Tag Archives: 4″ pneumatic body sander (Butch)

2015/08/25 (T) Turning The Corner

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It got pleasantly cool overnight and with the bedroom doorwall open it made for nice sleeping conditions.  Between being up a bit late last night and not wanting to get out from under the warm covers we slept in a few minutes longer than usual.  I put on my sweats, which I find very comfortable on a cool (or cold) morning, and made a pot of Costa Rican decaf coffee.  We had our usual granola for breakfast, took a few minutes to enjoy our coffee in the living room without our cats, who were off somewhere and probably up to no good, and then got to work.

In order to install the new seats in September we need to have the desk installed and in order to install the desk we need to have the floor installed and in order to install the floor we need to have the underlayment installed and in order to install the underlayment we need to have several things done.  First and foremost was finishing the patching and leveling of the subfloor, so that was my first task today.  While I pursued that Linda continued working on cleaning and waxing the walnut drawer fronts.  Given the limited work surface in the garage Linda can only work on three to six drawer fronts at a time depending on their size.  When she reached a stopping point with those and started working on the woodwork in the bedroom.

I have spent the last week patching, skimcoating, and sanding the entire area where the old tile was installed which I estimate to be about 80 square feet.  I went over it one more time this morning with 80 grit sandpaper on the orbital sander.  The sander has an integral dust collection bag so it did not get the coach too dusty.  I was satisfied with most of the job but still had some unevenness along the edges by the walls and especially in the toe kick spaces extending out about three inches from the cabinet bases.  That is because I did not get the last skimcoat as smooth as I needed to in those areas and the orbital sander cannot reach them.

 

I figured I would need to do one more application of floor leveling compound but did not want to open the second bag of mix for such a small job.  I decided to go the Lowe’s and buy a small pail of pre-mixed floor patching compound and the 3/4″ #8-32 machine screws we needed to install the new handles.  While I was there I noticed that they had 50 grit hook and loop sandpaper triangles designed to fit our Porter-Cable oscillating saw.  I was aware that we had a sanding pad attachment for the tool but had not considered using it until I saw the 50 grit paper.  I bought a pack and picked up some 120 grit as well.  I would also have bought 80 grit but they were out.  I had to go to The Home Depot for the machine screws as I wanted the same brass ones we had already purchased.

Back at the bus I decided to try sanding out the imperfections rather than filling them in with another round of patching and sanding.  I was, admittedly, tired of this phase of the work and anxious to be done with it so I could move on to next step.  August is slipping away and I am very aware of the date.  I was also not keen on creating more sanding dust inside the coach.

I don’t know why I did not try this tool sooner.  The design of the tool and shape of the sanding pad allowed me to work in the all of the areas the orbital sander could not reach and it worked very well with the 50 grit sandpaper.  The circular air sander can also reach these areas, and was the right tool for grinding down the old thinset and mastic, but the oscillating tool was the right one for this final smoothing.

When I thought I was done I vacuumed the floor and used the Revel Damp Mop to pick up any residual dust.  We then went inside to have lunch while the floor dried.  Linda heated up a can of Amy’s vegetable soup, made roll-up sandwiches, and served fresh black grapes and plums.  It beats fast food hands down.

After lunch I inspected the floor carefully and decided that the patching and leveling was done.  Although it was one task out of many, and there was no fanfare attached to the moment, I was very much aware that we had finally turned the corner.  We still have some minor disassembly to do, but from this point forward most of our tasks will involve putting the interior back together and installing new things.  All things being equal (which they never are) the building work should be more fun than the deconstruction work.

The major exception is the wallpaper.  We still need to remove the old paper, much of which is stained from old water leaks, and install the new paper, which Linda will be ordering tomorrow from Delux Drapery and Shades in Ann Arbor.  The critical pieces are the ones that go behind the desk and the built-in sofa.  Most of the rest of it can be finished later but we would prefer to have it all done by September 12th if possible.  The more stuff that gets installed the more awkward it will be to work on the walls.

With the floor leveling done the next impediment to installing the underlayment was getting the refrigerator out of the living room and into its alcove.  That, however, required three other things to be done.  First I needed to replace the electrical outlet with a recessed one.  Second, we needed to build up the base of the alcove and finally, we needed to install the pantry as we cannot get to the slides to mount them to the side of the alcove with the refrigerator in place.

The electrical outlet only took a few minutes to change.  With Linda’s help I used the template I made last Thursday to cut the base pieces from the 4′ x 8′ sheet of 3/4″ plywood we bought on Tuesday.  The bottom piece was the full width of the refrigerator alcove (34″ wide at the front and 33.75″ wide at the back) and 25.75″ deep.  We set it in place, checked the front setback, and screwed it to the subfloor.  The next piece was the same width as the first but 1/2″ deeper (26.25″).  We set it in place on top of the first piece and made sure the front edges were flush with the back edge extending 1/2″ farther back.  I used longer screws to go all the way through both pieces into the subfloor.

I was not happy with the way my circular saw blade was cutting and a few raindrops gave us an excuse to take a break.  We were working just outside the small garage bay and moved everything into the garage to keep it from getting wet.  I went to Lowe’s and bought a new 7.25″ blade with 60 teeth, which should give a very clean cut through plywood but still work on 2x4s and trim boards.  While I was there I checked their selection of driver bits again.  I was looking for a 3″ long No. 1 SR (square recessed) bit but they did not have any that long.  I found a 2″ bit for $2.48 but then I spotted a pack of seven 2″ long bits for under $4.  It had two #1, three #2 (the most common size), and two #3 bits from the same manufacturer as the single bit.  Can someone explain that pricing structure to me?  Apparently most of the cost is retail packaging.

Linda prepared large, wonderful salads for dinner.  She made her own dressing using balsamic vinegar, walnuts, raisins, garlic, and seasonings, and it was very good.  We finished the Pinot Grigio with the meal and then resumed our work.

I changed the blade on my saw and then we moved the wood and 2×4 supports back out into the driveway.  The new blade made very clean cuts confirming that changing it was long overdue.  The third piece of the alcove base was not as wide as the first two, measuring 28.25″ across the front and 28″ across the back.  (The alcove tapers in 1/4″ from front to rear along the right side.)  The depth was 26.75″ to match the refrigerator base depth, and a half inch deeper than the second piece.  I set it in place, snug to the right side of the alcove and flush with the front edge of the other two pieces, and checked for an even reveal along the left side of 5.75″.  Everything looked good so I screwed it down.

There are several reasons for this design/construction.  First, there is a large bundle of wires and two air lines that run across the floor of the alcove at the rear wall.  Using three layers of plywood allowed the top layer to be high enough for the base of the refrigerator to extend over the wire bundle and have its back about 1″ from the back wall (thus the reason for the recessed electrical outlet).  It will also leave about 1″ of clearance above the fridge, which is enough.  The second reason is that the 5.75″ width at the left, with only two pieces of plywood under it, is where the pull-out pantry will go.  But third, I will install a 24″ long 2″ x 2″ angle (steel or aluminum) on the middle sheet against the left edge of the top sheet to prevent the refrigerator from shifting to the left.  The front edges of the plywood base pieces will be covered (eventually) by a something, probably a piece of 3/4″ thick walnut hardwood, that will stick up above the top surface of the top piece just enough to keep the fridge from rolling out.  That piece, however, will have to be removable so I am still thinking about just how I want to secure the refrigerator case in the alcove.

Linda does her Vanna White impersonation, highlighting how the new pull-out pantry will look when it is installed. The pantry is in its extended position revealing the slides sections that will mount on the cabinet wall. The refrigerator is out so we can work in the alcove.

Linda does her Vanna White impersonation, highlighting how the new pull-out pantry will look when it is installed. The pantry is in its extended position revealing the slides sections that will mount on the cabinet wall. The refrigerator is out so we can work in the alcove.

We still had some light but with the heavy cloud cover it was darker than usual in the coach for this time of day (6:30 PM).  We rigged up a piece of twine to hang the work light and turned on as many interior lights as we could.  We then carried the pull-out pantry from the library (in the house) to the bus.  We brought all of the slides in as well, along with two pieces of 3/4″ plywood and a 4′ length of 2×4.

We set the two pieces of 3/4″ plywood in front of the left edge of the alcove flush with the two bottom base pieces.  We then set the 2×4 on flat (3.5″ side down) spanning the plywood inside and outside the alcove.  We installed the cabinet halves of the nine slides onto the pieces attached to the pantry and then set the unit in place with the bottom resting on the 2×4.  We moved the pantry in and out checking its position and considering where the slides needed to be attached to the alcove wall and exactly how we would do that so the front has an even reveal relative to the vertical front trim of the left alcove wall.

By this point it was after 8 PM, it was getting dark, and we were too tired to start something as critical as attaching the slides to the alcove wall.  We are behind schedule, but had enough sense to not push beyond our limits.  We closed up the bus, relaxed on the couch for a bit with our kitty cats, took some Advil PM, and went to bed at 9 PM.

 

2015/08/22 (S) Clean and Level

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We arrived at the SLAARC breakfast just before 8 AM.  We took the last two seats at the end of the long row of tables, but had to add another one as six more people came in after us.  We had a lively chat that lasted until almost 9:30.  After breakfast we stopped at the Tractor Supply Company store in New Hudson to get a couple more deer blocks and then headed for home.

We took a few minutes to put away tools and straighten up the garage enough that we could set up a work surface for Linda to use for cleaning the walnut drawer fronts for all of the bus drawers.  We set up the two sawhorses we got at Lowe’s yesterday, set two 8-foot 2x4s in the provided grooves, and set a 4’x8′ piece of 2″ rigid foam insulation across them to use as the work surface.  I found an old package of 4/0 steel wool and Linda found some old terry cloth towels.

Foam insulation work surface in garage with walnut drawer fronts laid out for cleaning with Touch of Oranges.

Foam insulation work surface in garage with walnut drawer fronts laid out for cleaning with Touch of Oranges.

Linda removed the drawer fronts from seven of the drawer boxes and tagged them so they could be reunited later as each front is uniquely paired with its box.  She then removed the handles from the drawer fronts and set them aside as they will be replaced with new ones once the cleaning is done.  She started with the back sides of the drawer fronts.  Following the directions she sprayed them liberally with Touch of Oranges wood cleaner, let them sit for 10 minutes, sprayed them again lightly, and rubbed them with the 4/0 steel wool.  She then wiped them off with a terry cloth towel and applied Touch of Beeswax using 4/0 steel wool, always working with the grain, of course.  The wax will have at least 24 hours to soak in before being wiped off.  Once that is done she will flip them over and repeat the process on the front side.

While Linda was doing all of that I hauled the 15 gallon DeWalt portable air compressor out by the bus, plugged it in, and connected the air hose.  I used the 4″ circular pneumatic sander on a few remaining high spots and decided I was done with it.  I had found some old packs of 80 grit half sheets and tried using them on my orbital sander but the grit disappeared very quickly and the sheets snagged and tore on splinters in the plywood.  I spent more time changing sheets than I did sanding with them so I abandoned this approach after the fifth sheet.  I did, however, find a half dozen splintered areas and prepared those by making stop cuts with a utility knife and then peeling the splinter free with a putty knife, creating voids that will be filled with leveling compound.

I was tired of sanding and was clearly not going to get the floor back down to bare wood.  I decided that the floor was as sanded and smooth as it was going to get and it was time to move to the next process; patching and leveling.  Before I could do that, however, I needed to clean the coach.  I vacuumed the floor three times and vacuumed all of the woodwork and wallpaper.  As I worked from the bedroom forward Linda followed behind with a microfiber cloth wiping down all of the woodwork.

I assembled the tools I needed to apply the Universal Patch and Skimcoat; a 3″ putty knife, a 5″ putty knife, a combination smooth and toothed rectangular trowel, a mixing bucket, and a 2 foot long wooden stir stick and a mixing paddle designed to go in a drill.  Each bag of UPS weighs 7 pounds and gets mixed with 1.75 quarts of water, which works out to 1 part water to 2 parts UPS.

The directions on the bag indicated that a full bag of UPS, properly mixed, would cover 20 to 25 square feet 1/8″ thick.  That’s only a 5’x5′ area, but I only had a few gouges that were 1/8″ deep, so an entire bag was going to cover a lot more than 25 square feet when applied as a skim coat.  Not having worked with this material before I had no idea how much working time I would have so I decided to mix half a bag.  The recommended mixing method using a paddle in an electric drill turned out to be a bad idea so used the 2-foot long wooden stir stick to mix the compound.

TEC Universal Patch and Skimcoat applied to the floor in that hallway.

TEC Universal Patch and Skimcoat applied to the floor in that hallway.

I started in the bathroom patching small depressions and then working out from the baseboards.  By the time I got out into the hallway I had not even used half the compound and it was starting to set up.  I hurried to use as much of it as I could, and tried adding a little extra water to extend its workability, but was only able to use about 60% of it before it was too stiff to spread and trowel off smoothly.  I could have waited 1 hour and then mixed and applied more compound but I did not want to risk disturbing what I had already done and it has to set for 24 hours before I can sand it, which I will have to do.

Cleanup required warm soapy water for the tools.  I then poured it into the 5 gallon compound bucket, topped it up with water, stirred it to dissolve the compound as much as possible, and let it sit.

For dinner Linda made Farro with mushrooms, onions garlic, glazed snow peas, and grated carrots.  She needed some dry white wine for the Farro dish and opened a bottle of Pinot Grigio, so we had a glass with the meal.  As rule if a wine is used in a dish it is also a good choice to drink with that meal.

After dinner I went to Lowe’s and got some more 4/0 steel wool and some 80 grit sandpaper sheets.  I stopped at O’Reilly’s for a battery disconnect switch for the lawn tractor but they did not have one.  I tried the Howell Tractor Supply Company but they did not have one either.  I drove to the Brighton Shell station, topped off the fuel in the Element, and went home.  We turned in at 9 PM and watched a 007 movie before going to sleep.

 

2015/08/20 (R) On The Level

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We awoke around 7 AM and noticed that it had rained overnight.  We had Linda’s homemade granola with fresh blueberries for breakfast, followed by a pot of coffee brewed from the Cafe Europe / Columbian Decaf blend I got from Teeko’s on Tuesday.  As we do most mornings we enjoyed our coffee while using our iPads to check in on the world (Linda) and write about our day yesterday (me).

While Linda went for a walk I checked e-mail and responded to several from Gary Hatt at Bus Conversion Magazine.  I then unloaded all of the boards, slides, battery terminal covers, and the pneumatic disc sander and discs from the car.  I set up our 15 gallon portable air compressor by the entrance door of the bus, got the long air hose out of its storage bay, and connected the air sander.

When Linda got back from her walk we unloaded the pull-out pantry from the car and stored it on top of some of the bookcases in the library.  We had a light lunch after which Linda settled in to work at her desk and I busied myself with sanding the floor in the bus with the air sander.

Floor prep tools: 4” belt sander, hammer and chisel, 4” rotary pneumatic body sander.

Floor prep tools: 4” belt sander, hammer and chisel, 4” rotary pneumatic body sander.

I was eager (anxious) to get the initial sanding done so I could apply the floor leveling compound.  Like drywall compound it will be a multi-day process.  I needed to fill any deep gouges and voids, let the compound dry, and then lightly sand it with an orbital pad sander and finer grit sandpaper to make sure it is smooth.  I then needed to fill the shallow grooves that exist between the ridges of thinset and mastic that I could not sand off completely.  Once that dried I would again sand it off lightly and then apply a final, very thin, skim coat to the entire area, feathering it into the areas where tile was never installed.  Finally I would go over the entire area gently with the pad sander one last time to make sure the surface is as smooth and flat as possible before installing the 1/4″ underlayment.  The tile will be installed directly on the underlayment.

I considered using self-leveling instead of troweled-on floor leveling compounded but decided against it.  Self-leveling is thin, like water, and flows.  As such it seeks its on level and forms a smooth flat surface that is “level” as determined by gravity.  Although it offers the possibility of a single step process with no sanding, it also offers the potential to go wrong and not be repairable.  The bus subfloor would have to be dead level side-to-side and front-to-rear.  There would also have to be a border to contain the liquid and there could not be any holes or cracks that it could leak through.  In particular it seemed I’ll-suited for feathering into the adjacent areas of the subfloor that were never tiled.  And so I decided to fill in and “level” the floor the slower and more labor intensive, but more controlled, way.

For dinner we had the other half of the gluten free pizza Linda made on Tuesday.  We had peaches, strawberries, bananas, and an orange melon that were all ripe so she made a fruit salad.  We finished the bottle of Cupcake Black Forest Decadent Red Wine.

We decided to turn in early and watch a little TV.  Part 2 of The Mystery of Matter: The Search for the Elements was on PBS at 8 PM.  We saw Part 3 last night and did not realize until 7:45 PM that Part 1 was on this evening at 7 PM, so we still have not seen it.

 

2015/08/19 (W) If It’s Wednesday This Must Be Indiana

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As we did last Wednesday we were up earlier than usual to drive to Indiana.  We wanted to be at Bontrager’s Surplus when they opened at 9 AM to pick up some battery terminal covers for Butch, and possibly ourselves, so we pulled out of our driveway at 6:16 AM.

We took our usual route west on M-59 to I-96W to Lansing Road south.  Rather than get on I-69S we stayed on Lansing Road all the way to Charlotte where we stopped at the Biggby’s Coffee to use the restroom and get coffee and bagels.  From there we then took I-69S to Coldwater and headed west on US-12 since Bontrager’s Surplus is located on US-12 in White Pigeon, Michigan.

We arrived at Bontrager’s Surplus just after 9 AM.  We looked around briefly but did not spot the battery terminal covers so we asked one of the employees where they might be and he took us directly to them.  We bought 36 (18 red and 18 black), 10 of each for Butch and 8 of each for us.  Bontrager’s is probably the best stocked of the surplus and salvage stores in this area and I could have spent hours here, but we had other places to be and a long day ahead of us.

Our shopping done we continued on to Coach Supply Direct in Edwardsburg, Michigan where we found Josh Leach hard at work on some interior remodeling of a Fleetwood Revolution.  He removed the Notion Linen sample from his Lambright Comfort Chairs book and we chatted for a while.

I reflected on fact that one of the nicest Class A motorhomes we ever saw was a Fleetwood Revolution.  The interior was a (faux) cherry wood with satin finish nickel hardware.  It had modern, clean cabinetry and light grey wall treatments and a light tile floor with nickel colored inserts, as best I can recall.  We eventually toured the American Coach factory in Decatur, Indiana where the Revolution was made and after seeing some of the construction methods we were less enamored with it.  Like all of the American Coach products it was out of our price range as a new unit but it was very much to our taste.

Before continuing our Journey Linda pulled up Jarel’s address in our GPS.  I then texted Jarel to give him a revised, and more accurate ETA.  We headed southwest out of Edwardsburg on M-62 which becomes IN-23 through Granger.  We turned onto IN-331 which bypasses most of Mishawaka east of town and delivered us to US-20 where we headed west.  We stopped at the Meijer’s, which has a filling station, fueled the car, and switched drivers.  We exited US-20 just south of South Bend, Indiana and headed south on US-31.  We exited US-31 at Rochester and took IN-25 south to Logansport.  I texted Jarel an updated ETA enroute.

We arrived at Jarel Beatty Cabinetry at 11:45 AM and pulled around back.  I texted Jarel to let him know we were there and he came out of the shop to meet us.  We chatted for a while, loaded up the pantry, the slides, the three pieces for the built-in sofa that we forgot last week, a piece of walnut trim for the pantry face, and a leftover  piece of 1/4″ Baltic birch plywood.  Linda wrote a check for the balance we owed.  The only thing left for Jarel to build is the HVAC/wiring chase cover but he cannot do that until I give him the length, which I cannot do him until the desk is installed in the bus.

We left the cabinet shop at 1 PM and stopped at the Martin’s supermarket in Logansport for lunch.  This particular Martin’s did not have a salad bar but they did have pre-made salads.  We each had one along with a bread roll.  I called Butch to let them know we were on our way, and headed for Twelve Mile, Indiana.

I gave Butch the battery terminal covers.  He and I figured their cost ($1.25 each) covered the cost of the 12 fiberglass pole mast sections ($2.00 each) we took last week and called it even.

I brought the small window frame stop block from our bus to see if Butch could make one.  He had some aluminum bar stock that looked like it would work.  We decided to make it longer than the original to accommodate three machine screws and cut it to size using a band saw.  Butch then marked three points to drill holes using the old block as a template.  Two holes were drilled through and one end hike was blind.  The blind hole will fit over the shaft of the old screw that would not come out in case any of it is still protruding above the surface.  The middle hole will line up with other existing hole and I will have to drill and tap a hole in the frame to match the third hole.  But first I need to get some brown spray paint, put some sacrificial screws in the holes, and paint the piece.

While we were working on the stop block I noticed that Butch had a torque multiplier sitting out.  He commented that it was available to a good home for a good price; hint, hint.  These torque multipliers are used to break the lug nuts loose on bus and truck wheels and I have had one on my mental wish list since I first became aware of them five years ago.  I had not pursued getting one as they tend to be expensive even used on Ebay.  Butch wanted $75 for it so I wrote a check and put it in the car.  It has three different lug nut sockets so I hope one of them first the ones on our bus.  I also hoped they would fit the very large torque wrench I bought from Butch last fall but they are 1″ square drive sockets and the torque wrench has a 3/4″ square stud.  I’m not sure I have a correct socket for the torque wrench so that’s another thing I still need to get.

Butch and Fonda bought a compact stacked clothes washer/dryer for their bus and asked if we would help them get it into their rig.  Of course we said yes.  We got it on a dolly and wheeled it out to the entrance door and then pondered the situation.  We have some recent experience getting things out of and into a bus entrance door and this did not look promising.  Butch handed me a tape measure and I determined that the maximum width that would fit through the step well was 23.5 inches due to the door hinges.  The washer/dryer is 24″ wide and 28″ deep with a recessed back on the washer (lower unit).  It is also tall, being a stacked unit, and we all agreed that the only way it was going in was on its back, through a window, using a forklift.  It was Deja vu all over again; been there, done that, didn’t even get a T-shirt.  That approach required more preparation than Butch cared to tackle today, and more time than we had to spare, so we moved the unit back under the overhang and left it covered with a blanket.

We all went back in the house and visited for a while longer.  Butch had found his 4″ pneumatic body sander and loaned it to me along with three boxes of AA50 sanding discs.  While not quite as aggressive as the #36 ceramic grit belts I have been using on the 4″ portable belt sander, this tool will allow me to get under the cabinet toe kicks where the belt sander won’t reach.

As much as we would have liked to stay and go out to dinner again, we did not want to be getting home at midnight.  We wished them a safe journey, again, but this time it really is unlikely that we will see them again before they leave for Arizona.  We left for home at 4:45 PM with Linda at the wheel.  From SR-16W (CR-700N) we took CR-700 (Meridian) north to its northernmost point and headed west into Fulton on W750S where we picked up IN-25 and headed north.  At Rochester we left IN-25 and took US-31N to US-20W.  We exited US-20 at SR-19 and drove north through Elkhart, finally arriving at the Martin’s supermarket at CR-4 around 6:15 PM.  This Martin’s has an excellent salad bar and a nice dining area with an upstairs, which is where we chose to sit and eat our dinner.

Linda continued to drive after dinner.  There is an entrance to the Indiana Toll Road (I-80/90) on SR-19 just south of CR-4 so we got on going east.  The toll road is a few extra miles compared to US-12 through Michigan, but it is posted 70 MPH (max) with no stops, compared to 55 MPH with six towns that have reduced speed limits and stops.

We exited the toll road, paid our $2.90 toll, and headed north on I-69.  A few miles later we were back in Michigan.  We left the Interstate at M-60 (exit 25) to refuel at the Shell station, use the restrooms, and switch drivers.  It was about 8 PM and still light, but it was cloudy to the west and the light was fading.  I find night driving easier than Linda does and I had been able rest while she drove so I was good to go.

I followed our usual route, leaving I-69N and using the Lansing Road cutoff to get to I-96E.  We passed mile marker 100 on the south side of Lansing, which meant we had 33 miles to the M-59 exit.  From there it was 11 miles to Hacker Road and then the final 2.5 miles to our house.

We arrived home at 10 PM, five hours and 15 minutes after we left Twelve Mile and just over 16 hours from when we left home this morning.  The trip odometer indicated 534.8 miles traveled today.  We unloaded the camera, phones, wallets, etc. from the car but decided to wait until tomorrow to unload the cabinetry, tools, and parts.  We headed off to bed and watched part 3 of a PBS program The Mystery of Matter:  The Search for the Elements.  Interesting stuff.  We both find programs that inform and educate to be entertaining.