It’s A Dirty Job, So He Made Me Do It!!

It was time to move onto the frame for the glazed side of the extension.  Steve was very pleased to get back to working with his chainsaw.  The trolley worked well, yet again, with the biggest trunk so far (weighing approx. 200kg) being transported safely.  Is there a chance that he actually over-engineers things?!  Of course, as this one was going to be the base of the glazed wall I had to dig yet another trench.  I’m sure Steve must have had a past life in the army, as every time he gets me to dig a trench he then makes me fill it back up!  This took two days – all that rain had certainly helped soften the ground up and I wasn’t going as deep this time.  The trench was filled with small stones, like the other, and once we had managed to manoeuvre the ‘beam’ into place I would back-fill the hole.  Once again Steve used his ‘to the millimetre’ measuring which meant that there was a bit of finangling to get the ‘beam’ into place.  But, it’s in now and I don’t think there’s much chance of it coming out again!

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Beam In-Situ

Next up was a fairly major job, probably the most significant or highest risk job that we have on the plan – fitting a lintel into the gable end of the two storey building so we can open a doorway through and, as I am sure you can remember from the photos, this is the wall with the bloody big crack down it!  The architects did have concerns with this modification as they thought that the likelihood of the wall collapsing was very high (we tended to agree with them!).  Steve did his best to stabilise the crack by placing several rocks in the gap and then it was his job to cut out the wall for the lintel.  I took this time to do a bit of tidying up – I cleared loose render and odd concrete bits from the walls and also the plants that were growing from the wet cob.  As Steve had said he would probably use some of the old slate tiles to wedge the lintel I thought it would be a good idea to collect them into one (and, for once) small pile.  I got a couple of surprises doing this!  First off, a red slug, all curled up in a ball – the first time I had seen one, and then when I moved a piece of slate, something underneath jumped – a cute little frog!

When Steve got to the last five or six inches of his knocking out he did feel a small stone land on his arm and he wondered if this was the moment that the wall would fall down, however with a couple of temporary blocks in place the wall above remained stable with only one additional crack to show for it – albeit 2 ft long and horizontal.  He was then able to complete the final removal of cob – it had only taken him two days and was a success, hole cut and wall still in place! I did manage to get into a little bit of trouble (well, time for yet another laugh moment!)  I knew that Steve had decided to use the large crack in the side wall as a gauge (to see whether the end wall was moving at all), using his fingers as his datum, but didn’t know which part of the gap he had used (because of his height, I assumed he would have used a higher up section) and in my exuberant render removal I had removed a vital part of his gauge!  At least I owned up quickly so he didn’t have to worry that the wall was actually moving, well, at least I don’t think it was!!

After the precision with which he had planned out the first wall frame I thought he had done the same with the lintel placement – however, his thinking had got as far as, get it resting on the wall beam and slide it in – but the wall beam was 2 metres up and the lintel weighs in excess of 120 kg!  So after one aborted attempt it was time to down tools, go back to the boat, think about it, drink wine and tackle the job tomorrow!  The following day arrived and this was the time Steve decided to test out his workbench (first job for it and a big one at that!)  With levers and strategically placed steps and rope, we slowly, but surely, got it in place.  We only had one minor hiccup where one of the ladders decided to go for a walk – landing Steve on his arse!  However, my timing was impeccable on this occasion and I managed to get my ladder into the right position to save any embarrassment or starting all over again!!

 

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At the end of the day the lintel was in and the wall was still there!!

Steve had been bleating on that he had lots of woodwork to do and he had decided that my job, being a menial task, was to open up the doorway in the cob.  I’m pretty sure he knew how hard it was going to be and that was why it was my job!!  Cob, what is cob?  It is just a combination of clay, sand and straw.  This cannot be that hard, can it?  However with a wall thickness of between 400 and 800mm, it bloody well is!  With my new first-hand experience of the strength of cob I set about the mammoth task of removing the doorway section, 1.2m wide x 2.4m high.  This was an incredibly dirty and sweaty job!  Not being a fan of dust masks we decided that a snood would be the way to go!  The same snood that had kept me warm in June 2012!

We thought that I should start inside the main building so as to be able to recover as much of the wall material as possible as we will be reusing it to build the new wall.  Standing on the spoil created previously I got into quite a rhythm with a club hammer and bolster. I love these mindless jobs!  If you are lucky and hit it just right it will sometimes come off in huge great clumps – great for this removal job, probably not so good for when we want to reuse it, I think I will be using a sledgehammer to break it up!  There was one good thing though, inside the house is incredibly cool and with the existing front door open there was occasionally a nice breeze blowing through and the really fine dust was being blown away from me to the outside! It didn’t stop me sweating though!  After four days I could walk through, even if it was onto a pile of rubble!  A morning of shovelling and it would be clear to walk straight through!  We were pretty sure that there was quite a difference in the floor levels of the two buildings but now we had a chance to check.  Steve just had to do a test with his fancy laser level and we discovered that it was just an optical illusion as the levels are similar enough that we won’t need a step between the two buildings.

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Midway through this job we were allowed a day off – there was a large ‘marche aux puces’ (flea-market) being held at Lanvollon.  We have been searching for a scythe but so far, at all the vide-greniers (similar to English car-boot sales) we have been to, we have been unsuccessful.  As the stalls at Lanvollon stretched through the whole town we were hopeful.  However, as is so often the case, we were to leave empty-handed.  Steve was all excited when he spotted my washing machine (a wash-board) and he could hardly contain himself when he saw what could be my perfect spin dryer – no idea what it really was but it looked like a commercial sized salad spinner – the size of a rubbish bin – he reckoned that if it wasn’t quite fit for purpose he would be able to modify it for me.  Surprisingly I didn’t agree with him and, as he had left his trolley behind and I would have had to transport any purchases on my bike rack I refused graciously (well, I gave him ‘the look’!) when he offered to buy them for me!!

We stopped at the property on the way back from Lanvollon as we had decided that we wanted to try and harvest some of the cherries before the birds get them all!  I’m hoping that, as there about 300 cherry trees, they will leave some for me!  As most of them are far too high for us to reach we thought we would pick up the windfall ones – quite a lot were resting nicely on the long grass and other weeds and hadn’t made it to the ground!  This year’s cherry vodka will be with my own cherries!!

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Cherry Vodka On The Way

My next job is yet another trench, this time where the original front door is.  (Technically the last building trench, well apart from drainage and other services).  The door is being replaced with a window so I have to dig a small trench (we have discovered that the property has no underground foundations) and build a stone plinth.   Steve insists that I have to do this one – I’m hoping it won’t be too difficult as I found a lot of rather nice, flat faced stones in the end wall which should make my jigsaw puzzle easy to do!)  Steve kindly lifted the door off its hinges (far too many thick, black cobwebs for me!) and I set to work.  I got about an inch or so down when I came across some large stones so I think I’ve found the original door jamb!  This means that my trench will not be as deep as I first thought as we have decided not to remove stones that have been in position for the last two-hundred years!  I am not enjoying digging this trench as much as it is a bit more fiddly!!  One side of the door frame has rotted at the bottom so Steve suggested that I might as well take it out – this involved using an auger (hand drill thing!) to drill out the peg.  I am not the tallest person (although I think I’m pretty much average height for French men) and unfortunately found that I was just a bit too short to drill comfortably, I ended up using my head as well as one hand to put pressure on the auger and taking frequent breaks to ‘rest’ my arms.  Two hundred year old oak is hard to get through, let me tell you, nothing like that green oak stuff Steve has been playing about with!!

Boots Are On!

With the frame in place it was time to start building our foundation!  We had the washed small stones to a depth of 100mm which creates the French drain (but as we are in France, do we just call it a drain?)  Steve drew me a little picture to explain what we needed to do!

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Technical(?) Drawing Of The Footings

Then it was selecting ‘as large as we could’ flat stones that would fill the width of the trench. This needed to be dry (unmortared) and was to stop any mortared stone reaching the painstakingly washed stones underneath.  We had decided to put a French drain in even though the existing property doesn’t appear to have one as we have dug below the level of the stone footing.  If nothing else it is an experiment in what is possible!

This next phase was to be my job – while I was doing it this would allow Steve to continue with his woodwork.  We knew that Steve would have to do the dry layer as the stones would be too heavy for me to move.  However, much as I was anticipating this activity it soon became apparent that I am not cut out for stonemasonry – a jigsaw puzzle with no interlocking pieces or even a picture to follow.  Amazingly I was able to convince Steve that he could leave his woodwork for the time being and become a mason.  After both of us had made batches of mortar we decided that my role in this important foundation wall build would be mortar-maker, cos my mortar-maker mate wasn’t as good at mortar-making as me!!  This also provided Steve with two new songs to sing – “muck-maker, muck-maker, make me some muck” to the tune of Beach Baby (which after some checking I discovered was a hit for The First Class back in 1974 – Steve would have been 9 and me 6 so how on earth do we remember that one!!) and also, “Muck-maker, muck-maker, make me some muck, find me some muck, make me some muck” – to the tune of Match-Maker from Fiddler On The Roof!!!

After doing some homework and much debate between us I had decided that I wanted a natural mortar with no chemical.  Steve had been advocating lime mortar whereas I was a fan of good old earth mortar which actually matches the existing.  The plus point to this type of mortar was that we didn’t need to buy anything to make it – win, win.  We had a 3:1 mix, 3 trowels of reclaimed cob (we have a large pile of this where the wall is falling down) to one part aggregate (my small stone mix) mixed together with enough water to make a gluey, sticky mud-pie batter!  Not too much water and not too little – just enough to make it workable.  One of the benefits is that even the following day you can make alterations as it takes quite a while to set (which bears no resemblance to the final product as a good dowsing of water can un-set it quite easily!)  Like a cold, stodgy, set rice pudding, you can add more milk and heat it and it will be brought back from the brink! (Just ask Steve’s mum!!)

Having no water supply at the property has meant me having to transport water – why, oh why did I go for the bike with the rack? – perhaps he aint as daft as he looks after all!  One of Steve’s previous skip acquisitions (all that time ago in Fleetwood 2013) was a 20 litre Mango Chutney container, which had been used by a fishing vessel called Prawn Star.  They had obviously decided that a broken handle was enough to make it an undesirable object – thankfully Steve felt differently and it has been used for various activities including eel killing, rope cleaning and now water storage and collection!  The gods have shone(?!) upon us as it has possibly been the wettest June since we sailed round Britain in 2012, meaning that after the first couple of water transportation runs we haven’t had to do any.  Wheelbarrow, buckets and canvas covers have all collected water for us and we haven’t lost too much (ahem!!) when harvesting the water from the canvas covers (Steve managed to get me once and I also managed to get him – I think mine was better as I was holding the bucket at an angle that shot the water straight back at him and a direct hit down his wellies!!) Another opportunity for laughter!  And now as I write this with the footings completed I have a full bowser of water.

So, to the technical side of these footings:  On top of the dry stones, the next layer was likely (depending on stone size) to reach ground level (or grade – which I understand is the official term for it!). So our target was to try and have as many flat facing stones, both external and internal spanning the width of the trench.  Steve reckoned I would soon get my eye in and would be able to take over from him – however that wasn’t EVER going to happen!  The stones were too heavy and far too difficult for me to figure out where to put them – and even if I did find one that I thought was suitable I was worried that there would be a better place for it later or another stone more suited that I hadn’t found yet! Steve tells me that there is an old saying that if you pick up a stone you shouldn’t put it down until you’ve laid it – this gave me an excuse not to pick up any!!!  So after doing the first day Steve’s thought processes were to put into the wall as many large stones as possible to reduce the number of joints and to be self-supporting.  Some of these stones probably weighed in the region of 50 – 60 kg each and we even had to transport some onto the footings by trolley.  (Note to self:  you should have insisted on finding some strong, burly firefighters to help us out).  Steve had to take a break from building a few times to go searching for more big stones – we had spotted some down by the troll bridge and knew there were quite a few inside the ‘house’ in the ‘what looks to have been a fireplace’ area.   With all the large stones used the jigsaw puzzle commenced – only after we had debated how high to make the footings.  This is when we finally took our first look at the plans (since February) and noted that with the window being 1m tall, the outside face of the wall – cob and stone – a total of 1.9m this meant that, in some areas we were already at the finish height.  Of course, with Steve’s method of building (effectively building an internal and external wall with a cavity between) there were ‘void areas’.  Steve had decided (in his head) that with my skill set I would be able to fill these areas which would therefore reduce the amount of building work he had to do as he was suffering chainsaw withdrawal.  I did actually start to enjoy filling my cavity, with Steve out of the way playing chainsaws again, it meant I could do things my way, even if it wasn’t Steve’s way!  Unfortunately the wall/foundation took longer than expected because of all the rain delays – some days it meant enforced days off and others meant indoor work as rain and natural earth mortars mix a bit too well!  We only experienced one minor wall failure after the first heavy downpour day – but it was actually a blessing as one of the stones slipped into the trench very nicely and we wouldn’t be able to move it now if we tried!  We were very kind to the wall and tucked it in snugly at the end of each work day – I think the most frustrating days for me were the two we were at the property but because of the soggy ground there was no way any building could take place. It coincided with the fact that there were only two days’ work left – c’est la vie!!

During the period of stone work a couple of local gentlemen took the opportunity to inspect our work.  Both commented (in French of course) that it looked good and was coming along nicely.  One even said that he knew it was hard work but we could look back and be proud once it was finished – well at least that’s what I translated it as – he could actually have said, “That looks shit, why don’t you quit?” but I don’t think my French is bad enough to make that translation mistake – this was reinforced by Steve’s translation of what we’d heard (and he does know his French expletives!!)

For the record we calculated that we have laid two and a half tonnes of stone and mortar and it has taken a month from ground breaking to completion of the footings!  I don’t think that’s too bad, considering it is all being done by hand with make shift equipment and recycling materials with some interludes gathering stone from the property and wood relocation from the paddock and it has cost us the princely sum of 8 Euros – two buckets and a colander!

With our enforced days off we have been a bit lost, but it has given us the opportunity for afternoon naps again!! We took a bus trip to Brico-Depot at Plerin (part of the B&Q group) to look at window and door frames.  Unfortunately we didn’t like what they had in store – they looked very insubstantial compared with the wood we have been using, so we need to look elsewhere.  We managed to spot a couple of window companies but, as is usually the case, we found them at lunchtime and yes, of course, they were shut!  Still windows and doors aren’t yet a priority so we’ll wait a bit on that – walls and a roof are needed first!!

We were also given a day off by Storm Miguel.  He wasn’t as bad as we expected but with the wind on the side of the boat we did get a bit of a lean-on.  At its worst (52 knots), we had a lean of about 15 degrees and, because I’m curious I chose to check out the webcam picture.  An excellent shot of our mast leaning!!  One of the funniest things was one of the marina staff trying to push the boat against the wind so he could replace a popped out fender – Steve did point out that it was unnecessary and he wouldn’t be able to do it – 30+ tonnes against 50 knot winds – it’s hard enough without wind!!

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Yes, That Is Our Mast Leaning!

After Steve had stolen the big stones from the fireplace area (or wheel trim storage area as it was when we bought it) we needed to sift through the cob/stone/possible lime mortar (maybe concrete).  This was my job as Steve had decided he was fed up with working on his knees so he was going to build himself a bench – yet another use for those crappy old nails his dad had sent!!

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It Isn’t Pretty, But I Bet It Will Work!!

Another indoor job we could do was to clear the hay loft!  This would enable Steve to fully understand the work required on the first floor!  Steve climbed the ladder with rake in hand; I removed the ladder and placed the one-tonne bag underneath the hole!  Easy – Steve would rake the hay to the hole, it would fall into the bag and I would empty the bag and replace it – hey, presto!! This worked for the first three minutes, and then Steve had a better idea.  I should move the bag, he would continue raking the hay and then whilst he was having a breather I could fill the bag, empty and repeat!  After about four bags worth and the pile reaching the ceiling height, Steve kindly offered to assist, so I struggled the ladder back in place and we worked together(?!).  This took longer than I expected (I obviously hadn’t taken notice of just how much hay was up there!)  He only found two more rotten floorboards and also a trap door with cut outs for a ladder – ooh, exciting!!  Surprisingly, considering the smell took me straight back to childhood memories of rats in the corn bin, (sorry mum, but it’s true!), there were no real signs of rodent infestation – just one red squirrel tail and one very desiccated mouse and not even any hint of Steve’s scary cat!!

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How Much Hay?