Tuesday, July 1, 2014

Seachest Project, Chapter Two


Below is a post about the Seachest Project, a kitchen on Nantucket for Seachest, the house Marcia and Toby's dad built in the 60s, and which Marcia and Toby, along with Marcia's brother Brad, are remodelling now, under the direction of Nantucket Builder Kyle Snell. This post is about taking the delivery and installation. I hope it gives the flavor of how we like to do things.

This first photo gives the general flavor of the renovation, a summer house in the old style

Approaching the new Seachest. The Nantucket Sound is visible in the distance.
 
Our strategy on loading the truck is to put the things we need last in the truck first. The hope is that when we get to the site, our tools, kickspace boxes, and layout templates are near the door. We build the level kicks using the template “sticks” as a guide, then, in theory the cabinets get brought in, one at a time, and just dropped on their marks, bingo! For some mysterious reason, it actually happened almost that way on this project. Here's the kitchen in the truck, at our shop.

Bound for Nantucket: the kitchen loaded in the truck, in the right order we hope!

Those boards on the floor we call “sticks”. The original measurements of the space are on them, as are all the critical dimensions of the cabinets. They get screwed to the floor in the right place, and then we install and level the kickspace boxes. If we get the boxes level, the cabinets will install with little fuss.

     Layout sticks, cabinet boxes in place. Those funny holes in the top of the cabinets are handles that make it easier to move them around.  We have to move each cabinet probably ten or a dozen times, at least.

Those funny holes in the top of the cabinets are handles that make it easier to move them around. We have to move each cabinet probably ten or a dozen times, at least.

Since we're far from home, we'll leave some of the installation for Kyle and his crew, but we'll get as much done as possible in few days. In this case, Toby and Brad worked with me on the installation, which made things both more fun and much quicker.

Toby

Brad  

Once the cabinets are nice and level, we can start putting the drawers in and hanging the doors. We used Valchromat, that blue material, for the doors. The color livens things up and the doors are very easy to make. The wood walls make it very easy to hang the upper shelf units.





I arrived Monday night, built the kicks Tuesday, put in the boxes Wednesday, and then something miraculous happened Thursday. Pat Garrett and Shane Thurston arrived Thursday morning on the early ferry, with 5 soapstone counters. The usual procedure is to put in the cabinets, then have the stone people make a full scale template, then eat pizza for about a month waiting for the counters to be fabricated. As the previous post shows, we assembled the kitchen in the shop. Shane made the template in our shop, and the counters were ready when the cabinets were. So as soon as the cabinets were in, we...went fishing. We don't get to go fishing on every job. In this case our customers treated us to some great fishing with Tom Mlezcko.

Jonathan, with fish

Now back to work.

I don't have a great shot of the counters going in. But this gives a sense of what the soapstone is like.

Soapstone Counter with Built-in Drainboard
Family members Marcia and Eli
Eli is oiling the counter after installation. He caught two bluefish, but the boat was jumping around quite a bit and I didn't get a photo of that.

The cabinets are mostly in, but there is a lot to do yet. We mounted the sink, but there is still plumbing and wiring to do. The stove has to be hooked up. And flooring.

The kitchen is taking shape, but still a lot to do - let's have some wine!



Friday, June 6, 2014

Seachest Project Photos

Work in progress, at the shop:





Metadrawers without the fronts (on cart at left).  On top, some of the jigs we use to create our custom work.

Ian at work in the shop putting together a dish drainer

Monday, June 2, 2014

Seachest Project, Chapter One

We are on deadline at Sam Clark Design. Todd and Steve are getting a massively renovated schoolhouse ready for the owners to move back in in mid-June, That very day, I have to meet the ferry to Nantucket with a truck packed to the roof with a complete load of cabinets for a house named Seachest. Brad and Marcia's dad built the house in the 60s, and now it's getting a major renovation.

We've been talking about this project for about three years or so. Now the contractor is doing the heavy lifting, and Ian and I are working to get the cabinets done in time, trying to make sure we haven't forgotten anything – it's not that easy to run back to the shop from Nantucket.

Here is the floor plan.  We looked at several different layout ideas, and there were many versions of this one, adjusting the size of the passages around the island, the depths of counters, the centerline of the window and sink, trying to get as much storage and workspace out of the layout as possible, while leaving a very open feeling. I'm guessing there were fifty or more emails just getting this layout right. The first time around, this drawing looked great. After repeated erasures, it's looking tired. But it tells us a lot about what is going to be built. During all these discussions, of course, we've been talking about the “work centers”, what work gets done where. The area left of stove is the “primary prep area.” The sink (with its stone counters) is cleanup. The area by the fridge will be dish storage, small appliances, coffee making, and so on. The wood counter right of the sink is a secondary prep area.

Seachest plan: after fifty emails and 4 major revisions

But we're just getting started. Our projects use lots of drawers, and often open shelves. So next is to figure how each run of cabinets will get divided up in detail. For example, here is the fridge wall.


The fridge wall, after many revisions:


If you look closely at the drawing you can see the shadow of two or three previous versions of this run of cabinets. The middle bay is a pullout holding two large trash cans, trash and recycle. We think a lot about what goes in each drawer. Or, as we have worked for Brad, Marcia, and Marcia's husband Toby before, they have thought about exactly what goes in each drawer. For example, here is the final spec for Cabinet A.

Sea Chest cabinet contents and dimensions (4 May 2014)
Fridge wall
Base A width 17.75”(accuride)
4“ silverware
6” misc., food processor blades, small cans
8” Beans, pasta
8”++ onions, potato, etc. (or pots and pans)

If you take a cabinet that's 30.5” tall, and subtract for the top and bottom of the cabinet, the drawer bottoms and other clearances, you have about 26” of storage space to distribute between the four drawers. Since this is custom cabinetry, it's easy for us to give each drawer just the right interior capacity.

The upper shelves were discussed in similar detail. For example, that gadget on the counter, some sort of spritzer, require 18” clearance. Usually I make the uppers 16” up, but we made an adjustment here.

Basically the idea is for the design to reflect the Founding Truth of kitchen design: storage at point of first use.

We do a similar analysis for all the runs of cabinets. Here's the “sink wall.”

The sink wall: every drawer is sized for its intended contents:


This is another fifty emails or so, another four or five revisions, and any number of phone calls.

Why bother? Why couldn't a kichen be designed with only 25 emails and two revisions? This may seem excessive, but we think it leads to a kitchen that functions better, stores maybe 40% more stuff in a given space, and will be more fun and less work to use.

Getting back to the deadline problem, here's a photo of where we were as of the end of last week. We've assembled the L in the shop, so that Pat and Shane, who will make the stone counters, can come to the shop and template the counter shape and details. This is a crucial step. Usually the cabs get installed, then the counter people come to the site, do their templating, and three or four weeks later, as the family is eating their 30th pizza, they show up with the counter. We think it's possible to compress this schedule a lot with a little planning. When we install the base cabinets, the counters are already fabricated, and get installed within a day or two, only four or five pizza dinners later. In this case, since we're on Nantucket, our goal is install the base cabinets Tuesday and Wednesday, install the counters Thursday, then go fishing! We'll see about that! Stay tuned.


Tuesday, March 18, 2014

Keeping Your Counters New Looking, and their Patina too!


In our work, we build, buy, and install a lot of counters. Right now, we use a lot of commercial butcher block, and also make a lot of wood counters. Our friends Pat Garrett and Shane Thurston make a lot of slate and soapstone counters for us. Occasionally we get into granite tops. Recently we've been using a green MDF product called Valchromat, which is easy to work, and has some of the virtues of stone counters. We still do a little Formica since it is such an inexpensive option, and let's face it, works pretty well.

Recently some of our customers have gotten in touch with us because their counters didn't stay new-looking. One was a slate counter, with under-mount sink, that got a little spotty under the drain board. The other was oiled butcher block that got drab -looking over time, after several years of food prep. That's fine – we'll do our best to fix these problems.

This got me thinking about my own counters. I think, between the apartments I've rented, the houses we've owned or co-owned, my little boat, and my late-lamented trailer, I've build myself about 20 or 25 counters. A couple of early ones were plywood, coated with fiberglass. Several others were plywood that was heavily varnished with oil-based varnish. These were intended as temporary counters, but at least three are still in use decades later. But most of them were wooden planks, glued edge to edge. Usually they were made out of whatever wood came to hand. Walnut, ash, red oak, white oak (that's nice!), mahogany, teak, sometime pine. Most of these oiled counters are still in service, except for the ones in that late lamented trailer.

I always thought of these kitchens as workplaces, analogous more to a woodshop or restaurant kitchen than to some kind of showplace. The wood counters were oiled with ordinary salad oil, sometimes mineral oil or tung oil. We chopped veggies of all kinds right on the counter. We rolled out the dough right on the counter. Except for meat, and particularly poultry, most foods we ate were in direct contact with these counters. We learned to take one precaution: don't let that carbon steel knife sit in a puddle or orange juice for too long, or you'll have a nice black chevron that will have to be scraped out.

Here is my current batch. This is the before picture.


The island is made from some ash planks. The green ones are Fireslate II, a concrete counter similar to your counters in chem lab. To the left is a commercial Boos butcher block. In the distance is a varnished pine table I made about 40 years ago.

In the great tradition of kitchen photography, I took this occasion to do the annual maintenance which I do every three or four years. I scrubbed the counters, dried them off, and gave them another dose of salad oil, including the Fireslate II.


If I saw stains or other defects at this point, I could have sanded or scraped them out. But as you can see, I did not do that.

Right from the first day, these counters have taken a terrific beating. It would be impossible to count the scratches in this wood. After all, just cutting up three cloves of garlic might lead to fifty unkind cuts. These fifteen or twenty year old counters have been hacked thousands of times. They have also been stained and re-stained over and over by beets, strawberries, coffee and lots of other foods. They have been used and abused.


The hardwood tops can take this pretty well; they can always be brought back to reasonable condition, ad infinitum. The Fireslate, like some natural stones, can get stains. Because of how much water they get, the oil finish gets drawn out pretty fast. That poor soft pine table in the background has really suffered. It's got scratches, divots, places where ball point pens have sort of printed through onto the soft wood.

I love these counters. These are nice, honest materials. You could find counters made a century or five centuries ago that were made much the same way. They'll last pretty much forever, and if they fail, they can be repaired.

They tell a story. People have been living here! They cook for each other. They eat a lot of vegetables! They chop up their garlic instead of buying it powdered. Why, they don't even take good care of that nice pine table! I see these honorably damaged surfaces, and remember the meals, the singing parties, the pizzas, the bread dough. The bread I'm slicing now, is somehow linked to all the meals that came before, all the people I've spent time with here. To be sentimental, the worn surface has some meaning for me; I hope I get to see it even more battered, to see the surface even more uneven than today.

When I revisit some of their older cousins (now owned by other people) I see they are still being put to work on a daily basis. You have no idea what a good feeling that is for a carpenter, to see something you've made going strong years later.

As we work with families developing their kitchen designs, we talk about what functions they want each counter to serve. We talk about what material fits with the work done at that work station. We take them to see kitchens we did a few years ago. If we're using slate, I'd like them to see what it's going to look like in a few years.

If they want a counter that will stay new-looking a long time, maybe we'll end up with those granite tops, or engineered quartz, or even on occasion, “solid surface.” If they choose maple or ash or soapstone or slate, I'll be glad. But I'll also be careful to say (once burned, twice shy), “These are patina materials. They'll last a long time, but they'll show their history, too.”