All the Countless Details

It’s been over a year since my last post. As of yesterday, I feel I’ve finished the last detail and can now call Arborion finished … although it will never really be finished. There’s always upkeep and improvements.

In the year I’ve lived (recreated) in Arborion, I’ve come to realize that so much heart, soul and reverence went into the build that I find myself staring at the choice of wood grain on the tansu stairs, or the joinery of the shoji bathroom door, and remembering just what went into the design and creation until it manifested into something physical.  Each detail compounding into a home.

Arborion

I’ve had to repair a fascia board that began rotting from the end. While I was at it I went ahead and restained all the exterior cypress trim again.

I added a walnut chair rail to cover the seam between maple and walnut paneling. A handsome ceiling fan with light has been installed. I was careful to recreate shorter fan blades so it would not be too close to my head as I ascend the stairs to the sleeping loft. Some of my family members banded together to purchase futon mattresses for both my bed and pull out bench/bed. Thank you, family! I also installed the weeping willow stained glass that my mom made for me in the sleeping loft gable, awning window. Thank you, Mom!

Sleeping Loft Weeping Willow Stained Glass

The lower kitchen cabinet now has maple doors. Walnut backsplashes are in place finishing out the countertops. Small maple trim has been used in some of the corners and joints of the maple paneling.  The shower/tub is functional and the final walnut trim has been installed. This was all with help from my Dad. Thank you, Dad!

Kitchen

Shower with trim

Shower with trim

Cozy reading nook

Micro trim in the reading nook

I have a rock climbing route to get up to the storage loft. And I hand-stitched curtains that hang from custom wooden curtain rods.

Rock climb route to the storage loft

I also found a solution to my tankless water heater. I needed to create an exhaust vent and fresh air intake for the propane water heater. The modifications also needed to keep the utility annex watertight. I achieved this by creating an aluminum hood for the water heater with a gap at the bottom. When the tankless water heater is in operation it draws air from the outside through soffit vents and into the heater where it is expelled, along with excess heat and moisture out of the utility annex through the aluminum hood.

Aluminum hood

Hood for tankless water heater exhaust

Vent screen

Vent port

Vent cover

This has been a labor of patience and love. And sometimes mostly patience. But at this moment, sitting at my fold-up walnut table, in front of my four-foot widow, with a view to my back yard homestead, I could not have imaged how wonderful and growth-inducing this project would become. And the journey continues on …

Thank you for joining me on this journey to completing my dream home — Arborion.

Bathroom Sink

I was in need of a compact bathroom sink that did not exist. The only one that came close was a tiny IKEA design, but it only came in one color — white porcelain. This is not what I was looking for.

Face frame and sides

Since my Dad is an expert woodworker, and always up to a new challenge, I talked him into helping me build a black walnut vanity.   The design measures 18″ tall, 19″ wide, 10″ deep with a 6″ deep sink. Just large enough to wash hands, shave over, or brush teeth.

Initial clamp up

Sink basin is added

Below the sink is a small amount of storage area.

Taped off for multiple coats of epoxy

Epoxied, oiled and drain installed

The inside of the sink basin is also epoxied to remain waterproof while the rest of the outside is oiled.

Look at that curly walnut!

Now that the shower panels are installed I can mount the bathroom sink.

Vanity mounted in place

A beautiful addition to the bathroom

Shower & Soaking Tub

When designing the shower for Arborion I knew I wanted a tub for multiple reasons. The first was to be able to soak in a bath. The Japanese often make use of small soaking tubs such as this. I also wanted a backup to washing clothes at a laundry mat. This tub would provide that utility if needed. A tub also provides more assurance that the water from a shower leaves through the drain instead of being held back by the low lip of a shower pan.

Tub parts stained and drying in the sun

The tub is constructed from marine grade fir plywood and maple. These pieces were stained dark on the faces that would be seen. The bottom of the tub was built up with an additional layer of maple and shaped by sanding a gradual slope to the drain location.

Tub assembled

Tub epoxied with several coats to keep it watertight

Tub installed with drain

Marine grade plywood wall substrate

Applying the Max-metal to shower wall surfaces starting with the ceiling

It took me months to locate a suitable material for the waterproof surface in the shower. Although, just about the time I was ready for the material I found a local supplier.

I did not have confidence in thin plastic liners or tile so I went a different route. This material goes by Dibond or Max-metal. It is two layers of aluminum with a core of poly ethylene. It can be cut easily enough so using it in a custom sized shower was not a problem. It is waterproof and will not corrode. It is also lightweight and durable.

Max-metal aluminum panels glued to plywood substrate

I chose a brushed aluminum surface which looks great in such a small space. Now all that is left is to use silicone in the corners and install the shower head and faucet.

All that is missing now is a bit of walnut trim

Propane & Water Hookup

This step of the build has been a long time coming. I saw it as the last big unknowns. With all the new disciplines I had to learn to construct Arborion, I felt completing the water and propane hookups were the final hurdles to overcome.

Piping water and propane into a wooden tiny house is serious business. I wanted to be sure I knew what I was doing to the final detail before tackling this myself. The last thing I wanted was to flood Arborion or burn it to the ground.

Several tips I’ll offer to anyone attempting this for the first time.

• Take your time to learn all you can
• Make sure you feel confident in your knowledge before proceeding
• Ask questions of other professionals
• Invest in the best systems, piping and fittings you can afford
• Continuous pipe runs are better than multiple fitting (especially within the wall or floor where you can not access it easily)
• Don’t give up in the face of setbacks

I used HomeFlex piping for the propane and Uponor ProPEX (compression fittings) for all water lines. There are no fitting inside the walls with the exception of the shower. This means a separate run for each hot and cold water lines (total of 6 lines) and propane lines (total of 2 lines).

Previous Related Post: Learning Curves and Flexible Pipes

Running hot and cold water

Propane cook top

Functioning kitchen

Tansu Stairs

Initially I was not going to build stairs for Arborion. I thought that the room they would take up was not worth accessing the sleeping loft more conveniently, nor the extra storage space. However, I slowly came around to seeing the benefits beautiful tansu style stairs could offer.

Initial clamping to make sure everything lines up before gluing

Where ever possible we used a datto for more strength when joining the 3/4″ maple plywood. The front edge is banded with walnut, but the inside is left the lighter maple in order to reflect more light.

Assembly begins

The largest cabinet opening will be used for hanging clothing like shirts and jackets.

A little chiseling and sanding

Dad built the pulls that will be inserted into the top right corner of each door.

Doors and pulls

The treads are red oak with a very dark stain to match the flooring.

Dark stain on red oak stair treads

Tansu stairs with treads

Tansu stairs up to sleeping loft

Kitchen Counter Tops

These kitchen cabinets have been in need of beautiful black walnut countertops for some time now. Here’s how my Dad and I made that happen.

Kitchen cabinets ready for countertops

It all starts with careful measurements and a cardboard template. The gas range and sink are located along with faucet and knobs.

Cardboard template for the countertop

We used a generous amount of marine grade epoxy and clamped up the strips of walnut to cure.

Strips of walnut are epoxied and clamped together

The countertop for the pantry cabinet is also complete. Now it’s time to transfer the final dimensions using the templates.

Template used to mark out the countertops

Using a router and straightedge, the edges of the countertops are trimmed.

Trimming with a router and guide

Marine grade epoxy is applied in coats on both sides to seal out moisture.

Countertop sealed with epoxy

The epoxy is sanded down to a satin finish. Drop in cutting board will cover the sink and add more counter space.

Countertop with drop in cutting board

The finished counter tops fit nicely. I oiled with with several coats of bee’s wax and linseed oil until the walnut looked beautiful.

Countertops in place and oiled

Extendable Futon

Just inside Arborion’s front door is a maple futon under a large window. As with all things in a tiny house it has to serve multiple functions to maximize the usefulness. This futon is both a bench and bed, but also Scout’s bed fits underneath.

The construction of a physical scale model was crucial to getting this project right the first time. From this I was able to experiment and learn what worked best and the trouble areas I might encounter during the actual build.

1/8 scale working model of the futon

Large maple boards for best yield

All the pieces for the futon are blanked out

The spacing between the slats was critical. Dad insisted on making Formica spacers to go between every one on both ends. This was a very important step! With each slat in the correct location I could make the attachments to the supports.

Assembly of the 46 slats with proper spacing

After a little more oiling it was time to install the futon in place.

Futon in bench mode

Futon extended into a 4′ x 6′ bed

 

Composting Toilet & Bathroom Cabinet

This post is about the business end of the bathroom. The bathroom measures 2′ 6″ wide by 7′ 4″ long. On the right side is the composting toilet and upper cabinet. This cabinet is for towels, toiletries and other bathroom supplies.

Bathroom cabinet frame

Bathroom cabinet doors

Bathroom cabinet

The composting toilet is a waterless system where waste is broken down through proper chemistry (nitrogen + carbon) into rich soil. The process takes about a year in an external bin, but it keeps the build simple and does not pollute water like traditional toilets.

Composting toilet base

Toilet lids clamped up

The center hole is where the human waste goes. The left and right holes are for sawdust (to cover the human waste) and regular trash.

Assembled top of toilet

Composting toilet

Bathroom perspective from tub

I’ve got the POWER!

The days of running an extension cord out of the main house in order to power Arborion are over. Its wonderful to be able to run the air conditioner with the turn of a knob or turn on the lights at the press of a switch.

The tiny house is supplied power through an RV style 30 amp receiver located under the utility annex. I installed a RV receptacle nearby fed from the main house and connected the two with hardy 10 gauge extension cable.

30 amp twist lock receiver

The circuit panel was a challenge to get into position with all the wires feeding from different angles. In the end, it just took a large measure of patience and sweat. Mostly patience.

Tight fit!

All tidy and buttoned up

Arborion feels ‘alive’ now that it has that warm glow.

Looking mighty cozy

Mysterious Leak

Last Wednesday I drove home from work during a fierce thunder storm. I was wondering how Arborion was doing since I had left the windows open on either end to allow for a little airflow while I was gone for the day. These particular windows are below a one foot overhang so they are fairly protected from the weather, except when it is windy. I was nervous because this storm was gusting heavily from the south as it plowed through.

I arrived home safely glad to be out of the traffic and dashed from my big house through the rain and standing water to the cozy tiny house and jumped inside trying to let as little water in as I could. I was pretty wet at this point, but there was cardboard on the floor to catch the drips.

I checked the interior and closed the windows. And that’s when I saw water all over the window casing beside the door. It appeared that it was the result of the rain being blown in through the previously open window, but I caught sight of a trickle of water from the top of the window frame. I opened the door and stood on the front landing and checked outside on top of the window, but that was well protected under the foot overhang directly above.

I jumped back inside, shut the door, and calmed myself. I tried to think about this as clearly as I could. I figured the water was making it’s way through the siding, then the storm guard, the plywood sheathing, and the waterproof closed cell spray foam insulation in order to find it’s way to the top of the window frame.

At this time the wind shifted and the rain came in from the north. I noticed that water was beginning to seep past one end of the threshold under the door. The rain was now blowing directly at the porch landing and front door. I grabbed a towel and mopped it up and  left it along the length of the threshold to hold back water. Then turned my attention back to the window frame leak.

The leak was much slower now. Barely a drip. This was a clue that the leak was on the south side of something as it all but stopped once the wind shifted. I then saw that the interior maple wall was dark along a seam directly above the window. I marked it with painter’s tape and followed the ‘line’ vertically up until I saw that it lined up with the south side of the awning window up in the storage loft. That was the moment when I knew I had it right. Rain must be getting in around the awning window in the loft.

I had never noticed this issue in the past even during many days of rain, but this was no ordinary storm. This was a wind driven thunder storm coming from just the right angle. Once I got over the shock, I was glad to have been there to witness the leak and identify the problem before it got any worse. I also recognize that if the weather had not been as fierce, or if I had not gone out into Arborion at that time then I may not have found this leak and it may have resulted in a bigger problem down the road.

The next day I carefully removed the window and added a generous dose of caulking to the window frame. I also recaulked around the threshold. Withing twenty-four hours I experienced another serious rain storm and I’m happy to report that it appears the window and threshold are both properly sealed. No more leaks.