stairs, since they are on the eave side of the house up against the wall. It works out to be (starting at the NE corner and going clockwise): 18′ 4 1/2″, 18’6″, 18′ 5 1/2″, 18′ 4 1/2″. Pretty good.

Now we finish with double-butt logs – these are not logs with 2 butts on them- they are logs that, instead of being normal “butt and pass” logs, are just logs that butt up against their neighbor logs on both ends. In this case, the logs they butt up against are the cap logs.

After that, we begin the next phase: installing the RPSL’s (Ridge Pole Support Logs). Two of these get bolted to the walls. Along with one in the middle. They are 30′ tall, and they hold up the Ridge Pole – which holds up the rafters and the roof.

The Ridge Pole is a monster sweet gum tree from our woods. It is by far the biggest heaviest longest and straightest log I’ve ever cut down. So far, it has evaded me being able to move it. But it won’t for long.

We also need to commit to a height for our girder log. This log spans the width of the house and holds up the 2nd floor. It also ties the East and West wall together so the rafters don’t push the house apart. It provides the “rigidness” that keeps the house tight. At least a little.

I don’t want to think too far, but I’m hoping we can get the roof on this summer.

We had a lovely visit from some LHBA members- Gary (Mosseyme) from East Tennessee came and looked one day in the rain and gave me a lot of good tips, and encouragement. Also, ‘Sdart’ on the LHBA forum- Sara and Rene were very nice and came out to see our progress. They are building in extreme Northern Idaho in an off grid location. They have been to many LHBA homes over the years all over the country and Sara told me, “even after looking at pictures, these homes are always impressive in person.”

I’m back on WordPress…

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Just finished peeling the very last wall log! Yay!

Hi everyone- I thought I had made my last post and was moving over to my other blog on google-owned Blogger. But with all the censorship over gun videos on YouTube (owned by Google, and they also own Blogger- where my new blog was going to be)  –  I’ve changed my mind again. I’ll explain…

The problem is that I have principles that I support – like freedom of speech- that are being attacked by the sites that host my videos and the other blog. They are now refusing to allow videos that show how guns are made and how to reload ammo. You may think guns are evil. That’s ok. But should they censor that content? Be careful- something you believe in may be censored eventually. I understand censoring child sex trafficking videos. I don’t understand infringing on the right to keep and bear arms by an American company.  Remember, they didn’t become so fabulously wealthy by opening their doors for business in some other country — they became fabulously wealthy here, in the U.S.A.. They live, do business in, and benefit from a country that protects their right to free speech and association.  And now they want to pay back the citizens of this great nation by censoring law-abiding individuals they disagree with? It’s like they are fighting against their own mother.  It’s un-American. Who does that?

The question for me is: should I allow YouTube, who is busily engaged in censoring “speech” that it doesn’t agree with, to make money off of my videos? They aren’t coming after me, so why should I care? Maybe they will. Maybe staying out of debt will eventually become hate speech.  I made a mistake, I think, in going over there to the dark side of blogging. I apologize. I didn’t think it had gotten this bad.

So I’m back to WordPress. If you like what you see, sign up to receive emails every time I post.

Progress of the build

 

Last weekend, I got the tractor stuck in the mud trying to move the 8,500 lb ridgepole, followed by getting the Landcruiser stuck in the mud to pull the tractor out. I called the neighbor who brought his loader over and pulled both of them out. Later the same day, Julie got some great video of me spinning my wheels again while we put up log #47. In the video, the log got stuck between two logs after it broke the 2×4 that was supposed to prevent it- a very frustrating situation.

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Today, I got my Honda Civic running again. My theory on what broke it: the crank position sensor got fried, causing the injectors to flood the engine with gas, washing the oil out of the cylinders, and causing complete compression loss. After replacing parts and letting two tablespoons of oil soak in the engine overnight, it sputtered back to life. Later, we went to an Easter Egg hunt in Hartselle:

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After the Easter Egg hunt, we decided to take the long way home and drove by the cabin. I finished pinning some logs, and then we decided to go ahead and put #48 up there, but didn’t pin it. We need to rotate it and pin it.  Julie counted the logs we have left and did some measurements- We are pretty sure we need 56 logs to complete the walls- fourteen layers. With #48 up, we have two layers or eight logs left.

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New blog location

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First tree

This will be the final progress post on loghomejourney.wordpress.com. New blog posts will appear on https://bawh-blog.blogspot.com/

Two years ago, I attended a class in Las Vegas, Nevada, taught by Ellsworth, son of Skip Ellsworth, founder of the Log Home Builders Association.

Soon after taking the 2 day class, my wife and I bought some land, and started cutting trees in preparation for building our log home.  Yes, they really can teach you everything you need to know to build a log home in 2 days, and they’ve taught thousands of people over the past 50 years how to get out of debt, gain more financial independence, and pursue their own version of freedom. Most people know the method Ellsworth taught by its common name, the “Butt and Pass” method.

untitledWe spent about a year cutting trees, drawing up plans, burning brush piles, and breaking lots of equipment along the way. I learned how to use an AutoCad program to modify my plans. I took the stock plans, and, using the computer, deleted all the interior walls, but left the structure intact, and after 30 or so iterations of the plan on paper, I re-drew and submitted our plan to the city and utilities for approval. Once the plans were approved, I applied for utilities, and we began digging a foundation.

20170412_182827_zpstlj2py88I learned how to survey a building site from my neighbor, a retired surveyor (and retired from a lot of other professions as well). I built plywood forms to hold the concrete. My wife and kids all came to help the day we poured concrete.

Using the traditional method as taught by Skip, and with a lot of help from the guys at church, we installed lifting poles and block and tackle, and laid our first log on June 15, 2017.

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More logs followed, and we are now about 4 courses (16 logs) away from reaching the finished wall height of 20 feet. At that height, we’ll be ready to install the Ridge Pole Support Logs (RPSL’s), and Girder log (GSL), and finally, the Ridge Pole itself- the largest, heaviest log, and also the highest log- at the peak of the roof line, 30 feet high.

While I like the format of WordPress, I’ve noticed a lot of formatting and code restrictions that are somewhat frustrating. As my blog grows and we finish building our log home, we will move into other areas of interest- gardening, building the garage, bees, chickens, woodworking- and I want to get into discussing old fashioned methods and tools. My wife has also posted some beautiful instructional videos regarding her passion- sewing- on our Youtube channel. Once we move into the log home, I’m sure we’ll continue the journey of independence. I am also slowly moving the original posts on this blog over to the new one.

Please sign up to be notified of our progress on https://bawh-blog.blogspot.com/

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Shipping Container

I thought the process of getting a shipping container would be straightforward, but like everything else, it was quite a stressful adventure.

How to store your stuff

From the beginning, we’ve worried about our stuff getting stolen. So far, I’ve lost a critter cam that was aimed at my tractor, some gas cans, some tow chains and two chain binders. I think it’s a theft of convenience. Our property backs up to some woods, and the woods back up to someone’s backyard, and beyond that is a trailer park. Our neighbor says that people have been walking from the trailer park through our property and on over to another neighborhood. I think some of them are thieves looking for easy pickings, but I can’t imagine the use of two chain binders, unless you’re a trucker or building a log home.

Many folks build a garage as their first project. Then they store their tools while they build their house. I wanted to build faster so we could move there ASAP. I considered building a shed, but that would require a permit and a foundation. A fence would only stop people who can’t climb. I needed something I can lock. We are at the point where we have some expensive stuff about to be left overnight- like a sawmill, and building materials.

I’ve seen ads for shipping containers for years, but they can be a little pricey in my estimation:

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All the ones I’ve seen for under $2,000 are also 20′ long or less. My plans call for 26′ rafters, so I needed at least a 40′ shipping container if I was going to use it for storing rafters.

I need 32 rafters, 4″x12″, and 26′ long. The shipping container is 8.5′ tall and 8.5′ wide. I can get 12 in a row in a space only 3′ wide, and then stack them 3 levels high, and still only be in a space 3′ high. Plenty of room for spacers to help them dry a little.

I’m starting to find some deals on rigid foam roof insulation, but I need somewhere dry to store 3 trailers-full of the stuff. I need stacks of plywood and car decking for the roof.  I expect to store hardware like joists, nails, screws, wiring, plumbing, and on and on in there as well. I can also put the sawmill in there, as well as the tractor, and all my tools. Currently, I store them in the neighbor’s garage. It would be nice to have everything on site.

I also like the idea that it can be locked tight, and that it weighs 8400 lbs empty, and takes specialized equipment to move.

Finding a shipping container

I’ve been watching craigslist for a while. Then this ad for a 40′ container popped up:

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I went to look at it. It was a 2 hour drive south of here. It looked nice and solid. The day I looked at it we received 4″ of rain. Inside was nearly dry- just a tiny pinhole leak near the door. I believe I can seal it with some silicone patch. I offered him $800 for it, and he accepted.

Dealing with shady individuals

That’s when the fun started. He wanted to drive up to Huntsville to meet me late one night while my wife was at the movies with the kids. At night. I was thinking, “wait, I give him my money, but who’s to say I can pick up the shipping container?” Maybe he found it while he was out driving, and knowing that it had been there a while, he just snaps a few pics, and tries to sell it. Maybe he sells it to me today, sells it to another guy tomorrow, then another guy on Friday, and whoever picks it up first wins? I discussed with my wife. She felt very uncomfortable with the whole thing. I started having a bad feeling about it too. But the price was very good.

I called a dozen wreckers and moving companies- no one could move it for a reasonable price. The container dealers don’t like moving containers they don’t sell. No one else had anything big enough to pick it up. One guy said call another company, who said to call a container company in Decatur, who said to call a wrecker company in Hartselle. The Hartselle company said they could do it for about $650. I thought that sounded reasonable.

But how to coordinate with the seller? I didn’t want to give him my money without getting the container. He seemed ok with me getting the container first and paying for it later- but was too relaxed about it- more suspicious behavior.

He agreed that I could pay him when I came to pick up the container on Tuesday. Then he called on Friday, and he was saying someone else was interested who would pay full price, but if I wanted it, he would give it to me for the price I offered, but I had to buy it now. I had to decide if it was a scam or not. Julie was livid. She thought it was a total scam, and said to call his bluff. I was so wrapped up in the idea that “this is the one”, that I couldn’t think straight. If this worked out, we would be saving $1000 over the other containers I’d found. Julie said there were some conditions he had to meet if I was going to buy it- I had to see his drivers license, and also go inside his house or business and see that it was a real place. I agreed and drove an hour to meet him at his “office.”

Stress for the holidays

He said he had a business license, and if I wanted to see it, I could (so Julie would feel more comfortable with the deal).

He met me in a gas station parking lot in Albertville, then had me follow him on a winding road where I lost cell signal for a little while. I was on the phone with Julie giving her a physical description and his van’s tag. If you think I’m over-reacting, just google how many people get killed answering a craigslist ad. Suspicious behavior checklist: meeting at night? check. meeting out on the end of some winding lonely road? check. Giving money to someone but not receiving the item you paid for immediately? check. Seller has a sad story? check. Seller forgot to bring his drivers license with him like he agreed to do? check. Can’t see the business license because the business is closed unexpectedly? Check. Meeting in the parking lot of the supposed business instead of going into the business? Check.

I took a breath and paid him. Then stressed out for the holiday weekend. With Christmas on Monday, the tow company couldn’t get it until Tuesday, they said, so call them on Christmas Day to arrange delivery for the next business day. I did that, but the driver who picks up containers had Tuesday off, and it wouldn’t be until Wednesday.

I didn’t want to drive 2 hours to find out the container was gone, and then still have to pay the towing company, so Julie suggested I go out 3 hours ahead of the towing company and make sure it was there before I dispatched them to come get it.

There was a Days Inn next door to where the container was parked. I called them on my way and asked if they could look out the window and tell me if a big orange container was still there. The lady answered and said, “No, there is nothing next door.” I freaked out. I still had an hour to go before I could see for myself.

Things work out ok

I finally rounded the last corner- and there it was- still there. Whew. I knitted while I waited for the tow company. The guy showed up and we had no problems getting it loaded. He said he didn’t have to use log books because federal law doesn’t require them for trips less than 100 miles. He said he was 95 miles from home. He was doing this move, and going home afterwards.

He followed me to the property, and we got it unloaded. I had previously measured the driveway- 20′. The road was also 20′. He said he could make it. It worked out ok.

Now to get some heavy duty locks, and start storing stuff in anticipation of getting the roof on.

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