START HERE!
Always start with this link to see the Order of Operations for the Mansion Style Advent House. That is where you'll have access to links to all of the most current instructions.

Monday, November 7, 2011

Illustrated Structure Build (Part 1)

The purpose of this post is to show you, step-by-step, how to build the main structure of the Advent House. The details/descriptions here, with the images, will provide you with greater detail and make your build faster and easier. Questions and comments can be posted in the AHP Forums.

As it is with all of the pieces included in these pictures, the dimensions and details about each piece are provided in the Advent House Plans, that you can purchase from the website. You’ll need a number of tools to build this advent house structure as shown in these images. Here is the intitial list:
—————————————————————————

  • 2+oz Super Thin CA Glue (Hobby/RC Airplane shop)
  • 2+oz Gap Filling CA Glue (Hobby/RC Airplane shop)
  • X-Acto Knife
  • 12″ Hard-edged Ruler
  • Paper Towels
  • Sharpened Pencil
  • Sandpaper (100-200 grit) or a dremel tool with sanding drum(s)
  • Wax Paper to protect surrounding areas from the CA Glue.

—————————————————————————-

There will be other tools needed as we get further into the build (like the Atrium and the Windows). But for the structure of it all, this is a pretty good list.

Be sure to follow these postings and post questions and comments on the AHP forums.


—————————————————————————-


So – let’s get started:

--------------------------------------------------------------------------------




Bottom Piece Ready

This first piece is the bottom piece. Find a large and sturdy building surface that you don’t mind getting a little dirty. The carpet shown in these images is probably not the best choice for you. The first step is to layout where the bottom bracing goes. Use two of the other available pieces (such as the soffits and/or the vertical bracing pieces) and mark the distance in from each edge of the bottom piece. If you are using the structural pieces available on this website, then the distance will be 1/4″ in from all edges.


--------------------------------------------------------------------------------



Trace Edge Lines

This shows how to use two of the other bracing pieces to mark the edges of the bottom piece. The soffits and vertical bracing work well.


--------------------------------------------------------------------------------


Trace All Edges

Showing the edge marking on another edge.


--------------------------------------------------------------------------------



Layout Bottom Bracing

Next – layout the Bottom Bracing pieces according to the plans. Ensure that the pieces all fit where they belong. Notice there is no bottom bracing on the very front of the house (where the front door will be), nor along the back. But you will want to mark both of those edges as well for future reference.


--------------------------------------------------------------------------------

- – WARNING – - Now seems like a good time to make a point of the caution needed while using CA glue. In case you are interested, you can read more about CA glue here, but in short, CA glue is a fast acting and powerful glue used in many different applications. I was introduced to CA Glue when I got into RC Model Airplanes. I found that CA Glue is particularly useful in bonding MDF due to how smooth and dense the material is. However, at the same time, CA Glue can be dangerous. Be very careful not to get it on your skin – it can take days to wear off, and please, please, please don’t get this in your eyes. Safety goggles aren’t a bad idea here. Lastly, once this stuff drys/cures – it’s solid and trying to separate 2 pieces of MDF once it is glued will result in broken MDF and not a broken bond. So please be sure you know where the piece is going before you glue it down. ok? – ok, enough of that.


--------------------------------------------------------------------------------


Gluing Bottom Bracing

So now we glue. I used the ‘Gap Filling’ CA Glue for the main attachments. I found the ‘Gap Filling’ version was far less likely to run, it didn't soak into the material too quickly and was just flexible enough to allow changes for just a few moments upon placing the part. If you work quickly (having planned ahead), you can probably get several pieces on (like the 3 right-side pieces) before they are fully set. However, better to plan on just putting them on correctly the first time.


--------------------------------------------------------------------------------


Gluing Bottom Bracing

The amount of glue needed will depend on surface area and will take some practice. Again – I’ll make a note here - if you have some glue push out and run, Please, do not wipe it with your finger. Use a paper towel and keep your fingers away from this glue. If the paper towel sticks too much, it’s easy to scrape off with your X-Acto knife or sand off with sandpaper. I can’t say the same about getting this glue on your skin.


--------------------------------------------------------------------------------




Bottom Bracing Glued Down

This picture shows the Bottom Bracing all glued down to the Bottom Piece. Make note that there are only 3 pieces on the left side and 3 pieces on the right side.

We are very impressed with how strong this bond is.


--------------------------------------------------------------------------------




Fit the Short Side Wall and Bracing

So after giving the bottom piece just a few moments to become solid, you are ready to start preparing the walls for attachment to the base. You start by fitting the short side wall into place (reference the plans for placement locations) and holding the Vertical Bracing in place. Again – check the plans for placing of the vertical bracing. Please make note that the vertical bracing sits on top of the bottom bracing, thus causing it to stick up and above the height of the wall, since the wall is actually sitting on the bottom piece. Yes, this has a reason that you will see when adding the Middle Bracing to the structure.


--------------------------------------------------------------------------------


Short Wall Marked

Here you can see the marks along the edge of the Short Wall. Make note that the bottom of the vertical piece does not reach all the way to the bottom of the wall, as described in the previous post. No, the vertical piece sites 1/4″ higher on the wall, thus causing it to stand 1/4″ taller above the wall piece as well. Note there is no glue at the very tip-top of the vertical brace.

While still using the Gap Filling CA Glue, glue this piece in place. You need to have it perfectly flush with the edge of the wall piece.


--------------------------------------------------------------------------------




Mark the Front Wall

Having added the vertical Braceing to the Side Wall, you can now trace the edge on the Front Wall where the sidewall and Bracing will connect. Again – make note that the Bracing does not reach clear to the bottom of the wall. This is because the Bracing sits on top of the bottom bracing that are already connected to the Bottom Piece.

The extra hand is helping me hold the outside edge flush with the edge of the front piece.


--------------------------------------------------------------------------------




Glueing Walls

Having the location marked, now glue the Side Wall and the Vertical Bracing to the Front Wall. (The glue pattern is optional.) When gluing these pieces, ensure a flush connection of the side wall with the front wall. This is essential so that the finished part will sit perfectly over the bottom bracing on the bottom piece.


--------------------------------------------------------------------------------




Front Wall Assembly

After gluing one of the short side walls into place, you’ll need to repeat the process for the other short side wall. And (at risk of beating a dead horse), ensure the vertical bracing reaches above the wall system by 1/4″ (or the thickness of the material you may have chosen).

With the front wall assembly complete, you’ll make note that now you’ll need to do the same things to both sides of the structure as you go through this process, just in the reverse/mirror.


--------------------------------------------------------------------------------




Fitting the Front to the Base

And now it will start to come together. In fact, at this point is when my son (he’s 5) recognized it as a house.

Now – in theory, if you cut all your pieces correctly, marked all the edges correctly, and glued everything correctly, this front piece should slip perfectly onto the base just snug as a bug….. oh – you get it. If you purchased the parts from our website, the cutting was perfect and all you had to do was glue things right.


--------------------------------------------------------------------------------




Front Walls Fit

And finally – a result. Assuming you did everything correctly, the front wall assembly will slip over the bottom bracing perfectly and tightly and sit nicely right where it belongs. If it doesn't – go back and figure out what went wrong.

Assuming it does, you can now add glue to the bottom of the front wall assembly, along with the bottom of the vertical bracing and the edges of the bottom bracing that will be in contact with the walls. This will ensure a tight fit and a secure hold.


--------------------------------------------------------------------------------
*** NOTE *** This seems like a great place to stop and explain the purpose of the ultra-thin CA glue. Up until now we have only been adding glue to the actual connection points and this is good. In the event that something did not fit correctly up until this point, cutting/scraping/hacking the incorrectly applied piece off to recut and reglue may still be considered possible. But if everything has gone correctly so far, if everything fits snugly, it’s time to really secure these things in place.

To do this – you use the thin CA glue and carefully run a very small line of glue along each seam where one piece connects to the other. In the previous image, you can see the darker ‘wet-looking’ lines between the bottom piece and the bottom bracing. Now – keep in mind that this ultrathin glue is –uh – well…. ULTRA thin and it will come screaming out of that bottle. Start small and work up to it. Unless you want to go buy another bottle or two of this stuff, use it semi-sparingly, while still ensuring a proper coverage.

This ultra thin CA glue will almost immediately soak into the two connecting pieces and penetrate into the seam, thus causing a seal that you probably will never get off of there short of some significant time on a band saw and belt sander. So please be sure you have everything where it belongs before you begin using the thin CA glue. And – once more – please be very careful not to get this on your skin.

Ok – enough of that – let’s keep assembling.


--------------------------------------------------------------------------------




Glue Long Side Wall

Once you have the Front Wall Assembly in place, this all gets a little easier. Dry-fit one of the long side walls into place.

* PLEASE, first refer to the plans to ensure you place the correct long side wall in the correct orientation in this step. *

Lay down a line of Gap filling CA Glue on the edges and glue this piece in place. An extra set of hands or maybe clamps will help ensure everything is square, right and tight.


--------------------------------------------------------------------------------




Add Side Wall Bracing

… And add the vertical Bracing on the outside corner of that inside wall connection. Please refer to the plans to ensure you place the bracing in the correct location. And one last time – this piece, along with all the vertical bracing will extend up and above the wall piece, so don't be concerned when it does!

Glue into place.


--------------------------------------------------------------------------------




Glue the Other Side

Repeat the last step, but with this other side. Again – please be sure you have the wall in the correct orientation before gluing in place.

Although not shown in this image, also add the vertical bracing to the outside corner of the inside wall connection, same as the other side.


--------------------------------------------------------------------------------




Mark the Side Walls

Mark the side wall using the vertical bracing. This is not the same as putting the 1/4″ mark. And – hopefully the last time, ensure the vertical bracing extends 1/4″ above the wall height.

You should now have all the front walls in place with just the two side walls to add. So let’s do that…..


--------------------------------------------------------------------------------




Glue Side Wall Bracing and Attach

After gluing the vertical bracing onto the side wall, you are now ready to glue the side wall into place. Following the same steps as previously mentioned, use the Gap filling glue and be sure to hit the outside edge of the bottom bracing. You’ll also want to be sure to add glue to the front edge of the side wall as well as the side of the vertical bracing.


--------------------------------------------------------------------------------




Main Walls Complete

And that’s the main structure of this Christmas Vacation Advent House. Be sure to run the Ultra thin glue lines on all inside connection points, as well as on the front of the inside corner between the short wall and the main window side wall.


--------------------------------------------------------------------------------







Main Walls Complete

This is another shot from the front. You can clearly see the vertical bracing extending up above the walls (reason forthcoming).

Now would be a good time to carefully test your connection points and add the Ultra Thin CA glue where needed to ensure you have a solid structure.


--------------------------------------------------------------------------------
This would make a great stopping point and encourage you to visit our forums to ask questions, relate to others going through this same process and look for additional tips and tricks.

--------------------------------------------------------------------------------

The next section involves angles so taking a short break here might provide you with a little extra patience in case things don’t line up exactly as you want them too. Keep in mind that you have the option of adding an exterior roof finish to cover any possible roof contruction flaws.

--------------------------------------------------------------------------------


To view the construction of the roof system, go HERE.