Project Roof: Week Three

This week I will be sharing both the Week Three and Four updates. Week Four quickly became overwhelming and I just didn’t have the energy or even the electricity to write up a post. I explain all the dramatic details about it on Saturday, but today let’s rewind two weeks to the third week of Project Roof.

1) Preparation – two three weeks

  • Remove pergola on back patio
  • Removing the 3′ addition on the front of carport
  • Add additional support in carport
  • Repair porch overhangs
  • Prune bushes and trees away from the roof
  • Remove remaining ceiling in our Great Room
  • Replace all our fascia
  • Fix our skylights
  • Prep plumbing
  • Put up plastic sheeting in the house to prevent debris from filtering down
  • Get the cats anxiety drugs

2) Tear off the existing roof – two days

3) Interior work – one week

  • Update our electrical lines to code
  • Replace and repair decking & soffits
  • Insulate the rafters
  • Rework our water and gas pipes so they run more efficiently
  • Installing a tank-less water heater
  • Prep the ceiling for our kitchen remodel by installing new range exhaust system and new electrical plugs
  • Install new exterior plugs for holiday lights, etc.

4) Roof install and Finishing – 3 to 4 days

  • Install fireproof base layer
  • Install insulation layer
  • Install thermoplastic polyolefin (TPO) single-ply roofing membrane
  • Install any vents that are needed
  • Install shingled roof on our addition
  • Install drainpipes
  • Finishing the plumbing on top of the roof
  • Install can lighting in the great room
  • Install sheetrock in great room, plaster and paint it

Project Roof: Back patio

The week started off well. Jim finished the porch overhang work and boxed the corner adjacent to our bedroom so we wouldn’t have future moisture issues (or paper wasps!) in that corner.

Project Roof: Master Bedroom Fascia

Next he replaced our sloped roof fascia board and started pulling off the shingles. The guys quickly found a soft spot in the corner where water had accumulated. We will add that to the decking that needs to be replaced.

We met with our plumber Larry to finalize his part of the project. We talked through the tankless water heater install as well. He gave us a couple of models to research. We want a 8 gallon tankless that has a built-in re-circulation pump. This will keep the hot water moving in our pipes and speed up the transition to hot water at any of our faucets. We are installing it on the outside of the house near the laundry area so it will be able to be hooked up to the gas pipes that heat our dryer as well. We played with the idea of installing the tankless in the middle of the house, but we really don’t have room and outside it will be fully accessible.

On Wednesday, we also got word that our roof removal was moved up to Friday (October 10th). This was great news except we had a ton of work to do inside the house to prepare.

Project Roof: Taking down the twinkle lights

I started by taking down the twinkle lights in the great room. The process was a little bittersweet. We loved having these up and rarely had a night without their pretty glow since I put them up last year. But by taking them down, we are getting an insulated roof plus a brand new ceiling and lighting.

Cat's Anxiety Pills

I also picked up anxiety pills for the cats. They each get a 1/4 to a 1/2 a pill to “relax” them for 8 hours. We are definitely giving them meds when they tear off the roof. I’m not sure what we will do next week yet.

Project Roof: Covering the furniture in plastic

Then Nate and I attempted to lining our ceilings with plastic. We expected a lot of dust, gravel and random debris to fall through the ceiling board as the roof was removed. We wanted to protect our belonging as best we could.

Unfortunately, I bought the heavier plastic sheeting that was impossible to put up without a staple gun. We started installing the sheeting late Thursday night and realized we had no staples. We tried tape which didn’t work so we decided to just cover the furniture and hope for the best. In the great room, Nate nailed up the plastic sheeting on our rafter boards. We had to cover that are since we knew a lot of debris would fall into the room without a ceiling.

Project Removal: Deck removal

I was told to expect the work crew at 7:30am on Friday, but they had already started when I drove up to the house at 7:15am from the gym. Luckily Nate had already given the cats their meds before leaving for work and I had thought ahead and showered and laid my clothes out for work the night before.

The removal was so loud and actually quite scary. I quickly got ready for work and got out of there. The cats would not have been able to handle it without meds.

Termite text from Nate

Later that day, Nate send me this text message. I got home expecting the worst, but the termite damage seemed to be contained next to the fireplace. We had a good idea we may find more in this general area after the Bath Crashers project so this wasn’t a huge surprise. (Bath Crashers replaced all the damage in the bathroom, but was not required the find the full extent of the damage that extended past our master suite.) Regardless, it was an additional amount of work for Jim to fix.

Project Roof: Great room mess

In the great room, the moldy patch of decking was gone. We think someone may have fallen through the deck there. The rest of the plastic sheeting was holding an enormous amount of gravel and debris that fell when the roof was removed.

Project Roof: Nate cleaning up gravel

Because it was a little precarious and the fact our stupid cats kept jumping down into it, Nate used the shop-vac to clean it up later that night.

Project Roof: Decking

Here’s the what the roof decking looked the next morning. As you can see, many of the planks were damaged in one way or another. The whole deck was soft to walk on and you had to tread pretty carefully to avoid all the pitfalls.

Project Roof: Removing decking

We had grand plans to remove the deck, clean the bays and install installation ALL over the weekend, but by Sunday evening, we had finished removing the deck and half the insulation with help from my uncle Terry, cousin Moses and our friend David. We actually paid both boys to help as an incentive – and it was totally worth it given all the work they did. (We just paid Terry in food, beer and bear hugs.)

Project Roof: Deck removal

Doing the deck removal ourselves was a tremendous amount of work, but it did allow us to move to get the electricians out on Monday which was the whole point.

Project Roof: Nate's hole through the roof

Unfortunately poor Nate did have a couple missteps over the weekend including busting through the sheetrock in our hallway. Luckily he didn’t hurt himself badly – just his dignity as my dear cousin Moses stated.

Project Roof: Deck removed

Here’s what the roof looked like with the deck completely removed. You can see found insulation in the main house which was a major surprise. There is also a bunch of gravel that overtime accumulated from the roof.

Project Roof: Pile 1

Here’s our giant pile of decking and insulation in the front of the house.

Project Roof: Pile 2

And here’s a sneaky photo of David working on organizing the back pile. There’s a lot more deck work coming up – and I’ll go in great detail of what we found as well. Stay tuned.

Project Roof: Week Two

Project Roof: Carport structure goes in

Let’s start with an update on our project’s timeline because our timing has increased slightly.

1) Preparation – two three weeks

  • Remove pergola on back patio
  • Removing the 3′ addition on the front of carport
  • Add additional support in carport
  • Repair porch overhangs
  • Prune bushes and trees away from the roof
  • Remove remaining ceiling in our Great Room
  • Replace all our fascia
  • Fix our skylights
  • Prep plumbing
  • Put up plastic sheeting in the house to prevent debris from filtering down
  • Get the cats anxiety drugs

2) Tear off the existing roof – 1 to 2 days (moved back a week due to scheduling)

3) Interior work – one week

  • Update our electrical lines to code
  • Replace and repair decking & soffits
  • Insulate the rafters
  • Rework our water and gas pipes so they run more efficiently
  • Installing a tank-less water heater
  • Prep the ceiling for our kitchen remodel by installing new range exhaust system

4) Roof install and Finishing – 3 to 4 days

  • Install fireproof base layer
  • Install insulation layer
  • Install thermoplastic polyolefin (TPO) single-ply roofing membrane
  • Install any vents that are needed
  • Install shingled roof on our addition
  • Install drainpipes
  • Finishing the plumbing on top of the roof

Project Roof: Week 1 End

Here is where we left off last week with the carport structure upgraded.

Project Roof: Carport Week 2

This week, Jim added the new 2×10″ fascia to the full parameter. One early decision we made was to upgrade all the fascia from 1×10″ to 2×10″. It’s the one piece of the roof that will be visible so we felt it was an important splurge. And yes before someone asks, we are saving as much wood as we can for other projects.

Project Roof: New fascia

Jim hung the fascia slightly lower than the original which gives it this nice clean line compared to how the fascia and soffit boards used to meet.

Project Roof: Back porch overhang

He also began to work on our back porch issues. Our back overhang has always been an eyesore. It leaks water during the rainy season and sags miserably.

Project Roof: Back porch overhang

We’ve always wondered why it sags so badly and it was great to finally get the answer. This part of the overhang (different from all the rest on the house) was built to collect water and have it drain down one drain pipe. The rafters were an inch shorter (2×6″ instead of 2×7″) than the rest on the house which allowed the water to collect here. I am certainly not an expert on drainage, but what I do know is overtime this section of the roof became a sponge because the concept didn’t work.

Project Roof: Back porch overhang

On top of that, the original beam that ran the length of the overhang, was not secured correctly to our master bedroom wall (see above). Instead of sitting the beam on top of the studs in the wall, it was just secured to the plywood. Overtime, because of both of these decisions, the overhang began to sag even more. When Jim removed it, the middle was 4″ lower than the sides.

Project Roof: Back porch overhang fixed

To fix the overhang, Jim replaced the beam that ran the length of the porch. He sat it (correctly) on the studs in the master bedroom wall and built up the support on the opposite side as well. Next week, he will replace the rafters as well.

Over the weekend, I finally pruned back our lemon and kumquat trees to give the guys a little more room to work as well.

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General Thoughts

It’s been great to see the fascia go up. I am so happy we went with the 2×10″s instead of the 1×10″s that were originally used on the house. These thicker boards give such a nice finished look to our roofline.

And I can’t talk enough about how different the back porch looks. Straightening it out just has changed the feel of the back porch. I know that sounds dramatic, but its like someone with bad posture compared to someone standing straight. It completely changes the porch’s demeanor.

Project Roof: Backyard setup

Next up

Our roof removal has been scheduled for Monday, October 13th which is a week later than we had hoped for. There was a bit of negotiating that had to happen on the price before we could schedule, but we are happy with the final outcome even if it’s a little later than expected.

Next week, the back porch and fascia will be finished up so we are all ready to go with the removal.