Five year project

The laundry room has been the project that keeps on giving. It started out that I was just going to replace the back stairs in August 2011. Then I ran into problems waterproofing, so I stopped the stairs, and started working on the laundry room. Five years later, it’s finally DONE! So I thought a before-and-after photo post is in order:

Checklist

This is the checklist I scribbled on our white board, back when I thought it would be a quick project. I kept adding items as I went. Very satisfying to have all boxes checked.

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Above left is the back door to the kitchen before. Above right is the same view after, with the door moved to approximately where the window used to be.

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Looking a bit to the right, the dryer used to be jammed into the corner so tightly that the back door wouldn’t open unless you pushed against the dryer. Actually, it was such a tight fit, that the previous owners had cut out part of the back wall to make it fit. You can see the old back door location at the right side of the photo. Now it’s all windows in that area, looking out to the garden. I’ve put a small couch in this space… Hmm, maybe I should have used a photo with the couch in it. Oh well… You’ll have to come visit to see.

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Here are two more photos of the old back wall of the laundry room. You can see the door opening into the moldy ‘tear-off’ room. Funny, in these photos it looks so sunny and airy, and you can hardly notice that to walk in there, you have to be under 5′-10″. On the right side is the wood door to the toilet. Actually, it was more like a closet with an always stinky toilet in it.

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This is the same side, now. I put a wall all the way across that side, so made the laundry room a little smaller, but a more functional bathroom. Bathroom door is now a nice restored redwood door that I hung on sliders to make it a pocket door.

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The washing machine is in a similar location, but there’s now a sink behind it, instead of next to it. The new arrangement is not perfect – but was the only way I could figure out how to make this work. One other solution was to not put a sink in this room at all, but I find it so useful to have a utility sink.

This room used to have loads of shelving, so I added some shelves. Living in earthquake country, shelves scare me a bit, so nothing on them yet… We used to have lots of plants in this space, but I’ve found that if I put plants in there now, they die because I don’t go in there often enough to remember to water them.

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Instead of that stinky little closet with the toilet in it (sorry, no photo), I expanded the space to make a tiny, but functional, bathroom. On the left is the shower.

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And last weekend, I finished putting up the mirror and an electric towel warmer. There’s no heating in this space, so hopefully this will help a little (?) I’ve still got to figure out how to deal with the power cord – probably just some white wiremold aligned over the grout lines would do it.

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prrrrr

Finishing up: Paint and a Bathroom

Finally: Paint.

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Painting the wood trim is always the hardest part. I tried (and failed) to use the airless sprayer to paint the walls and the trim. The result was sagging, dripping paint on the trim, because it puts far too much on. Had to wait a week, sand out all the sags, and repaint by hand.

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Paint colors are so difficult; even more so because when they mix them, it seems like the mixed colors just don’t match the samples. Luckily I have mole to pick colors. She picked the ‘november skies’ (medium blue on the card in the photo above). But when it was mixed, I put a bit on the wall and it was way too light – looked like the powder blue that old VW bugs were sometimes painted. My feeling: Hate is not too strong a word for that color. So I went back to the paint store and asked them to add pigment. I used the recipe for the darkest color on the sample card. They fought me, because they said that the darkest color used a different base. Eventually, they agreed, and we got the color that’s on the background. Not a standard color, but we like it more than either!

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Some painting action photos!

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All painted, before the washing machine went back in.

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Here’s the bathroom before the toilet. Actually, the sprayer worked well in here. The difference? I used cheap paint. Seems like cheap paint sprays better.

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Painting the wood wainscot and window trim was a lot of work.

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I bought the glass shower door very cheaply at overstock.com about a year or more ago. At the time I bought it, I hadn’t put the tile on yet, so I estimated the space. The door also allowed some adjustment for width, so I thought I was safe. Not! Once the tile was on, the space was one eighth inch less than I’d estimated. All the adjustment happens on the wall opposite the hinges, at a 12 inch wide fixed panel. I spent an entire day trying to grind down the aluminum adjustment piece so that it would fit. No luck.

Eventually the solution I came up with was to order some stainless steel brackets from China, and screwed them to the wall and to the aluminum edge piece on the glass. Instead of the supplied slotted aluminum piece that was supposed to close the gap at the wall, I just used silicone caulk. But it looks fine now, and I didn’t have to buy a new glass piece. Lesson learned: Order the glass after the tile is finished.

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The sink is tiny tiny. This room is so small, that there’s not much room for the sink, and to allow the shower door to open. When I laid out the tile, I put that diamond shaped decorative tile above where I thought the sink should go. But once the sink was attached there, it was obvious that it was much too close to the shower door (see the door handle relative to the sink edge, above). Very awkward.

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So I took it off the wall, and re-did it. That required some tricky plumbing for the waste line (which I had to redo three times.) The glass shelves are part of the shower door – quite a neat solution to bracing the fixed panel. The only sad part for me is that there is a hole in one of the tiles to the left of the sink. Maybe I can glue a decorative tile on top of it, or find some way to make not show. Suggestions welcomed!

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And now there’s a toilet. Now I just need a towel rail, a mirror, and to finish the lights.

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The sliding pocket door for the bathroom has a beautiful old-style lock. Unfortunately it’s impossible to find the correct keys for them now, so I bought a nice solid cast bronze key and filed it down to fit. Only problem is that traditionally, the key would have had a loop that could fold flat so the key wouldn’t get in the way when the door slides closed. We’ll just have to remember to take the key out before trying to slide the door into the pocket…

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So, trying to take a selfie while riding a bike is a bit dangerous, and doesn’t work very well. Here’s Janeen and me while riding the Primavera century in April. I think Janeen was suffering a bit from the headwinds at this point so I was trying to ride in front to block the wind. We had a great time, and also rode it with a couple of good friends (Kirk and his twin brother Derrick).

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Brewing, Tiling, Riding, Waterproofing, Siding…

Wow time goes by quickly. Well, I’ve actually done something in the last few months. And here’s some of it:

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I bought a jug of apple juice at the farmer’s market, added some yeast & a bubbler: Cider! Much easier than brewing beer. I finished laying the tile in the laundry room bathroom, but am going to wait on grouting it until I’ve also tiled the laundry room.

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And of course, we rode AIDS/Lifecycle together this year. Here’s a picture from the opening ceremony.

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Here’s me trying to capture the party atmosphere in the Cow Palace…

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A photo with our friend Alex who rode one day, but work stopped him from doing the whole week.

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Well, these front steps have been an ongoing project. Seems I have to fix them every year. The temporary fixes from past years finally gave out. The photo shows how the front of two steps broke off completely. There is also another problem with these steps: The height between steps varies too much for code compliance, so it was high time I did something about it.

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The reason the step heights vary so much is originally they were built with thick boards. Then (before we got the house), some repairs were done with thinner wood. To fix this, I had to make new steps out of thicker wood. I re-used some old wood that I still have in the garage. Lots of planing, gluing and clamping to make boards that are wide enough for the steps.

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I forgot to take photos while I was working on it. There’s one photo where I’ve replaced part of one step. I also replaced the step below it. The one below that was concrete, but it had a piece of wood glued on top. This made the step heights very uneven, so I took the wood off: The reason they’d glued the wood on top was the concrete underneath was cracked and uneven. So I had to repair the concrete, also. Above right is after I’ve repaired the bottom five steps. Looking further up, you can see that some of the upper steps are also uneven and need to be fixed: Next year!

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OK, to head off the ‘no cat photos’ complaint: I think Bella was sleeping under the table, and Arwen (love-bug) decided she needed some cuddling. They were actually sleeping like this for a while.

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One other project that I got partially finished with, but stopped because of ALC and life, was the siding and waterproofing on the back. In the photo above left, you can see where I left things for the past two years. The building paper is exposed (getting damaged by the sun), and I’ve “sealed” the top with some blue tape. Above right, I’ve taken out the wall of the back porch, so that I can take out the siding boards and re-use them. Clearly the rear porch was not part of the original building construction.

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Here’s all the siding removed. The wiring for the porch lights is hanging loose, and you can see in under the roof.

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Here I’m getting plywood on. It’s a bit complicated because the drain for the kitchen sink goes through this wall. Luckily (for the house) we’ve had very little rain for the past few years. But there’s predictions of ‘el niño’ this year: hopefully lots of rain. But I have to get this properly waterproofed and finished first.

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Here I’ve added the porch wall back in. Wiring is now much neater.

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The siding was is very poor shape. Lots of holes cut for various plumbing iterations over the life of the house. But the wood, once the peeling paint is removed, is still good. Thousand-year-old redwood is too good to waste. So I carefully repaired all the boards.

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Here are the same two boards after I’ve glued in pieces to repair them, and sanded ready for primer.

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The photo above left is titled “One Weekend of Work”: Repairing and re-using the old siding takes masses of time. Six boards in two days: Not the sort of thing a contractor would do. Above right, I’m getting the building paper on, and waterproofing around the drain pipes. I also got a new wall vent for the attic space.

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Here are photos of the process of putting the siding back on. Cutting around the pipe penetrations is tricky.

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And here’s where I’ve got to. I’ve ordered new windows for the porch, so can’t go much further here until they arrive. Above right is a view under the porch.

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Here I’ve added insulation, and installed wood to cover it. This is re-used wood left over from the laundry room wainscot. It still needs some trim around the edges and paint, but looks much better – and the porch will be more insulated now.

Hexagon Tile Patterns

I finished up the base of the shower. For the base, I switched to a 2″ square, white tile that had a flat finish, to make it less slippery. I also turned the tile 45 degrees. Because the walls are not parallel, there would be no way I could get the grout joints to line up properly.
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Once it’s grouted, the grout lines don’t show up much. I decided to stick with white grout in the shower, but for the floor, we’ll use a grey — I think.

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Then I started laying out the hexagon tile for the floor. [That makes it sound like I didn’t leave this project alone for a month…]

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We’d already decided that we are going to use black tile to make a border, or pattern of some sort in the floor tile. I like it for two reasons: First, it has more of an old Victorian decoration quality. Second, patterned borders catch your eye, and take it away from any flaws or imperfections. Deciding on a pattern, though, is not easy.

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I like the whimsical quality of the pattern above left, but is also has an animal tracks feeling…

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Then I thought: Maybe it would be nice to do a very simple border, and put a pattern in the center of the floor

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Hmmm, more on that later…

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Here’s another thought: a double border. We like it, but it uses a lot of black tile. I didn’t buy nearly enough to do this in the laundry room too. But they may exchange some sheets of the white for black.

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More ideas, trying to reduce the amount of back tile.

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After trying lots of different patterns, I started to go back to my initial pattern. Instead of running the animal tracks all the way around, how about just doing a pattern in the corner?

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Hmmm, how about a pattern in the corner, with a dotted border? No.

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The following six are my favorites.

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What happens when I get carried away with hexagon patterns?

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Slow season

We are approaching my slow season (even slower) for working on the house. Training for ALC is in full swing, so I only have one weekend day to work on the house, assuming we don’t see friends or family!

But, I did finish doing the grout for the walls…

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The last tiles at the top and around the windows take a lot of time. Every tile needs to be cut, and the top tiles are not all the same size. Cutting the tiles at the sloped ceiling was tricky: I made a wood template for the angle, and held the tiles against it while I cut them. I really pushed my luck with the order, too: only 8 extra tiles. Good thing I didn’t run out (custom-made tile!)

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Above left: Before I put the tile on, I added a strip of kerdi waterproofing membrane around the wall-to-floor joint. Just in case there’s a leak in the bathroom, it won’t get into the walls. Above right, starting grouting the white tile. The grout is smeared onto the the surface with a rubber trowel, working it in diagonally to fill the cracks, and then the excess is wiped off. This leaves a haze of grout that you let dry for a couple of hours before polishing it off with a dry cloth.

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Above left, smearing the grout. Above right, wiping off the excess. Do I look like I’m having fun? My shoulder was hurting!

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Here’s what perfectionism looks like: Above left, the cuts in the tile to fit it around the top right pipe (barely visible in the photograph) bothered me so much that I chipped out the tile, and made a new one…

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Here’s the new tile installed and grouted. I’ll be the only person who will notice, but at least it won’t be bothering me now!

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While I was grouting the tile, we heard a huge thunderclap. Mole ran outside to catch a photo of the clouds. It didn’t rain here, but apparently we got some snow in the Sierras.

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More grouting action shots…

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Arwen was wondering what I was up to: “Why are you making it all smudged with white goo? I liked it better before.” Above right: The white tile after grouting.

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Here’s how the green tile looks when grouted. I took the lower photos in daylight to give a better idea of the actual colors. I think it’s looking good.

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Here are a couple of tile detail shots: Above left, I used curved base tile around the shower pan, because that joint between the wall and the floor (particularly at the corner), is really difficult to scrub. Hopefully with the curved profile, it won’t be so difficult. Above right: The niche with the two decorative fireclay tiles. I like them.

Now on to the floors…

Green Eyes

The tile continues. Most of the tile is now on the wall – save the last fiddly bits.

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I put up all the whole tiles first, then fill in the cut pieces. I’m getting quite good at cutting out the tricky tiles that go around pipes and electrical boxes. In the upper two photos, I’ve got almost all the whole pieces of tile on. Just one more row at the top, and above the windows.

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Cutting the tile to fit around the windows is quite slow work. The tile at this window took all day. I’m standing on a ladder in the photo – Mole came downstairs to check on me, because it was past 9pm and we’d not had dinner!

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The next parts to finish: the difficult sloping cuts up close to the ceiling (left), and the other window (right). I just ordered the shower door: The price was so low at overstock.com that I just couldn’t resist (less than $600 including shipping for a frameless 3/8″ thick shower door with side panel.) Hopefully it’s not junk!

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I didn’t include any photos of cats in my last post, so here’s a close-up of Arwen.

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and Bella looking at her water fountain.

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Arwen taking a nap…

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If you were a small creature in our house, this would be the last thing you would see. Where do you think Mole got the idea for the tile color?

Starting Green Tile

I finished up the white tile. The last part was much slower than I expected: Fitting up against the ceiling was really difficult on the left side, because the ceiling slopes.

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Above right is the finished tile before grouting.

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We had planned to buy one color of green tile for the remaining wall. We really liked the tile we had found, because it had some variation in the glaze, and a nice crackle in the glaze. Unfortunately, Fireclay no longer makes the color, and we’d already bought about half the tile we needed last year. So it came down to buying a selection of colors that were close, and mixing them. I was so daunted by the prospect of trying to make them look random that it took me a couple of weeks just to get started. I drew the outline of the wall on the floor of the garage, and did a layout on the floor.

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The second hiccup was that I thought I’d forgotten to install the solid wood blocking in the wall where the sink will be mounted. Without something solid to attach the sink to, the sink would fall off the wall eventually. The only options are either to build a floor mounted cabinet to support the sink, or to tear open the wall and add the blocking.

This would be my last opportunity to fix it (before the tile is installed), so I’d resigned myself to cutting the wall open, and installing the wood. Luckily, before doing that, I checked by drilling holes in the wall where I’d need to attach the sink. Apparently, probably because this project is taking me so long, I’d forgotten that I did install it, but hadn’t taken photos. Note to self: Always take photos before closing up walls! The photo above right shows where I found the wood in the wall, and a tape measure, so I will know when it’s time to drill through the tile for the sink attachment.

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Here’s the start of the green tile. I picked it up carefully, in order, from the garage floor. Then transferred it in the same order when I put it on the wall. This tile is much harder to work with than the white tile: it’s all slightly different thickness, and dimensions, so I have to be very careful to lay it out to a grid. The handy rubber tile spacers (that were so great for the white tile) don’t really help much with this tile. You can see the grid marked on the wall in the above right photo.

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There was some tricky tile cutting to fit around the electrical boxes and the pipes.

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Here it is almost up to the windows. Above left, I skipped the tile around the shower valve. Above right: I put the third decorative tile (similar to those I used in the niche) centered above where the sink will be.

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Cutting the tile to fit around the shower valve was the most difficult. In the photo above left, the tile at the lower right corner of the valve is almost completely cut away. I think I spent almost an hour cutting that one piece! I also put the window sills on (cut from the same stone that we used on the niche shelves).

The stone for the window sill is thicker than the tile, but I’d only allowed for tile thickness back when I was putting up the cement board. For the window above left, I had to grind the back of the stone shelf to get it thin enough to fit under the window, because the waterproofing was already installed. Above right, on this window, because it’s not in the shower, there’s no waterproofing membrane, so I could change the cement board to get it to fit.

I’m about half way up this wall. The green is looking good, I think. It’s probably difficult to see from the photos, but I varied the random pattern across the wall so that more of the dark green tile was on the right, and more of the light green on the left. It’s still quite varied, but I think less ‘speckled’ looking than when it was totally random…

Tile progress (turtle pace)

At long last, we ordered the tile. We waited so long, that the original color was discontinued! So now, because we already have a couple of boxes of the discontinued color, we ordered three other close shades, and will be mixing them up. More on that in a later post. We also decided, since the Fireclay tile is so expensive ($28 per square foot!!), that we’d just use that tile on the wall that’s facing the door, and use white ceramic tile ($1.30 per square foot) on the other two walls. It also is in stock (we have to wait about a month for the fancy tile to be made). Value engineering!

So I got started on the white tile. I covered about half a wall before I realized I hadn’t been thinking.

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The white tile has special spacers built into the edges, so you can lay it out with very tight gaps. It’s almost perfectly uniform, too. So I thought “great, I’ll make the grout gaps as small as possible.” Then I realized that the Fireclay tile requires a minimum gap of 1/8″ because it’s hand made and dimensionally irregular. So I need to also space the white tile to match, if I want the grout lines to match up (of course I do — you know me). Luckily I realized this before the end of the day, so I spent the rest of the day pulling tile OFF the wall, and scraping thinset off the back. One day, and I’d have got just as far by going for a bike ride!

The next time I started I decided to start with the wall had has a niche (photo above right). I’m making the shelves out of a piece of stone back-splash.

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Above right, you can see one of the decorative Fireclay tiles we got at their “boneyard” (over-runs and imperfect pieces at discount). I’m adding it as an accent in the white tile.

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After three days tiling, above right is where I’m at. All the grout lines are 1/8″ and lining up. I have to make one more shelf, and continue the tile up to the ceiling…

And I have to include a picture of Arwen. I hope you’re keeping as cozy as she is:

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Kerdi Shower

I finally started doing the Kerdi waterproofing membrane on the shower. I’m always talking about it with people, so I tried to document the process a bit.

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Above left, I’m test fitting the piece that will be used in the base of the shower. I’ve cut it so that it turns up 2″ around all the edges, and laps over the curb. It’s a simple circular cutout at the drain, because the special drain flange bonds directly to the membrane. Above right, I’m wetting the cement board and mortar bed so that all the moisture doesn’t get sucked out of the thinset. I trowelled the thinset mortar onto the cement board and base, then laid the membrane on top.

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The membrane is carefully pressed into the thinset mortar (the waterproofing membrane has a fleece-like surface on both sides, so the thinset bonds to it). I use a wide putty knife (above left). An important point is you must use unmodified thinset mortar: The modified thinset mortars do not set up or cure between two layers of waterproofing membrane – that would be total disaster.

Above right I’ve installed the membrane onto the left wall also. At the base, I run the membrane over the top of the 2″ that laps up the sides. You can see a patch I had to put on the wall: I accidentally poked a hole into it while smoothing it (corner of the trowel dug in and tore a notch). The membrane is quite strong, but you have to be careful if the surface under the membrane is uneven.

I like to work from the base up, because I like the idea of the membrane layering over the piece below, but apparently it’s not necessary. The difficulty with the way I do it, is the bottom piece has to be carefully protected while I’m working on the sides.

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Here’s a bit more of the process. I’ve troweled the thinset on the wall above left, then laid the kerdi membrane on and flattened it (above right).

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Above left I’ve put the membrane on the right wall, and above right shows the waterproofing at the window. I’ve lapped it a bit onto the window frame, so that I can seal that joint. I don’t want water seeping between the edge of the membrane and the window frame. I’ll also add silicone caulk when I tile it, but apparently the thinset mortar will adhere to the vinyl window ok.

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Totally unrelated, but I liked this Dilbert cartoon: Reminds me of someone I know.