November 26 - Rocking the Ceiling and Some Outside Work

A Big Flat Ceiling -
The ceiling over the kitchen, dining area, narthex and restrooms are all in one plane. The current project is hanging the drywall from the trusses to close up the ceiling over all of those spaces. Being inside work, it can be as easily done after sunset as during daylight hours. No matter when it is done, it is heavy work. A twelve by four foot sheet can be carried by one strong man but it is a workout.

Hanging the material on a ceiling means you must fight gravity the whole time. My father used to talk about innertron, the solid matter that is lighter than air. He claimed you could put some in your pockets to hold up your pants. He was in the bakery business and said it was useful for moving 100 pound flour sacks to the mixer - much easier than carrying them. I never saw the material but I recall it being often mentioned as I was growing up. Watching the guys hoisting, positioning and then attaching the large drywall sheets made me think that a little innertron would come in mighty handy for this job. With no innertron available, manual labor was employed.

Aare and Eric would draw pencil lines across the sheet using a t-square. The lines are drawn 24" apart, the same as the truss spacing. These guidelines are then where the screws are to be located when the sheet is hung. They then carried it to the lift where the screwy hanger guys waited.

The lift was jockeyed into position for the next sheet to be hung. The three men in the lift, in this case Ed, Dave and Phil, gripped the edge of the sheet, and on the count of three (or seventeen depending on how much of a rest they needed) flipped the sheet over and and maneuvered it into the next available spot.

Then, using their heads, this time for holding up the heavy panel and not for thinking, pulled out their drills, spit the screws out of their mouths and following the guidelines provided, proceeded to drive a few dozen screws into the sheet, securing it firmly to the trusses above. The process was then repeated over and over and over and over. Well, you get the idea. It is a size large area and many panels are needed to cover it.
Meanwhile, in the entryway and coatroom,Eric, his son Byron and Loren were going through similar gyrations to rock that ceiling.

Big Flat Ceiling Done -
When the last sheet was installed by lunchtime on Saturday, about 150 four by twelve sheets of drywall had been screwed into place. Each sheet requires something in the the neighborhood of 50 screws to hold it. Heavy work and repetitious work. But now this task is completed.

The Front Door -
With the windows installed and the service doors covered, the main gate, the front door, had to be covered to keep the wind and weather on the outside. Large equipment, like lifts still need to get in and get out. So, an operable door is required. The first iteration was re-implementing Ken's ratchet pulley and boat anchor rope mechanism attached to a 2x4 and a large sheet of poly. This system worked well, but alas, it is again short lived.










Ami works in the garage door installation business and came up with a really-o truly-o all season garage door, shown here both closed and open. This is real class. Not many churches can claim an overhead door as the main entry. We are now one step closer to a heated building.













There is a space heater hanging from the ceiling waiting for a fuel line to be connected. Bob mentioned something about on-going negotiations to get some propane hooked up. I did not follow the whole thing very well so I can't accurately report on the status. I can tell you that the heater looks nice and I expect it will put out adequate heat for the building should the fuel line ever be connected.

In the meantime, some folks are concerned about the possibility of cold weather sinking its icy fingers into the ground before the heater is connected. In Minnesota, winter weather is certainly a distinct possibility. So, to prevent those icy fingers from penetrating under the footings inside the building, preventative insulation has been imported in the form of hay bales. With the Christmas season now upon us maybe the Sunday school Christmas program could be held in the new church, with genuine hay bales to make a more realistic manger scene. But I suppose not many people would agree with me on this thought.

Warm Weather Continues -
While it is necessary to prepare for cold weather, we are enjoying unseasonably warm temperatures. Saturday saw bright sunshine throughout the day which melted the snow off the roof. No gutters have been installed on the new roof so the folks installing material on the soffits had to deal with a bit of drip from the roof. But no worry here. A little ingenuity, a little poly, and a few staples and voila! A runoff protection system that is much cheaper than gutters. Bob, Brandon and Eric do the assembly.

 I believe it was dry and cozy under the rain sheet. With the sun beaming as it was I suspect it was like a hot house under the plastic.

Other father and son teams were working together on Saturday. Eric and Brandon were already noted.








Ben and Laif Huhta installed soffit covers on the gable end, riding together in the lift basket while at ground level, Ed and son Justin installed the ground skirt.

Runoff from the roof also required some civil engineering work to get the water away from the building. Aaron keeps his gardening skills sharp by using a hoe to dig irrigation trenches.

November 19 - Windows!

The Beautiful Donate Button -
Well, it did not happen while I vacated, but now I will offer an explanation of the "Donate" button now residing in the blog heading. Early on in the building project, after one of the very early posts I got a phone call from a non-Elk River congregation member, suggesting that the blog should include a place for readers to donate if they so wished. So a link to the LLCER website was added to static area on the right side of of the blog. However, donating to the project through the LLCER website required leaving the blog, finding the proper tab on the website, locating the correct fund on the drop down menu and finally making a donation. A seemingly cumbersome and somewhat daunting process for someone who just wanted to make a contribution. I know if I were a follower of the blog, I would have been discouraged by the multi-step process required. It also may have seemed intimidating to go through all those steps and only make a $10 or $20 spur of the moment donation.

Now then, to make it very easy and convenient to help out our building project in Nowthen, all you have to do is click on the Donate button in the blog heading. It looks like the one shown here, although tastefully smaller. Notice that many popular credit cards are accepted. And please understand that any and all donations are appreciated.
The whole project is dependent on free will offerings of labor and money. We understand that even with supreme effort and financial sacrifice, the project will succeed only if God blesses these efforts. As the Psalmist wrote long ago, "Except the Lord build the house, they labour in vain that build it:" (Psalm 127:1). We have seen that God has blessed the project with many willing workers and generous donors. We thank God for these blessings.
The Race Against Winter -
While I was away, many things happened on the building site. For one thing, a beautiful, mild autumn season abruptly surrendered to the first snowfall of the season as winter barged in and dislodged the fair weather fall. Another happening was that windows showed up. Fortunately, the windows showed up before winter. I was told that Andy got a start installing the windows, but it was one man against many windows and many openings.


Fortunately, eight workers from Niemela Construction showed up to help install the windows. Trevor Hillukka is shown preparing the opening as Ken Kako looks on.

As nice as it is to have the windows on site, it is even nicer to have them installed in the wall openings.

I have reason to believe that Kevin Loukusa, the worker pictured, is aiming the hammer at the nail head on the frame piece and not testing the strength of the glass. At any rate, the glass was not broken.

While they were in the neighborhood, they also help finish sheeting the gable ends.

So, the chronicler returned to find closed up gable ends and all the windows installed. But as the chronicler was returning from the west, winter came racing in bearing snow (yuck), cold (yuck, yuck) and wind (more yucks) on its shoulders. I spoke with Ken Friday evening, to check up on the project status. He announced that he was standing inside the church, out of the wind, where because of windows and enclosed gables, the wind is banned from entering. This is not totally accurate since there are still door openigs to be sealed up, but it is possible to find a wind protected spot inside the building.
Saturday Update -

The snow showed up on Friday, but the windows were all installed. Now with the roof complete and all the windows in place it looks like it will be possible to get some heat in the building so the inside work can continue through the winter. It was a close race, but it looks like winter finished a close second.

Anybody Need a Window? -

While on site Saturday morning, I noticed this window, sitting in a shipping frame, inside the building. I asked Ken where this was going to be used since I saw no unused window openings in the building. He said it was an extra. I am not sure if we will sell it or what will ultimately happen to it. We also have an extra piggy back truss. Know anybody who needs a green window or a piggy back truss? It seems like all the projects I ever tried had extra parts left over too.

Ken did point out on the drawing where the window was originally planned but had been Xed out. Apparently the X showed up after the window order had been placed.












The Heated Box -
One other interesting sight was a covered box with a cord attached. The cord is visible just to the left of the far corner in the picture. I was not exposed to the contents of the box but I suspected that it is an incubator for chickens or geese or some such thing. I was reminded of the late spring day one of our boys found a goose egg outside and brought it in the house to hatch. He knew it needed to be kept warm until the gosling decided to come out of its shell. He placed the egg in a cardboard box adjacent to the heat register in his bedroom. He then turned the thermostat up to 90 degrees, thus turning our house into a 2,000 square foot incubator for this one goose egg. When Mom got home to a very warm house the box was placed under a heat lamp and the house was allowed to return to normal, human comfort level temperatures.

So what is the need for a heated box? There are things that should not freeze and with winter now here in force these items, like caulk and the Keurig coffee maker need to be kept from freezing. Therefore, build an insulated box and drop in an electric heater. Another of the short-lived construction steps necessary on this kind of a project. I understand that heat will be pumped into the building in the next week or so. I suppose the box may need to stay in use for a while but eventually it will make its way to the dumpster.

November 5 - Roof Fully Shingled

Completing the Shingling -
Bob sent this picture at 7:18 Friday evening as the last shingle on the ridge cap was being secured in place. Loren, Phil (I think) and Dave had the honor. As was mentioned in an earlier post, this is a size large roof with lots of shingles. I suspect that all the guys that spent time up there are very happy that this phase of the project is complete. Dave mentioned on Saturday how pleased his is that his feet and ankles will have some time to recuperate and get back to normal again. Clambering around on such a steep pitch for hours at a time takes its toll on lower extremities.

On to the Next Task -
Saturday was a beautiful, almost summer-like day. Bright sunshine and warm. The atmosphere at the work site was perceptibly less intense and pressure-packed than the days spent shingling. I think there is a general sense of relief at getting the housetop sealed up before the winter snow set in. There was time to do some work site cleaning.

 Phil, with a basket-load of shingle scraps, boxes and assorted other refuse, chauffeured the mobile lift to make a deposit in the dumpster.

Dave joined the parade to the dumpster with his load, using a smaller, more maneuverable vehicle.

Meanwhile, Bob was marching back and forth on the roof in a regular pattern, covering the entire length and breadth of the surface. I thought he might be practicing to be an insurance adjuster inspecting for hail damage, even though I know there had been no hail applied to the new roof. When he came back to earth, I inquired as to his mission while appearing to be aloof on the roof. "Checking for shiners," he said. (Searching my accumulated knowledge bin for a likely construction-oriented-jargonesque use of the word shiner, I came up empty. I could only come up with a black eye or a minnow, neither of which seemed to fit very well.) He continued, "exposed nail heads need to be covered. Exposed nail heads indicate a miss of the designated nailing area. Covering the nail heads with roofing tar reduces the risk of rain infiltration."  (I think it might also prevent some leaks}. So a shiner is just a nail head reflecting the bright sunshine. He reported finding only about 10 or so on the whole roof. Pretty small number considering the 62,000 or so nails anchoring the roofing shingles. Good work, you shingle nailers.
Do You Know About Bracing? -
Having subjected the readers of the  blog to my earlier rant about the bracing required for the gable ends of the building, I will dispense with further editorial commentary. And remembering that pictures are worth a lot of words (and probably easier to understand), I will include a couple of photos for illustration.

Sam is in the picture, fully imprisoned by his own carpentry. I worried that he would not be able to extricate himself in time for lunch.

It appears that Jackson, Brent and Grant were also worried as they used the lift to try to rescue Sam.
I should have known not to worry. Sam made it down of his own accord just fine. It was probably predictable that he would not be late for pizza.

The bracers just kept adding braces. They kept adding 2x4s and nails. It started to look a lot like fun, like they were building a size large jungle gym for the kids to climb on after services. But it will all be covered up and inaccessible for climbing purposes. By mid afternoon Saturday the bracing was complete in the gable end over the front entryway. I asked if all of the gables had to be similarly braced. "Yes", Bob explained. "The wind blows from all four directions."

Bob took me up in the lift to check up on the rescue vehicle and also to admire the finished roof. I can attest that it is a thing of beauty.

After the bracing is done, nailing strips are added to the outside of the gable so plywood can nailed up to seal the end. By the end of the day, the south facing gable end was completed.
One down and three to go.
The Chronicler Vacates -
I am leaving for the west coast. So, it may be that whatever exciting and noteworthy things happen before I return will go unreported. Someone might be inclined to send some pictures for me to post in the meantime, so it may be possible to still get a timely update. If not, then news will be coming upon my return.
While vacating, I may be inspired to publish a post explaining the beautiful and eminently practical "Donate" button now adorning a prominent spot in the blog heading. If so inspired, I will explain how you, too, can be involved in helping us bring this church building project to a successful completion. You might want to have your credit cards handy just in case the inspiration strikes.

October 29 & November 1 - Roofing, Lunching and Bracing

The Size Large Roof Nearly All Shingled -
A Saturday without rain is a real treat. If the rain holds off until after lunch it is still a good day. Many workers turned out and many shingles got nailed down.

After a full Saturday of work, Sam announced Sunday morning that the roof was 7/8ths complete.

The picture on the right shows the remaining one eighth. I am not sure how he came up with the amount unfinished. I wonder if he counted out 1,287 shingles left in the inventory. 

Work fascinates me. I can watch it for hours. There are always interesting things to see and hear.  Some of the guys climb up a ladder to get topside. Kevin and Steve called a cab. 

No matter the means of transport, there is plenty of work to be done and they all get about the business of finishing the roof.

Joe apparently does not take to scrambling around on the steeply sloped rooftop. 

Some shingles need to be custom fit so Joe sets up shop with this oversize paper cutter and does the required trimming. 

His workstation is in the big basket. I am not certain, but Joe might have been whispering in Sam's ear, bucking for a raise. And Sam, being the agreeable sort of a fellow that he is, jumped in the cab and right soon gave Joe a raise, right up to where his trimming would be of most benefit. 

Lunch Served Under a Shingled Roof -

Tom is the first chef I have seen that needs to wear knee pads while flipping burgers. Hot pads for the hands yes, but knee pads? Never. But he knows his frying technique better than I do. In spite of his attire, his customers eagerly lined up to prepare the buns with condiments then came over to the grill for the slab of burger. Judging by the amount consumed, I believe he did a good job.

Randy used the grill for a hand warmer while waiting for the next batch to be done.

The dining room is not yet complete but that does not stop a group of hungry workers from enjoying a gourmet meal.

 Folding chairs provide seating and a chance for the workers to relax while on a flat, level surface.

Chairs were in short supply so some enjoyed their meal at the stand up counter.

By all appearances, Spencer is earning his living these days as a painter, and not an artist that daubs with tiny brushes on stretched canvas. He obviously uses big gear and an abundance of paint. Someone noted that he "wears his colors on his sleeve." It looks to me like he shares his colors with his chest and legs also.














Embracing the Trusses -
The engineer who provided the structural design wanted to make sure that if it does have to do battle with high winds, the building will at least put up a good fight, even if it does not ultimately prevail. Bracing, bracing and more bracing is called for. Nail up more and more 2x4s. Put them in flat, put them in on an angle. Any truss standing without 40 or 50 2x4s nailed to it is highly suspect. Phil commented that this engineer is no tree lover. I am beginning to think he/she may also doubt the staying power of gravity. Well, I suppose if it should come to pass that a storm comes and we have the only building in the area with roof still attached, I will have to ask forgiveness for my smart mouth comments.

The young and agile Justin scrambles among the trusses with a nail gun securing bracing in the front bump out. These braces look very much like rat runs, but apparently rats are banned from this part of the church. The rat runs braces are spaced three feet apart from the front door back to the laminated beam truss.

The older and wiser Glen uses his laser-like vision to help Justin adjust the 2x4 into its proper alignment with the beam truss.

Bill and Ed study the design plan for the bracing.

Bill and Ed continue to study the design plan for the bracing. You may think this is redundant, but they studied it for a long time. After a while, Bill commented, "If we study this long enough, it will be time to go home."

Phil joined the study group to add his interpretation. It must be a complicated plan.

Still later, Sam showed up and added his knowledge. He probably knows how to interpret the plan, but I know that the plan is on paper and not on a touch screen as he seems to think.