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Thursday, September 27, 2012

Chapter 59 - Left Hand Porch Awnings

Masking tape to hold in place for fitting.
Sanding down one piece for fitting.
September 18 - 27th 2012

This chapter came with the awnings which needed to be fitted onto the outside of the porch.  Fitting was necessary because during the build, the porch is not quite perfectly lined up around.  The instructions had me using double sided tape to keep the pieces in place while I measured and sanded the pieces down to fit.  Course the tape wouldn’t hold so I just used regular masking tape which leaves less damage and holds the pieces on while I sanded then fitted, sanded and refitted etc.

One piece in particular needed some heavy sanding.  It was off by quite a bit.  The trick was to sand to fit the front without distorting the back end.  I had to use the power sander for this one but in the end it seems to fit fairly well.

Next part was adding the underside beaming.  These needed to be spaced about 18mm from each other.  Since the corners need to line up underneath with larger corner beams, I had to leave some spaces on the end to be attached once the awnings are actually installed.  After that, it was just a matter of staining, varnishing and adding in the white tips for the overall decoration. 
Spacing the beams....

Painting the ends of the beams with white.

See through wood!

 In this chapter they gave us a sheet of thin wood paper (for lack of a better word).  The wood was so thin you could see thru it.  First I had to apply the double sided tape to the back, then measure out 1 cm lines where I would cut the wood.  Next was to actually paint some of the pieces darker so I just painted half the board with darker brown paint.  The first awnings on the ground floor we were given white wood board a little thicker than this one.  Consequently, I ended up with quite a few pieces of white shingles.  Something that this piece doesn’t have.  Luckily I saved all the other shingles as well as a sheet of the wood unstained.  Also because in the instructions, they say to stain the cut 1cm strips.  But I learned that this tends to bow out incredibly and I ended up with most of the shingles bowing out (and I still don’t know how to fix that) on the first floor awnings.  It looks rustic and I may play with that look more but I figured if I could get these shingles to lay down flatter it would be better.  Hence painting before and then flattening it under the cutting pad until dry.  Then cutting up the shingles into individual pieces.  It seems they were less bowed so this will be the procedure from now on.
Double sided tape underneath.

1cm height measured out for cutting.
Stained and then.....

Cut up strips around 1cm each, then irregular sized shingles.
Sorted by color for easier application.

Placing the shingles.  A little uneven is nice.
Finished awning.

After painting and cutting them into various width pieces, I began attaching them to the awnings.  The time consuming factor was simply peeling the tape off the back.  It was a total pain in the ass.  The tape never came off cleanly.  So, after a week of peeling, I managed to complete the 4 awnings.  Since they met up sort of off (with too much space) I decided to actually apply a few shingles over the junction of the awnings.  A little glue and masking tape to hold it in place over nite and the trick was done.

Masking tape to hold the awnings in place overnite.

Glue to hold the filler shingles.
Filler shingles did the trick.  Much cleaner.

Clamping the larger underside beams overnite.

 The underside just needed the larger beams and fill in small beams (with painting the tips) and this chapter was complete.  It really was hard to match up the awnings - I even have them off a bit on the right - but instead of unattaching everything that is the way it’s gonna be!

Finished port awnings! Only took a week!