Howard Hall Farm Blog

Wednesday, November 28, 2007

Fireless Fireplaces and the Bee that's re-building the Beehive

While they're installing the new environmentally friendly heat system at the Federal manor over at Howard hall Farm, our working environment has become decidedly unfriendly: It's FREEEEEZING there in the very pretty, open-air office on the balcony atop the windy hill. Reggie and I finally caved in and have been going between a toasty (indoor!) impromptu office we set up in our friend Peter's house and HHF (where they're currently digging through a series of awful "restoration" efforts made by previous owners of the house to get to the original fireplaces). Naturally, I was overwhelmed by warm-envy, because I adore the house at HHF, but couldn't handle the temperature.....so I was scrolling through the blog entries about fireplaces that were featured in Houseblogs.net, looking at stunning finished examples, like the white-hot Black Forest fireplace in DOORSIXTEEN's house, and House In Progress's pretty fireplace wish list...........(Their motto:"We call it Home IMPROVEMENT because it can't get any worse").

Needless to say, I'm drooling....metaphorically, at least. At the moment, the boys are uncovering the basement fireplace, and have made one very heartening discovery. Buried deep in the walls of the basement, lurking for all these years, there are remnants of an original Beehive Oven!More on this soon.



Reference: (From Wikipedia)

Beehive oven

A beehive oven was used to turn coal into coke.

Coke (fuel)

Coke is a solid carbonaceous material derived from destructive distillation of low-ash, low-sulfur bituminous coal.

The volatile constituents of the coal including water, coal-gas, and coal-tar are driven off by baking in an airless oven at temperatures as high as 2,000 degrees Celsius. This fuses together the fixed carbon and residual ash. Most coke in modern facilities is produced in "by-product" coke ovens, such as in the upper photograph, and the resultant coke is used as the main fuel in iron-making blast furnaces. Today, the hydrocarbons are considered to be by-products of modern coke-making facilities (though they are usually captured and used to produce valuable products). Non by-product coke ovens, such as in the lower photograph, burn hydrocarbon off-gases on site to provide the heat needed to drive the carbonization process.

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Monday, November 19, 2007

Age of Restoration: Times Union

This just came out in the Times Union.

(There was one tiny mistake, but it's less than a century long, so... for the record, the house was built in 1780, not 1870.)

From: timesunion.com

Age of restoration Tinsmith Dennis Heaphy is turning a 19th-century house into a workshop

By TOM KEYSER, Staff writer First published: Sunday, November 18, 2007

Dennis Heaphy doesn't require affirmation of what he does as often as most workers do. But every now and then, even for Heaphy, affirmation is nice.

"I was having a glass of wine last night, and the bartender asks, 'How was your day?' " Heaphy says. "I said, 'Well, you know, I'm really enjoying this. I'm laying on the roof, and I'm intent on what I'm doing; I'm scraping off the existing tar on the metal to prep it to be soldered. And then I realize that it's a beautiful day, and I'm looking out on the Hudson from the highest point.' "

From his rooftop perch at Howard Hall Farm, Heaphy can watch the Hudson River hug the bank as it pushes past the village of Athens, near Hudson. A fourth-generation tinsmith, he is restoring the roof of the 1870s house.

A beefy man with flowing hair and a bushy mustache, Heaphy usually divides his time between New York City, where he is resident tinsmith at the Statue of Liberty, and Syracuse, where his great-grandfather opened a metal shop 115 years ago. But for several weeks over the next several months, he will be in the Hudson River Valley helping restore the old Federal-style house and giving lessons in tinsmithing.

Platform for school

Heaphy's participation exemplifies how Howard Hall Farm is a laboratory for "sustainable, environmentally conscious restoration techniques," as its owner Reggie Young puts it. He and his partner, Nora Johnson, bought the house in 2005 as "the platform for a school of restoration that I had fantasized about," Young says.

It was in rough shape -- perfect for what Young had in mind. He's a former restaurateur in New York City and Connecticut who grew up on a farm in eastern Pennsylvania. His parents did restoration work, and he did, too, even while owning restaurants. But he wanted to do more.

At Howard Hall Farm, he and Johnson started by ripping out the electrical system, plumbing, ceilings, floors, walls and siding as well as tearing down all additions.

"We gutted it back to everything that was original," Young says.

That took about six months. Then reconstruction began. Young and his partner are bringing in preservation and restoration experts from around the country to oversee the work and give seminars in, for example, masonry and historic paints and finishes.

The real thing

Young recruited Heaphy this summer after reading about him in an article in a New York newspaper. The article was headlined "The Tin Man."

"He told me the house was built in 1780. That was the hook," Heaphy says. "The opportunities don't come up that often to come in and try to salvage old work.

"This is not theoretical. This is the real thing. You watch some television show, and you can muse about it. But actually to get your hands in it ... "

And Heaphy's hands are full with this project. Standing on the roof, he says: "You're looking at a map of people's mistakes over 200 years."

He has the expertise to correct them. He learned to work with metal from the old men in his family's shop in Syracuse that supported the family's hardware store and heating and roofing companies. What turned out to be a fortunate happenstance started as a nuisance.

"I inadvertently learned a trade that very few people have anymore," says Heaphy, 48. "I really only do work that I find interesting, like this. Having this talent has given me the freedom to do that. But when I was 11 years old I didn't want to be a tinsmith."

He wanted to be with friends. Instead, he worked after school, Saturdays and summers learning to solder, bend metal, corrugate pipe, lay out a job and envision how it would look when finished. By the time he was 15 or 16, he says, he was master of the shop.

"I learned to appreciate the craft," he says, "to love working with metal."

To the statue

He also loves performing, and that led him to the Statue of Liberty. His mother was a singer, and Heaphy, while running the shop, did summer stock and regional theater. Through people he'd met acting, he got a job transforming a room of the Ellis Island museum in New York City into a theater. Then he befriended workers in the Ellis Island maintenance department, the same workers who oversee the Statue of Liberty. He told them about his family business.

"I said, 'So what do I have to do to become the resident tinsmith for the statue?' " Heaphy says. "I'm positive the guy's going to laugh in my face. And instead he goes, 'I don't know. We can probably find you something.' And inside, as a tinsmith, I'm thinking, 'What did he say? Did he really say that?' "

They found him a job repairing the brass windows in the statue's crown. Then he repaired the brass grating in the lobby.

"They kept on giving me different projects," Heaphy says, "and I became the go-to guy."

He also got a job performing, five times a day at the base of the statue, a dramatic re-enactment of how the statue was built. He puts the show aside when there's work to do on the statue.

Bringing it back

He's been the statue tinsmith for eight years, working from April to October and then going home to Syracuse for the winter. Until it snows, he says, he'll continue working on and off on the Howard Hall Farm roof. He's planning on finishing in the spring.

"The tin roof is still intact," Heaphy says. "But over the years people have dropped things on it and punctured it, and they put nails in it to hold it down, or they put tar on it, or they put caulk on it, and when they ripped out fireplaces and chimneys they put aluminum over it."

He is removing as much tar with a chisel as he can, and then he'll have helpers remove the rest with paint thinner. They'll wash it with soap and water, and he'll use a brush to get it as smooth as possible. It will eventually be painted red.

Heaphy will solder the holes and remove any exposed nails. A tin roof like this, he says, should be bent and folded to create waterproof seams. He'll peel the roof back so the soffits can be replaced, and he'll create drains. He'll replace the tin around the new chimneys.

In the process, he'll teach contractors and others about the art of tinsmithing.

"What Reggie's trying to do here is give people a window to the past and the opportunity to get their hands into these processes, to appreciate the original process," Heaphy says. "Happily, these old roofs do exist, and there are people out there trying to keep them."

Tom Keyser can be reached at 454-5448 or by e-mail at tkeyser@timesunion.com.

Classes for restorers

For more information about lessons with Dennis Heaphy or Howard Hall Farm renovation and seminars, call Reggie Young at 945-1945. (or 945-1253)

Upcoming seminars:

Dec. 1-2: Rory Brennan (plasterer from "This Old House"): Lime washes and finishes.

Dec. 2: Brigit Binns, spokesperson for Williams-Sonoma and author of cookbooks: Green-friendly cooking.

Dec. 8 (tentative): Shannon Hayes, author of "The Grassfed Gourmet," "The Farmer and the Grill" and "The Carnivore Chronicles": Cooking class.

Dec. 15: Mercy Ingraham, author of "Open Hearth Cook": Hearth cooking from the Federal era.

Next year's seminars begin in April. Topics include kiln building, Dutch-barn building, historic sash restoration and historic doors.

A green-technology conference, exploring options and costs for restoration, is scheduled May 17-19. Heaphy will give seminars in tinsmithing June 21-22.

All Times Union materials copyright 1996-2007, Capital Newspapers Division of The Hearst Corporation, Albany, N.Y.

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Sunday, November 18, 2007

Breathing Fire

As we embark on this chimney building project I found myself compelled to think of the births, deaths, and everything in between that was once shared in front of these fires.

At this point, just having a fire will seem like a dream 2 years in the making. We had so many other things that had to happen before we could do the chimney. But now that we are here it is very exciting.

The photos of the chimneys core with the flue channel gives one a wonderful feeling for how they were built originally. Due to years of water coming both down the chimneys as well as around them,the lime mortar, and many of the bricks finally gave out. In the process of taking the chimney down, we found the remains of the fireplace on the second floor, which we are restoring as art of this process.

Next Spring, we will plaster the chimneys to bring back their 18th century appearance.

The mantles have made it through all these many years, and in almost perfect condition. We do have to replace one hearth, flash into the old terne tin roof, and then line and protect the flues. After the chimneys are up we can plaster the rooms and finally move into them as living space after 2 years of work.

Whew! That was a big one!

-Reggie
-----


The 2nd floor fireplace we uncovered and brick coming down on the first floor (showing guts):






The exposed flue.

pre-chimney showing cracks


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Monday, November 5, 2007

Howard Hall Farm is about to be free watt ready!

Here's the scoop on our new heating system:
Mind you, we are not engineers, but have a practical approach to these issues.
After much researching of what is available out there(and there are other cogeneration systems that we did not choose),we chose to go with a product from [**Climate Energy**], which
will eventually both produce our heat, as well as provide the bulk of our electricity, all in a highly efficient system that has been developed by Honda.

On Saturday we (the heat system installers and myself)went to Climate Energy's training session. We saw units running and working. The only down side is that we have to wait to get the electric side of the system until it gets through UL approval, unless we get a test unit, which we are
working on...

For now we have the boiler that will be ready for the final
install next year. If we were doing hot air, and not propane, we could be up on line with the whole system right now. But the wait will be worth it. Once we have it, even if the power goes out we will still have electricity, and not from the grid.

It will be **much more efficient** making wattage from our unit than from the fossil fuel plant that feeds the grid as they aren't very efficient at all. We feel that this is the greenest option out there at this time for all kinds of reasons, and one that makes a big difference in terms of pay back in less time than geothermal, which we can hardly afford right now anyway.

We will be discussing the system on the blog as we get it installed and going. We're looking forward to installing the whole deal with the hot air natural gas option (that does make electricity now) for a client soon,
so we will have practical experience on that end soon. (We couldn't do that in our own house, since we can't do duct work here without destroying the historic fabric of the
building).

Our installer will become the dealer for the Upstate New York area soon and we will posts links as soon as all that is arranged. Very exciting technology that is just out, and we are getting the first Climate Energy system in New York State. **I believe we're number 57 in the chain of
installs in this country.**

Keep posted for more info on this topic if you are an energy enthusiast!


The following photo's are our ancient old oil tank coming out (which was once a water tank). We are setting this room up so that it can be a viewing room for the system.

-Reggie






THIS IS SO MUCH BETTER:


THIS NEW SYSTEM IS A BREATH OF FRESH AIR.....


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