Removing old knob and tube porcelain fixtures

This isn’t a post about replacing old wiring with new three strand Romex.  (There will be posts on that, don’t you worry your pretty little heads.)  No, this is a post about a seemingly small but very poorly documented task related to such replacements – removing the knob and tube porcelain fixtures themselves.  Note: The following pictures are of completely dead, orphaned wiring segments – they have not been attached to the electrical panel for decades.  Never muck with live wiring, especially live knob and tube.

 
In this image you’ll see both knobs – the thicker cylinders jutting out from the beam – and tubes – the thin, hollow cylinders, one of which is strung horizontally for some reason, one of which is inserted into the beam next to the first knob.  Tubes are pretty easy to remove -the hole drilled for them years ago is snug but usually a bit bigger than they are.  All you should have to do is slide it out – at worst, a quick yank with pliers will do you.
The knobs seem somewhat more daunting.  They don’t unscrew or come apart on their own.  Each should consist of two porcelain segments, one thicker than the other, and a heavy nail running through them into the beam:

The nail likely extends an inch or less into the beam:

Removing knobs, then, is a fairly straightforward matter of wedging a hammer between the beam and the porcelain, and levering the nail out using the entire fixture. This next picture doesn’t show how far I actually inserted the hammer – quite close to the nail:

I was a little unsure at the start of this project for fear of shattering porcelain everywhere. It doesn’t seem to be an issue – the porcelain will likely chip and flake, especially as you’re first working the hammer in behind the knob…

… but it’s stronger than you might think.  A gentle-but-firm approach had a half-dozen knobs out in less than ten minutes, and even an overzealous pull on one resulting in it flying from the beam and clattering to the floor didn’t cause any of them to break. 

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…and then I hotwired my house.

New high tech boilers?  Insulate all the walls of the house?  Sure, these things will help reduce energy usage.  But in an old house like mine, one with partial infrastructure upgrades, most a few decades old, there’s a smart, simple place to start – the thermostat.
The old thermostat, likely installed in the 80s or earlier.
Old mercury-based thermostats are typically less accurate than modern digital systems – their temperature reading alone can be off by four or more degrees.  Plus a new programmable thermostat comes with all sorts of fancy ways to make your life easier with just a push of a button etc etc end rampant advertising here.
If you’re upgrading to a new thermostat on an older heating system – and especially if your thermostat looks like the one in the picture above – you might run into some of the same issues I did.  The instructions on the Honeywell model RTH6300B I picked up (note – they’ll probably fix it soon, but the Lowes’ website shows a previous price of $100K on the thermostat, discounted all the way to $49. Quite the deal, I know…) were pretty straightforward, and I won’t take you through all the step-by-steps.  I’ll just annotate where things weren’t as simple as advertised.
The main problem was figuring out the wire labels. The instructions assumed that your old thermostat had a label at each terminal – when you unhook the wire from the old setup, you just make a note of the letter and then attach as appropriate to the new thermostat. Suffice to say, no such labels existed on the old thermostat:
Thus some detective work was now in order. Those of you who know me know that the preceding sentence was met with some amount of glee. Anyhoo – first I did a quick check online for the old thermostat’s manual (paperwork for many old systems, appliances, and tools can be found from the manufacturer, or at specialty websites). Unsurprisingly this didn’t have the answer – it showed generic hookup plans for multiple types of heating systems.  Time to head to the basement…
 

Tracing the wires from the living room wall to the boiler, I found a splice – important to note because it told me I was now looking for where the red and white wires connected to the boiler controls, instead of the red and yellow wires from the living room wall.  This is truly an important but subtle distinction when you see where all this was leading:

With the power already off, it was a simple(ish) matter of unscrewing the terminals where the red and white wires (from the bundle on the top left) ran.  Some of the terminal labels were easy to see:

Most, including the two I cared about, were not:
 
 
After some poking and moving, I found what I needed.  Except it wasn’t at all what I needed.  The boiler control might have had letters on it that matched expected letters for wiring up environmental controls and thermostats in this day and age, but they turned out to mean nothing. I dutifully attached wires G and Y to their appropriate terminals, plugged the thermostat faceplate back in, programmed it, and sat back on my couch… the thermostat then failed to talk to the boiler, even though everything else was working fine.
Quick sidebar explaining the title of this post: Honeywell technical support was closed by the time I tried to call them so I was sitting in a slowly cooling house.  Pieces of the old thermostat had come loose when I was removing it, and I wasn’t sure if I could successfully put it back together.  Soon after I’d posted online griping about the problem I got a call from a high school friend who had dealt with a similar issue on an old heating system.  To test to make sure that everything was still working beyond the thermostat, he had me hold the two wires together (the voltage is stepped down from 120 thanks to a transformer on or near the boiler) to complete the circuit and see if the boiler came on. It did, and we were back to musing about possible fixes.  Meanwhile, though, I looped the two wires together so they would stay connected – and keep my heat on.  My friend on the phone is a firefighter and he assured me this was perfectly safe – at the same time, you follow in my footsteps at your own risk; hotwiring houses is not on a list of great solutions. It’s barely on a list of temporary ones.
 
In any case, when I did get Honeywell on the phone it was a quick conversation.  The wire labels I had were useless – Y was for compressors, I think – but the phone rep had the correct info in front of him.  If you’re dealing with a boiler control that looks like the one in these pictures, you may want to call the thermostat manufacturer at the outset and see what terminals should be used for an old 2-wire basic I/O system.  Might save some time, might not.
Everything else proceeded pretty much as the instructions said.  One reminder – if you’re dealing with old plaster walls like these, even if you’re only making minor changes, it’s best to wear a mask or, better yet, a respirator.  Drilling the two screw holes to mount the unit will kick up a little dust, not to mention you don’t know what will be knocked loose when you remove the old mounting plate, jerk the wires around, etc, etc, etc.
 
All plugged in an programmed!
Two minor quibbles with this model – First, the instructions call for using a 7/32″ drill bit to make the holes on a plaster wall for the wall anchors; this is too large – the anchors slide right in with very little tension.  I’ll have to redrill smaller holes and reset the mounting plate tomorrow.  Second, the mounting plate doesn’t have fins or bumps from the back to make it more flush with the wall.  As a result, you get a very slight rocking when you press the control buttons – not a big deal by any stretch, but I wish they’d thought about this given that they included wall anchors as part of the installation and could easily have balanced that slight depth with equivalent bumps on the bracket.
 
Oooo. It even has backlight…

As always, there are really no small jobs on an old house.

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So much for that schedule…

The blog-updating one, not the house-working-on one. Apparently I didn’t make a single post while on vacation (surprise, surprise), so I’ll have to catch up … some other time. Meanwhile, let’s get the typing started again with, if nothing else, a not-very-elucidating list of things I did around the house today.

– husked the last of the walnuts
– raked the last of the leaves from the front and side yards
– plugged the couple of carpenter bee holes from last summer with that savior of old houses, Abatron
– created more tool hooks in the back room

More stuff later, as always.

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Flora

Wow. Has it really been two months since I posted anything? The mini vacation I’m taking will give me a chance to catch you all up I’m sure. Meanwhile, here’s a little bit of what grows on three tenths of an acre (untended for a few years):


That’s a vast amount of buckthorn pulled out of the area around the old shed foundation. There’s some more on the west edge of the property, but I’m not going to deal with that until I decide what I’m planting over there.

And here’s most of the leaves that fell in the yard. I know! This blog is just so scintillating sometimes:

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Shelve it

The good news is I’m doing things around the house. The bad news is I’m doing many things around the house (as well as client work, the very start of ObieGame planning, and a campaign) so updates will probably be horribly behind going forward.

Yes, that made sense.

Here’s a project from the other week that, of course, was more involved than I expected. The newer cabinetry in the kitchen included a microwave shelf – handy, but it made the counter space in that area feel too cramped. I decided to pull it and put in a simple open shelf in its place.

Taking it down was a little tricky. The shelf, and the cabinet above it, were screwed into a stud on one side, but didn’t line up with one on the other. They were mounted, as you do, by sandwiching screws with heads coming out the back of the units between two pieces of 3/4″ particle board screwed to the studs and into the wall with plastic anchors. I should have taken a picture for you, but the short of it was to get to this point:

… took half an hour so the wall wasn’t damaged more than it needed to be. Some spackle in the screw holes and in scraped areas, a cover plate for the outlet I decided to remove, and we’re in good shape.

Oh, the outlet – it’s on the same circuit as the pair below, and it was real easy to deal with. Turn off the breaker, remove the faceplate, pull the outlet out of the box, unhook all wires – there will be many more than you’d expect since it’s in series – and simply attach all wires of the same color to each other (all blacks together, all grounds together, all whites together) making sure they’re capped and taped so the only exposed wire in the box is the ground (which should be pigtailed to the box still). Push the bundles back into the box and you’re done.

Wall painted (thanks to Mike for hauling reclaimed remainders of a variety of useful products down from Michigan; I love freecycling) a nice plain white. The shelf supports are actually from my local garden supply store – the simple design stood out last summer when I wanted to install another simple shelf in the kitchen (see bottom of this entry). Both had to be mounted using plastic anchors into the drywall – this is one of the redone walls of the house so it has drywall over insulation as opposed to the heavy plaster and lathe elsewhere.

The shelf is reclaimed pine from what looks like it was a shed shelf many years ago (there was a finish applied that had weathered in much the same way your wooden school desk might have looked, and faded bracket mount prints on one face). A half hour out back with the random orbit sander, and this thing looks pretty good, if I do say so myself. I may stain it at some point (installation involved one screw per support, so it’s pretty easy to take apart if need be).

No more parentheses. Here’s it’s sibling from last summer:

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Can you identify these holes?

They’re by a section of wood that is largely rotted/eaten away and that is going to be replaced (I hope) in the next couple of weeks. Meanwhile, I’m dreading searching online and finding out that these are clear signs of a _______ invasion where _______ equals carnivorous and unkillable bugs from hell.


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Pump piping

Loyal readers (hi Ezra!) will recall last summer’s adventure with my sump pump, and later issues with the hose getting tangled and once getting frozen. I said last year that I should just replace the hose with PVC piping – and now I’m finally getting to it.

First things first, turn everything off, pull the pump, and see if the pit can’t be dug a bit deeper. This will keep the water level lower in relation to the basement floor. I’d poked at this last year and thought the pit had a concrete bottom – meaning no digging. Upon closer inspection though, turns out there was just a LOT of accumulated silt…
and two large bricks acting as a ledge on the dirt bottom (not pictured). Pull everything, dig some more, find two bricks of equal depth, place them carefully, lower sump pump. Now we’re getting somewhere.

As usual, these project require way more tools and equipment than one might think. Ignore the caulk gun – that was actually for something else.

Here came the fun part. The sump pump manual has a basic diagram for setting up piping. It calls for a roughly 15″ run of pipe running from the pump to the check valve (a one way valve, necessary to keep your pump from getting slammed over and over with water still in the pipes) with a small relief hole drilled into it; then the check valve, then a run of pipe to an elbow joint, then a run from the joint to the outside. This is actually fairly straightforward and should take about 15 minutes, cutting included, EXCEPT most check valves I’ve seen have one threaded end and one smooth end. I found it easier to buy a couple of connectors to make the whole system a) fit and b) be somewhat disassemble… able.

The above pic shows the end result. A male thread connector at the bottom going into the pump itself, cemented to the short run of PVC. Two different connectors (you might be able to do it with one, but this is what the hardware store had) ending up with a female thread end pointing up. The check valve will screw into this, and on its other end it’s cemented to the longer run of pipe with one last connector.

Yes, I did finish this project:

One last important note: I put PVC cement on everything at the bottom of this contraption since I knew how it would fit together. I held off on cementing the check valve to the pipe (which requires all-purpose cement, incidentally – the check valve is made out of a different kind of plastic) and on cementing the pipes at the top (the elbow joint) together so I could make sure the whole thing was placed correctly, allowed for a slant on the horizontal run (to reduce the chances of anything freezing closed this winter), etc. This was a good idea since I discovered that a couple of additional trims and refittings would reap benefit in the long-term. HOWEVER – I was measuring and refiguring and left this all fit together, but not cemented, overnight – and of course that night it rained. Even PVC fittings you have to wrench apart may not be snug enough to withstand repeated pushes of water against the joints – in other words, the following morning, the joint finally separated and water spilled onto the floor a couple of times. No big deal for my unfinished basement, but if you’re doing this project you might want to try and complete everything, including cementing, as soon as you can.

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Baseboard – your key to not looking like a hovel

The previous owner had mostly redone the upstairs bathroom, but, among a few other things, hadn’t had the chance to install baseboard. While prepping the composite baseboard I was planning to install, I realized that there was no stud located at a convenient enough place to put a doorstop, giving me the opportunity to add a small architectural flourish:

I suspect you could do the same thing with an already milled corner block or the like to directly match the profile of your baseboard, but making your own is pretty easy. A simple 45-degree mitre at the top edge will match most simpler baseboard styles. I cut this block about an inch taller than the surrounding baseboard.

Mark off and pre-drill for the doorstop itself.

Testing to make sure it’s straight and centered. Remove the doorstop, paint, and voila:

Ignore the lousy linoleum and odd spots on the wall, if you would. The entire bathroom will probably be redone in the next few years.

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Jeepers…

These trees are three stories tall. All of the brown leaves are (now dead) creeper vines. I was so busy with the summer theater festival back in July that I didn’t notice the massive infestation that was threatening to envelop the trees. Fortunately my dad was in town and pointed it out (thanks dad!) When I delved into the bush to find the main stem, it turned out to be a dual stemmed monstrosity about an inch thick. Heavy pruning shears did the trick, but not without a fight.

Let this be a lesson to us all – have your parents visit more often.

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Why it took four weeks to get a porch swing

I have high hopes for building a porch swing from scratch one of these days, but the initial idea was to use wood from a black walnut in the backyard which a friend and I have yet to examine and see if it can be milled. Meanwhile, my neighbors tossed a broken porch swing a few months ago and I figured a rebuilt swing was better than no swing, at least until I carve my own swing straight from the raw timber of my land.

The swing is a bit old but in overall good shape save for the four cracked boards that connect the back of the seat to the bench:
No problem, thought I – I have enough 1×4 (which is wider than the existing boards, but that’s not an issue) and I can even use my new dado blade set to easily carve the groove. Of course it wouldn’t be so simple. The arbor nut on the table saw didn’t want to budge, so I was forced to improvise using just the normal blade. I ran each board through multiple times, shifting the cut width to cut the outer edges of the groove and remove some of the wood in the middle, then used a chisel to clean everything out. The only tricky thing, really, is to remember that the blade will cut further on the underside of the board than on the top – I marked a second line further down the board to compensate and tell me when to stop.

Since this isn’t the ‘final’ porch swing for the house, I took the opportunity to test out some all-natural stain samples to see how they look, and how they weather:

Reassembly:
And a porch swing chain set from Lowes:

Now to paint the porch.

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