Windows and Doors (Part 2) - End of Summer Update 2

 

So much has happened this summer that I needed to split my post into two. Click here to go to End of Summer Update 1.  This second part is dedicated to just windows and doors. We have finally gotten all the big windows and doors installed. All we have left are the small skylight windows that will be installed after we move in. There are a total of 41 of those.

We took a week vacation and successfully installed both the very large arch window and the equally as large door system on the front of the house. This is a huge milestone for us. It completes the exterior envelope and we have already done more spray foam. (we have just a small amount left to do before it gets cold)

Without more delay here are the photos of the large arch window installation. We are very thankful to have friends that still answer their phones when we call for extra muscle! First step that took most of the day was removing the airform and wood spray block that helped create the shape of the front overhang.

First look at the view that we designed the house around! This was a huge step forward.

It was hot sweaty work getting the concrete encrusted forms off!

Getting there but still have more wood edge forms to pull off.

Finally all the forms are off and you can see the edge shape.

Our exterior plumbing cleanout gets a scrap section of pipe as a marker in case we ever need to dig down to it.

Patio area gets filled with stone so we can drive on it with the skid steer.

After prepping the window edges with zip tape it was time to put the window in. I was very concerned that we wouldn't be able to do it. Originally this window was supposed to be three separate ones but due to a mistake it had to be shipped as a single unit.

Discussing the best way to get this thing installed.

Somehow the four of us managed to get it off the forks of the skidsteer and into place without damaging anything. There was a time during the process where I was pretty sure we were all going to be crushed under a giant broken window. There are no photos of that time period because I was busy trying not to be crushed.

After we spent the evening congratulating ourselves for not dying under the giant window, we spent the next day beginning to prep for the sliding door system. First up in this step was to fabricate our copper flashing edge to protect the exterior foundation insulation. The house has several inches of sprayed insulation on the exterior of the foundation going a minimum of 24" underground. This insulation can't be exposed to sunlight and is too fragile (and ugly) to stand up to regular foot traffic. We decided that the best solution was to buy copper roof flashing and make a protective edge.

We decided to bend the copper edge down after installing the door to make sure it stayed secure. We again used the Prosoco R-Gaurd Fast Flash to water proof under the copper and glue it down. The next step was to level the bottom with shims and install the frame. This sounds simple but it took an entire day to get it perfect.

After an entire day of playing with the laser and getting the frame perfect we started installing the glass panels. The directions call for two people to install. I am clearly not considered a whole person. They really mean two people who can easily carry and manipulate very large (8ft tall) glass panels. While I did somehow manage, it was a huge struggle.

We have many other projects waiting in the wings or partially started. We find ourselves jumping around based on available materials and what the weather is doing. This fall will continue to be very busy for us. We have started on our pocket door installations but I will cover that in the next update.