Project Roof: Week One

Project Roof: Original Carport

Hello and welcome to Project Roof! I cannot begin to tell you how excited we are to get this project started. It’s been so long in the planning.

The first construction project was removing a poorly designed extension to our carport. This part is not original to the house and overtime begun to sag at the seam. We decided to remove it to cut down on our roof square footage and to restore the carport to its original length. Eventually we plan on making it into a proper garage, but that’s something we will tackle later on. For the present, we wanted Jim our carpenter, to just remove the extension, repair the overhang structure, any major dry-rot he found and add new posts to the front that were actually cemented securely into the driveway.

Project Roof: Side view of carport

Here’s the side view so you can see the full extension better. Our best guess is that the old owner may have had a Cadillac to want the carport extended? Who really knows…

Project Roof: Carport sagging

From the opposite side, the sagging and dry-rot along the seam is pretty obvious. You can see a gap along the side where the boards have rotted and warped.

Project Roof: Removing the extension

Jim removed the extension and fascia along the entire roof line. This allowed him to get a good look at what was holding up our carport and overhangs. He found that our carport structure was pretty flimsy especially along the front and side. The photo above shows the replacement wood he added along the front of the carport.

Dry-rot on the carport

Here’s a bad photo of the dry-rot boards. Jim told me he also found a giant rats nest which he very nicely got rid of without showing us. All the damaged boards were replaced and Jim added extra support that was missing from the structure especially along the side.

Carport supports

He also dug and cemented new posts for the front of the carport. These guys won’t budge which is a good thing. The last set was not secured at the base and I’ve always been worried I might nudge them with the car.

Project Roof: Week 1 End

At the end of the week, the carport structure was done. Doesn’t the roof line look better? I am so happy with it.

General Thoughts

I thought the first week went really well. We not only got the carport part moving along, but we signed our roofing contract.

Jim was able to a take a look at the roof deck when he pulled off the fascia. He thinks that most of the deck (the layer of wood sitting on the rafters) will need to be replaced. From what he could see, there was a lot of mold. To combat this in the future, we plan on adding vents to the underside all the overhangs to prevent moisture buildup.

Our biggest decision this week was who would subcontract our the roof removal – Jim or the roofing company. In the end, it made more sense to have Jim do it so he could begin working on the dry-rot. Unfortunately since Sacramento got a little rain this week all the roof removal companies are booked up for the next couple weeks. A little rain apparently bring roof hysteria in these parts. We are still waiting to find out when we can schedule the removal, but are hoping it will be next week.

And finally, the cats. Loki has spent a large chunk of the week in our clothes closets hiding from Jim. He seems to be okay in the evenings, but I am still going to call the vet to see what I can do for him when there is a lot more activity on the roof. Pixel, of course, is absolutely fine with the work so far.

Project Roof

Project Roof

Project Roof is on!! Can you believe it? The much-anticipated new roof is coming!

Contracts have been signed and our loan will been funded this week so we are legitimately ready for this. We have hired a carpenter, electrician, plumber and a roof company so far on this job. We still need to find someone to do the insulation or decide to do it ourselves.

As I have reported before, our flat roof is more complicated than your average sloped roof because all of our utilities run on top of it. Plus, our ceiling is tongue-and-grove so we have no access to the interior of it. So, we are taking this opportunity to update all our existing utilities (electrical, plumbing and insulation) from the top down.

Instead of writing up a tutorial type post for this project, I am going to give weekly updates talking about the scope of the work and what assumptions/goals we’ve made for each part of the project. Then I’ll report on how the project moves forward, what pitfalls and surprises we find and our general thoughts on how it is going.

Scope of Work + Estimated Timeline

Project Roof is going to be broken into four major parts so we can address all of our issues. The timeline is estimated based on what we can assume with the scope of work. We have scheduled our carpenter for the next two weeks to start and are working on scheduling the rest of our vendors right now.

1) Preparation – two weeks

  • Remove pergola on back patio
  • Removing the 3′ addition on the front of carport
  • Prune bushes and trees away from the roof
  • Remove remaining ceiling in our Great Room
  • Replacing 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

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

General Thoughts

I am really excited to get moving on the roof. I am sick of looking at moldy rafters and worrying about leaks.

I am worried about all the moving pieces and scheduling the contractors correctly. I don’t want to have an open roof longer than we need.

I am excited to work on projects we have put on hold until the roof got fixed. Our prison bath has been on hold for over a year once we realized the ceiling had issues.

I’m also worried about the amount of money we are spending on the roof, but know we’ve done all the research necessary. Plus, we are getting so much done in this project that will greatly improve our home.

Regardless of my feelings, I am so ready for this. Let’s do it!

Next week, I go over the first part of the project and what progress has been made. Yahoo!