Finishing up the Light Clay Wood Chip

Here is a video update of the shed.  Winter and other projects and responsibilities have slowed down the progress of the shed, but I have been working more on it lately.  I am just about done with the light clay wood chip infill, and am getting ready for the plaster.  This weekend we installed the door and started putting up the chicken wire over the pallets in preparation for the plaster.

Looking back on this project, I have decided that it has taken A LOT OF WORK!  This way of building is not for the faint of heart.  Some of the painstakingly time consuming things I have done so far are:

1. The foundation:  stone by stone trying to save as much mortar as possible by fitting each rock neatly within the wall.  Usually masons will slop on a large wad of mortar and roughly fit the rocks together.  It takes much less time, but uses about twice as much mortar.  I used 15 bags.  Even easier would have been to pour cement footings.  The way I did it saved me money, and used up a pile of rocks and used cement curbing dumped in my yard by my neighbor (dumped before I bought the lot[he did insist on taking care of the pile, but I told him I had a use for it])
2. Salvaging the materials:  I spent hours dumpster diving looking for useful materials. Then, when I got them, I usually had to take out nails, cut of bad parts, or reinforce sections.  Pallet wood is tough and ornery.  The nails don't come out easily, it is hard to cut, and never straight.  
3. The light clay wood chips: Even though I used a cement mixer this process took forever.  We dug by hand a hole big enough for our trampoline to get enough clay.  We found that the term "light clay wood chips" isn't really "light" at all.  When you try and use a light clay slip to hold the wood chips together, they just become flaky when they dry out (even worse if they freeze while still wet).  It takes a lot of clay to keep the chips stuck together.  Our recipe ended up being something like 1/2 parts water, 1 1/2 parts clay, 1 part wood chips.  The end consistency ended up a lot like plaster.  In fact, I ended up using it much like plaster to patch holes.  That is another problem with the way I used pallets; There were many gaps that I missed while filling up the walls that I had to patch later.

Other time consuming things I have still waiting for me to complete include plastering both inside and outside and putting down the earthen floor.  The upside of both of these is that I will be using far less material to make both products.  The walls of the shed are about 10 inches thick and took a few tones of clay and wood to fill. I plan on putting just two coats of plaster on the walls, so they shouldn't take as much clay .  I will need to sift the clay better, but a good chunk of the plaster will be made of sand.

I am not saying that the methods I have employed are bad, but they are just more than I originally reckoned for.  When I am done, I will have a large, sturdy, environmentally friendly, warm, and comfy shed.  I think I'll turn it into my glass shop.

A poor video of me putting light clay wood chips in the wall

I know I need to work on my video technique, but I was also working at the time and it is hard to pay attention to both where the camera is pointed and what you are doing while slopping mud.  I just wanted to show what it is like using light clay wood chip.  From the video you can see that the clay isn't too light.  It definitely isn't cob, but we found that if we didn't have enough clay in the mix, the small wood chips wouldn't stick together very well.  The first few batches we did had about the same recipe as light clay straw, but with wood chips replacing the straw.  The results of those first batches were unsatisfactory and the walls started flaking off wood chips when they were rubbed.  With more clay in the mix, it makes it less insulative, it has  more thermal mass, and it is much stronger.

Salvaging a Shed

Along with the salvaging we have been doing on a house that is slated to be demolished, we were able to salvage a shed.  This was much more of a process than it originally looked to be.  We got permission to use a fork lift to move it, but it was just too big.

 We tried to strap some dunnage 4x4s onto the tines to be able to span the distance to the back wall.  As you can see by the picture, the shed was way too heavy and snapped two 4x4s in half.  We gave it a few weeks to think about it and came back with a plan that ultimately worked.

 We were able to get some tube steel to attach to the tines that spanned all the way across.  We also tied the shed onto the fork lift to keep it from rocking.

 We were lucky that the shed balanced out.  Finally we were able to move it out of the back yard and 6 blocks away onto our new lot.  The shed will be a temporary storage while we are building.
 Along with making sure we didn't hit any power lines on the way there, the scariest part was that to get it out of the back yard we had to lift it over one of the houses.  Luckily both houses are going to be torn down.  I don't know if I would have dared trying that stunt over an occupied house. We did loose a few shingles on the yellow house.


I almost forgot, we also flattened a chainsaw in the process.

Stained Glass Bountiful Utah Temple

This year for Christmas we had Sarah’s brother Joseph and his family to give presents to.  So, following the traditions of previous years, I made them a stained glass picture of the Bountiful Utah Temple where they were married.  I wasn’t able to use much recycled glass on this one, only the windows, but I was able to put to good use some of the wood floor we have been salvaging to use as a frame.  The floor boards are tongue and groove.  The stained glass fit nicely into the groove.  So, I sanded off the old paint, trimmed off the tongue side, routed an edge on it and turned it into a picture frame.

 Another innovation this piece has on it are a couple of female ends to chain locks.  I have been struggling to find a secure way to hang heavy stained glass on a wall and I hope this will finally be the solution.

 I bought an LED light bar from IKEA to mount on the back.  The problem is that there is n o sign at IKEA that says that when you buy an LED light strip, you have to buy a plug to go with it.  So, I don’t have any pictures with the light working.   In fact, I haven’t seen it work yet.  We sent the plug to them after the picture was delivered and haven’t had a chance to see the whole ensemble together.

Look Ma, no plug

Salvaging for a new home.

Free Toilets in good condition

These doors are solid wood from the early 1900s

We are officially getting ready to build our new house in Ephraim Utah. We are going to build a Straw Bale House, which will be the subject of several posts I’m sure. Because this blog is dedicated to sustainable living (recycled glass and gardening) I have decided to add the home construction in as well. Besides, right now there is a lot more going on with the house construction than there is with either of the other two topics. This entry will be dedicated to salvaging materials for the new house.



Here in Ephraim there are a few houses slated for demolition to make way for a new shiny parking lot. We were given permission to go in one of them (hopefully in the near future the other two as well) and take out anything we want. The house had already been picked apart by some other people, but we were able to salvage 10 doors, two toilets, several light fixtures, an armoire, the electrical breaker box and a few really old window frames as well as a few other odds and ends. Over all we have probably saved a couple thousand dollars towards the new construction. Next we are going to try and pull out the old wood floor and some of the cool old moldings.



These are the original windows from the house.  We found them in the root celar



The first batch of wood floor.  We will have to pull the nails and plane each peice before we can refinish it.

Another amaizing door knob