Secret Fortress Hideout

SFH on MSN.com

2009-12-03T17:41:00.006-06:00

Earlier this week I received a Google Alert with a link to this article and slide show on MSN.com. I was surprised--and happy--to see the home they chose to feature in the first two slides. Look familiar?

Speed Metal

2009-11-08T21:27:00.007-06:00

There's a new addition to Secret Fortress Hideout. Earlier this year, I began researching garage options that would give us some extra stowage with style. The search concluded with a decision to create an original modern structure that could be erected in a month using mostly local materials and labor. Based on these criteria, it became clear that my best option would be a metal building supplier that could handle custom design requests. It turns out that Floyd's Sales & Construction in nearby Berryville, AR, had just the right combination of experience and ingenuity. Not to mention, Floyd's is the only metal builder in the region with the ability to fabricate steel trusses for a single-slope shed roof.

I designed the basic form for the building using Google Sketch-Up in September. We started construction in October, and Floyd's completed the job last week. Now we need a little landscaping to beautify the dirt work surrounding the slab.

Rocio Romero On NPR

2009-01-23T11:26:00.002-06:00

NPR ran a story today on the LV and the success of Rocio's prefab business model in this economy. The story aired nationally and and featured 10 seconds of yours truly. Kudos to the editor who boiled 20 minutes of my rambling down to one 10-second quote!

Here's the story.

Going Green

2008-10-01T11:29:00.006-05:00

Once SFH was built and looking fantastic, we realized something was missing. Like a great masterpiece, it deserved a fine frame. So, we added a lawn. After clearing a few trees and adding rich topsoil, Don and Jeremy layed down about 6,000 sq. feet of zoysia sod. The visual effect was immediate and dramatic. Best of all, zoysia grass is drought tolerant and requires little maintenance once established, making perfect for xeriscaping.

This got me thinking about how we've made the house green in other ways and I decided to make a list of all the eco friendly materials used in SFH.

• passive-solar home orientation on shaded lot
• high-efficiency multi-stage heat pump
• soy-based spray insulation on interior walls
• formaldehyde-free bat fiberglass insulation in faux walls
• VOC-free interior paint
• formaldehyde-free strand bamboo flooring
• natural formaldehyde-free cork flooring
• PaperStone 100% post-consumer recycled paper counter tops
• low-e glass
• Energy Star appliances
• high-efficiency Rais wood stove
• insulated concrete form foundation walls for crawlspace
• electric radiant bathroom flooring
• drought resistant zoysia grass
• energy efficient TPO reflective white roofing
• water-conserving dual-flush toilets
• dimmable compact flourescent light bulbs
• LED outdoor lighting
• sustainable, recycled pecan shell mulch
• locally quarried stone wall, stepping stones and river gravel paths
• Ipe deck from certified sustainable forests in Brazil
• CUZN (Copper-Zinc) water filter system

Flat-Roof Resolution

2008-09-01T20:52:00.010-05:00

I thought this may be helpful for other LV owners who have built in the woods. Last fall we had to make regular ladder runs to the roof to keep the scupper's clear of deciduous debris. To prevent drainage issues this autumn, Don and Jeremy designed a filter box that fits over the scuppers. The device should block larger objects and reduce clogging by increasing the surface area of the grate. Wider-guage screening should improve flow and a "cover" fabricated with Kynar-color-matched steel keeps twigs and leaves from falling directly into the drain. I'll keep you posted on how well this works!

Mom's Day Getaway

2008-05-11T23:44:00.006-05:00

We heard Don's sheet metal crew had made a lot of progress and we were anxious to see the finished deck, so we celebrated Mother's Day at SFH. The weather was absolutely gorgeous after Saturday storms--breezy, fair, low 60s. Using a remnant piece of ipe decking and an old dock line, we improvised a rope swing for the ancient, broken oak that dominates our east view. After discovering several ticks in our flight path (and in our pants), we spent the rest of the weekend hangin' on the deck with Durga and Pedro.

The Hills Are Alive with the Sound of SFH

2008-04-29T20:41:00.007-05:00

Don sent this amazing note last week. His message was so passionate, I just had to post it. I'm thinking his suggestion at the end will become a favorite Secret Fortress tradition and a great way to remember our guests--like an audio guest book! But I'm telling you now, NO Celine Dion. I would hate for you to have to spend the night in the storm cellar.

"On Thursday, we made it back to the SFH. I turned on the radio to get some nice background music while working on the deck. The first piece of music played that morning was Toccata and Fugue in D Minor by Bach. Wow! There was no way I would work while that was playing, so I sat down on the couch to soak up the music. Your speakers are sensational! My goodness, I have never heard that music that well. It was so brilliant! I'm getting excited just thinking about it. It sounded like the organ was in the room. Great choice on speakers. Your guests are going to love it. I would recommend you begin a small library of great music and each guest can make a contribution. That way you'll have an eclectic music choice. I will contribute the first CD. Racmimaninoff's Vespers performed by the Robert Shaw Festival Singers. It's my favorite and can't wait to hear it on your stereo."

In other news, Don and Jeremy completed most of the deck railing. The posts were custom fab from L & L Metal Fabrication of Springdale, AR, and the steel cable rail was manufactured by American Metal Specialties of Tacoma, WA.

Radio Free SFH

2008-04-29T16:54:00.003-05:00

The Rocio revolution will not be televised...or will it? At the very least, it's getting good air play on news and talk radio stations. Here's an interview from last Sunday that aired on Kansas City NPR station KCUR's popular show KC Currents. The show's very gracious host, Sylvia Gross, interviewed Rocio at my office after a knowledge-exchange breakfast with our creative team. Sylvia also discussed Secret Fortress Hideout with me. Listen to the broadcast here.

Rais You to SFH

2008-04-10T08:17:00.009-05:00

We had a free weekend so we made a quick trip to SFH. While there, we helped Don and Jeremy install the Rais Pina wood stove. We placed it on an aluminum-clad pad in the corner of the living room. I have to say the build quality of this product is impressive. To reduce weight while positioning it, we were able to easily disassemble the side panels and door. Can't wait to try it in colder weather. Actually, after this brutal winter, maybe I can.

SFH also received a small mention in Vox Magazine's print edition and a special online feature today. Vox is a weekly paper published by the Missourian in Columbia. I guess the secret is getting out about Secret Fortress Hideout.

Breaking It In

2008-03-21T22:44:00.005-05:00

It's spring break for the family and we had a chance to spend the week in Secret Fortress Hideout. We loaded a U-Haul with furniture we've collected over the last twelve months, strapped the kids into the Highlander and caravaned to Eureka Springs. Amazingly, the contents of the van arrived completely intact despite the rough county roads and our not-so-careful packing.

We emptied the van the Saturday we arrived and were joined by friends John, Cindy, Anson and Archer on Sunday. After the Ikea assemblethon, we stayed busy putting the house to the test. And with four boys between the ages of four and seven, what a test it was. Running, wrestling and launching projectiles--at the brand new 42" LCD TV. (Tip: should your LCD screen become chipped by a certain metal-nosed balsa wood glider, you can camouflage the stuck pixels with a tiny bit of black electrical tape.)

On the second night, we were joined by a few more friends. This group, however, preferred to stay in the crawlspace with the acorns they had saved all winter long. We discovered these guests at about 11 pm, when one decided to have a noisy late-night snack right below the master bedroom. (Tip: the mouse bait from Wal-Mart really works.)

Although it rained hard the first part of the week, Thursday and Friday gave me the perfect opportunity to get shots of Secret Fortress' fantastic morning light.

Kitchen Counter Intelligence

2008-02-28T23:09:00.003-06:00

Just a quick report to share a few spy photos from the fortress. Mission accomplished on the countertop, sink and faucet in the kitchen. The final quasi-industrial look reminds me of science class for some reason--in a good way--without the Bunsen burners.

Our Private Island

2008-02-20T23:03:00.005-06:00

Now we're cooking! The kitchen is looking incredible with the island countertop in place. I was a little hesitant about my decision to go with the obsidian Paperstone surface, but I think the stainless really balances the dark counter by reflecting so much light. We love how the island adds some nice mass and creates a dramatic focal point to the space.

Be My LValentine

2008-02-10T21:20:00.001-06:00

Valentine's Day is just around the corner and we're LoVing the LV. The cabinets are going up in the kitchen and the bathroom elements are coming together. We really got a sense of the space this weekend.

The light is simply amazing as it moves through the place. Not to mention the excellent passive solar heat from the southern windows. It was 39º outside, 70º inside, and the heat pump didn't kick on once during the day.

The cultured marble bathroom vanities look fantastic with the stainless steel basins and frames custom fabricated by L & L Metal Fab. The white, vein-free counter material creates a nice contrast with the dark wall tile.

Floors Galore

2008-02-01T16:45:00.000-06:00

Interior painting was finished more than a month ago and the bamboo flooring is down.

This week I picked up a stainless kitchen sink with integrated drainboard from Teka. Should look great with the stainless base cabinet and obsidian Paperstone counter.

The Zen tub has finally arrived and the bathrooms are moving forward. The tile is going in and the stainless steel frames for the sinks have been installed. You can see the heat strips for the electric radiant floor system in these shots as well as the Ditra uncoupling membrane. My bare feet can't wait to try out all this great flooring!

Interior painting was finished more than a month ago and the bamboo flooring is down.

This week I picked up a stainless kitchen sink with integrated drainboard from Teka. Should look great with the stainless base cabinet and obsidian Paperstone counter.

The Zen tub has finally arrived and the bathrooms are moving forward. The tile is going in and the stainless steel frames for the sinks have been installed. You can see the heat strips for the electric radiant floor system in these shots as well as the Ditra uncoupling membrane. My bare feet can't wait to try out all this great flooring!

Deck the Halls

2007-12-12T22:26:00.000-06:00

Don and Jeremy attacked the ipe and banged out a beautiful deck. Next up, stainless posts, steel cables and turnbuckles from www.cablerailings.com.

Travis completed the HVAC with the heat pump install this weekend. The two-stage Trane and 4-ton Lennox are super quite and arrived just in time to heat up the space for the floor and paint. And speaking of paint, check out the SMOOTH ceilings and walls. A layer of SpeedSkim spray on skim coat makes the tape seams disappear, a nice extra step with all the horizontal natural light.

I also ordered our kitchen counter material from PaperStone. We're going with their line that is made from 100% post-consumer waste and petroleum-free, formaldehyde-free resins. Because PaperStone's dark colors are more stable in UV light, we selected Obsidian. If you're considering PaperStone, be sure to check out their Handyman Specials on off-spec panels.

So Close

2007-11-27T21:42:00.000-06:00

But yet so far. Heidi and I made a down-and-back run to Arkansas Saturday to deliver toilets, faucets and mirrors. While there, we caught up with Don, shot some pics and measured a few spaces. Everything seemed to be humming along.

Then, Monday came. A few critical path items jumped the track and will push us back about a week.

The stainless kitchen cabinets we ordered from Lasertron will be delayed due to an email mixup.
The heat won't be connected for two weeks, which delays the floor installation.
We found out cultured marble won't work for the tub or bathroom sinks and devised a Plan B (Neptune Zen Soaker Tub and custom-fabricated under-mount stainless trough sinks).
And, last, but not least, the company Don scheduled to prime the drywall bumped us a week.

I guess these things happen in building. It's just wild that they all happened in the last two days.

Here are the updated shots from Saturday. As you might expect, we're getting very excited and anxious!

Dog House

2007-11-19T22:11:00.000-06:00

What fearsome beasts will guard the gates of Secret Fortress Hideout? It's Durga the giant schnauzer puppy and Pedro the, uh, um, stray Chihuahua and ????? mix (actually, we hope to solve the mystery of his parentage soon thanks to a DIY mail-away DNA test).

The Home Stretch

2007-11-15T21:30:00.000-06:00

Tons to show and tell from the last post. The sheetrock is up and the deck is framed. The electrician has completed the lighting plan and the plumbing is in. Next up, exterior sheet metal, paint, tile, flooring and kitchen cabinets.

So, naturally, we decided it was time for a trip to Ikea in Chicago for mirrors, shelving, storage, bathroom hardware, kitchen supplies and bedding. Oh, and we picked up a giant schnauzer puppy from a breeder in Yorkville, Il. It was a wild and wacky trip.

Trick or Treat

2007-10-31T22:10:00.000-05:00

It's Halloween night and Don sent some nice photos for trick or treat. For the treat, these are the first images I've seen of the completed glass. For the trick, our insulators have sprayed the inside walls and ceiling with soy-based spray insulation. Pretty cool stuff.

Earlier this week Don dropped off the RAIS Pina wood stove--all 500 lbs. of it! Today, I also had a security company wire the place with a fire and security system. The system includes motion detectors, glass break sensors, door sensors, smoke detectors and a temperature monitor that will alert me if the inside temp drops below a certain limit. We also ran RG6 cable for satellite tv and internet.

The drywaller starts tomorrow and the ipe wood for the deck and bridge should arrive Friday. Found a good source for cable railings and posts in Tacoma, WA--American Metal Specialties.

In a few weeks I'll order the flooring from Green Building Supply. We're going with natural strand bamboo in living and bedrooms and natural cork for the utility room. We'll do 1x1 daltile in the bathrooms with whisper-quiet Panasonic exhaust fans. At this point we're shooting for an early December move-in date.

Octoberfest

2007-10-14T23:17:00.000-05:00

The leaves may not have changed yet, but SFH certainly has since my last post. Lots to celebrate. The tar paper is on the outside. Don added a coat of green-gray paint to the foundation wall. Many of the interior walls have been framed out. Travis and crew from All-Weather Control installed the ductwork and air handler for the heat pump. The electrician and plumber are on the job next week. And the windows are in progress.

Don and I spoke about a few modifications to the original plan. We will take the guest bath walls to the ceiling rather than the 7 feet or so in the plan. Also, we'll be pulling return air through wall vents in the hallway and bedrooms. We'll locate the electrical panel on the exterior porch wall in the utility room and run circuits for radiant floors in both baths.

I dropped off a few finish items as well:
• two in-wall and two ceiling speakers for install (Accurian brand from RadioShack)
• mounting bracket for 42" LCD tv
• tub valve and tub/shower valve for bathroom fixtures (Pharma and Como by Danze)

Lighting Design

2007-10-06T13:32:00.000-05:00

Here's a preliminary design for placement of recessed lights throughout. We'll most likely use 5" cans. The yellow dots indicate light fixtures and the green represent outside power locations. The yellow rectangle in the master bath is a fixed skylight.

R-19 and Counting

2007-10-06T13:23:00.001-05:00

The faux walls are up and insulated with Johns Manville formaldehyde-free fiberglass batt. Kraft paper backing was removed to reduce the probability of mold issues. We plan to use a soy-based spray insulation inside the interior walls bringing the R value well over 20 (35+ for some walls). The minimum for our area is R-11. The roof will get the same treatment with 1" of insulation where the insulating roof board is thicker and 3" where the board tapers for drainage on the east side (back).

Full Steam Ahead

2007-10-03T22:35:00.000-05:00

Don and crew are really cruising now. The TPO roof is down and we've added a skylight to brighten the master bathroom. The electrician has started on wiring and Don has started framing out the interior walls. A crew will spray soy-based insulation into the interior wall spaces next. This alone should provide a high R-value, but we're also investigating using a formaldehyde-free fiberglass batt for the exterior faux walls.

We needed to lower the porch to accommodate a three-layer floor made with tapered insulation board, waterproof barrier and ipe wood planks. We could do this because we went with a floor design using 2" x 10" joists rather than I-joists. The intent is to level out the transition between the outside ipe and inside bamboo flooring (natural, horizontal). Don is fabricating a 14-foot steel ramp that will connect the entry with the higher ground on the west side. We'll use ipe here as well.

Big Weekend at SFH

2007-09-22T22:05:00.000-05:00

Don and crew have made a lot of progress in the last two days. The faux wall sections are up with the exception of a few panels. These will support the siding. They also completed the roof decking. Don used strapping to reinforce a point above the southwest corner of the house This was a precaution to correct for a missing beam hanger. We were comfortable not using the hanger because the non-load-bearing beam is bolted to the post plate and Don's solution is stronger than the original hanger.

Labor (of Love) Day

2007-09-05T22:35:00.000-05:00

The roof trusses are going up and the house is taking shape. Grandpa came down for the weekend with us and it was a great holiday. Boat maintenance, swimming in the pool, swimming in the lake, Sonny's Pizza, fort making and house building. The boys slept very well!

Beam Me Up!

2007-07-29T18:09:00.000-05:00

Don and Jeremy are cruising on the framing. Friday morning they used a boom truck to hoist the six beams into place. You can start to appreciate the views!

Oh, Now I See It!

2007-07-25T21:36:00.000-05:00

Just a few days after delivery and you can already see the house take shape. Don put up 10 steel posts and 10 wall panels. In the last image you can clearly see the entry and the lower windows for the kitchen, utility room and guest bath. Check out the rainbow--evidence of Secret Fortress Hideout's magical energy! (Or, was it left over from that Diversity Parade in Eureka Springs? Hmmmmm.)

Happy Birthday, Heidi!

2007-07-22T22:07:00.000-05:00

Now this is what I call a birthday! The family headed down to Eureka Springs on Heidi's birthday to take delivery of the house kit. Everything arrived flat packed on a massive truck (that, fortunately, was able to navigate the narrow, chip-and-field road).

Before materials were unloaded, the floor needed to be leveled. Jeremy and Travis worked the jack and shimmed the beam on all the posts in the "cozy" crawlspace.

Don tied straps to the forks of the sky lift to remove the structural wall panels. The judges gave Don a "10" for perfect form on dismount.

Travis and his fiancee, Dana, joined us for the weekend. Travis will be designing and installing the HVAC for SFH. At this point we're thinking of a high-efficiency, three-ton, two-stage heat pump. The air handler will be hung in the crawl space from joists in the west corner of the home under master bedroom's big, walk-in closet.

Not to be outdone by the big guys, George and Nate initiate construction on Mini Secret Fortress Hideout.

Seven Days and Counting

2007-07-14T21:49:00.000-05:00

Only one week until the kit arrives at Secret Fortress Hideout. As you can see, Don has covered the ICFs with a layer of concrete and the floor decking is ready.

With Heidi's birthday next Friday, we're planning to celebrate in Eureka Springs by watching the kit delivery and unloading! Should make for some great pix!

Rain and Mud(sill)

2007-06-30T22:26:00.000-05:00

Don worked all day in the rain today. We planned to camp on the land Saturday, but rain was in the forecast all weekend. Looks like he put the mudsill on and the big center beam is in place. The kit for the house will ship and arrive on July 20.

Pouring Concrete, Running Water

2007-06-06T22:01:00.000-05:00

Don and crew poured the concrete into the insulated forms today. He said it was the easiest pour he's done and it took only 45 minutes using the pump and crane.

Don also verified that the well works--good news!

Next step: build the floor.

Crawlspace Takes Shape

2007-05-27T22:32:00.000-05:00

Visited SFH over Memorial Day weekend. Don and Jeremy have really made progress. Here you can see the insulated concrete forms in place. They go together like giant styrofoam Lego blocks. The hollow middle will be filled with concrete next week.

George and Nate "helped" rake a load of sand that will be the subfloor of the crawlspace. We'll eventually add plastic sheeting as a vapor barrier. But until then, who knows, we could make miniature Secret Fortress Hideout Sand Castles under the house...

Footings

2007-05-21T22:30:00.000-05:00

Don and Jeremy got the footings poured over the weekend. According to Don, the house is now "officially connected to the earth."

Elevations

2007-04-26T20:24:00.000-05:00

Julie from RR sent the elevations today. They look great. The only changes in the actual plan will be the taller crawlspace which brings the floor closer to street level and above the storm cellar's rooftop patio.

Rocio's Prototype

2007-04-22T23:36:00.000-05:00

I'm posting images of Rocio's prototype in Perryville, MO for reference (credit to her site for the images). This is her actual home located on some acreage in rural eastern Missouri about 45 minutes south of St. Louis. Heidi and I toured the home in mid-January and knew this was the perfect design for Secret Fortress Hideout.

The Plans

2007-04-22T22:45:00.000-05:00

Here are the plans as they stand so far. Click on the image for a larger version.

The Property

2007-04-22T21:59:00.000-05:00

Our property is east of Eureka Springs, AR, close to Beaver Lake. It includes 33 wooded acres that stretch across three hilltops. We chose to build on the western end of the middle hill--an area previously occupied by a doublewide trailer (Google Earth still shows the trailer).

The last owners had installed a 500-foot well, a septic system and a concrete storm cellar (east of the build site) around 2003. You can see the cellar and old concrete footings in the image.

The house will be oriented with the length running north and south. This puts the majority of windows facing east and south.

This is the eastern side of the storm cellar. We plan to keep it and use the roof as a walkout patio. The house's floor will actually sit a few feet above the cellar.

Don built a temporary platform to check the crawlspace height. Nate and I test it out.

When completed, the floor will be level with the road that is maybe 100 feet from the house. We will build a short footbridge to the front door to span the dropoff before the foundation. The plan is to make this a gravel moat with a french drain.