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Authors: Ed Zotti

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BOOK: The Barn House
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18
I
t's a commonplace to say of old houses that they don't build 'em that way anymore, and in fact they seldom do, but that's not because the skills are lost or the materials can't be obtained or even, in the last analysis, because the cost is too high. The main reason they don't build 'em that way is that nobody asks. I had worked on old houses most of my life, but even so there were things I didn't know to ask for and consequently didn't get—for example, quartersawn oak flooring, which sad story I'll relate a couple chapters hence. But I'd learned I could get custom millwork, and meant to, since few interior features so palpably distinguished an old house from a newly constructed one as the elaborate wood detailing commonly found in the former. I was in the happy position of not having to design the woodwork from scratch, although no doubt Charlie could have worked up something suitable if asked; I simply needed to copy the resplendent molding I already had. Duplicating old woodwork wasn't difficult—all you had to do was give the mill shop a few representative pieces, and of course a wad of cash.
I'd made arrangements in this regard with a young mill shop owner named Guido. His prices were reasonable, but at this point that was immaterial—we'd spent our savings, maxed out our credit cards and could barely afford a cup of coffee, much less a truckload of custom millwork. I'd gone ahead and ordered the stuff anyway, hoping something would develop. The millwork arrived one morning; I opened the mail while the workers piled it in the hall. In the stack I found an envelope from a publisher—a book I'd written had unexpectedly gone into royalties and they'd sent me a good-sized check, which would cover Guido's bill and leave us a little for groceries. For all the unseen forces watching out for us, we had our share of just plain luck.
A staggering number of tasks remained to be completed in addition to the woodwork, many of them made more complicated by the fact that we now lived in the house. A bathroom, for example, required a good deal of intricate finishing under any circumstances, with a long series of tasks that had to be accomplished in a certain order, but attempting to schedule the work, which often involved lengthy delays for processes such as curing that couldn't wisely be rushed, became positively nightmarish once the bathroom was in regular use. I found myself making timelines and checklists worthy of a missile launch, and about as prone to mishap.
Some setbacks were of the more mundane variety. While lowering an old washing machine down the basement steps—we hadn't made up our minds to discard it, and it looked a little rummy rusting in the yard—I lost my grip on the dolly. The washing machine bounced down the steps; I fell on top of it at the bottom. An X-ray established that I'd only suffered contusions, but for a good two weeks afterward my ribs hurt like hell.
After the usual false starts and distractions, we'd assembled the finishing materials for the bathroom walls—tile for the showers, wooden wainscoting elsewhere—and one day Tony sent a carpenter named Mirek over to install them. I was downstairs that afternoon when I heard a splashing sound in the walls, and on investigating found water pouring from the basement ceiling. I ran upstairs to find Mirek pounding nails into the wainscoting in the bathroom directly above. Mirek spoke no English, but by means of frantic gestures I persuaded him to stop. Seeing the alarming cataract downstairs, he pulled out a carpenter's pencil and began writing on the wall, the first instinct of all tradespeople in times of crisis. It was an equation—I realized Mirek was trying to persuade me on mathematical grounds that his nails weren't long enough to cause the leak. I warmly replied that the lack of dripping water antecedent to his hammering strongly argued for his involvement. We pulled off the wainscoting and were doused by spurting water. Acknowledging the reality of the situation, Mirek disappeared briefly to scare up the necessities to put the matter right, my plumbing inventory being momentarily depleted. The repair concluded—Mirek was one of those dependable sorts who might not do everything right, but at least lost minimal time fixing what he'd done wrong—it was back to the wainscoting. A week later I got the shower door and shower head mounted, plus a spout for the half-inch copper pipe, and after that a toilet and sink.
In early November Tom K—the finish carpenter and his helper Frank arrived to begin installing the woodwork. Tom was Greek and retained a heavy accent despite long residence in the United States; Tony had warned me he could be temperamental. He was, but that posed no great difficulty; he was a member of the brotherhood. Early on I learned that when Tom was especially proud of some bit of craftsmanship he announced, “You no like it, I tear it out,” whereas if he had his doubts he said, “You can't do nothing, forget it.” When the latter occurred I gazed mournfully at the item in silence, then offered a modest suggestion about whatever defect had caused Tom pain. Invariably after some coaxing he relented and did it over.
Few such occasions arose, though. Tom's work was exquisite—“like furniture,” he declared periodically. It was hard to disagree. He and Frank built what amounted to a picture frame around the doors and windows, each an elegant composition of casing and backband plus a sill (in the case of the windows) or high flanking baseboards (in the case of the doors). They did one room at a time. The change in appearance was extraordinary—the finished rooms seemed positively palatial. “Looks rich,” Tom agreed. We at last had tangible evidence that the house's interior would someday match its now-handsome exterior.
Like the framing carpenters before them, Tom and Frank took it upon themselves to rectify occasional weak points in the house's original construction. The closet under the front hall stairs had the tiny window of which we've already spoken—the glass measured just twelve and a half by sixteen inches. Originally it had been surrounded by the massive five-inch-wide casing used elsewhere in the house—beautiful there, but in this context absurdly overscaled. Tom and Frank sliced the casing down to three inches wide—the result looked much better. Once again the brotherhood had improved on the house's original design.
 
O
ne may ask: Was
every
tradesman who ambled into the Barn House a member of the Brotherhood of the Right Way? The answer manifestly was no, but I do have to say we encountered quite a few more than might be expected in a random sampling of the population, especially considering the lamentations about declining craftsmanship and incompetent contractors that one routinely hears. To a large extent, I concede, that was Tony's doing, because he hired the bulk of the subcontractors, but even in projects in which he had no involvement the brothers turned up far more often than not. I could claim I had a gift for spotting talent, but that would be like saying I had a knack for picking people who spoke English—assuming you had the eye, about which more in a moment, no special skill was required to detect members of this scorned cult.
Which, frankly, is what it was. In reality, I think, the Brotherhood of the Right Way was respectably numerous; its members just kept their heads low lest they attract unwanted attention, like the Huguenots or fans of the White Sox.
85
Fact was, the brotherhood coexisted uneasily with the bottom-line crowd, who recognized that the profit lay in knowing when to say:
good enough.
(Not a problem confined to the building trades, incidentally—ask any software developer.) You were an artist in a world that didn't reward artistry—I knew that from my own experience. As a writer I occasionally got compliments for a well-turned paragraph—people expected such things of writers. But rare was the electrical job at the end of which people came up to me and said:
Hey, nice pipes.
I think the main reason so many craftsmen worked on the Barn House, and we got such a beautiful job as a result, was simply that I recognized them when they showed up. The Brothers of the Right Way liked having their work appreciated, and would go to a great deal of trouble for anyone who acknowledged their efforts. For all that you heard, standards of craftsmanship in the United States hadn't deteriorated to any remarkable extent that I'd ever noticed. The real problem, it seemed to me, was with those who did the hiring. A lot of people wouldn't know quality work if it came up and introduced itself. They lacked the critical eye.
A good eye wasn't a matter of being hard to please. Any contractor can tell you stories about clients who thought they knew more than the tradesmen, asked for impossibilities, and got thrown off job sites. That wasn't the mark of a good eye; that was just being obnoxious. Nor was it merely a knack for judging level, straight, and true, although that was an essential skill. The real trick lay in the ability to give intelligent direction to the project.
That meant knowing what the job was supposed to look like when it was done, and equally important, what was achievable and at what cost.
No question it helped to have some basic familiarity with the trades, and for that matter with manual labor. I'd had the advantage of having grown up watching people work on houses and doing a fair amount of work myself. I'd also had the good luck to come along at a point when my family wasn't so far removed from its working-class origins to have decided this kind of thing was beneath them—if my father had been a stockbroker I'd likely have been as adrift as the next guy. One of my fears, in fact, was that I'd fail to transmit the principles of the right way to my own children, a matter I'll return to. But first, if you don't mind, a few more practical tips:
■ Anyone who gazes upon a deft piece of finish carpentry (or sometimes even framing carpentry, as happened a few times with us) will marvel at the beauty of the wood in its natural state, which is an understandable reaction, and may conclude it's his duty to leave the wood exposed or otherwise inadequately finished, which is foolish. You see evidence of the latter tendency most conspicuously in the treatment of new cedar siding. It's possible to leave cedar unpainted, and if the cedar-sided object in question is a tool shed on the Maine coast, in a quarter century or so it will weather to a lustrous silver-gray. In the city, on the other hand—and here I speak from the evidence of my own eyes—in ten years it will look like hell.
Despite urgings to the contrary we were steadfast regarding the painting of our cedar (typically nowadays new cedar is stained, but we had to match the painted original). However, we waffled on the matter of interior trim, much of which frankly is also better off painted. Most rehabbers believe they owe it to posterity to strip away the thick encrustation of paint with which previous generations have befouled the woodwork, and doing so in fact often reveals details that the accretion of years has obscured. It doesn't follow that you're obligated to leave the uncovered result forever bare. Oak, of course, stains handsomely, and old pine often does so as well (good luck with new pine—although I realize stained pine furniture is fairly common, I've never seen a house with new stained-pine trim that rose above the level of a summer cabin). However, poplar, Tom's species of choice for trim intended for painting (hard, fine grain, no knots), won't take stain worth squat.
After I'd proven to my satisfaction that my collection of old pine doors would stain beautifully, I tortured myself for months about what to do with the surrounding poplar trim, thinking I needed to stain it as well. Charlie finally persuaded me to relinquish this misguided notion, and I can report with confidence that a stained old-pine door surrounded by painted poplar (and further set off by oak flooring, a rich wall paint color, and other details) produces as agreeable an effect as one could want.
 
■ While we're on the subject of exterior work, I may as well say that if you're going to go to all the trouble to have your house sided in cedar, make sure all the other exterior trim is cedar, too. For some reason nobody involved with the restoration of the Barn House thought there was anything odd about using trim made of pine, which predictably proceeded to rot. We patched the trim, but eventually had the decaying front and rear porch steps rebuilt of cedar.
 
■ Should the opportunity arise—and consider yourself lucky if it doesn't, since the project isn't practical unless you've gutted much of your house—you'll want to equip your hot-water supply with a recirculation pipe. The concept isn't widely known even among plumbers, and I had to thumb through a stack of home improvement books looking for an explanation of how it was done, but the idea isn't complicated. At the top of your hot-water riser, you connect a half-inch pipe run that descends to the basement monotonically (again that wonderful word) and splices into the drain tap at the bottom of the water heater, thereby forming a loop. The idea is that, even with all the faucets closed, convection will keep hot water circulating steadily, drifting upward in the riser when warm and buoyant, then returning via the recirculation pipe when cool and dense. Turn on the second-floor shower, therefore, and you'll have hot water in seconds, without the usual frigid delay. I embraced the idea as Parisian youth embraced socialism—thinking it an ideal worth pursuing, but having doubts that it would actually work. I was gratified to discover on taking my inaugural shower that it worked just fine, and have enjoyed prompt hot water ever since. One concedes that a recirculation pipe slightly enlarges one's carbon footprint, since convection depends on constant discharge of heat to the void, but since I assiduously recycle and am otherwise virtuous, I figure I can indulge myself this once.
 
■ The following information will be useless to anyone not installing a hot-water radiator system (which is to say, pretty much anyone), but in my opinion significantly advances this ancient art. I wanted to install radiators in the basement of the Barn House, since we planned to use part of it as a rec room. Plumbers whom I spoke to on this subject seemed to think the job would be indescribably difficult, and admittedly in the days of gravity-fed systems it was something of a trick, since the exigencies of convection required that all the radiators, including those in the basement, be above the level of the boiler. For this reason, the radiators in basement apartments, including the one formerly at the Barn House, were flat units suspended horizontally just below the ceiling. Since heat rose and cold sank, basement apartments were usually cold in winter. I didn't propose to put up with that nonsense. I'd read in the
McGraw-Hill Encyclopedia of Science & Technology
, in which I reposed great trust, that in a pump-fed hot-water heating system the water could be forced in any direction, including down, which I considered license to put the basement radiators on the floor where they belonged. As I say, plumbers (including the legendary Polish plumber Boniek, of whom unfortunately we will have no occasion to hear further in this book
86
) were certain this wouldn't work, and that at minimum I needed to install a separate basement loop with a separate pump and for all I knew a separate furnace.
Paying these warnings no heed, I installed the basement radiators according to my own lights, then was mortified, and frankly mystified, to find they didn't always work. Sometimes after the system had been drained, refilled, and restarted due to some project or other, a couple of the basement radiators would remain cold, although for no apparent reason they might resume operation without human intervention after some months. I spent years trying to noodle out what was up, removing pipes, looking for blockages, and so on. Finally, in a flash of insight that in my estimation ranks with Newton's apple, I realized that (a) sometimes air got trapped in the pipes serving the basement radiators, blocking the flow of hot water, and (b) to avoid this problem, I simply needed to repipe both supply and return lines for said radiators so that they provided a route rising monotonically to a radiator on the floor above, making it possible to vent trapped air when filling via the upper bleed valves—see illustrations on preceding page. (In fact, had I not been so compulsive about ensuring a continuous slope, I might have had trapped-air problems all over.) The piping having been appropriately modified, I was gratified that all the basement radiators warmed up satisfactorily from the start. The system has worked unremarkably ever since.
AIR TRAPPED IN RADIATOR PIPING (NO HEAT)
AIR ESCAPES RADIATOR PIPING (HEAT!)
BOOK: The Barn House
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