Allen from TOMTEK arrived a little before 9 AM to do the annual maintenance service on the air-conditioning system.  The A-C system looks to me like it was retrofitted to the house, but it’s hard to say how long ago.  The house has a hot water baseboard heating system so the air-handling portion of the A-C system (evaporator, blower, and flexible ducts) is all in the attic.  The air delivery registers are all in the ceiling of the main floor (it’s a ranch style house).  There is one air return grill in the living room with a 12″ flexible return duct a smaller register and duct from each of the three bedrooms.  The system does not supply conditioned air to the finished basement.

To service the air-handler Allen had to use a step ladder to gain access to the attic through an opening in the ceiling of a hall closet and then work his way through the trusses to the west end of the house.  He had to work by flashlight while lying down, having pushed insulation out of the way to make space.  It was a cool, but sunny, morning so at least the temperature in the attic was pleasant.  He cleaned and inspected the unit and checked it for refrigerant leaks and then had me turn it on.  He checked its operation while running and pronounced it good to go.  He also indicated that there was no evidence of an air filter anywhere in the attic.

The only other place there could be air filters was behind the return air grills.  The living room grill is up high on a wall in the northeast corner of the living room (cathedral ceilings).  I set up my 8′ step ladder so Allen could remove the grill and have a look.  Sure enough, there it was, only it wasn’t a typical furnace/A-C filter with pleated material surrounded by a frame and held in place by a wire fence.  Rather, it was just an oversized piece of loose fiber mesh filter material pressed into the square box that the return air duct attaches to inside the top of the other hall closet.  He removed it, took it outside, cleaned it, and re-installed it.  It was dirty but not completely clogged and Allen said the system was now drawing air better than before.  He then turned his attention to the outside compressor (condenser) unit.

The outside unit is a Coleman, and that is about all we know.  The information plate was so badly faded that Allen was unable to get any of the information he needed from it.  He cleaned and inspected the unit, checked it for refrigerant leaks, and then hooked up his special test fixture.  He said it was working properly and did not need refrigerant, which was a good thing because refrigerant is very expensive and is not included as part of the pre-paid service call.

After Allen was done and had left I climbed back up and measured the return air box.  It was 16″ x 16″.  We checked Lowe’s and Home Depot online and could order one that size but it would not get here until next week.  With company coming Sunday I wanted to complete this project and put the furniture back in place and not have to move it again.  I drove into Howell to check the local stores but they did not stock that size filter.  The guy at Lowe’s suggested I try AAA Appliance (AAA Service Network) just down the street.  They did not have that size in stock either, but they could order one and have it by Monday.  They were cheap enough that I ordered four of the 2″ thick ones.  (I got a call at 5 PM that they had arrived and were available for pickup.). While I was out I also shopped for a new electrical panel for the garage.  I checked Home Depot, Lowe’s, City Electric, and Standard Electric Supply.  I did not buy anything, but that’s a story for another post.

While I was out Linda moved a few more items into the storage container and dealt with much of the stuff we had moved into the library yesterday.  When I got back we worked together to move even more stuff into the container.  That, in turn, freed up space in part of the garage that allowed us to move three of the large stationery shop tools out of the area where Darryll and I will be working.  The whole impetus for the storage container is to clear out the east half of the garage so Darryll can install the garage heater and the new HVAC unit for the library.  As long as we had to make space for him to work, it was an opportunity to further empty out the garage, repair some things, and rearrange where/how we have things stored.  It seems sometimes like a never-ending process as there isn’t really a place for everything so it isn’t possible for everything to be in its place.

In the center area of the back (north) wall the previous owners had removed the drywall and installed Wonderboard to act as a heat shield for a wood burning stove.  The husband restored old cars and used the garage as a shop.  We saw the stove when we looked at the house in January 2013.  Wonderboard is normally used as the substrate for laying tile but contains concrete, so it also works as an insulator against heat and doesn’t burn.  I wanted to drywall this area and decided to remove the Wonderboard.

I removed the Wonderboard and discovered two things:  There was another layer of Wonderboard underneath and there was visible evidence of a fire.  When I removed the second layer of Wonderboard the extent of the damage was fully revealed.  One 2×4 stud was burned almost completely through for about 12″ and the paper facing on the insulation on either side of it was charred.  An electrical wire also ran through that wall and the insulation was discolored.  Such is the nature of remodeling projects; you never know what you are going to find.

I spent a little time after dinner trying to figure out what each of the circuit breakers in the garage sub-panel controlled.  There are 12 breakers occupying 14 of the 16 positions.  I figured out that four of them controlled about 90% of the outlets in the garage.  It dawned on me later as I was discussing this with Linda that the other breakers might supply power to the library.  I will have to verify that tomorrow.