A Virtual Second Look

This is another video walk-through of the new house, to show progress since the first one.  This one includes the new siding, electric, plumbing, lighting, and A/V wiring.

 

Scatter-Brained and Over Budget!

I woke up the other day and couldn’t believe I still live in Hoboken.  I was supposed to be out in late 2016 in my worst-case scenario.  Yet, as I headed into year three of the construction phase, the light at the end of the tunnel is beginning to show.  Progress has been taking place at a rapid clip, and it’s a lot of fun to watch the house get built.  It is a fascinating process that I never knew anything about until now.  I’m also getting to make more and more decisions about how I want it to come out.  The questions are coming my way fast and furious from the contractors and it has made me a bit scatter-brained, but this is the fun part and I’m certainly enjoying it.

Homemade Japanese Siding

The siding project took an interesting turn, and unfortunately set the project back a few weeks, and of course jacked up the price!  I recall asking my architect early in the process what the siding on the front of the house was supposed to be, I couldn’t tell from the renderings he showed me.  He muttered something about using “charred cedar planks” and I didn’t think much of it, assuming that we could just go to the lumberyard and buy some.  I turned my attention towards other aspects of the project and didn’t ask about it again until the framing and roof were done.

As it turns out, I should have asked more questions a lot sooner in the process.  As I mentioned in my last blog post, the architect wanted to do use Shou Sugi Ban siding, and that is definitely not something that you can just walk up to a local store and buy.  In late November, we found ourselves in the position of having to buy it from a specialist (nowhere near new Jersey) or build it, or pick a different siding material.  Since I wanted to remain true to the original plan, I decided that we should go ahead with Shou Sugi Ban siding.  This decision set us back some time as we then had to figure out what to do.  If I had asked more questions earlier, we could have gotten ahead of things and had the siding ready to go on time.  Lesson learned for the next time (just kidding, there is NO next time!).

We looked into buying it, but the cost of the materials and the shipping was absolutely prohibitive.  So, my contractor had to learn to become an expert in Shou Sugi Ban siding fabrication in his backyard.  During some of the coldest days of December, his crew grabbed makeshift blowtorches and about 10 canisters of propane. They spent four days torching tongue-and-groove cedar planks.

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Making Japanese siding in a backyard in New Jersey

When the burning phase was complete, they carefully wrapped the charred sides of the boards and transported them to my house.  They laid everything out on all three floors of the house and applied two coats of polyurethane to each board to weather treat them.

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Pre-treated Shou Sugi Ban siding after the charring phase is done

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The siding was carefully wrapped before they sent it to the house

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The entire house was used as a staging area for adding coats of polyurethane to the siding

The architect suggested that we use the Shou Sugi Ban siding on the front face of the house, and just far back enough on the sides where it would be visible from the street.  He also wanted us to use it for the back face of the house, but I felt that would be too costly.

We bought Ply Gem Mastic Quest Double 4” vinyl siding in “Misty Shadow” for the rest of the house and prepared to get the process of fastening all of the siding to the house started.  The first problem was how to hang the cedar planks vertically to match the plans.  Since some of the planks would fall in-between where the interior studs were, there was no way to nail them to the house.  So, we put up fireproof plywood across the front and sides of the house.  That way, we could nail the finished planks to them.

The siding guy proceeded to hang the vinyl siding on the house and finished it all in the matter of one week.  At long last, we had a finished-looking house that was water tight!

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Adding the plywood layer so we have something to nail the wood planks to

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Putting up the wood planks

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Installing the vinyl siding in back

So far, there have been no leaks from the new roof and the new siding.  We’ve had some pretty bad rain and snow so it has been tested well.

My contractor told me that the first day they had the Shou Sugi Ban siding on the house, someone driving by slammed on his breaks outside the house to ask what it was.  He said that it looked fantastic.  I’ve been back to the house many times since, and I’ve witnessed it myself.  People stop and stare and point out how cool it looks.

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The finished vinyl siding in the back

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The vinyl siding on the east side of the house

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The front of the house.  Make sure to stop and stare!

I’m a bit concerned that the siding is already beginning to patina.  That will either need to be touched up, or it will simply be part of the look.  I’ll have to decide over time.  Either way, I took the risk with backyard-made Shou Sugi Ban siding, let’s see how it holds up!

Now Let’s Get the Inside Going

Completing the siding was a huge milestone, because for the first time since we started, it put us in the position to work on multiple things at the same time.  My general contractor brought in his team of specialists that he’s been working with for years to get started on the interior plumbing, electric, and HVAC.  All three of these processes required that we have an idea of the final layout of the finished house.  So, a lot of decisions had to be made.

Plumbing

The house plumbing design has to accommodate the following:

  • Two full bathrooms on the second floor.
  • A half-bathroom on the first floor
  • A kitchen with a sink and a pot filler
  • Water and a drain for the washing machine on the second floor
  • A natural gas cooktop
  • A natural gas dryer on the second floor
  • All drain vents must exit through the roof

There was some discussion with my GC about the type of piping to use for fresh water.  Ultimately, we decided on pex tubing over copper to save money.  There were a few advantages to pex, one of which is that they have a tendency to be harder to burst in situations where they freeze.

In order to prepare for the rough plumbing for the bathrooms, we needed to know where all of the faucets were going to be located so we could install the rough-in valves.  Each faucet I selected was wall mounted, so they all have a different set of valves than a typical vanity-mounted faucet.  They had to be set precisely in place before the walls are built.

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Tubing and valve for the first floor bathroom sink

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Tubing and valve for second floor bathroom sink

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Tubing and valve for the master bathroom sink

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Tubing and valve for the master bathroom shower head and hand sprayer

There was some trouble understanding how one of the bathroom faucets was supposed to be installed.  I selected a GROHE shower head, sprayer, and faucet for the main bathroom that had a “double-el” valve that my plumber had never seen before.  We had to call the plumbing supply showroom a few times to understand what to do.  Eventually, we got clear instructions for how it would have to be installed.

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Tubing and valve for the main bathroom shower, faucet, and hand sprayer.  The controversial “Double-El” valve is highlighted in the red square in this photo.

Each of the drains and the bathroom exhaust fans needed to be vented through the roof.  The open floor plan on the first floor made it tricky to navigate pipes through between the floor joists.  For the most part, all piping and vents were run through the half bathroom ceiling on the first floor and straight up to the roof.  Others were routed straight up the east wall.

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There’s a lot going on above the drop ceiling in the half bathroom on the first floor

The kitchen fume hood was a bit of a controversial topic.  There was no obvious way in the plans to fit an 8” pipe and route it outside the house.  The wall the kitchen is on is too close to the neighbor’s house to simply punch a hole in it and vent the fume hood right there.  We kicked around a few ideas, my two favorites of which were to install it illegally after the inspections were done, or to forget it and install a fume hood that re-circulated air inside the house through a filter!  Both were terrible ideas so after much debate, we decided to sacrifice a corner of the middle bedroom and use that to vent the fume hood properly through the roof.  It will now be forever referred to as the “Cattywampus Corner”.  It is a small sacrifice to make if I can fry three pounds of bacon at once without setting off the smoke detector.

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The “Cattywampus Corner” in the middle bedroom will be built around this pipe for the fume hood

The gas line into the house had to be rebuilt entirely because the regulator was dangerously located in the garage near where the car would park.  We had PSE&G come in and create a new pipe that went through an old window that we bricked over in order to make a pouch for the new meter and regulator.

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The new gas line coming through the pouch we created where the basement window used to be

The new gas line inside the house had to be routed to the kitchen for the range, the upstairs washer/dryer closet, the basement machine room and the roof for the upstairs heater.  We also installed a “T” on the gas line so in the future we can use it for the outdoor kitchen range.

Electric

The electric wiring design was a combination of what was on the original plans, and a re-think of the lighting and TV layouts once I was able to walk around inside the house.  At all times, building code needed to be observed.

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The original plans for the first floor.  We moved the island closer to the kitchen counter, and re-worked the recessed lighting plan a little bit to be more in line across the room.  Our changes didn’t radically alter the design.

On the first floor, we had to finish the layout so we could plan the wiring.  That included, the kitchen layout, the location of the dining room table, the couch, my computer desk, and the couch.  This was the most involved decision-making process so far.

We started with the kitchen.  The final layout varied from the plans somewhat due to some decisions about the placement about the kitchen island and the cabinet designs.  We moved the kitchen island a bit closer to the cabinets, and we made it a bit longer.  We also added a pantry which moved over the placement of the refrigerator.

Once everything was drawn out on the floor and walls, we were able to plan where all the outlets needed to be.  That included the outlets for the refrigerator, warming tray, oven, and the convection steam oven.  It also helped us place the lights on the ceiling.  We started with three pendant lights over the island, and then planned two rows of recessed lights that travelled the entire downstairs.  In the kitchen, the recessed lights illuminate the space on either side of the island.

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The kitchen wall

After the kitchen was in place, we were able to lay out roughly where the dining room table would be.  My kitchen designer asked me if I had any details about what kind of table I’d be using so that we could make a better idea about where to place the dining room chandelier.  I really don’t have an idea yet so we aligned it roughly with the kitchen island.  We also placed it somewhere in the middle of the south wall and the end of the island.  That then gave us an idea of where to put the television so we could place the outlet on the wall behind it.

The living room was up next.  This room was a bit simpler because there are no hanging lights, we simply had to finish travelling the recessed lights through the area.  We also added a third row of lights in the area over the television because this room was a bit wider than the other two.  We identified where the television was going to go and placed an outlet behind it.

We also planned out where the speakers were going to be, with a plan to install 7.2 surround sound.  We placed the two required subwoofers in each corner of the room and put an outlet behind each.  The front three speakers will be mounted on the walls, assuming a TV size of 65 inches.

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Row of recessed lights for the living room

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Both rows of recessed lights across the first floor zones

Lastly for the first floor, we planned out the computer desk and all of the various inputs and outputs we’ll need for audio/visual and data.  It will be along the back wall of the living room behind the couch.  The downstairs will include a mix of hardwired Internet connections for gaming and computing, and WiFi for everything else, including smart home devices.

We planned the switch layouts such that I can control all three rooms as zones and have “layered” control in each zone as well.  For example, in the dining room

The second floor was a bit simpler to plan out.  Each room was compartmentalized and treated separately, so there was less to align and match.

The first bedroom in the front of the house will be lit by one hanging light in the center of the room.  The same with the middle bedroom.

The master bedroom will be lit by both recessed lighting and by a hanging light in the center of the room.

The outlets in the bedrooms were arranged by building code.  I added them all up and there are 20 outlets in total, for a total of 40 sockets.  I can’t imagine having enough things to plug in that require that many sockets, but building code is building code.

The hallway will be lit by sconces.  There will be exposed ducts running along the ceiling so we won’t be able to light them from above.

One area that is still under discussion is how to light the stairs.  I didn’t like the idea of overhead lighting above the stairs because I’d have no way to reach it to change the bulb.  So, we are working out a plan to install recessed lighting in the wall along the staircase.  The final design has yet to be decided.

Each bedroom and the hallway required a hard-wired smoke detector.  They were all placed out of the way from the lights in each area.

HVAC

While this was all going on the tin knocker was busy installing all the rough items needed for the HVAC system which will be put in place at a later time.  He can’t put the duct work in until the walls are in place, but everything that goes inside a wall or a ceiling or exits the house through the roof needs to be installed now.

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All of this has to exit through the roof

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HVAC ducts which will go inside the walls

In order to have two-zoned heating and cooling, and in order to fit everything in the house and not take up backyard space, we are going to use a combination of the roof and the basement to store all heating and cooling machinery.  So, all intakes and vents had to be planned out accordingly.  The house doesn’t have a chimney so we are using PVC flues where needed. All of the bathroom exhausts were installed and vented through the roof as well.

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The various exhausts and intakes that exit through the roof

Finishes

Also on the to-do list are all of the finishing items, especially those that require cabling or plumbing before the walls are put into place.  I’ve been keeping track of all of my ideas using OneNote and researching ideas and modifying the list as I go.

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My scatter-brained notes

The most interesting part is planning out the audio/visual and data connections and making sure they are future proof.  The plan is to store most of the equipment in the basement, and route HDMI and speaker cables throughout the house where needed.   My brother does commercial A/V installations for a living so he has graciously offered to help design and install everything we need before the walls go in.

The working plan includes the following:

  • DirecTV (for television)
  • Verizon Fios (for Internet)
  • Five indoor televisions (two living room, one kitchen, one dining room, one master bedroom)
  • 7.2 surround sound in the living room
  • Stereo speakers in the dining room, master bedroom, master bathroom (I like listening to music when getting ready in the morning)
  • Amazon Echo integration throughout the house
  • WiFi throughout the house and outside
  • Xbox One for gaming in the living room
  • Amazon Fire TV for media streaming

We have an unorthodox plan for running the necessary cabling throughout the house before the spray foam insulation goes in such that we can pull ore replace cables as necessary.  We are going to use some hoses we found at a hardware store as cheap conduit.

There are a few other non-A/V items that I’m planning for, some of which I’ve already purchased so we can install them when they are ready:

The Hunter Douglas shades required a power supply which I purchased to be installed in the basement.  All three shades will be connected to the same power supply and the electrician will install the wiring.

The hand dryer will not only be practical but will add to the ambience on the first floor.  I want it to look and feel like a trendy restaurant or club.

The Nest Hello was just released this March and I got in on the first shipment.  It will provide video security for the front door and will also alert me anytime someone rings the bell, whether I am home or not.

Amazon Key is a new product as well, and it will allow for keyless entry using a keypad to the front door, and the delivery hatch we are building to the basement.  This will allow Amazon to deliver packages and leave them inside the house.  Each Amazon Key is coupled with a security camera that stores footage in the Amazon Cloud.  Every time someone uses the keypad to open the door, I get an alert and I can watch what is going on using an app.

Inspections

With equal parts optimism and dread, I was looking forward to the separate plumbing and electric inspections which were scheduled for March 19.  My GC put his crew on a deadline to have everything ready to go before then, and they worked through the weekend to complete everything.  I wanted to get these two inspections, but also calculated about a 100% chance of failing them both for some reason.

Much to my surprise, we passed both without issue.  My GC was so surprised, he told me he couldn’t sleep that night because he was so excited!  He also forgot to attend a meeting with a perspective customer because his emotions got the best of him.  I’ve never been so happy to be 100% wrong about something.

 

What’s Next

Our next inspection is the building inspection on Wednesday.  This one is going to check on everything we built including the frame, the roof, and the siding.  One of the inspectors who was at the house a few months ago noted that he believed that wood siding was not allowed on the sides of a house.  But our siding plan was on the original approved plans, and I checked the building code myself and nowhere does it say we can’t have wood siding.  I don’t know what to make of his comment, but I’m hoping for the best on Wednesday.

Once we get past inspection, we can install the bespoke conduit for the AV equipment.  Once we are sure everything is in place on the exterior walls, we will spray-foam insulate everything.  That will be the last step before we can put floors and walls in.

Over Budget

Not only is almost every single item on original plan over budget, but I’m still bleeding cash each month as I pay off two mortgages.  Everything I wrote about in this blog has been a lot of fun and I’m very much enjoying the decision making and implementation process.  Waking up every morning knowing that I’m going broke from paying two mortgages since I bought the place in December 2015 and knowing that I’m nowhere near completion is becoming very stressful and upsetting.  Any cash I had on hand for cost overruns has pretty much evaporated and I’m looking for new ways to borrow and fund the rest of the project.  In the end, this will probably cost me time getting started on phase 2 (mainly the backyard), but I can’t worry about any of it now.  We’ve picked up the pace in 2018 and I’m doing my best to keep everything moving as quickly as possible.