Now We're Cooking

After a lot of consideration we opted to basically reframe the kitchen from the foundation up.  We had to reframe the back corner of the house anyhow.  There was heavy dry rot and insect damage in this back corner of the house, including two sides of the kitchen.  Two key reasons: Number one, at some point they installed a back patio which was higher than the sill plates on the abutting walls, with no expansion joint or treatment - it was basically sand and soil against untreated wood.  Not good.  Number two, and this is key, it's the roof stupid!  It's counter-intuitive, but if you have a rot problem at your sill (or anywhere for that matter), backtrack all the way to the roof.  In this case a moron installed gutters at some point and put a plastic mesh over the gutters to keep leaves out, and installed the mesh by nailing it into the roof and the metal valley where the kitchen el meets the main hose (center of picture).

One little nail hole three inches from the bottom edge of the valley, caused a little drip, drip, drip into the wall cavity, down the structural timbers, down to the foundation plate.  Soggy wood = rot = a juicy stew for termites and ants = THIS -------------------------->

In any case, there was a lot of damage, and prior modifications of the old framing.  Even where there were a few good studs, they were placed at irregular intervals - typically anywhere from 30" to 45" on center - so trying to frame for new windows and doors and cabinets where we needed was going to be basically impossible.  The greenish panel under the right side of the window in the below pictures is the remnant of a door.  At some point there was an exterior door there.  They basically cut away the top half, installed a double wide double hung window, and used the bottom half of the door as sheathing for the new shingles.  Resourceful. 

We saved the few timbers we could.  You can see the collar ties laying on the new crawl space floor.  These will go back up and be part of the structural framing.  The old dirt floor used to be about 10" below the sill plate.  There was no insulation and the floor was rotted and soft in many places.  And, it was pretty smelly.  The resident mice we're still sleeping in the oven insulation when we ripped it out of the wall.  They were startled.  So were we, although we shouldn't have been.

The new foundation was a major improvement.  We basically dug down below the frost line and poured an 8 -10" slab behind the existing stacked rubble walls so it locks in the existing foundation. Then we poured a "rat slab" on the floor to lock out the moisture and critters.  You will notice we also had to take down the fireplace in the kitchen.  We kept trying to take down one course at a time to get to a stable course to rebuild on, but each course was as loose as the next.  By the time we got to the firebox we knew we were beat - it was about an inch out of plumb from right to left, and the foundation simply wasn't solid enough to build off of.  I wasted a couple of days and a few hundred dollars trying to save what was there, but in the end we had to make the call for the sake of safety and soundness to take it all the way down and have it rebuilt.  I have a mason who has done these Rumford-style fireplaces in an old house restoration in Connecticut, so I'm excited to see him re-execute it.  We saved all the brick we could and will use it on the face inside, or the exterior portion, to ensure it looks "old" from outside.  We'll put back the iron pot hanger too.

This gable wall was funny.  It was literally

hanging from the rafters - you could lean on it and swing it back and forth over the foundation (the sill was totally gone.  There were no studs top to bottom which were complete and un-rotten.  And yet, we couldn't simply smash it apart.  Basically the exterior shingles were holding the whole dang thing together, so we sliced through them with a Sawzall in sections and tossed them in the dumpster.  Man triumphs. 

And when the weather turned crap AGAIN, we did the old hang a tarp routine, which NEVER works.  You just end up with holes and puddles in the tarp that pour down your neck at the most inopportune time.  We tried the yellow rubber suits too (mine was blue - ever the fashion plate), and that was just painful.  It was like being wrapped in cellophane and tossed in a steam room.  We decided to be wet and cold and comfortable instead.  Thank goodness the weathermen were wrong yet again, and the sun came out about an hour later.

The toughest part about this wasn't the demo or the framing...it was the measuring.  Ultimately we had to work with what was there in terms of a footprint and the existing roof we're keeping, but of course nothing was perfectly aligned.  It's not such a big deal if you know you have one straight wall to work off of, but which one to choose as our "base" wall to strike 3-4-5 triangles off of?  In the end, we did the best we could and it all fell within generally a 1/2" - 3/4" of plumb and square, which isn't so bad.  Once we straightened the top plates on the roof, the whole roof line fell in line and looks stable and true now, which is exciting.  I remember the first fussy engineer I had look at the house who almost lost his breakfast over the wobbly roof line.  He approached the house, gave it a once over, looked at the roof, and exclaimed in his frenchie accent - "eet is a gut reno'..."  My real estate agent had sized him up a few minutes earlier when he refused to step in snow to get to the back door.  In any case, I digress. 

With the demo done and the lines struck, we quickly knocked out the new framing.  We used 6x6 treated timbers for the new sills - I figured we'd keep it as close to the original timber dimensions and framing style as we could.  With the sill and top plates laid out, we went to town.  We realized a 1 1/2" height screw up once we had the first wall up, we simply cut the nails securing the bottom plate to the 6x6, jacked it up,and put another 2x4 under it.  Presto!  Tinker Toys are so much fun.  My nephews were so amazed how you can lift a wall with a couple of car jacks and basically hold up a whole house temporarily with a couple of 4x4's.  I fear a stupid frat house prank at some point...

And then the sheathing.  Progress again!!!!

The waning daylight, and me being drenched to the core from earlier rain, eventually won out at the end of the day.  But the progress was solid, and the gods were pleased.