Since the beginning of this project, stuff has been breaking: Logs are too heavy, I do dumb things, money is tight, I have another job, etc.
My whole life, I’ve been working in jobs where I see areas that need improvement- more efficient methods, outdated standards, etc, and every new job I get, I try to implement changes that are more efficient. I guess my whole life has been one of “process improvement”:
I had this old Nissan Sentra my grandma sold me for $1.00. It had been through several cousins as a starter car. Finally came to me. One time, I was driving it home late at night from work while I was struggling through college and the lights went dim. When I looked under the hood, I found the belt to the alternator was loose- the tensioner bolt had fallen out. I looked in the trunk for something to brace it with or an extra bolt- and found an old screwdriver. I jammed the screwdriver in there, and I meant to fix it, but a few weeks later, the clutch went out on it. I got it to a mechanic, and when I came to pick it up, he said, “Oh, by the way, while we were in there fixing your clutch, we found this:” <holds up screwdriver>.
They start laughing. “Yeah, we fixed it for ya.”
Hopefully, I’ve come a long way since those days (baby steps). Building this log home, I’m improving my methods as I go, but there are some set-backs.
Logs are too heavy (Process improvement)
This is a given. The logs are always too heavy. I can’t stress how dangerous this is. They are very heavy. Tractor can’t lift them, so I have gone through several improvements:
- 2 tractor jacks- one on each side of the log. very unstable. Tend to “max out” at just under the height needed to get the log on the trailer.
- lifting tripod made out of large branches: works pretty good- very heavy, hard to set up.
- a trailer- works pretty good. very heavy, hard to maneuver to get it under the log- usually has to be maneuvered by hand- can’t always get tractor involved with tight turns that might bump the log while it’s hanging in mid-air and knock everything down.
- a log arch attached to the trailer….and a broken finger, so…
- ….log arch NOT attached to trailer…so far so good…
“Why don’t you use smaller logs?”
It’s a thought…That I don’t have. Go big or go home. Because Manly.
OK, seriously- a log home made out of 12″ logs has been proven to be at least twice as efficient as a home made from 2×4’s in a standard fashion. Most log home folks report paying 1/3 the cost in AC/heating costs as they did in their “stick-built” homes. The logs I’m using range from 14 inches to 27 inches. I’m expecting a cheap utility bill when this is all said and done.
There’s also the artistic factor: Big logs are inspiring. Look at the two homes below:
Which one has the “Oh…wow” factor? Yeah. I thought so.
The tractor is kinda light
I think the tractor must weigh in at about 3,500 pounds. The logs are probably about 5,000 + lbs. In a tug-o-war, the logs sometimes win. I’ve broken the tractor a few times:
- broken steering column
- broken pins on three point hitch (several times).
- bent the 3 point hitch mounting points.
- broken front grill, smashed front cowl
- flat tire on rear (I’m suspicious that it came that way as a slow leak that got faster with use).
- broken/stripped out lift arm screw – right side
- broken/stripped out lift arm screw – left side
For #6 & #7: 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.
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?
I do dumb things:
Did you know that you can’t interchange a 80-link bar on a chainsaw with a 72-link bar? Yeah, I got bad advice: “just change out the bar”. They forgot to mention the drive sprocket aligns with the links on the chains. For a few days, I couldn’t figure out how the teeth on that sprocket got all chewed up. Now I know, and I now have a new drive sprocket on order from Ebay for my saw….
Money is tight:
This was part of the plan- do the build super cheap. With unlimited funds, I could build this thing in about 3 weeks. With no funds, I can’t build it at all. With some funds, I can afford some equipment, but not the expensive kind, so the build timeline is in between 3 weeks and forever. I’m going for 2 years…
Without a lot of money, I’ve got to stick to being innovative – do more with less. Lesson from class:
You can only pick two. I guess I have to pick #1 & #3. Which means any cool trick I want to try has to be cheap and good, or forget it.
I have another job:
Believe it or not, I work full time as a support engineer (no, I’m not usually the white collar guy with pink hands, so this is a huge career improvement for me- usually, I’m crawling under raised floor panels dragging some CAT-V cable). Yes, this affects the build: I’m trying to hurry as much as I can because of my limited time to build. There are those in our organization who only work on their cabins for 4 weeks out of the summer. Then there are those who do it for a living. I’m in the “do it every night after work” group. This creates problems of being too hasty:
- Like the time I came within five feet of smashing my tractor while felling a tree- I was in too much of a hurry before it got dark to go grab my 60′ cable. So I used my 20′ chain to hook it and pull instead. I had to dive off the tractor as the tree came down. Luckily, the tree missed. You can’t really get away from a falling tree while chained to it with a tractor. Whew.
- Borating the logs before the bugs get to them: I have to make my brew on the weekends. I was using a “rocket stove” design on my cinder blocks for the fire. I changed it this weekend to a new design with more airflow. Process improvement? yes: the first way of cooking, the brew took 3 hours. This time, it took me 1 hour.
The conclusion is: Stuff breaks. Lessons?
- Learn how to fix it.
- Process improvement.
- Focus on the task at hand.
- Figure out what isn’t working, what is working, and the difference between the two.
#1 and #2 are my bright spots. #3 can be hard, but if I get ahead of myself, really heavy logs bring me back to what really matters at the moment. #4 is where I get stuck, believe it or not- it’s good to be married to a level-headed woman: whenever I get harebrained ideas like: “I know- let’s buy a 1 ton truck to drag logs around,” she straightens me out with “what you’re doing is working- you just need to stick with it.”