Attic insulation and van repair
End of Feb beginning of March 08

Considerable thinking went into the insulation project over the past year
I came to realize that the blown-in insulation we put in years ago has deteriorated
Not only has it deteriorated, but it has weighted down the fiberglass insulation so now we have less insulation than if we never put blown-in over the top of the 6” of fiberglass
The one plus about blown-in is that it filled cavities the fiberglass missed
The other big plus, unknown until the day I started re-insulating the attic, was that the blown-in made the re-insulation job possible! The dusty insulation created a slippery surface that let me slide 6” of new fiberglass into position over the top of existing insulation. With the slippery surface, I was able to slide the new insulation with a minimum of effort.

Among the things I thought about during the past year:
- I knew the attic was small (only 5’ 4” at the tallest point) and filled with A/C duct and equipment throughout
- I knew with certainty that neither my wife nor I could get sufficiently into the attic to spread batts of 6” fiberglass insulation (a certainty which turned out to be false!!)
- To circumvent the problems, I calculated I could cut holes through sheetrock in the pantry and master closet to get up into the attic
- I also figured I could remove the gable end vents from outside while on a ladder and maybe crawl in that way
-I figured too that Holly could hand me insulation down through the roof turbines if she could get on the roof and we could get the turbine loose from the base
- I figured I could remove 1 sheet of plywood from the covered porch to get into attic over the master bedroom
- The biggest quandary was the ceiling over the big room since it was 18’ across and only 28” high at the highest point.

-a lot of thinking and worry went into the project because I didn’t think there was any way I could get around in the attic with my age-weight-health

The beginning:
Early in the week I purchased 1 roll 6 ½” x 15” at Lowes for $40.
My van wouldn’t start one morning because the headlights shorted-out the night before

With the van not working and having nothing to do that day, I went up in the attic and laid 4 pieces of insulation using a ¾” x 5/8” x 6’ stick
-as luck would have it, the paper-side of the new insulation slid across the dusty surface of the blown in insulation > this meant I could slide the insulation into place from the center of the attic!!! I didn’t have to get my body way over to the edge of the low-tapered attic.
I also realized that the leftover oak trim from the den paneling was lying in the way of more progress – it had been up there all these years and I forgot about it.
For a moment, I thought about laying insulation over the trim. But I wouldn’t sleep right doing a cobb-job like that. I had to move all that trim out of the way.

Holly arrived homes and took a nap.
My van was dead and needed a battery.
I opened the van hood and removed the battery using vice grips since the bolt is metric and I couldn’t find my small crescent wrenches
I took Holly’s car to the nearby auto parts store. They had a battery for $98 – including a metric socket
The new battery worked but the lights were still shorting out after the van was turned off, so I loosened the battery cable.
I also added a small board to the hood spring so the hood will pop up
Holly and I went to KFC for dinner – and stopped by the auto parts store on the way – they found a headlight switch for $215 at another parts dealer – I asked about the repair shop there along 36 – they said they’re honest and expensive

Later that night or the next, Holly helped me remove the oak trim from attic. The attic was ready for more insulation.

After brainstorming all manner of ideas, I realized a few days later that one of the oak trim pieces from the attic is long enough to reach almost all the way across the big room
Later I discovered that a long screw could be added to the end of the long trim to stab-in and hold the insulation while I slid it across the big room
I also prepared 2 other shorter sizes of stick with long screws (although the screw addition evolved later after a few tries without anything except the bare stick)

The screw-in-the-stick idea was the key to success > it became the ultimate evolution of the stick idea

The next evening I was ready to try the long-stick-across-the-big-room idea
Holly helped me > I handed down the pet carriers etc and she handed up pieces of insulation
I laid a piece of plywood to the side of the water heater and pulled my large ass into place, laying on my side. The attic pinched low near the edge so I had to lay the insulation on top of myself before moving it into final position.
The long stick idea would have worked but there were too many things in the way across the big room > the insulation got stuck after about 12’ > I couldn’t push it all the way across > I had to compromise on the big room and laid a few pieces before concluding that I just wasn’t going to be able to lay insulation in the smallest areas of the big room
I pushed a few pieces as far as they would go > and that was that
I then moved the plywood away and insulated as far as I could reach around the water heater and A/C unit
With the sticks, I was satisfied that I had a plan that would work for the rest of the attic

The next day the van started stalling a bit, but the damn lights turned off !! Eureka it fixed itself!

I had another problem however. I wore a dust mask the first couple times in the attic, but it didn’t stop debris from entering my lungs and throat. I stopped by Lowes. They had a paint mask so I took it. Turned out the $25 mask was just the ticket. I had NO problem breathing while in the dusty attic after that. My lungs and throat were not at risk, and this was important since I spent so many years breathing paint and suffering hoarseness from that exposure.
 
The day I got the mask, I went into the attic with boards from the barn
I had a couple short lengths of 2x8, several 30” long 2x4’s plus three 5/4 x 6’ fence pickets > this was plenty to hold my weight so I wouldn’t need to balance on the joists
I also had a few stout fir 2x3’s from Lowes
Bit by bit > shaky at first > I worked from the attic stairway all the way back to the den area
I installed a handrail next to the water heater which became the third great technological breakthrough
The slick surface of the blown-in insulation was breakthrough #1 > the stick was breakthrough #2 > the screw on the end of the stick was #3 > and the handrail idea was #4
I realized that if I could attach a handrail between vertical attic supports, then I could keep my balance & have a place to sit while spreading insulation
I set up everything for the next day > 3 handrails were in place > several step boards were in place > Holly handed up 3 bales of insulation and I scooted them down to the den on top of the duct using one of the long sticks

The next day I would begin putting insulation over the den > I dreamed about insulation all night long

My van was in the shop the next day >

I was anticipating some progress on the first big day, but I accomplished a lot more. I did the entire den plus, to my absolute amazement I did the kitchen and dining room too!!!

I went into the attic for my big push over the den > after a year of planning, I never dreamed I could get over there, let alone do the insulation without removing sheetrock or exterior siding
The insulation went fast > it was a success > and it didn’t take long
After the den, I started filling along the side > one more row and I would meet the insulation from the first time up in the attic

After the den was finished, I started looking at the low crawlway across the big room leading to the kitchen/dining > I stared at it > I worried about it > it was only 28” high and claustrophobically filled with dusty insulation > but then I just cranked my courage and said I would crawl across the big room over to the kitchen
Two things worked to my advantage:
-First I had installed attic lights in the far recesses of the attic > so I had ample light without flashlights or extension cords
    -Second I planned-ahead years ago when I built the house. I laid a two-foot wide crawlway made of siding across the entire length of the big room. This meant I could crawl across on a flat strong surface
I got my sticks and short 2x4s and pushed a bale of insulation ahead of me > I was laying in 2” of dusty blown-in insulation that clouded up the crawlway with each move forward > I made it across the big room and rolled down into the attic space over the kitchen/dining room. It was the same 5’ 2” height as the rest of the house, but at least I wasn’t laying prone with my face buried in the blown-in insulation
It was obvious that I needed a place to sit and couldn’t do any work stooped over, so after 10 minutes, I assessed everything and retreated back across the crawlway.

When Holly got home we picked up my van at the shop > they couldn’t find the problem after they opened the dash > $54 and it was ‘fixed’ > I laughed and said I’d see them in a couple days. The lights worked for another day before the short came back.

That same night I carried insulation into the attic. I was preparing to crawl across the big room and insulate the kitchen/dining the next day. I had done the den that morning. After crawling to the kitchen in the afternoon, I saw that I could do it > I was filled with surprise and eager to move forward.
I was tired from the day’s work so far, but the idea of having to do the kitchen the next day was a morale destroyer.

I gritted my nerve. I had to do it that night. I didn’t want to, but I had to.

A big boost came when I discovered the long oak trim could be used to push two insulation bales completely across the big room ahead of me > wow, what a help that was! > it meant I only had to crawl across with a 2x3 and hammer > I didn’t have to push-pull bales of insulation too. That made it a lot easier, especially in the confined crawlway.

The crawlway was unbelievably dusty and dirty and my elbow was getting scraped badly with each move, but I forced myself across.
After getting across, I still faced a challenge. Before I could lay any insulation, I had to nail-up a railing to sit on. I put the board in place and swung the hammer but the first nail bent-over half way in. I was breathing so hard I thought I was going to have a heart attack. I had to get it nailed or crawl back up in the dust to rest. A moment later I had a good nail in one end > now I started a nail in the second end > that nail bent too > I was on the verge of panic > I told myself to calmly gather strength and make the next nail count > with the best luck possible, that nail went in > one nail in each end and that was enough > I sat down.

It must have been 5 minutes before my breathing slowed and I stopped paying attention to it.

The insulation spread perfectly > I had the right number of pieces > I could move the bales toward me when needed by using the stick with a screw > everything notched together.
I was finished within an hour and ready to crawl back > I had just enough pieces to fill up the first row over the big room > I laid those pieces as I started crawling out.

The crawl back was exhausting > when I got to the end near the attic stairway, I was willing to fall over just to get out of there > fortunately I didn’t fall and had surprising strength, but I went immediately downstairs and closed the attic door. Enough of that for one day. I was covered in dust and took a shower.

Wow, I did it. My emotions were brimming. I was proud, astounded and exhausted all at once.

I took the next day off. My butt was sore from sitting on that narrow 2x3 for several hours. I had really done it. I was so amazed with my progress. I simply couldn’t believe it. It was good recouping for a day so I could wash the dust out of my clothes.

I went to Lowes for more insulation. Unknown to me, the insulation had been on sale. I was getting 25% off, but the sale just ended. I was paying $30. Now the price was $40. The manager couldn’t honor the sale price because it was below cost. She agreed to $35, and I was happy. I bought 10 more bales > enough to do the rest of the house.

The van was back in the shop > it needed a new headlight switch > the total price was 138 labor and materials + 98 for the battery + 60 for first trip to the shop = $300 (after 6 ½ years and 45,000 miles that was the first payment on the van)

The next day in the attic, I had to finish insulating the crawlspace over the big room. I told myself that I wanted to do a good job but there was no way I was going to crawl up there again. I would have to depend on the long piece of oak trim. It worked great. I was a bit short in 2 places > but good enough was going to be good enough. After finishing the big room, I laid more pieces near the den until they joined up with the insulation already laid. Wow, just like that, the house was done over to the attic stairway.

I pulled out my boards as I retreated.

Flush with success, I had confidence to face the next challenge. I knew I could crawl over the air conditioner box and finish the rest of the attic.

That night I laid a 2x3 across the A/C unit between 2 vertical braces. The far side was not nailed > it was wedged against an angled 2x4, but the plan was ingenious > I had found a way over the A/C box!! I would lay a 2x6 across the box itself and divide my weight between the 2x3 and 2x6. I knew it would work.

About this time, I decided to make a shelf in the attic. The idea had been in the back of my mind the whole time. I want to be able to store a few things in the attic, but the place is dang small and the A/C takes up all the prime space. I didn’t want to store boxes and other stuff over the top of the new insulation. In order to make it work, I would need to suspend the shelf above the ductwork. The time was now or never.

I did it the next day.

Because of the limited working space, I had to devise a careful series of steps. The first board would be held by a brace while I leaned across the ductwork and nailed it. The second board would be pre-fitted with brace blocks to hold it steady while it was being nailed. It took many small steps and lots of pre-assembly but with Holly holding the last board in place, I finally got the frame nailed. I had a hard time nailing that last piece. The problem was a design flaw. I intended on leaning over the ductwork, but now part of the new frame was in my way. My weight kept me from being able to maneuver. Finally I sat on top of the new rail and put both legs over the ductwork. After a deep leg bend, I was able to shoot 3 nails with the big nail gun. Afterwards, the precut pieces of plywood fit like a glove and the shelf was done.

But wait, I could build more shelves!! A carpenter always wants more shelving. Besides I needed a place to put all that oak trim that I pulled out during the beginning.

Yep, one set of shelves was not enough. The next day was going to bring another set of shelves.

I was walking down the hall towards the attic and noticed a bright green tree frog on the tile. He jumped in front of me as if to attract my attention. I think animals ask you for help. I know moths trapped inside the house have flown into my face before. They never do that outside. I help insects and other beasts find their way back outdoors. That includes a possum, lizards, salamanders, moths and any other thing I find indoors. I even helped the termites relocate after discovering them inside the wall of Holly’s office last year.

The frog was very amiable. He jumped in front of me and I walked behind trying to aim him at the open door. I steered him out the patio door. Miraculously he jumped right through the doorway and stuck himself to a 2’ ladder on the back porch. He and I shared the deck the rest of the afternoon. I sat in the chair enjoying the day and he stayed stuck to the ladder a foot away in plain view.

The tree frogs like our back porch area. One night there were three of them on one pane of glass. Anyway the frog was out. I figured he must have been stuck to one of the bales of insulation that were stored on the back porch. He probable got inside the house when I drug the bale indoors. From then on I did a visual check of the bales before moving them inside.

The second set of shelves was going to be combined with the first trip across the A/C box. I set up the pencils and tape measure and boards and crawled over the box. I put in another hand rail and the big nail gun blew a head gasket with the first nail. I hand nailed the hand rail and then sat down to re-do the shelf-plan on site. With the big nail gun gone, I had to devise a new strategy. The new plan was going to use the small nail gun, but that was alright since the frame didn’t have to be very heavy.

After crawling down from the attic, I went to the shop and cut the shelving boards. I pre-assembled the bottom supports. I returned to the attic, crawled over the A/C box again and nailed up the shelf supports > it was a better plan than the first set of shelves, but the first set is better space because the frame is completely out of the way. The small nail gun was a lot easier to use. Afterwards, I filled-in insulation around the supports. Things were progressing.

After dinner, I carried up the plywood and scooted it across on top of the ¾” x ¾” oak boards I had been using to spread insulation. Holly handed up four bales of insulation.
I went over the A/C box again. A few adjustments were needed on the shelf. Dang it, my measurements were off by a bit. But this would have to wait until the next time when I could bring up a hack saw to notch the plywood.

I put up a second handrail and sat down. I begin spreading insulation. I filled in the edges and worked all the way back to the far bedroom.

I took a few more measurements. It was getting late at night. Two more handrails would be needed over the bedroom area. Because of my age and weight, I absolutely have to sit down while pushing insulation. I can’t stoop over in the attic and keep my balance for a full hour.

The final plan was made. I made a list of everything needed. It would take one more day to finish the insulation and shelf. I estimated that I had just the right amount of insulation > 5 bales downstairs and 2 left upstairs plus 2 additional pieces to fill in by the attic door.

I was done with the nail gun and tape measure. I brought a few things down from the attic and contemplated the completion of the project.

I decided that there were a lot of other things that needed to be done downstairs. These things plus the job of carrying the last bunch of stuff up into the attic would be enough work for a full day. Yes, I would do all the peripheral things the next day and spread the last of the insulation the following day. (but my fatigue delayed things a few days more)

I also wanted to pick up some plumbing and electrical supplies at Lowes. These things would really top the project off nicely.

However the next day I was too tired to do anything except go to Lowes and Walmart. I woke up stiff with arthritis. The scheduled was pushed back another day. It was okay.

I made it to Walmart and got squeekie some tuna!!! I barely made it to Lowes and stumbled around the store in a fatigued frazzle. They had what I needed. I needed supplies to put 2 cover plates on octagon boxes I discovered uncovered in the attic. I also wanted to make it easier to blow out the A/C drain pipes, so I got a few fittings for that job too. The attic project keeps expanding!

The next two days I was very tired. I couldn’t go into the attic. My hands were swollen and my wrists hurt. I had to get the project finished and take a long rest or my arthritis could return with a vengeance.

I did a bit of work the first of those two days. I put termite treatment under the small deck off the back door. I also dug up the dirt around the concrete step to make it level with the yard. The next day was a bit more energetic. I bought more termite chemical and treated under the second small deck. After that I put the deck boards in final position and nailed the handrail. I cut down the long oak trim that is going back into the attic.

And guess what else finally got finished? I put a nail in the house-number on the front porch that keeps going crooked.

I cooked chicken and stove-top for dinner. Holly got home from her first day of testing at school and we had dinner.

Next day, Thursday I moved the lumber and insulation into the attic. Everything was ready for the final push. It was going to be cold on Friday so the attic temperature was going to be perfect.

Friday I crawled over the A/C unit for the last time. I cut a notch in the shelf so it would fit. I put an octagon box cover over a box above the office.

I moved 2x4s and insulation to the furthest point I could reach. I was over the master bedroom. The long 2x4 just made it to the rat run over the bedroom. It was angled at a downward slope which made sitting a bit more difficult, but I made do. The insulation spread easier than I figured it would and before an hour was gone, I was pulling boards out and moving back toward the attic stairway.

I was really finishing the attic insulation.

Retreating and pulling boards back, I finally reached the A/C unit. I piled all the boards back over the unit and crawled across. Only 1 more piece of insulation was needed. Fortunately I had one more piece downstairs.

I started carrying stuff down. I grabbed the last piece and leaned over the A/C unit and put it in place. The rest of the work day I brought stuff down from the attic. I fit a 2x4 under the last shelf.

There were three full bales of insulation left. The next day I took the extra insulation back to Lowes. While there I picked up a sheet of insulation board. I wanted to build a foam box cover to fit over the attic doorway. This would end energy loss at the stair.

Sunday Holly handed up the attic storage items. We put the oak trim back up in the attic. The extra carpet, cat carriers and Christmas tree stand came up also. I did a bit more work on the shelf. I ran a support wire and connected it to a rafter. The other end was connected to a board under the shelf. I twisted the wire to make the support firm.

At this point there were two basic projects left. The first was to install blow-out tubes for the A/C drains. The last was to build the foam cover for the door and finish the insulation surrounding the attic door.


Gene Haynes