Our design process – Part 3 – how to make the tiny house HUGE

One of our key design requirements was to make a gourmet kitchen. Another was to bring the outside in.  Today we want to share what has become the center of our design, the feature around which the rest evolved, and perhaps one of the most distinctive elements of our Tiny Home.  Yes, it is the 12′ wide open window door combination. It allowed us to take this Tiny Home kitchen and open it up to the HUGE outdoors.

We had seen folding glass windows as well as folding glass doors.  There were even some very innovative uses of a glass paneled garage door to open the tiny interior to the vast outdoors.   But it was this unique combination of windows and doors working seamlessly together that truly inspired us.

The pictures here show it opened and closed. It is an approximately 12ft (3.66m) wide unit split in half doors (to the right) and windows (to the left). A key feature is that there is no center post when it is opened, leaving a completely unobstructed view.

This was not without its challenges.  First we had to find the right supplier. After some research we identified several top notch companies that engineered some very impressive bifold units. We progressed with one at a time for several weeks until for some reason or another (legal Dept worried about liability of units in moving unit, design not capable of handling potential bumps in the road, won’t be able to handle this new design in 2018, etc.) they backed out. We went through this for a couple of months and then decided to design our own. A simple two door two window design with two way hinges should do the trick. We even found a custom door designer that was willing to create a door from our idea, but their legal department also said no warranty. For what they wanted to charge, sorry, no go.

So there we were, add custom door and window manufacturing to the to do list.

One evening, before we ventured into this new endeavor, we did one more desperate search. Julia found this fairly obscure, but promising provider out of Florida. A call the next morning revealed that they were the US arm of a German manufacturer, Sunflex and they said they were up for the challenge. They made sure to incorporate steel bearings and heavy duty parts at any stress points. They even offered triple pane glass for extra strength and insulation.

That this was a well engineered product was evident. It was shipped by boat from Europe and when it arrived even the packaging was impressive.

Secondly, making sure the structure could accommodate this wide span with a deck on top was not trivial.  This is where our selection of Volstrukt and their agile steel framing paid major dividends again.   They were able to design all the right supports and reinforcements necessary to make this a perfect fit.  Tiny Home Builders, provider of our trailer, also came up huge by working with us to get the necessary steel beam to allow for that large opening.

We love how it all turned out and this picture taken from the inside really shows it off well. We are doing our best in making this tiny home HUGE. It is Tiny Living Living Large.

Next up is the metal roof, incorporating the various vents and our roof top window.

Cheers for now.

Insulation – What a difference a day makes

Sidebyside of tiny with or without insulation

Finally

The weather got warm enough so we could do our install of insulation.  Without it, we could not progress much further with the interior.  Over the last month or so, we have been watching the weather, prepping the inside, installing LOTS of wire and in-wall plumbing.

Preparation

There are quite a few items that require us to put wires, tubes, etc. through the walls.   This includes our bathroom fans, our outdoor shower unit, the Lunos  heat recovery ventilation (HRV) system, the kitchen vent, wood stove vent, and several electrical plugs.   We are coordinating the kitchen and wood stove vents with the roof installer.  This is to ensure the flashing is done just right.  The outdoor electrical outlets are just a simple wire, so we can do that at a later date.  But the rest all had to be in place.   After some back and forth, we also decided to draw speaker wires for the outdoors and the lounge.  Yes, we could go wireless, but sound is important and we wanted the option to go direct.

We figured the insulation company would cover up windows, floors, and anything we did not want sprayed.  However, having read about a few horror stories, we thought we would do our own prep too.   We thought it best to ensure all the electrical boxes, fans, hanging wire, and any plumbing lines, were all covered.

The crew arrives and insulation work begins

The day finally arrived and the Truck and Trailer of the installer smoothly backed into the driveway and started up the machinery.    There was a crew of three.  The master sprayer (he had 15 years of experience and was a bit of an artist with the spray gun) and two others who did the prep and cleanup.  Plastic sheathing went on all the windows, floors, and even the stairway and loft support pole were covered.  Nice job.

Closed Cell foam insulation is made of two separate chemicals that are heated and fed into two separate hoses.  They are mixed and combined with air pressure when sprayed onto the surface.   It expands very quickly and seeks every nook and cranny, turning solid hard within minutes.  The result – an airtight and very rigid structure.

As you can see in this picture here, proper protection is required during the application process.  However, all gasses dissipate within minutes and the resulting foam is actually biodegradable.

 

After the interior was done (and it took probably 4 hours), the underside of the gooseneck and a couple of spots under the trailer were also sprayed.

The wrapup

The cleanup crew now went at it, removing any overspray, cleaning the studs, and taking care of any areas where the insulation found a gap and expanded to the outside.

We had been awaiting for this day for a long time and were also very nervous, hoping  that everything would go smoothly.  Given the perfect weather we are so glad we waited rather than push for an earlier date.   Here is a summary video, including a side by side compare.