You're Going To Build A What?

The saga of J building his tiny off-grid house

Archive for the ‘welding’ tag

Braking news…

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John came down for a couple of days and we worked on the trailer brakes. Pulled the hubs off and cleaned everything out as they were in quite a state, gunged up with dirt and grime to an almost unrecognisable degree. A can of suitable solvent and a roll of rags later and they looked much more reasonable. Almost no wear on the bearings so back in they went along with a large amount of high temperature grease.

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In the process I discovered that one of the hubs didn’t even have brake shoes in it which, after some of the other things I’ve found as I’ve worked through the trailer renovation, doesn’t come as much of a surprise, and another set of shoes came apart in my hands as I removed them. I’m off to the trailer spares place tomorrow to get some new sets.

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The other puzzle to the brakes is that the actuating rods seem to have been connected backwards, as I can’t find any way that they could work in the correct manner in their current state. I’m hoping to have a look at a trailer or two at the spares place and see if I can figure out the correct way to put it all together.

I also took the other 6 batteries over to where they’re currently living and swapped them onto the panel. The first 6 seem to have charged up to where I expect them to be after the past couple of week’s sunshine which bodes well. Another couple of week on the panel for the new set should put them in good shape too and then they can all be tied in together and left to stay topped up until such time as I can put them in place. Which reminds me, I should think about designing a folding stand for the panels to ensure they stay securely positioned.

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I’m thinking I may just rent a welder for a couple of days and do the trailer welding myself after my holiday. Nick taught me the basics and I reckon that if I work on the side supports first, of which there are 14, then I should know whether I can safely tackle the main structural members after that. Otherwise it’s going to be winter before I’m getting anywhere and the delays are just driving me nuts. Besides, it gives me a chance to play with things that make fire and sparks and, after all, what could possibly go……… oh!

Peace, out.

Written by justin

September 14th, 2009 at 2:46 pm

Powering up.

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The bad news is that my welder is definitely knackered, so I’m looking at alternatives to get the trailer fixed and finished, probably I’ll just either hire a welder if my brother can make it down soon or I’ll just find a friendly welder to come over and do the welding for me.

In the meantime, I finally got half the power system up and running. The batteries have been in storage for a while, which isn’t the best thing for them, so the first 6 are now wired up and connected to one of the panels. It’s only temporary, which is why the cabling looks shoddy, but at least they’re under charge and being taken care of properly. In a week or so I’ll have the other 6 in place too. I can then monitor them to see what condition they are in as I have a couple of spares if any of them have been damaged by their storage time. All the cells were reading between 1.98 and 2.02v, which isn’t too bad, but we’ll leave them on charge for a week and then remeasure them when I take the next lot up.

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One of my next jobs will be to design and build a decent support frame for both panels. They’re going to stay on a ground based frame so they can be moved when needed. If they were mounted on the roof and I had to park the house anywhere that I can’t get the best angle I’d lose a lot of power generating ability. The solar hot water panel will be on the roof as this is less susceptible to angle changes.

I’ve also managed to pick up a few days work this week and next, so that will pay for a short holiday I’m taking later this month and put a bit of money back in the coffers for continuing the build. However, it also means I won’t be doing much on the house for the next week or so.

Swings and roundabouts.

Written by justin

September 1st, 2009 at 11:34 am

Another wall is finished.

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I’m really enjoying the framing, it’s best done alone where I can take my time and think it through, there’s a real sense of accomplishment seeing a wall going together and, if you do make a mistake, it’s generally not difficult to undo it and fix it.

Today was the turn of the North wall, this will only have one small window in, for the bathroom, so its a fairly simple and straightforward build. Once it was all put together, I couldn’t resist standing it up to have a look at it. Fortunately the wind was light and it just stood there, being all wall-like.

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Of course, once that one was up, I couldn’t resist putting the other two in place as well, and then walking around within the space it enclosed. Tomorrow if the weather stays good, the final wall will be done and I’ll really be able to feel the space properly.

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It looks like I’ve found someone to fix the welder for me, they’re going to look at it tomorrow and give me the verdict, so hopefully the trailer won’t be holding me back much longer. I’m picking up the last pieces of steel on Wednesday so fingers crossed the welding will be complete shortly.

Peace, out.

Written by justin

August 24th, 2009 at 5:17 pm

Two steps forward, one step back!

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Unexpectedly on Saturday morning I had a phone call from my little brother Nic to say he was free on Sunday and how about he came down to do the welding. Jumping at the chance to get the trailer finally finished I gave an enthusiastic ‘hell yes!’ and ran off to find a hire shop that had a suitable generator I could get on short notice. Fortunately it turns out there’s a very helpful rental place in Harrow who had a 5Kva unit available for the princely sum of £25 that I could collect before 5 and return Monday morning. Things were looking up.

Sunday morning came and I texted Nic to see how he was doing on the drive down from Sheffield. Time went by and eventually I rang at lunchtime to find a rather bleary Nic en-route but running a little late. Something to do with falling asleep at the kitchen table while drinking his morning tea, where he was found by a housemate some hours later still manfully holding his tea, dead to the world. Ah the joys of youthful carousing on a Saturday night :) .

Once he arrived we headed over to the house and set to work. First up was cutting out all the bits we no longer wanted, which is where two angle grinders come in very handy. Here you can see Nic working on the old, rusty and bent front section, along with the generator and the big welder.

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And a closer view of the front bar, you can just see the cuts through it and Nic finishing off the final cut with a hacksaw, as we couldn’t quite get the grinder into the gap.

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Now you can see just which bits were taken out, quite a lot removed.

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With that clear it was time to start welding the new pieces in.

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Shortly after that though, the welder started playing up. Not sure what’s wrong with it, just doesn’t seem to be creating the arc properly, it feeds wire, starts to spark and then just fades out. After poking and fiddling with it for a while we realised it wasn’t going to magically fix itself, despite the percussive maintenance we tried (i.e. hitting it) so we packed up for the day and went home.

The main front bar is on but not the extra pieces of the drawbar and supports.  Yesterday Pinky came over again and we finished grinding down the old support sections and tidying them up, plus painting all but the bits that don’t require welding, the silver sections are covered in weld-through primer to stop them going rusty where they’ve been ground down. I sat and drew up a slightly different front end configuration that will fit better and be stronger, though I need to pick up a couple more pieces of steel for it.

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So, progress, but I have to admit I’ve become quite fed up with the trailer now. I wish I’d spent the extra on a better second-hand unit in the first place. It’ll end up costing me the same, just taken months longer getting it all ready. Now, admittedly I’ll have learned a bunch of new things, but it’s putting a strain on the budget and the time. I want to have the roof and walls up by the end of September if there’s to be any hope of moving in before the winter arrives, which is my big hope. Next week I’ll be starting on the floor and wall framing, using the trailer as a construction base and then putting the panels aside until the welding’s finished. In the meantime I need to find someone who can service the welder without it costing me more than the thing’s worth.

Ho hum.

Peace, out.

Written by justin

August 4th, 2009 at 9:10 am

Two steps forward, one step back.

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It’s been a very busy couple of weeks here, but there’s less progress than I’d hoped there would be. Let’s start with the good news, my Ebay-fu is still rocking. The recent purchases are as follows:

Shower door: £10.50

I nipped up to oxford to collect this last week, only took 45 mins to get there and also allowed me to drop in on some friends who lived nearby for a quick cuppa and a chance to catch up. The door just needs a clean and the frame just needs the silicon sealant removing and it’ll be perfect.

Chimney Flue: £228

Now this comprises of 6 sections of double-walled, insulated, stainless-steel flue, plus the cap and a couple of 45degree bends. Each section is about a meter long and in the shops would cost around £100 each, so that’s £700-worth of flue. Found a courier company to pick them up from Kendal and bring them down to London for £30. Bargain. Just need a bit of a polish and they’ll be as good as new.

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Kitchen Sink: £26

Another Ebay bargain, this is a Kohler sink, brand new, still in it’s box and which retails for £285. I was actually bidding on another, identical looking, sink but which in actual fact was smaller. That went beyond my set budget (£30) so I started bidding on, and ultimately won, this one. It wasn’t till I picked it up that I realised it was a chunk bigger, as the seller had used the same photo for both and just changed the size in the description. Still, although it’s a bit bigger than planned, it’s a really solid sink for an absolute steal and, in emergencies, I can use it as a bath.

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Construction was planned for a bit of a boost this week as I took delivery of a mig welder to repair the trailer. Once again bought from Ebay for the bargain price of £136. It’s a bit rough around the edges and, when we plugged it in, it decided not to feed wire out. Opening it up and blasting away years of dust and assorted crud with the air blaster and winding off the first couple of layers of rusty wire soon had it running smoothly.

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We spent a morning chasing around to find some gas for it, turns out you need an account with BOC to buy gas, as you have to rent the bottles from them and that’s about £60/year plus the cost of the gas. Found a place that does it’s own bottles and for £103 picked up a big bottle of Argoshield gas, got three years rental on the bottle included and can swap out for gas at £20 a fill for the next 3 years any time I want. Nice.

It’s a big beast of a welder and you can’t run it at full power off a 13A plug but it seemed to be fine at lower power so my brother Nicky sat me down and taught me the basics of welding. I had some offcuts of steel from the trailer sides that we’d removed so we cleaned a couple of those up and got stuck in. It’s fun, I’m going ot enjoy doing more of that and you can see my efforts below. Need some more practice, but I think they’ll hold things together.

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The next morning we were up bright and early to go and collect the steel pieces we’d ordered and then set up to cut out the bad sections and weld in the new. That’s when we discovered that the power was out to the garage where I’m running my extension from. There was no-one home to ask if we could check the breakers so that was that for the day. Nick had to leave at lunchtime so we decided to leave everything as it was. I’ve got plenty to be getting along with in the meantime such as practicing my welding, fixing some other bits of the trailer etc.I’m considering picking up a small generator off ebay (wherelse) so that I can guarantee having power in future.

We did measure everything out properly so that now I know exactly how big the house is going to be, where I’m running the framing out to and how wide I’m going to extend the house out to (just a little bit less than the wheel widths. I can now sit down and properly plan the framing. I may even start building some of the framing as individual panels, getting them nice and square and cladding them in OSB, this means I can effectively pre-fab them, store them and then put them up once the trailer’s done, it also means they’ll be straight, true and, hopefully, will go together quickly and without gaps.

Meanwhile, Nick has managed to sort a new job out this week and will be moving to Sheffield in a couple of week’s time. This means that instead of being in Ireland, he’s a couple of hours up the motorway and can come back down soon to oversee the cutting out of the trailer parts and do the main structural welding for me, something that makes me a lot happier about the longevity of my tiny house being towed around the place.

In hindsight, I should have bought a better, more expensive trailer. This has set back the building several weeks and added to the cost, something I could well do without. That said, I’m learning new skills and collecting new tools. I may sell the welder when it’s all finished to recoup some cost, or I may keep it and add it to my workshop. I said originally that this wasn’t about the end product, it wasn’t about building with the absolute minimum cost, it was much more about the ethos of building small, about learning new skills and the journey of actually building my own house. Some of these things are priceless, such as sitting with my brother and learning a new skill from him. I wouldn’t change a thing about what I’ve done so far.

Peace, out.

Written by justin

May 16th, 2009 at 1:33 pm