Chapter 11 “A week’s worth of carpentry, or… Pocket screws and Piano building”

Originally posted June 5, 2023

With any journey through life, it can be said there are but two paths. The path of least resistance, which most of the time leads to an acceptable outcome. Then there is the road less traveled, the more arduous journey, the uphill climb, which always leads to a destination of greater beauty and accomplishment. I have not always chosen the more difficult path in life, but as of late I find it to be the preferred path. 

I’ve always been a fan of the old timber framed buildings, with the artistry of their design. Every board is cut and placed with intention, and every piece supports the other. I try to adhere to that mindset, believing that the skeleton of a building is equally, if not more, important that the final appearance of the interior. With a very  specific idea in mind for the geometry of the upper wall edge and ceiling, I knew the carpentry wouldn’t be easy, but I did understand how it would be possible. With some determination, sweat, and one or two bruises, we were rewarded with exactly what we wanted.

The goal was to leave the angled braces of the original steel structure exposed, to create an architectural accent. In order to achieve this, the upper level of the side walls had to be assembled in smaller separate pieces rather than in longer continuous sections. That, coupled with the fact that in several spots the insulation had to be cut back to allow the wall to be level, slowed the process down a bit. In the end though, it worked out perfectly.

With the side walls completed, the rest of the upstairs could be framed out, and the ceiling framing was partially completed.

On a technical note, I have become intrigued by the utility of pocket screws. They became the most effective way to join the upper side wall sections together, due to the orientation of the studs.

Additionally, I decided they would be better than nailing the ceiling rafters in place. First, to avoid any splitting of the timber, which occasionally happens regardless of how careful one can be with a nail gun. Secondly, the use of the screws effectively locks the ceiling parts together into one solid piece when done. Even though a bit less time efficient, the payoff is a stronger build that acts like a solid, resonant structure… much like a piano. 

We are so happy with the progress, and grateful to GOD for showing us the path and keeping us safe along the way.

Thanks for reading and GOD bless you all!