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Phil & Aven's SunPorch Adventure (A True Story)

Intro
Summer 2008 Install
Summer 2011 (3 years later)
Aug 2011 Hurricane Irene

My name is Phil R. I'm 62 years old and retired.

"Retired" is another way of saying we've got a lot of time on our hands and little money.

My wife Aven and I spent the last 469 days building our new 2350 square foot home ourselves (literally) to reduce the cost per square foot with "sweat equity" AKA "cheap labor". Our project was finally completed when we added our SunPorch.

I decided to document the adventure for posterity.

Phil & Aven R., North Carolina - Apr 2008

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skip to photos

TABLE OF CONTENTS

1. OVERVIEW (Page 1)
2. OBSERVATIONS (Pages 2 thru 5)
3. PICTORIAL TOUR (Pages 6 thru 26)
4. PROJECT TIME (Page 27)
5. PROJECT SUMMARY (Page 28)

1. OVERVIEW

We designed a 12'X36' deck overlooking the water with 3 sliders from the house and took pains to construct it plumb and level. We wanted to be able to access the SunPorch sunroom from our master bedroom as well as the great room. The third slider accesses the open part of the deck from the great room.

We ordered a 12'X24' SunPorch Model EZS1224 and took delivery in October 2007. Our order was customized to withstand 130MPH winds at an additional cost since we are in Eastern North Carolina and are host to many hurricanes.

Construction of the SunPorch sunroom started March 18th 2008 and was completed April 13th. The duration isn't important because we had a lot of other building projects going concurrently to finish the house, but I did keep track of the time spent from a project management perspective. continue...

skip to photos2. OBSERVATIONS (1 of 4)

Some observations and advice in no special order follow:

1) We ordered and budgeted for a 12'X24' SunPorch. Comparable "turn-key" units we researched with local builders ranged from $28,000 to $40,000.

2) Getting it delivered was easy. With our assistance, the driver helped offload everything and placed in our garage. There were 18 cartons all together and most of them were light enough to be easily handled by the two of us.

3) The support from Joe Burns at the factory was simply superb. I did management advisory consulting for 5 years after I retired and I can tell you having a personal construction advisor who answers his own phone and returns E-mail within hours is an order of magnitude better than all of my fortune 50 clients! continue...

skip to photos2. OBSERVATIONS (2 of 4)

4) Some people only use directions as a last resort. I'm overly anal about following and understanding the directions, probably because I'm slightly dyslexic and left handed. Of all the directions in the substantial book of 195 pages, there is one that we used to call "mission critical" in the consulting world, and that is (paraphrased) the base channel and columns must be level, plumb, square, and perpendicular.

5) If I were heading this project in Corporate America, I would collect my construction team and say: "I want to give you some simple instructions--make sure the base channel and columns are level, plumb, square, and perpendicular". If you don't make sure the base channel and columns are level, plumb, square, and perpendicular, your next merit rating will reflect the fact that you can't follow simple instructions!

6) Re-read #4 and #5 again! I know, I know, but it is that important! Screw it up and you are in for a world class nightmare. The best news is getting it right isn't rocket science or as difficult as mating Pandas, it's simple math and the ability to read a level or stretch a mason's line. I used the Pythagorean calculation to determine my diagonal measurement should be 27' 1/2" and took all the time necessary to make it so. "Stick me with a fork, I'm done lecturing!"

7) The glossies say the SunPorch can be erected in times ranging from a weekend to a week. I worked mostly alone and it took me 48 hours. I did have some special constraints. I only had about 4 inches from the mullions to my soffit which made everything at the top end more difficult, especially for a 250 lb left hander. Our deck was built 12' off the ground with the SunPorch occupying 24' of the 36' length. This meant I had to have two levels of scaffolding to install the windows, and at 62, I don't climb as well or move as fast as I did when I was a kid. On the positive side I had a complete workshop full of tools like a low profile air ratchet to help in the tight places. Clearly the SunPorch comes in different sizes. Ours was the next to largest, therefore should obviously take longer to erect than the smallest unit. continue...

skip to photos2. OBSERVATIONS (3 of 4)

8) Concurrent task management isn't covered at all in the instruction manual. The instructions say to do everything by the numbers. There are however tasks which can be done concurrently for those who really have to "git er done" before having to go back to work Monday morning.

   - Installation of the vents and taping the ends of the roof panels in my case took 5 hours and could have been done anytime before they were needed.

   - Gasketing of the battens and roof rafters could have been done anytime as long as the tape backing was left on. In my case this was a 3 ! hour job. Timing the roof rafter gasketing to be a few bays ahead would allow the roof panel installation team to operate concurrently.

   - Window/door installation could start as soon as the frame is up and run concurrently with the roofing. This was just over a 9 hour task for me alone.

   - Base channel caulking could be done as soon as the base channel is laid.

9) There are risks however to any concurrent task management adventure. Someone has to "watch the store" who knows the drill and none of us know the drill initially. We all have to go up the learning curve. Everyone has to be able to follow "simple instructions"! There has to be redundant tools and areas to work. My point is you can't have 6 of your closest friends arrive Saturday morning with 2 cases of beer and expect to be done by the time the game starts.

10) My guess is the SunPorch folks, having to deal with the bell curve of human intelligence, decided to publish directions "by the numbers" rather than indicate which tasks could be concurrent and risk a major screw-up. A reasonable decision IMHO. continue...

skip to photos2. OBSERVATIONS (4 of 4)

11) The directions say "read the entire book before starting". My book was 195 pages and the first pass through left me with all the nightmares in the "some assembly required" cartoons. Once I got started, I found there is a rhythm to the directions which makes sense once you are tuned in. Since every process can be improved, I documented many pages of notes and recommended changes which, I believe, will improve the clarity of the directions for the next "pilgrim". They are attached for those of you who are serious about taking on the project.

3. PICTORIAL TOUR

Since a picture is worth a thousand words, the following pages are the pictorial tour. continue...

Getting started: It makes sense to take the time to sort everything out
and get it arranged for easy installation.

I was probably too anal and labeled all the fastenings etc...
It was sure made it easy to find everything.

Base Channel laid out square and bolted down.

Stretch masons string and make sure it is
straight and square before you bolt it down.

End wall framing complete. Fit perfectly below the eave.

Directions don't call for scaffolding, but it sure is handy!

The "Admiral" supervising installation of columns and rafters.

Any less room from the mullion to the soffit and I would have been in trouble.
I used a low profile air ratchet as it was.

Directions say to place the vent and then flip the panel, but I found this way is easier to line up.
Make sure you do it right the first time, the tape can be a mess!

Roof panel vents complete and ready for installation.

Framing complete and attached to the house.

It's always a good sign when everything is straight, square and level.

First roof panel goes up. When you are 12' above ground,
make sure you do the calking before cocktails!

Clamps are handy if you opt to "dry-fit" everything first.

The "Admiral" and the air ratchet which will extend her reach.

Installing the windows was quite easy. All the parts have stripes so they can be level & square.

Roof panels complete. Because of the scaffolding, I didn't do the right side first as directions say.
I wanted to "go up the learning curve" with my feet on terra-firma!

Only 3 windows to go!

The screw covers gave it a real finished look.

Our view from the SunPorch is magnificent...

SunPorch is Complete! 52.25 hours according to my timekeeper.

4. PROJECT TIME

My overall time for completing the project took me 52.25 hours! I worked mostly alone and took my darn sweet time. Look where I was working! I don't move as quickly as I used to when I was a kid.

Hours Tasks 2.00 Unload 18 wheeler at roadside 2.00 Inventory-match contents to bill of lading 2.00 Sort and arrange parts for assembly 2.00 Square and install base channel 1.50 Install rafter and header brackets 1.00 Square header and vertical tubes 2.50 Install frame assembly 0.75 Install top mullions 2.00 Install rafter caps 0.75 Install eave mullions 5.00 Install vents and taping 3.50 Gasketing roof & Battens 6.50 Install roof panels 0.50 G1M Fillers 2.50 Install door 8.75 Install Windows and trapezoids 10.00 Install Skylight/wall shades 52.25 TOTAL hours

continue...

5. PROJECT SUMMARY

The bottom line is SunPorch Structures Inc. offers a well crafted product at a fair price with excellent factory support. If you can "follow simple instructions" you can do this project with a successful result.

We are more than pleased with our SunPorch and have no second thoughts about recommending their product.

Phil & Aven R., North Carolina - Apr 2008

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"The fact is that 3 years later we are still very pleased with quality and durability of our SunPorch and enjoy it every day"

Phil & Aven R., North Carolina - Aug 2011

The SunPorch is still tight as a drum and not a single water leak
All of the vents still work perfectly and nothing has broken
Our "winter" configuration is all shades retracted and all vents shut. The SunPorch produces a lot of heat in the winter sun and we open the sliders to the house from around 10AM to 4PM every day the sun is out.
Our "summer" configuration is all vents wide open and all windows configured with the top half down and the bottom half up leaving open screens at the top and bottom. All roof shades are extended and sometimes we use the side wall shades in the morning. We sometimes use the western sidewall shades in the afternoon.
We have our morning coffee and sometimes breakfast out in the SunPorch from March through November.
We do "adult beverages" on all but the 100 degree days at 4PM sharp.
We bought a "Big Buddy" propane heater which warms up the SunPorch on the coldest of North Carolina winter days when the sun isn't out.

continue...

Having spent many years living aboard our 44' motor yacht, we felt we really needed a
"Tiki Bar" in the SunPorch to remind us of the Exumas and Abaco Islands.

The hot tub is a delight in and so soothing...

The opposite end of the sunroom is "living area" with our "breakfast-for-two" table.

Aven's nook and reading area are adjacent to the uncovered part
of the deck which is covered by a pergola.

The best chair in the sunroom is usually occupied by "Mutley" and "Chumley",
our rescue dogs. The pool is just at the bottom of the stairs.

And heeeeeeeeeeere's Chumley!

This is the pergola side of the SunPorch where we barbeque and the stairs to the pool.

Here is the view from our breakfast table. What a view it is...

There's one more picture for our story 3 years later. Our SunPorch survived Hurricane Irene, in fact, we sat out in the SunPorch for most of the hurricane which went on for two full moon high tides. SunPorch didn't leak a drop and although the wind flexed the Duraplex windows in the gusts over 100MPH, she held together with no damage. We were amazed!

<< See Intro

Closer to the ground, not so lucky -the water was 3' over the 100 year flood mark and our Roadtrek RV AKA "Mutt-Mobile" went for a swim up to her dashboard along with our old 380SL Mercedes, PT Cruiser, Chevy Pickup, Lumina Van, and our new Kubota tractor.

The picture shows the SunPorch and the spot where our pool used to be...

Phil & Aven R., North Carolina
Sept 3, 2011

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