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Home > Bob on TV > Home Again > Modular Mountain Retreat > Modular Construction, Wiring, and Drywall > 1416 Transcript
1416 - Modular Construction, Wiring, and Drywall
December 22-28, 2003 | June 21-27, 2004
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HI. I'M BOB VILA.
WELCOME "HOME AGAIN."
WE'RE IN SCRANTON,
PENNSYLVANIA
AT THE SIMPLEX PLANT,
WHERE OUR MODULAR HOUSE
IS BEING BUILT.
TODAY WE'RE GONNA LOOK AT
ALL THE BASICS:
HOW THESE DIFFERENT BOXES
ARE BUILT,
BUILDING THE FLOOR SYSTEMS
AS WELL AS THE WALL SYSTEMS
AND THE ROOF SYSTEMS,
AND WE'LL TAKE A LOOK AT
HOW THEY BUILD
THE STAIRCASES
AND THE NEWEL POSTS.
STICK AROUND. IT'S GOOD
TO HAVE YOU "HOME AGAIN."
CAPTIONING MADE POSSIBLE BY
SEARS
OUR MODULAR HOME
IS BEING BUILT
HERE AT THE SIMPLEX PLANT
IN SCRANTON, PENNSYLVANIA.
LET'S GO INSIDE AND MEET
DAVE BONIELLO
TO TAKE A CLOSE LOOK
AT THE WHOLE ASSEMBLY PROCESS.
Bob: WE'RE TOURING
THE PLANT HERE
WITH DAVE BONIELLO,
WHO'S THE VICE PRESIDENT
OF MARKETING.
AND THIS LOOKS LIKE
PRETTY TRADITIONAL WORK
THAT THEY'RE DOING HERE,
RIPPING DOWN
SHEETS OF PLYWOOD,
BUT, BOY, WE'RE
OUT OF THE WEATHER.
OH, IT'S GREAT, BOB.
WHAT WE'RE DOING HERE IS,
WE HAVE PARTS LISTS
THAT COME DOWN FROM
OUR ENGINEERING DEPARTMENT
THAT GIVE THESE GUYS
A WORK LIST FOR THEIR
DAY'S WORK.
AND THEY'RE BASICALLY TAKING
ALL DIFFERENT SIZE PLYWOOD--
1/2, 3/4--
CUTTING IT TO THE SIZES
AND THE QUANTITIES
THAT ARE REQUIRED,
PUTTING IT ON BUGGIES
AND SHIPPING IT OVER
INTO OTHER DEPARTMENTS.
BUT AGAIN, IT'S GREAT.
IT'S OUT OF THE WEATHER,
AND THERE'S NO PROBLEM.
NOW, WHAT HAPPENS
WITH ALL THE WASTE?
WELL, WE HAVE A STRICT
RECYCLING PROGRAM.
WE WORK WITH OUR
LUMBER SUPPLIERS
ON LUMBER AND PLYWOOD,
AND A LOT OF THAT STUFF
IS PUT IN BUGGIES
AND SHIPPED BACK TO THEM
WHEN THEY'RE DELIVERING
US NEW MATERIAL.
SO IT'S RECYCLED.
YES.
WHAT'S GOING ON OVER
AT THIS STATION?
WELL, JOE'S
CUTTING HEADERS.
AND BASICALLY,
THE PLYWOOD STRIPS
ARE BEING CUT TO LENGTH
FOR THE HEADERS,
AND JOE'S CUTTING
TWO BY TENS FOR--
THE HEADERS
ARE THE ELEMENTS
OF THE FRAME
THAT ARE HORIZONTAL,
STRUCTURAL,
AND USUALLY OVER THE
WINDOW OPENINGS OR
THE DOOR OPENINGS.
THAT'S CORRECT.
SO THESE ARE
ALL PRECUT,
AND THEY HAVE TO
BE DOUBLED UP.
YEAH. WE STILL
BUILD HEADERS
THE OLD-FASHIONED
WAY, BOB.
IT'S A SOLID HEADER
WITH 3 PIECES OF FRAMING
WITH TWO PIECES
OF PLYWOOD SANDWICHED
AND NAILED TOGETHER.
ALL RIGHT.
SO THERE HE IS
PUTTING IN
THE PIECE OF PLYWOOD
IN BETWEEN THEM.
AND THAT'S DONE
TO BUILD UP THE
THICKNESS OF IT
SO THAT
IT MATCHES UP TO
TWO BY FOUR WALLS.
RIGHT.
Bob: TELL ME SOMETHING.
THERE'S SO MUCH LUMBER.
HOW DO YOU KEEP TRACK?
I MEAN, HOW MANY HOUSES
ARE BEING BUILT AT ONE TIME?
WELL, IN THE ENTIRE
BUILDING, BOB,
WE'RE WORKING ON
ANYWHERE
FROM 8-10 HOUSES
A DAY.
THESE GUYS COULD
GENERALLY BE
CUTTING LUMBER
FOR 1-2 HOUSES
AT A TIME.
WOW.
ALL RIGHT, SO ONCE
YOU'VE GOT ALL OF
YOUR PIECES PRECUT,
WHAT HAPPENS NEXT?
WELL, BOB, WE COME
OVER HERE TO OUR
FRAMING TABLES.
AS YOU CAN SEE,
THERE IS A TOP PLATE
AND A BOTTOM PLATE--
WAIT A MINUTE.
LET'S TALK ABOUT
THE FRAMING TABLES.
THERE ARE
TWO PLATFORMS HERE
THAT ARE HOW LONG?
WELL, WE'RE
BUILDING WALLS
ANYWHERE FROM
30-64 FEET GENERALLY
FOR ANY OF
THE HOUSES WE BUILD,
SO THEY'RE QUITE
LARGE WALLS.
AND THIS TABLE HERE
IS USUALLY
THE OUTSIDE WALL--
WHICH IS ALWAYS
A TWO BY SIX WALL
FOR OUR PRODUCTS.
AND THEN THE MATING WALL,
OR THE MARRIAGE WALL
AS WE CALL IT--
WHICH COULD BE
A TWO BY THREE
OR A TWO BY FOUR WALL--
IS GENERALLY
BUILT ON THAT OTHER
LARGE TABLE OVER THERE.
OK, SO TWO BY SIX
IS ALWAYS THE CASE
FOR EXTERIOR WALLS.
YES. OUR EXTERIORS ARE
ALL TWO BY SIX WALLS.
AND THE TABLE IS
BASICALLY SET UP
AT THIS END
WITH A COUPLE
OF ANGLE IRONS
TO KIND OF CREATE
A JIG
SO THAT YOU ALWAYS
START OFF SQUARE?
GENERALLY
IT'S A SQUARE JIG.
WE PLACE ALL THE MATERIAL
DOWN IN THERE.
IS A BOX ALWAYS
THE SAME HEIGHT?
NO. WE'RE BUILDING
8-FOOT CEILINGS,
9-FOOT CEILINGS.
WE'VE EVEN GONE AS HIGH
AS BUILT SOME THINGS
WITH 10-FOOT CEILINGS.
WELL,
OUR PARTICULAR HOUSE
HAS A HIGH CEILING
IN SOME SECTIONS.
IT'S A CUSTOM BOX.
AND IT'S NOT 10-FOOT-HIGH
STUDS, BUT IT IS--
IT'S VERY UNIQUE STUDDING.
RIGHT. SO JUST LIKE
ON A REGULAR JOB,
THEY LAY
EVERYTHING OUT;
THEY PUT
ALL THE STUDS ON
16 INCH CENTERS.
TYPICALLY, BOB.
WE'RE BUILDING PRODUCTS
FOR DIFFERENT MARKETPLACES,
SO WE DO BUILD 16
AND 24 ON CENTER PRODUCTS.
GENERALLY THIS PARTICULAR
PRODUCT WE'RE WORKING ON
IS 16 ON CENTER.
THE HOUSE FOR THE BERKSHIRES,
NATURALLY, WAS 16 ON CENTER,
SO WE ARE FLEXIBLE
DEPENDING ON THE MARKETPLACE
WE'RE BUILDING IN.
NOW, DAVE,
WHAT'S THE PURPOSE
OF ALL THE METAL
THAT'S STAPLED ON
HERE?
AGAIN, IT'S
SOMETHING UNIQUE FOR
OUR INDUSTRY, BOB.
WHAT WE'RE DOING HERE IS,
WE'RE PUTTING METAL PLATES
ON THE HEADERS
AND TYING IT TO
THE JACK AND FULL STUD
AND AGAIN ON THE SILL,
TYING IT TO THE JACK
AND FULL STUD.
THE BEAUTY OF THIS IS,
IT'S GONNA HELP PREVENT
ANY STRESSING AND PULLING
IN THE TRANSPORTATION
AND THE SETTING IN THE UNITS
THAT COULD ADD TO
DRYWALL CRACKING.
GREAT.
SO, THIS IS UNUSUAL.
WE'RE ACTUALLY
PUTTING THE DRYWALL
ONTO...
THE SURFACE OF
THE STUD WALL
AT THIS STAGE.
YES, BOB. AGAIN,
IT'S SOMETHING UNIQUE
FOR OUR INDUSTRY.
WHAT WE DO IS,
WE ACTUALLY BUILD A HOUSE
FROM THE INSIDE OUT.
IN THE STICK BUILT
INDUSTRY,
IF YOU BUILD A HOUSE,
YOU FRAME IT
AND YOU SHEATH IT
FROM THE OUTSIDE IN.
BUT WE'RE GONNA PLACE
THE DRYWALL ON--
AGAIN, IT'S ON THE TABLE,
THE WALL'S BEEN SQUARED UP,
AND THEN WE'LL
PLACE THE DRYWALL
ON TOP OF THE STUDS
AND SCREW IT DOWN.
IT'S ACTUALLY GLUED
AND SCREWED DOWN.
WHAT KIND
OF ADHESIVE IS IT
THAT YOU'RE USING?
IT'S A PL 200 ADHESIVE.
OK.
OH, THAT'S CLEVER.
SO YOU'VE JUST GOT
A DOLLY
THAT'S GOT
THE STACKS OF
DRYWALL ON IT,
AND IT MOVES
DOWN THE TABLE
AND DELIVERS
THE DRYWALL
TO WHEREVER
YOU NEED IT.
YEAH. AGAIN, BOB,
EVERYTHING IS BUILT ON
SPEED IN THIS PROCESS,
SO BRINGING THE MATERIAL
AS CLOSE TO THE WORKERS
AS POSSIBLE
HELPS SPEED THE PROCESS,
AND IT ALSO HELPS
REDUCE THE LIFTING,
WHICH COULD CREATE
BACK INJURIES.
RIGHT. EVERYTHING IS UP
AT ALMOST A DESK HEIGHT,
SO YOU'RE NOT BENDING
OVER AND PICKING UP
AT ANY POINT.
EXACTLY. EXACTLY.
WELL, IT'S PRETTY
IMPRESSIVE,
THE SPEED AT WHICH
THEY'RE WORKING
AROUND HERE.
OF COURSE,
THE DRYWALL SCREWS
ARE MOUNTED IN
THESE MAGAZINES,
AND THE AIR GUNS
JUST PUT THEM
IN THERE
VERY QUICKLY.
NOW, YOU'RE JUST
REACHING A POINT
OVER HERE
WHERE YOU'VE GOT
A WINDOW OPENING,
AND, I GUESS,
TWO THINGS:
DO YOU JUST SHEATH
RIGHT OVER IT AND
THEN CUT IT OUT?
YES, WE WILL, BOB.
WE'LL ACTUALLY SHEATH OVER
THE ENTIRE WALL,
TAKE A ROUTER WITH
A CUTTING BIT ON IT,
AND JUST GET
A NICE, CLEAN CUT
AROUND THE WINDOWS.
NOW, THIS IS
PRETTY IMPRESSIVE.
YOU'VE JUST
BASICALLY PUT IN
THESE BIG EYEBOLTS
IN HERE
SO THAT
YOU CAN CRANE
THE THING AWAY.
WHAT HAPPENS NEXT?
WELL, WE PICK IT UP
WITH THE HOIST,
AND WE BRING IT UP,
AND WE STORE IT OVER INTO
THAT WALL STORAGE AREA.
AND THEN TOMORROW
THEY'LL BE PUT TOGETHER.
THEY'LL BE PICKED UP
AGAIN AND HOISTED OVER
ONTO THE ASSEMBLY LINE
AND DROPPED DOWN
ON TOP OF THE FLOORS.
RIGHT. TAKES SOME
GOOD PLANNING.
YES, IT DOES.
WE'VE BEEN DOING IT
A LONG TIME.
WE'RE GETTING
REAL GOOD AT IT NOW.
ALL RIGHT, WE'RE
BASICALLY LOOKING AT
THE ASSEMBLY
PROCESS HERE WHERE
YOU'RE PUTTING
THE PREMANUFACTURED
WALLS TOGETHER
TO CREATE A BOX.
WHAT'S
THE FIRST STEP?
WELL, THE FIRST STEP,
LIKE ANYTHING ELSE,
IS STARTING WITH
THE FLOOR SYSTEM.
AND WE'RE BUILDING,
BASICALLY, A RECTANGLE--
SOMETIMES WITH SOME
ODD CUTOUTS IN IT,
BUT BASICALLY IT'S
A RECTANGULAR FLOOR.
AND WE'LL FRAME IT OUT OF
EITHER TWO BY EIGHTS
OR TWO BY TENS
DEPENDING ON THE
FRAMING DESIGNATION
FOR THAT PRODUCT.
I LIKE THIS TERM
"MARRIAGE WALL."
SINCE WE'RE
PUTTING TOGETHER
SEPARATE BOXES,
WHEREVER THE BOXES
ARE JOINED TOGETHER,
YOU CALL IT
A MARRIAGE.
MARRIAGE WALL
OR MATING WALL, YES.
NOW, WHAT ABOUT
THE ROOF FRAME?
ROOF BUILDING--
OUR ROOF SYSTEM'S
ON A TABLE,
AND WE'RE BASICALLY
PUTTING THE DRYWALL
FACEDOWN
AND FRAMING ON TOP OF THAT.
LET ME ASK YOU
A QUESTION ABOUT
INSPECTIONAL SERVICES.
I MEAN,
IF YOU'RE SELLING
A MANUFACTURED HOUSE
IN MASSACHUSETTS,
HOW DO THEY SIGN OFF
ON WIRING AND PLUMBING
AND THE LIKE?
THAT'S A GREAT QUESTION.
THE BUILDING INSPECTOR
ISN'T ABLE TO COME HERE
TO THE FACTORY
AND CHECK THE BOXES OUT,
SO WE USE AN INDEPENDENT
THIRD-PARTY SYSTEM.
IT'S UNIQUE
IN OUR INDUSTRY.
IT'S DONE, AND IT'S
ACCEPTED IN ALL STATES.
THAT THIRD PARTY IS BASICALLY
REVIEWING OUR PLANS
AND THEN TAKING THE PLANS OUT
ONTO THE PRODUCTION LINE
AND MAKING SURE THAT
THE BOXES ARE BUILT IN
ACCORDANCE TO THE PLANS
WHICH THEY REVIEW
AND THEY APPROVE.
Bob: WHEN WE COME BACK,
WE'LL START FINISH WORK ON THE
INTERIOR OF THE MODULAR HOUSE
WITH SOME WALL PRIMER.
Bob: ALL RIGHT, DAVE,
WHAT'S THIS CONTRAPTION
OVER HERE?
Dave: WELL, BOB,
THIS IS CALLED A BAZOOKA.
YEAH.
AND I'M SURE
YOU'RE A LITTLE BIT
FAMILIAR WITH IT.
IT'S USED IN
THE SPACKLE PROCESS.
AGAIN, EVERYTHING WE DO HERE
IS TIED IN TO SPEED,
SO AGAIN, THIS CONTRAPTION
HELPS US TO INSTALL
THE SPACKLE AND THE TAPE
AT THE SAME TIME
IN A MUCH FASTER PROCESS
THAN YOU WOULD DO
IF YOU WERE DOING
EACH PROCESS MANUALLY.
SO YOU CALL IT
SPACKLE.
I CALL IT
JOINT COMPOUND,
BUT IT'S THE SAME
THING, RIGHT?
OK. AND SO...
SO YOU'LL SEE HERE
THAT HE'S GONNA START
THE PROCESS.
AND HE'LL JUST WALK
RIGHT ALONG;
TAPE AND THE MUD COMING OUT
AT THE SAME TIME.
AND THEN...
WE'LL FOLLOW UP
THIS PROCESS
WITH THE SCRAPER.
YEAH. THIS IS NOT
THE KIND OF TOOL
THAT THE AVERAGE
DO-IT-YOURSELFER'S
GONNA BE USING.
NO, IT'S NOT.
I DON'T KNOW
IF YOU CAN RENT
THEM, BUT...
I'M SURE YOU PROBABLY CAN,
BUT IT'S SOMETHING THAT
TAKES SOME TIME TO MASTER.
IT TAKES SOME PRACTICE
TO MASTER USING IT,
RIGHT.
ABSOLUTELY.
SO IS IT
QUICK-DRYING SPACKLE?
A LOT OF THE STUFF
WE USE HERE, BOB,
IT DOES HAVE ADDITIVES
IN IT TO HELP THE SPEED,
SPEED UP THE DRYING
PROCESS, BECAUSE AGAIN,
WE'RE BUILDING A HOUSE
IN A LOT QUICKER TIME FRAME
THAN THE AVERAGE
STICK BUILDER.
AND YOU'RE TAPING IT
HERE AT ONE STATION,
AND THEN DOES IT
GET A SECOND COAT?
IT'S GONNA GET
TWO MORE COATS,
AND THAT'S GONNA HAPPEN
OVER THE REST OF THE DAY.
OK, SO ONCE
YOU'VE HAD--WHAT?--
3 COATS OF SPACKLING
OR JOINT COMPOUND,
YOU'RE AT THE
SANDING POINT HERE.
RIGHT. WE'RE FINISHING UP
OUR SANDING HERE.
THEY'VE GONE THROUGH
WITH THE POLE SANDERS.
NOW THEY'RE JUST
FINE SANDING, AND ONCE--
DON'T YOU HAVE TO
WORRY ABOUT A LOT
OF THIS CRACKING
WHILE IT'S BEING TAKEN
DOWN THE ROADWAY?
WELL, WE ALWAYS HAVE TO
WORRY ABOUT IT, BOB,
AND THAT'S WHY WE GO BACK TO
ALL THAT SCREWING, NAILING,
AND METAL STRAPS THAT WE'VE
BEEN PUTTING ON ALL ALONG.
THAT'S TO HELP PREVENT
THIS CRACKING IN PROCESS.
SURE. AND SO AT
THIS END OF THE BOX,
THEY'RE ALREADY
PAINTING.
YEAH, BOB.
WHAT WE DO, IT'S--
THE PROCESS WE HAVE,
IT'S A SPRAY PROCESS.
THE FIRST GENTLEMAN'S
SPRAYING,
AND THEN ONCE THE SPRAY
PROCESS IS DONE,
WE BACK ROLL IT.
WHAT IS
BACK ROLLING?
WELL, BACK ROLL IS,
HE'S FOLLOWING IT UP WITH
A LARGE 12 INCH WIDE ROLLER,
AND WHAT HE'S DOING IS PUT
A TEXTURE ONTO THE WALL
AFTER IT'S SPRAYED.
THIS IS JUST PRIMER,
SO YOU DON'T GET
ANY FINISHES, RIGHT?
NO, IT'S JUST THE PRIMER.
OK. WHAT'S NEXT?
WHAT'S NEXT? WE'RE GONNA GO
AND SEE SOME FINISHES.
Bob: NEXT,
THE STAIRCASE SPECIALIST
BUILDS A RATHER COMPLICATED
DETAIL FOR OUR MODULAR HOUSE.
NEXT TIME ON
"BOB VILA'S HOME AGAIN,"
WE'LL BE IN SCRANTON,
PENNSYLVANIA
AT THE FACTORY WHERE
OUR MODULAR HOME IS BEING BUILT.
WE'LL LOOK AT ALL THE BASICS OF
HOW THESE BOXES ARE ASSEMBLED.
WE'RE BUILDING THE WALL,
FLOOR, AND ROOF SYSTEMS
FROM THE INSIDE OUT
WITH SPECIAL DETAILS NEEDED
FOR TRANSPORTING THE MODULES
TO THE BUILDING SITE.
WE'LL ALSO GET STARTED ON
THE INTERIOR FINISHES,
AND WE'LL SEE HOW
A STAIRCASE EXPERT CONSTRUCTS
THE STAIRS FOR A MODULAR HOME.
SO DON'T MISS IT.
THAT'S NEXT TIME
ON "HOME AGAIN."
NEXT TIME ON
"BOB VILA'S HOME AGAIN,"
WE'RE FRAMING OUR MODULAR HOUSE
IN THE FACTORY
AND BUILDING A STAIRCASE.
DON'T MISS IT.
ALL RIGHT. SO NOW ONCE
THEY ARE PUT TOGETHER,
THEY COME OUT
INTO THIS LOT,
AND YOU'VE GOT ALL
THE BOXES OUT HERE
ALMOST READY
TO ROLL, RIGHT?
RIGHT.
WHAT HAPPENS IS,
WE GET THE BOXES TO A POINT
WHERE THEY'RE WEATHERTIGHT,
AND WE CAN BRING THEM
OUTSIDE.
ANY KIND OF
SPECIALTY FINISHES
THAT WE HAVE TO DO,
WE WORK ON OUTSIDE
TO KEEP THE LINE MOVING
AND NOT SLOW DOWN
THE PACE.
WHAT KIND OF
SPECIALTY FINISHES?
OH, IT COULD BE ANYTHING
FROM SPECIALTY COUNTERTOPS--
IN THIS PARTICULAR CASE,
WE'RE WORKING ON STAIRS.
OH, GREAT.
ALL RIGHT.
SO, DAVE, THIS IS
OUR FRONT HALL
IN THIS BOX.
YES, BOB.
I WANT TO TAKE YOU IN
AND SHOW YOU THE STAIR
THAT OUR STAIRMAN HERE--
DOC--IS WORKING ON.
HI, DOC. HOW ARE YOU?
HOW YOU DOING, BOB?
SO YOU ARE
THE STAIRCASE SPECIALIST?
YES, I AM.
TELL US ABOUT
WHAT YOU'RE BUILDING HERE.
WELL, ACTUALLY,
THIS IS A, UH,
ALL-OPEN STAIR
WITH OAK TREADS;
PINE RISERS,
PINE STRINGERS.
EVIDENTLY
THEY'RE GONNA BE
PAINTING ALL THAT
AND STAINING
THE TREADS.
Bob: AND STAINING
THE TREADS.
YES, SIR.
THEN WE'RE DOING
A LITTLE GLITCH
ON THE BOTTOM.
WE'RE CONVERTING--
WELL, BEFORE YOU
GET TO THE BOTTOM,
WHAT HAPPENS AT THE TOP?
I MEAN,
THIS IS ONE MODULE,
AND THERE'LL BE
ANOTHER BOX OR MODULE
ATTACHED TO THE TOP
OF IT, RIGHT?
Dave:
RIGHT, BOB. WHAT HAPPENS
IN MODULAR STAIR SYSTEMS
GENERALLY ON A TWO-STORY,
BECAUSE THE CEILING IS
SEPARATE FROM THE FLOOR ABOVE,
WHEN THE SECOND-FLOOR BOX
GOES INTO PLACE,
THAT STAIR THEN
WILL JUST BE LIFTED UP
TO MEET THE SECOND FLOOR.
SO THAT'LL BE INSTALLED
IN THE FIELD.
YES. THAT'S HOW IT'LL SHIP FOR
SHIPPING PURPOSES.
OK, IT'LL SHIP
JUST LIKE THAT.
DO MOST MODULAR COMPANIES
BUILD THEIR OWN STAIRCASES?
NO, ACTUALLY, BOB,
PROBABLY MOST COMPANIES
DON'T BUILD THEIR STAIRS.
THEY EITHER HAVE THEM MADE BY
A STAIR COMPANY,
OR THEY JUST LET THE BUILDER
MAKE THEM JOB SITE.
THAT'S WHAT SEPARATES US
A LITTLE BIT
FROM OUR COMPETITORS
AND EVEN STICK BUILDERS.
WE'RE BUILDING
A STAIR SYSTEM HERE
THAT REALLY ISN'T
YOUR TYPICAL AVERAGE
STAIR BY ANY MEANS.
ALL RIGHT. SO, DOC,
DOES THAT MEAN
YOU HAVE YOUR OWN
DEDICATED STAIRCASE SHOP
HERE AT THE PLANT?
YES, I DO.
WHAT SORT OF THINGS
DO YOU DO THERE?
WELL, I GET
ALL MY PRINTS
FROM THE DRAFTING,
AND THEY TELL ME HOW
TO MAKE THE STAIR--
WHETHER IT'LL BE
ALL PINE STAIR,
OAK TREADS,
ALL OAK STAIR.
A LOT OF TIMES
THEY HAVE IT
WITH THE VOLUTE
ON THE BOTTOM--
WITH THE CURLYCUE
STEP ON THE BOTTOM--
AND WE ALSO DO THAT.
AND IF A STAIR CALLS
FOR A RAILING--
THAT'S, SAY,
LIKE A CAPE DESIGN--
WE ALSO PUT
THE RAILING
ON THE STAIRS,
SO WHEN THEY
INSTALL IT IN THE
BACK OF THE PLANT,
THE RAILING IS ON
ALREADY.
ALL RIGHT.
WE'VE INTERRUPTED YOU.
WHAT WERE YOU WORKING ON?
WELL, ACTUALLY,
THAT'S WHAT I WAS
TRYING TO SAY BEFORE,
IS THERE'S
A LITTLE QUIRK HERE.
WHAT WE'RE DOING WITH
THIS PARTICULAR ITEM,
MY BOTTOM TWO TREADS
AND RISERS,
WE'RE SHOOTING THIS
BACK,
AND I'M GONNA
DEAD-END MY STAIR
APPROXIMATELY A FOOT
AND A HALF BEYOND.
SO THAT'S WHAT
THIS LITTLE STRINGER IS?
YES, SIR.
I SEE. SO THIS IS
GONNA GO HERE...
ACTUALLY,
THAT'S GONNA GO
LIKE THIS HERE.
LIKE THAT.
AND I'M GONNA
DEAD-END MY TWO RISERS
AND MY BOTTOM TREAD.
AND THEN WHAT
WE'RE GONNA DO
IS CANTILEVER
MY SECOND TREAD
TO ATTACH INTO
THIS ONE HERE
AND CHANGE IT INTO
A WINDOW SEAT.
SO THIS IS GONNA RECEIVE,
LIKE, A BENCH.
YES, SIR.
WOW. THAT'S PRETTY
COMPLICATED.
Doc: SO ALL THIS
IS A CONTINUATION
OF MY SECOND TREAD
FROM THE BOTTOM COMING OVER.
I'M JUST TRYING TO SEE
HOW MY JOINTS LOOK...
LOOKS PRETTY GOOD.
WITH THE WALL
AND THE SECOND TREAD.
AND THEN I WAS GONNA...
JUST GIVE A LOOK-SEE
FOR MY STRINGER,
SEE HOW THAT WAS GONNA FIT
UNDERNEATH.
I'LL PUT A HAND
ON IT FOR YOU.
THANK YOU.
SEE HOW THAT'S GONNA BE.
SO EVERYTHING'S GONNA
DEAD-END
FROM THIS PARTICULAR STAIR
COMING OVER HERE.
JUST EYING THAT UP...
AND LOOKS LIKE WE'RE GONNA HAVE
A NICE SETUP HERE.
Bob: SO, DOC,
IN ORDER TO MAKE SURE
THESE DON'T SQUEAK,
YOU'VE GOT A NICE
LITTLE BOX OF WEDGES
AND THINGS THERE, RIGHT?
YES. THAT'S WHAT WE DO, BOB.
WE ROUT OUT OUR STAIRS
TO ACCEPT THE WEDGES
SO WE CAN WEDGE THEM,
LIKE YOU SAID,
SO THEY DON'T SQUEAK,
WHICH MAKES FOR
A REAL NICE STAIR.
SO THERE'S
A LITTLE GLUE USED,
AND THEN SOME BRADS
WILL BE SHOT IN
JUST LIKE THESE.
THAT WEDGE IS ONLY REPRESENTING
MY TREAD COMING UP.
Bob: AND THAT IS
THE PURPOSE OF
THE WEDGE.
TO HOLD EVERYTHING
IN PLACE.
THE DOVETAIL BITS
THAT HOLD THEM IN PLACE--
THE DOVETAIL ROUTER BITS.
YEAH.
ACTUALLY, IT'S A DOVETAIL
WITH A 7-DEGREE ANGLE ON IT
SO WHEN THE WEDGE
IS WORKING...
IT'S PUSHING AGAINST
THAT ANGLE,
SO NOTHING SHOULD EVER MOVE.
THANK YOU, BOB.
YOU MAKE ALL YOUR
MITER CUTS INSIDE THAT
SHOP, THOUGH, RIGHT?
YES, I DO.
ALL MY MITER CUTS
ON MY STRINGERS
AND MY...
BASICALLY,
MY STRINGERS ARE CUT
WITH A POWER SAW.
MM-HMM.
ABOUT THERE
WILL BE GOOD.
ALL RIGHT.
I'M ACTING AS A HUMAN
CLAMP HERE, BUT, UH...
OK, BOB,
WHAT I'D LIKE TO DO IS
DRY FIT MY TREAD HERE.
NOTHING'S GONNA BE
DRIVEN HOME
UNTIL WE SEE
ALL OF OUR PARTS
PUT TOGETHER FIRST.
LOOKS LIKE A NICE,
GOOD FIT.
THAT LOOKS
PRETTY GOOD, YEAH.
OK, NEXT WE'RE GONNA TRY
OUR BOTTOM RISER.
AND DAVE'S GOT IT
OVER HERE.
ALREADY HAD THAT
CUT TO SIZE.
THAT'S OUR BOTTOM RISE.
OK, SO THAT'S
THE LAST RISER,
AND NOW WE START TO
SEE THE GEOMETRY.
THE FINAL OAK TREAD
WILL COME AROUND
AND TURN AROUND
JUST LIKE THIS ONE.
AND IT'S GONNA BE
A WORK OF ART.
THANKS, DOC.
THANK YOU, BOB.
BOY. WELL, DAVE,
THANK YOU FOR THE TOUR.
IT'S BEEN TERRIFIC.
IT WAS
MY PLEASURE, BOB.
Bob: WE'LL BE BACK IN A MOMENT
WITH A PREVIEW OF OUR NEXT SHOW.
STICK AROUND.
AND WE GET A FRONT DOOR, TOO.
THAT'S ALL SHE WROTE.
COME "HOME AGAIN" NEXT WEEK.
WE'RE GONNA BE SHOWING YOU HOW
WE INSTALL THE KITCHEN CABINETS,
THE HARD WOOD FLOORING,
AND SOME WINDOWS.
TILL THEN, I'M BOB VILA.
IT'S GOOD TO HAVE YOU
"HOME AGAIN."
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