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Posted by Steven in Colorado Springs, CO on 10/20/2017

So once I got the door blocked in a bit to accommodate the bad weather last week I found I at  had a decent weather weekend.  I took advantage of the bout of warmer weather to get the exterior sealed up properly against cold infiltration; once that's done I can insulate and do a lot of the rest of the work from the inside.

The plan was to do this in two stages.  First, I had to get the wall cut and blocked in.  That was a bit tricky given the arched parts, but I broke it into stages and got most of the overhead sections done in two big(ger) chunks.  The straight bits along either side of the frame were easier for a good two thirds of the run since those basically narrow but uniform sections.

There was a bit of a dilemma I ran into cutting these bits--did I want the drywall to basically be flush with the outside of the frame, or flush from the wall?  The frame itself is 6" deep but the doors themselves are mounted on the inner edge, and with the wall set back a bit from the frame I had a choice about which way I wanted to go.  I decided after a bit of consideration that the drywall would be flush to the frame -- this way when I set the stone around the arch it'll be "raised up" a bit from the rest of the wall.  I've always liked that look, it rather gives it some definition.

So after working out what I was going to do I set to it.  I took my time and went through most of my weatherproofing tape, but I'd selected this type for a reason--it's rather heavy duty and not easy to tear as well as sealing very well.  The drywall cutting was a bit more of a nuisance; I originally intended to cut concrete board and put that up but I realized that a.) I didn't have enough of it on hard and b.) I didn't have any tools to make good "clean" cuts anyway.  Normally I'd resist putting ordinary drywall on a surface that might get water, but after some consideration I realized that the mortar covering the drywall would seal it up nicely anyway.

It took all day but danged if it doesn't look pretty danged good all things considered.  I did some test "presses" against it from the inside and everything was nice and firm, so I think I shouldn't have any problems when I stuff the insulation into those cavities next (probably tomorrow or Sunday).

Glad to get this done.  Good weather is starting to get short now.....


Steven in Colorado

Photos

Starting the left hand side. That tape is a heavy duty weatherproofing tape intended for "outdoor exposure", so I'm hoping it'll do what I need it to do.
More up the left hand side. Above this I had to get a bit more creative to fit to the curve.
Very nice and tight; no light around it at all. Helps a lot to do this in good and calm weather.
You can see some of the drywall now where it extends out from the edge to the curved frame.
Got the upper left part of the arch done....took a bit though. I used that weatherproofing tape quite liberally.
Working my way up the right hand side. After having done the left I knew better what I was doing and work more quickly.
Worked my way up the gap and starting to get the drywall in place.
Good shot of the last bit on the right hand upper part of the arch. That section was really a bit of a pain in the butt.
A decent shot of the arch....in this shot I hadn't taken the protective tape off of the weatherproof tape yet.
The view from the inside, sealed up. Sweet.


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