Embarking on a comprehensive home renovation project often unveils layers of unforeseen challenges, transforming a carefully planned schedule into an arduous test of endurance. Such was the saga of Calderwood Cottage, a journey chronicled in our previous update, where the anticipation of a brand-new HVAC system set the stage for a series of unexpected structural modifications. To satisfy the precise requirements of our air optimization engineer, a crucial element involved relocating the master bedroom doorway and constructing a dedicated closet to house essential ductwork. This seemingly straightforward adjustment, however, necessitated a far more foundational change: the excavation of an 18-inch trench beneath the home to accommodate the primary duct run. The initial phase of this demanding project began with the strategic removal of an interior wall and a section of the subfloor, clearing the path for the extensive digging that lay ahead. This preparatory work, while a necessary step, felt like a literal and figurative step backward in the overall renovation timeline, yet it was indispensable for progressing with the HVAC installation.
The Initial Excavation: Battling the Clay
With the structural impediments cleared, our focus shifted entirely to the formidable task of digging. The soil beneath Calderwood Cottage proved to be a challenging adversary: hard, compacted clay that resisted conventional shoveling. To tackle this, we wisely rented an “electric shovel,” a tool that proved indispensable for breaking up the stubborn earth. Julie spearheaded the effort, skillfully operating the electric shovel to fracture the dense clay, while I followed behind, diligently scooping the loosened soil into sturdy buckets. This two-person operation continued relentlessly, each full bucket then transferred to our somewhat precarious wheelbarrow. The journey from the trench to the exterior dump site was an adventure in itself, precariously balancing the heavy load down a makeshift wheelchair ramp, a task that added an unexpected layer of excitement and physical demand to an already strenuous day.
Our initial enthusiasm was palpable. We began the excavation with strong spirits and a determined pace, fueled by the vision of a perfectly optimized HVAC system. However, the sheer volume and tenacity of the clay quickly began to take its toll.
Unexpected Delays and a Timely Rescue
Five hours into what we had optimistically estimated as a much shorter endeavor, the reality of the situation set in. I sent a succinct, weary text to Wes, informing him of our significant delay, the sole word “Digging” conveying the depth of our exhaustion. Despite my reluctance to ask for assistance, Wes, ever the hero, offered his help without hesitation. His timely arrival was nothing short of a godsend for Julie and me, who showered him with profuse gratitude. He arrived not only with his strong muscles but also with fresh shovels and much-needed dinner, a welcome sight after hours of grueling labor.
We optimistically predicted it would take another hour to complete the trench, a forecast that proved to be wildly inaccurate. Three more hours passed before we finally achieved our goal. To ensure ample clearance for the 18-inch ductwork, which needed to hang securely from the floor joists and remain well off the ground, we decided to dig an additional six inches beyond the initial requirement. This decision meant our trench ultimately reached a formidable depth of 24 inches. With the first trench finally complete, Wes departed, leaving Julie and me to spend another hour restoring the subfloor and rebuilding the relocated wall, now with the master bedroom doorway in its new, optimized position.
The HVAC Installation and a Crushing Realization
Buoyed by the success of our initial digging effort, we rose bright and early the following morning, ready to welcome the HVAC technicians to Calderwood Cottage. There’s a particular excitement that comes with seeing a complex project progress on schedule, and as the new equipment was carefully maneuvered into place and the installation of the ductwork began, our spirits were high. The weather had turned decidedly colder, dipping into the mid-30s, yet the visible progress kept us warm with optimism.
However, the day concluded with a disheartening discovery. Upon inspecting the newly installed ductwork, we found it was not hanging as intended within our meticulously dug trench. Worse yet, it appeared somewhat “smooshed,” compressed within the 24-inch depth we had so strenuously achieved. Our initial awe quickly gave way to a sinking feeling of dread. The inner diameter of the ductwork might have been 18 inches, but the substantial layer of insulation surrounding it significantly increased its overall dimension. Furthermore, the design required two lines to be run through this section, necessitating a much wider trench than we had initially prepared. The crushing reality was clear: we had to dig again. Deeper and considerably wider.
The Second Excavation: A Trench to China
The revised specifications called for a formidable trench, measuring 48 inches wide by 30 inches deep. This meant dismantling our newly reconstructed wall—again—and pulling up the subfloor—again. The revelation struck us on a Friday, granting us the entire weekend to tackle what we sarcastically dubbed the “dig to China.” The sheer scale of the task was daunting, transforming a minor setback into a monumental challenge that threatened to derail both our timeline and our morale.
More Digging: Calling in the Cavalry
Saturday brought welcome relief in the form of extra hands: Wes and Madison joined us, significantly boosting our progress. Despite their dedicated efforts, the sheer magnitude of a 48-inch-wide by 30-inch-deep trench was immense, and we still had a substantial amount of work ahead. Complicating matters further, a smaller, yet equally challenging, trench needed to be excavated under a section of the house where the subfloor remained intact, creating a cramped and awkward workspace. It became abundantly clear that more help was essential if we were to meet the looming deadlines.
Enter Mario Mark: The Professional Digger
Sunday brought what we had desperately sought: professional help. Through a referral from our plumber, we secured the services of a man named Bucket, our future drywall installer, who in turn knew a specialist. And what a specialist he was! This individual, whom we affectionately dubbed “Mario Mark” for his incredible efficiency and tireless energy, tackled the unyielding ground with two spiked tools, resembling a character straight out of a video game. He even humorously referred to himself as a “gopher,” burrowing through the earth with astonishing speed. Mark took the lead, expertly breaking up the compacted dirt and shoveling it onto the subfloor. Julie and I then worked in tandem, scooping the excavated soil into the wheelbarrow and hauling it outside, a repetitive but crucial process.
As midnight approached, Mark and I converged from opposite ends, working under the subfloor on the narrower trench section. The rhythmic sound of shovels against earth continued until the early hours of Monday morning, finally concluding around 12:30 AM. The trench was, once again, complete.
The exhaustion was profound. Every muscle ached, and a deep weariness settled over us. We were sore, tired, and utterly fed up with digging. Yet, there was an undeniable sense of accomplishment in having overcome such a monumental physical challenge. We collapsed onto the subfloor in the completed section of the house, briefly contemplating succumbing to sleep right there, despite the uncomfortable hardness and the biting cold that permeated the cottage.
Beyond the Trenches: Preparing for the Next Phase
The following morning, Julie, ever the early riser, took on the responsibility of letting the HVAC technicians into the house while I managed to steal a precious extra bit of sleep. Her natural inclination for early mornings made her the designated “opener” for incoming tradespeople, a role she performed admirably even after our late-night digging marathon. While the HVAC crew diligently continued their work, installing the extensive ductwork into our newly expanded trenches, Julie and I shifted our focus to the next critical phase: preparing the cottage for spray foam insulation, scheduled for the very next day.
This preparation involved another round of late-night work, extending well past midnight, with our headlamps illuminating the areas that needed attention. The beauty of working alongside Julie is the ability to push through immense physical and mental fatigue while still finding moments of laughter and camaraderie. Despite the cold, the dirt, and the perpetual soreness that became our nightly companion, our shared determination and good humor kept our spirits high. This renovation journey at Calderwood Cottage is undoubtedly far from glamorous; it’s a constant battle against the elements and unexpected setbacks, leaving us smelly and aching every single night.
Our motivation remains steadfast, anchored by the anticipation of significant milestones. We constantly look forward to the end of the week, when the walls of Calderwood Cottage will finally receive their drywall. This step, more than any other thus far, promises to transform the raw, skeletal structure into something that truly resembles a home, making it look and feel dramatically different. Each shovel of dirt, every rebuilt wall, and every late-night task brings us closer to realizing the vision for this cherished cottage. Stay tuned for Part 3, where we hope to share the exciting progress of drywall installation and the continuing evolution of Calderwood Cottage!