Kitchen exterior south side with shutters
This morning, architectural historian, Willie Graham, captured a bumper crop of images of the Anderson Blacksmith Shop vacated and ready for dismantling in early March. Most of us have experienced this building full of noise and activity: the ring of hammers on iron and the jockeying of school groups for a better look. Willie’s images seem strangely quiet, but are a reminder of all of the wonderful details incorporated into that building.
To counter the bittersweet images of the vacant blacksmith shop, Willie provides progress pictures from the kitchen construction…many of them from vantage points that the webcam can’t access. We hope you enjoy them all.
- Overall of the kitchen first floor
- Door in the Partition
- Anderson kitchen construction detail
- Looking down the stairs from above new kitchen
- Kitchen exterior south side with shutters
- Kitchen exterior north side
- Blacksmith shop from the north
- Carpenter, Garland Wood
- Interior shop window detail
- Carpenter,Garland Wood, and blacksmith Ken Schwarz.
- The Anderson blacksmith shop interior
- Shop interior door detail
Dave- For nails, I usually anticipate a production rate of almost two a minute. That rate can vary widely, depending on the skill of the workman, and the size of the nail. Nailmaking, like many repetitive tasks, allows the worker to develop a rhythm of production and therefore, improved efficiency. After awhile, the rhythm makes routine production almost automatic. This also helps to make a uniform product.
Because much repetition can lead to boredom, I usually plan to have the shop members make 100 - 200 nails a day in between other work. By year’s end we should have 40,000 - 50,000 nails on hand. Thirty minutes of nailmaking as a morning warmup, and thirty minutes at the end of the day when it is too late to start a new project keeps us ahead of consumption by the carpenters.
Please tell me you did not use hand made nails to fasten the lath to the studs!
Dave- Every nail used in construction of the kitchen was traditionally made in the blacksmith shop- approximately 10,000 nails in all. That includes the lath nails. With the exception of details required by modern code (a concealed source for power necessary for cleaning, fire detection, and security, modern materials used to discourage bugs and fire, etc) construction of the kitchen employed all tradtitional methods, right down to hand split lath and handmade nails that will be completely covered by plaster. We are currently beginning work on hardware for the armoury building. You can watch us working (including making nails) at the Elkanah Deane site on Prince George Street if you are in town.
Ken
WOW! I shot a video last October of one of the blacksmiths making a nail. It took almost 1 minute to make 1 nail!
I am enjoying watching the construction. I loved the sign to someone when the chimney was being built. I had commented to my husband that the window was enlarged. Thanks for the information. As I see the lathe installed, it seems a shame to cover such fine work. Fascinating to watch. Glad I found the comments section, good information.
Kerry Lancaster says
The Lath work is looking neat.I have never seen lathing installed,however I ran a home inspection service for six years and saw a few homes in the old part of town with some of the walls that were damaged and the lath work showing.I was amazed and don’t recall anyone who knew how to install it let alone plaster the stuff.That being said ,has anyone figured out he R value of walls using wood siding, lath and plaster.I think pine wood siding, half inch X 4-6 inch lap is approx.0.81 and half inch plaster 0.32. Would half to factor in the lath and dead air space.Guess this would mean Brrrrrr in the winter. I would be interested to find more about the weatherization of houses during the period.Thanks for the great works. Kerry
Good morning, I want to say, I visited the area this past weekend and it was amazing how much different the kitchen setting looks in person. Fortionately the weather worked out and we had a great visit in CW. One question , was it a common practice to install the shelving units before the walls were plastered. It sure does make hanging the shelving directly to the wall timbers easier than locating studs. I never did any plastering so maybe it just as easy to plastic around those shelving units just curious thanks. The project is defintely moving along very nice.
Mike Lynch says
ON March 1, I posted a comment regarding the cost of imported glass at the time of original construction and its impact on the buildiong’s design. I saw the post, logged out and when I returned, it had disappeared. Any ideas?
Mike<
You posted your comment under the last blog entry ("Come On In"). Both your question….and two very complete responses…are still there!
Mike Lynch says
Thanks. Saw your replies. I’m new to this blog thing. That being said, as I looked again at the fireplace this a.m., firepalces in other production buildings came to mind, such as the Palace and Monticello kitchens. Hence, if this was a kitchen intended to serve some number of workers on the site, why would the fireplace design not include an oven compatment? Also, as the shelving has been already built into the studs, has the firepace hardware been already set into the brickwork?
Mike,
Remember that the Anderson kitchen was not designed to serve the Armoury. Rather, it was built to serve a tavern (which sat where the Anderson house is today) and later used by Anderson to provide food for Amoury workers.
Paul Hook says
Wow guys looking good, I know what a pleasure splitting lath can be. carpal tunnel is for wimps! keep doin’ what you’re doin’ and you will have the “last LATH” …… PH.
John Montague says
Ok,I have to ask…why did the north window get enlarged on the kitchen? If I missed an explanation, I apologize.
Thanks for the updates,
John
John,
You are either our bravest, or our most observant, webcam watcher. We wondered when someone would ask! In truth, we’re planning to write up something more detailed, but the long and the short of the window replacement is this:
Plans for the reconstructed kitchen included two relatively small windows on the rear and one on the front. Once these were installed, we discovered that the limited light entering through those windows made the prospect of cooking within the space (this will be a working kitchen)rather daunting. Archaeological evidence suggested a solution. It appears that there were significant improvements made to the kitchen in the late 1770s when the Armoury was built. We have therefore decided to enlarge the north window opening (the first one will be used elsewhere on the project)and will show this as an Armoury period alteration.
Thanks for asking. And thanks to Architectural Historian,Willie Graham, for his contribution to this response!
John Montague says
Thanks to Mr. Graham for his response and to CW Archaeology for keeping the blog up to date.
mitch says
I enjoy this site tremendously! Thank You.
I do have to say, the picture of the “door in the partition” gave me a chuckle, as what was clearly marked TOP is upside down on the bottom : )
Oh dear….you’re right! Didn’t notice that when I posted the picture. We can always count on blog-readers to keep us honest!
mitch says
lol! no worries, it fits beautifully, which is a testament to extraordinary craftsmanship!
Hi :
I have enjoyed watching the progress. I have a few questions
1. At the coffee house wire lath was used, why are you using split wood lath in this application?
2.Why is the partition wall overlapped as opposed to butted?
3.What is the indent in the back of the fireplace for?
4.Is the resemblance to the Pear Valley building in Northampton VA a coincidence?
Thank you.
Jim Barringer
Bill!
Your thoughtful array of questions challenged my knowledge of 18th century building techniques. Fortunately, Willie Graham, one of our Architectural Historians was able to supply informed answers:
1. We intended the Coffeehouse project to be a joint exercise between modern and historic trades. The intent was to leverage the talents of both groups to complete the building so that it both looked as it did in the 18th century, but also so that it would be completed in a timely fashion. One compromise that was made-and one often used in Williamsburg reconstructions-was to use metal lath for the sake of better rigidity, speed in application, and hopefully less maintenance over time. Since the Armoury project, including the kitchen, is intended largely as a Historic Trades’ endeavor, we have chosen to recreate most aspects of the building process as it was undertaken in the period (except where it conflicts with modern code or engineering needs). We have and will continue to make a few modern concessions for the sake of expediency (such as using modern screws to secure the roof sheathing on the Armoury, since these won’t be seen), but in general, the making of materials for these buildings and their application will be done faithful to 18th-century standards.
2. Butting and toe-nailing of studs in partitions wasn’t unknown in the period, but was very rare until the middle of the 19th century. It’s popularity is related to the rise of balloon framing. Traditional framing usually involves the connecting of two abutting members with a joint that requires one member to penetrate the other in some fashion. One of the simplest of joints is a bevel lap-the joint selected for the partition studs in the attic of the kitchen. A bevel is cut on the top end of the stud and a corresponding slot is cut in the collar to receive it. The two are then held tight with a nail.
There are a few instances in a traditional building in which a butted, nailed joint is routinely used. That conditions is when a structurally superficial member is crippled-such as when a stud is interrupted by a down brace. The stud is cut on the same angle as the rake of the brace and is then nailed to it to hold it in place. Likewise, gable studs that are interrupted by rafters (as opposed to the collars) are butted and nailed.
3. The indent in the back of the fireplace is a smoke channel, a feature commonly seen in 18th-century fireboxes. They are often found in early chimneys and in wider later ones. The size of this firebox and its pre-Revolutionary dates made it a likely candidate for having one. Note that the cellar kitchen fireplace in the Coffeehouse is also designed with one.
4. Pear Valley is a traditional Virginia building about a decade and a half older than the Anderson kitchen, but the two were certainly of the same character. Both are about the same size, were traditionally framed, both were likely first covered with riven (split instead of being sawn) clapboards, and both had exterior end chimneys. We did indeed use the chimney as part of the inspiration for the design of that at the Anderson Kitchen because of their shared unusually large footprint.
John Montague says
Jim,
Great post and kudos for noticing the similarity to Pear Valley. After your post and Mr. Graham’s excellent reply, I checked the Pear Valley website and looked at the historic structure report. Very informative.
Like all the others, I am really enjoying this blog, just as I enjoyed the coffeehouse blog. CW is performing a great service by providing it.
John Montague
Rick Brouse says
Great idea about the volumes of the Coffee House & Armoury & I too will be in line. PLUS….I’d be interested in purchasing a piece of the old armoury…hint, hint!
Matt Given says
Iv’e been enjoying watching this blog. After todays entry I was struck with a question. When the old Anderson Shop is dismantled, will any of the material be recycled for use in the new construction. Just curious. It’s such a great building with so many nice details would hate to see go to waste.
Matt,
This is a good (and very conservation-minded) question. According to project manager Clyde Kestner, the doors, window sashes, hardware, attic flooring and work benches will be salvaged, but will be put to use elsewhere. The brick bats on the old shop floor will, however, make an appearance in the new Armoury building, as may the anvil stumps if, after removal, they seem to be sound.
Kerry has a good idea. Great pictures, I am getting more excited to see everything first hand next week. I do remember visiting this old blacksmith shop two years ago and there were several people busy at work. I found it quite interesting. Thanks for the pictures.
I have been following the web cam site since the coffee house began and check it several times a day never get tired of the wonderful dedicated people who work so hard to preserve history right before our eyes.I was thinking tonight while looking at old Armory pictures before the new and thought wouldn’t be great for the good folks at CW to print two volumes of pictures with history of both the coffee house and the armory for all to learn from such a important time.I would be the first to stand in line to buy both volumes.
please pass this along.
,Kindest regards KTL
Kerry,
Thanks for the kind words. We have certainly learned enough, both from the Coffeehouse and the Armoury projects, to fill many volumes. They have been very enlightening, and team-building projects. Perhaps when we are able to catch our collective breath……