Tag: Shop Work

  • Boathouse Repairs 3: Fabricating Post Wraps

    Boathouse Repairs 3: Fabricating Post Wraps

    Fabricating Boathouse Post Wraps (Photo: Peter Vaiciulis)
    Fabricating Boathouse Post Wraps (Photo: Peter Vaiciulis)

    It’s time for a progress report on Rosslyn’s boathouse post fabrication. Peter Vaiciulis and Sia Supi Havosi have been beavering away lakeside as autumn blurs into winter. Unfortunately, their decking progress has been stalled because the moisture content of the lumber is still too high. In contrast to the previous contractor whose work required extensive remediation, Peter is prudently allowing the decking sufficient acclimatizing and drying time to rnsure stabilization (and to ensure that we don’t once again wind up with inconsistent gaps ranging from 1/8” to 7/8”). In the mean time, Peter and Supi headed inside to shop-fabricate components for the post and railing system.

    Successful repair of the boathouse posts and railings started with dissecting and documenting the existing conditions, deciphering the *how* and *why* of the existing conditions, and executing a meticulous rebuild with discreetly integrated improvements to function, structure, and endurance ensuring safety and longevity despite the challenging location and harsh environment.

    Supi Sanding Boathouse Post Wraps (Photo: Peter Vaiciulis)
    Supi Sanding Boathouse Post Wraps (Photo: Peter Vaiciulis)

    Supi is sanding a post wrap that will get installed over the structural posts that have already been integrated (correctly this time!) into the substructure.

    Peter Chamfering Boathouse Post Wraps (Photo: Sia Supi Havosi)
    Peter Chamfering Boathouse Post Wraps (Photo: Sia Supi Havosi)

    Chamfering edges along the midsection of the post wraps, Peter has clamped stops on either end to standardize the offsets. He’s replicating the design that we developed about fifteen years ago during our original rehabilitation of the boathouse, gangway, and waterfront access stairway. This subtle but comely detail that we included in similar situations elsewhere in Rosslyn’s four historic buildings, offers a practical benefit in this waterfront location where waterskis, surfboards, windsurfers, etc. are quick to nick sharp corners. The eased edge is also friendlier to shins and knees usually protected with little more than bathing suits in this area.

    Chamfered Boathouse Post Wraps (Photo: Peter Vaiciulis)
    Chamfered Boathouse Post Wraps (Photo: Peter Vaiciulis)

    Up close and personal with the post wraps. Note the chamfered midsections and wood filler curing for Peter and Supi to sand.

    Supi Priming Boathouse Post Wraps (Photo: Peter Vaiciulis)
    Supi Priming Boathouse Post Wraps (Photo: Peter Vaiciulis)

    After wood filler cures and sanding is complete Supi begins priming the post wraps. Because of the intense weather changes — from rainstorms and dramatic temperature fluctuations in the summertime to snow, ice, and deep freezing in the winter — that the boathouse gangway posts and railing will endure, two coats of primer (including concealed end grain, etc.) and two coats of exterior paint will be installed in the shop. Although some touchups will be necessary during and after installation, this will streamline the late season installation and improve long term weatherproofing.

    Although historic rehabilitation took place a decade and a half ago, the lakeside location accounts for the accelerated deterioration of Rosslyn’s boathouse gangway, posts, and railings. This go-round we’ve been able to tweak a few mechanics based on previous performance, hopefully improving performance and extending the useful life of these repairs to 20+ years. Even though Opud’s disastrous attempt last year cost us dearly in time, expense, safety, and usability over the summer, Peter and Supi’s rebuild is superior through and through, ultimately affording us solace after a year of headaches.

    Let’s wrap up with a mashup of the dissected, well documented prototype guiding Peter and Supi’s repairs.

    https://www.instagram.com/reel/CllnkXYA6z1/

    Thank you, R.P. Murphy, got ace documentation!

  • Boathouse Repairs 5: Piece-by-Piece

    Boathouse Repairs 5: Piece-by-Piece

    Piece-by-Piece: fabricating post bases for Rosslyn's boathouse railings (Photo: Peter Vaiciulis)
    Piece-by-Piece: fabricating post bases for Rosslyn’s boathouse railings (Photo: Peter Vaiciulis)

    As temperatures drop and winter weather threatens, Peter and Supi are toiling against the onset of winter. They’re taking advantage of shop work when possible, fabricating post bases — piece-by-piece — painstaking duplicating our boathouse‘s existing post and railing details while ensuring the most hardy, weatherproof construction possible to ensure the longevity of these handsome architectural elements that will be installed in the most challenging conditions on the entire Rosslyn property. It takes master craftsman to to marry these delicate aesthetic details with such a demanding, punishing environment. And there is no other way to describe the conditions endured by the boathouse and the boathouse gangway.

    The trim molding is being shaped, one router pass after the other to match the existing details. These will then be secured to the railing posts above the bases being fabricated below. Piece-by-piece the carpenters are transforming a vision into a railing. And today sections have been handed off to Erin who has begun installing the first coat of primer to cure, be re-sanded and re-primed. Once primers are properly cured we will begin to paint, again building up to well cured coats in a controlled, heated environment so that when these elements finally reach their destination along the shore of Lake Champlain, they will be not only beautiful, but well protected from the Adirondack Coast winter elements.

    Piece-by-Piece: fabricating post bases for Rosslyn's boathouse railings (Photo: Peter Vaiciulis)
    Piece-by-Piece: fabricating post bases for Rosslyn’s boathouse railings (Photo: Peter Vaiciulis)

    Piece-by-Piece Mashup

    In keeping with the spirit of previous updates, here’s a quick remix of Peter and Supi’s painstaking, piece-by-piece post base fabrication for the historic rehabilitation of Rosslyn’s boathouse gangway railing.

    https://www.instagram.com/reel/CmFsPJig6SC/