Parlor Renovation, Part III - Water Leak Repaired

November, 2013...

The hole in the wall had become larger due to my eagerness (see Part I).  I had contracted with Sunderland Period Homes to repair the south facing parlor window.  As promised in Part I, the following are the procedures that were taken to repair the window frame:

Sunderland Period Homes

The crew of two started with the removal of the siding. Each board was removed, numbered and stacked in the front yard. The boards were scraped for a clean edge while the paper around the window was torn off.  A product they had called "ice and water" (branded as Protecto Wrap) was used as a first layer of defense around the window.  The product is a tacky tar-like membrane that helps secure the joint between the clapboards and window frame from water.  It came in a roll and was placed first along the bottom of the window, then the sides which overlapped the bottom and finally across the top of the window, overlapping the sides.

Siding removed, "ice & water" partially installed, storm window being removed. 

Rotted wood on the frame was marked for removal.  The marking delineated an area that was easy to cut and replicate. A scraper was used to remove paint to expose the wood's surface.  A straight edge was then used to complete the mark out.

Scraping the paint off the damaged area.

Using a straight edge for mark out.  

Once the area to be removed is marked, it is then removed using a router.  

The depth of the router is adjusted prior to the removal.

Starting from the outside edge, the carpenter carefully routers the wood to the indicated shape.

A stock piece of wood slightly thicker than the area being patched is used.  It is laid against the frame and the cutout is traced onto the stock wood.  A jigsaw was used to cut it out.

Scrap of wood being cut using a jigsaw.  Note the clapboards on the sawhorses.

Perfect match.

 With the patch ready, time to install.  The carpenter recommended that a 3x construction adhesive be used instead of stronger adhesives (such as the 8x) as the stronger varieties tend to be too gritty for this application.

Construction adhesive, 3x strength.

The application of the adhesive into the cut out.

The previously sized stock piece of wood is squeezed into the fresh adhesive.  The carpenter pre-drills screw holes and secures the patch with stainless screws.  Once the adhesive sets, the patch is planned flush with the original frame.

Pre-drilling for the screws.

This process was repeated several times around the perimeter of the window's frame.  Once complete, the crew moved on to the siding.  

Patchwork complete.  Note the Great Stuff insulating foam in between the planked wall boards.

It was suggested by the carpenter that while the siding is off, we should fill the gaps between the planks with foam.  What an excellent idea.  Now, I realize this is not going to be anywhere near as efficient as R15 insulation batting; however, compared to having no insulation versus this sprayed into the one inch cavities to help button up our home, I was all too eager to go out and purchase a whole bunch for the crew.  I was told to purchase the blue bottle for windows and doors.  This is because, per the carpenter, it was formulated to fill the spaces around windows and doors without making them un-plum.  The regular red can applies more pressure to the surfaces it comes into contact with which can cause alignment issues.  

Great Stuff, Window and Door.

Felt paper is now installed as a secondary wind and rain barrier.  It's installed with small siding nails.

Felt installed overlapping each other.

Siding nail.

Flashing installation is done in the same manner as the "water and ice" except the flashing needs to be scewed into the side of the house.

Flashing is installed over the "ice and water" membrane and under the frame's lip.  It is secured through the window frame.

The flashing is installed similar to the "water and ice" membrane starting at the bottom, overlapping the sides onto the bottom and then the top overlapping the sides.

A clear caulk was then used to seal the perimeter of the window.

Clear caulk.

Once caulked, the clapboards were re-installed with new pieces being added where needed.

For the next couple of days, this is how the side of my home looked.  The work finished within a week with the installation of lead flashing above the window (sorry, I ran out of vacation time, no photos of that installation).  The remaining clapboards were replaced and the work was done on the outside.  However, in the estimate, Sunderland Period Homes specified rosehead nails for the siding, the carpenter used regular siding nails.  It was a deviation that was very disappointing.  Upon pointing this oversight to Edward, he ordered the correct nails and had his carpenter install them.  His reasoning for not using it was because even though he wrote it down in the estimate, the existing nails in the siding were regular nails so he didn't think that he needed to install the more expensive rosehead nails.

On to the inside...

Interior face of the south exterior parlor wall before any repair work.

Sunderland himself worked on the plaster patching.  He took a sample of one of the window's trim and had it replicated exactly.  He also did the same with the sill.  Both of the components were damaged by yours truly in my feeble attempt to "fix" the window.

Plaster placement in progress.

Plaster material used.

Done.  Plaster and trim completed.

Once Edward and his crew were done, now, it was my turn to fix the cracks in the walls.

Big Wally's Plaster Magic, Contractor's Pack.

So the total cost for Sunderland Period Homes was:  $3,450.00 (does not include the Plaster Magic).  Pricing included an extra $250 due to there being more plaster repair than Edward had initially thought.  I don't yet know how much a 50 pound bag of Structo-Lite costs, but I doubt its anywhere near that price.

This truly was very expensive.  I have to admit that towards the end of this project, I lost my temper with Edward.  He tended to want to do 'this' and 'that', seemingly pull numbers out of the air and make me feel quite idiotic on a continual basis.  He didn't realize that we are not one of his wealthy clients that are restoring their vacation house.  This is our home, we live here and we only have so much money to spend.  I snapped at him one evening and told him that I just cannot afford him.  With his posh attitude, he didn't seem to care and we haven't spoken since.

Now with that being said, he was able to stop the window leak, perfectly duplicate the trim and do a decent job of plaster repair.  He also did not mind that I was asking questions of his crew most of the time and also did not mind the photographs.  Would I hire him again... eh, simply because of the expense, I think I'll shop around next time.  At least I was able to get a decent idea of how to seal a window.  I thank Chris, the lead carpenter, for being so educational.

Future plans are to prime the exterior surfaces left exposed and continue working on the interior of the parlor myself with paint removal and crack repair.

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Parlor Renovation, Part I

August 4, 2012...

"OK!  I know it looks bad, but it looks worse than it really is.  I swear!"

That's the only thing I could say to my wife when she came into the parlor.  It's only a hole in the wall, right?  A frown, and the look of "what did you do now" was the kindest of greetings one could receive...

From the survey of our parlor, a rubber-cement glued wallpaper could be seen hiding the water damage plaster underneath (thanks to the previous owner).  As I peeled away the God-awful wallpaper, I opened a can of worms....the wallpaper was holding together the damaged plaster underneath.  In my unknowing nature at that time, the "loosened" plaster fell out and I had continued to remove what I had thought was damaged plaster resulting in a gaping hole in our exterior wall.

Before , left:  Rubber cemented (and painted) wallpaper.         After, right:  Wallpaper removed, punky plaster exposed.

Wallpaper removed, "loose" plaster gone (lathe saved) and the window trim removed (some damaged), I found myself dug deep into a pit.  My knowledge was limited, my hopes high.  I wanted to do the work myself, pride took the better of me.  I continued to knock "loose" the surrounding plaster away.  In the end, I was left with an annoyed wife and crushed pride.

More wallpaper being removed, wetted areas are now visible below the window.

Without the knowledge to repair my deeds, the wall sat there for the remainder of the summer, fall, winter, spring... yes yes, and then summer.  I must have sub-consciously buried the plan to have it fixed for each time I said out loud to my wife that I am busy and can't do this or that right now, she would interject and say, "Like the hole in the wall?" It was painful to have to be reminded of my error or lack of ability.

I removed the wall paper entirely, along with the two sashes, sill, molding and punky plaster.  Notice the solid piece of wood at the window sill height that is where the original chair rail would have been.

August, 2013...

I had a plan (in my head).  I needed to learn how to do repairs on my own home yet books only showed vague interpretations of other jobs but I am a visual and hands-on person.  My plan was to contact Mr. Sunderland of Sunderland Period Homes.  I had the idea that since he's employed several talented persons, perhaps I could hire but one to show me how.  I wanted to learn how to do this and that and thought that perhaps I could "rent" one of his carpenters or plasters for a day to show me the ropes.  An email was sent off.

View from the southeast corner of the home towards the west.  The window is just west of our coffin door.  Notice the slight bump that is just below the window.

South exterior wall.

South exterior wall, window and coffin door.

Mr. Sunderland was confused by my questions and request.  He asked to come over and I can surmise that his trip was to evaluate a future job as oppose to a learning experience for the home owner.  We spoke of several topics while he was at our home including making our coffin door functional, adding a chair rail, siding, identifying a possible structural issue below the window... oh, and yes, the window and plaster mess yours truly created.  The idea of instruction was thrown out the window very quickly as Mr. Sunderland was too confused (perhaps on purpose) to follow.  So, we discussed how he would repair the window and bring it to new (along with the aforementioned items).  As I walked Mr. Sunderland to his car, we discussed a budget.  After pricing out how much a new window was from a few sources, to include the sashes and frame, (minus installation) I figured that a repair for such a window would surely not cost anywhere near the estimated $2,000 for the uninstalled package.  Considering our finances, my wife and I decided that $2,000 seemed a reasonable maximum amount to repair that plaster wall, reset the window sashes and stop the water leak.  Mr. Sunderland nodded as if he understood, yet said that it may be a bit more.  It was a one hour chat and an email to follow within the week that blew my mind, and not in a good way.

Here was the estimated total (are you ready for a jaw drop?):  $6,800.00

My mouth dropped open, I even imagine a bit of saliva dribbled out as I was dumb struck.  My wife had to cover my child's ears as, in my delirium, extraordinarily colorful words expelled from my drooling mouth to such extent that my opinion of Mr. Sunderland dropped dramatically.

I emailed/called Sunderland Period Homes to explain to me why it would cost nearly $7,000 to fix a leaky window and patch the plaster?  Here was his response, in layman's terms:

$2,600 is for the chair rail restoration.  The rail had been removed by a previous owner and replacing it would bring the room back to an original appearance.  The cost included the materials and labor which involved scribing the wood chair rail to match the uneven plaster wall along three walls (the fourth being paneled).  I'll pass on a scribed chair rail, saving myself 30% of the estimate upfront.

$600 is for removing paint from the existing reproduction sashes on one window.  Ah, thanks, but I'll spend a few hours over a weekend doing that myself...

$400 is for weatherstripping the two existing reproduction sashes.  What?!  It costs less than a dollar a foot to purchase!  There's no way that labor could be that expensive!

$3,200 is for (quoted from the estimate):

1. Flash the header window with lead.
2. Attach wood lathe properly under the window.
3. Plaster over existing lathe.
4. Re-install sash and window trim.
5. Remove exterior storm window.
6. Strip paint from exterior window frame.
7. Restore shape of exterior sill.
8. Remove siding at left, right and beneath window to assess condition of sheathing.
9. Install new 30 lb. tar paper around and under window.
10. Install "ice and water" for water proofing around window.
11. Caulk edges around window frame and re-install siding with rosehead nails.

In addition to the above items, he wrote up an estimate for "custom made interior storm windows" to replace the exterior aluminum units currently installed, restore the clapboard siding and restore the coffin door.  The other estimates combined grossed around $46,000.  All I wanted was to stop the water leak, but at least I can see where Mr. Sunderland's pricing is in other aspects.

I bit the bullet.  I signed a contract with Sunderland Period Homes for the $3,200 + (and yes, plus the outrageous $400 for weatherstripping).  I must seem insane to you, honestly though, I have a reason.  After asking for references, I spoke with a few of his former and current clients.  They all shared one answer.  He is insanely expensive, but he gets the job done right once.  This gave me an idea.  I figured, if I am paying an excessive amount of money for this small job, why not be present, mentally record what would be done and, replicate it on the other 20+ windows that need some sort of repair.  The work will be done for me and I'll be educated in how it's being done by a qualified crew.

My readers, when the job is complete, and time allows, look for a how-to for waterproofing and restoring a leaking 250+ year old window and frame (to be updated in 2014).

Side note (but important):  After the fiasco with my son's lead levels, I decided to take a sample of the underlying paint from our parlor's newly exposed surfaces.

D-Lead test samples.

The test came back negative.  It is assumed that while removing wallpaper, I had inadvertently released this trace amount of lead into the air.  I can rule out this room as being a cause for the lead in my son's system.  See this post:  Lead Poisoning, for the full story regarding lead issues.

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Review: Big Wally's Plaster Repair Kit

Watching the PBS program "This Old House", I saw contractor Tom Silva use Big Wally's branded plaster repair kit on a rather large crack.  The process looked simple enough and having plaster everywhere in the home with every wall having some sort of crack, I decided to buy a small pack to try out.

In our future baby room, where a closet was built (circa 1960's), are a series of exposed cracks on the west exterior wall.  This area will eventually be covered by a closet system, so I figured I can't make it look any worse.  You can see the previous owners attempts of sloppy repair along the corner.

Following the directions, I drilled my first hole near the crack to locate the lathe behind.  With a set spacing between each lathe, I drilled along the crack keeping far enough away not make it bigger, yet close enough for the process to work.  I believe the directions said about an inch to two away.  I vacuumed each hole to clean it of all dust and you'll also want to vacuum the floor and other nearby items, plaster dust gets everywhere.

Once this was complete, the holes are primed with a chemical within a squeeze bottle, left to sit for 15 minutes, then the glue is pumped into each hole using a caulk gun.  The directions stated that one full pull of the caulk gun's trigger is needed per each hole or until the glue pops out of the hole.  That may be overkill.  On a series of drilled holes, I found myself squeezing two to three pulls of the trigger with no glue being forced back out of the hole.  I must have hit a pocket or found a void between the lathe.  Either way, the purchased kit was stated at repairing 9 linear feet of crack.  I believe you could get more out of the kit once you get used to it.  The kit isn't cheap, so making it effectively last is an excellent goal.

After filling all the holes, a special washer was screwed into selected holes which, when screwed in, pulls the lathe and plaster back together again while the glue cured.  

The directions said that I should give time to allow the glue to dry; I waited a week, just to be sure.  Then  I removed all the washers with a putty knife.  Did a little sanding and applied joint compound on the surface to fill the drilled holes and cracks.  I let it dry, sanded and repeated until the wall was smooth.  After I painted the surface, the final product looked amazing!  See the special note at the bottom of this post.

The kit came with glue, special washers, primer, gloves and directions.  Extras needed were a drill, masonry bits, vacuum, scraper (to pry off the washers), joint compound and a plaster knife/trowel.  But these are tools that every handyman (or woman) should have laying around.

The entire process is messy mainly because of the joint compound, plaster dust, glue and my inexperience.  Gloves are included in the kit, and thinking that I was a tough guy, I didn't bother with them.  Use them, the glue does sting if you have any cuts on your hands.  Protect your floors too and don't be a tough guy.

Total cost was $79.00 for the small nine foot kit with shipping being an extra $17.50! (in 2012).  As pricing becomes more affordable per foot once you buy in bulk, I may consider going after the larger Contractor kit.  However, it is still on the expensive side for my budget.  I will admit, that without trying any other kit, Big Wally's does what is should and was relatively simple to complete.

For more information, see Big Wally's site:  http://www.plastermagic.com/

Here is the video from "This Old House" that inspired this repair:
How to Repair Plaster Walls with Tom Silva

Note:  No, I have not been paid in any way to review this product.  Though I have to say that I had to pay them to try it.

Special note regarding painting:
1.  DO NOT assume the paint the previous owner labeled innocently enough as "White Interior Paint" on an attached post-it note is not (in actuality) yellow tinted white exterior trim paint.

2.  DO NOT forget to open the only window in the room for ventilation.

... and this one is really important...

3.  DO NOT assume 1. to be true, conduct 2. and forget that the storm window is closed.

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