Video summary
The video documents a significant renovation challenge involving the removal of an old, failing door frame and the subsequent installation of a new concrete lintel to support the wall above. The builders quickly realize that simply patching the existing structure is impossible because the current setup will collapse once the old lintel is removed. Consequently, they decide to remove the entire door opening and rebuild the blockwork from scratch to create a proper foundation for the new concrete beam. This process involves carefully cutting out the old materials, managing the heavy weight of the components, and ensuring that all structural elements are securely propped before any demolition begins to prevent accidents or further damage to the building.
As the work progresses, the team encounters several complications, including discovering that their initial cuts were too deep and had to be corrected by rebuilding two courses of blocks on the exterior to gain necessary working space. They also address issues with the wooden joists above, which are found to be uneven and potentially unsafe; therefore, they pack them tightly with new blockwork and secure them with screws to ensure stability before removing the old lintel. The plan evolves to include temporarily boarding up the large opening with OSB sheets while they wait for the concrete lintel to arrive, allowing them to work safely at a comfortable height on scaffolding rather than struggling from above the ceiling.
The project highlights the hidden complexities and extra labor involved in structural repairs that are often overlooked during initial cost estimates. By choosing to open up the wall completely rather than trying to patch it from above, the builders ensure a much more solid and durable finish, even if it means doing additional work on the outside of the house. They meticulously install tie wires and damp courses to create a "rock solid" connection between the new concrete lintel and the surrounding masonry, filling gaps with thermal blocks and insulation once the main structure is in place. The video concludes with the site prepared for the next day's critical task: removing the old heavy lintel and installing the new one to finalize the conversion of the doorway into a window.
Read the full video transcript
There's no way we can patch all that.
That's all going to fall out as soon as
we take that lint out. Can take this
waste of space out.
Anybody?
>> Right. My dossier is back. [bell]
He's turned up today.
So, Alex should do the lint first. I
think we should take the door out first.
Reason being we take the door out first
and get the block work done first and we
can prop the off the block work. We did
lint first. We've got nothing to prop
the little have we
>> right. Whichever. I'm just hoping that
we can get all done in time.
>> Getting the back the back concrete lint
in as well, isn't it?
>> Yeah.
>> Yeah. Cuz that's got to be built up for
the lint, isn't it? No, not down. That's
got to be built up.
>> So, we can't just l anyway. We've got to
build it. We've got to build the hope
opening. So, we've got to take the doors
out,
>> right? Everything's got to be built
first.
There's so much to think about.
So, right, let's get on time. I probably
get this door out.
Okay.
that smell.
>> Can't smell it.
>> Smells sweet.
>> Yes.
Can you grab me mask, please?
Heat. Heat.
>> [music]
[music]
>> screws from the
Can't see anything.
Looks like it's just foamed.
>> Yeah.
Just straight across.
Right. Bottom frame next.
Then I clean out the uh this chop the
cyling rack
better, won't it?
packers.
Get the hop. Just go straight through
that.
>> You might want to You might want to hold
this
as I cut it.
>> Yeah.
That's going to be heavy.
Done for as dread would say. Now you
chop it off.
Back to me a bit.
Right. Come on.
[music]
>> [music]
[music]
>> Hey,
[music]
hey, hey.
>> [music]
[music]
>> Is that out?
Ready for the skit.
Just getting these out now.
Cute.
Shame the job's done in a different top.
Wouldn't have had to find any bricks.
So that's uh that top one won't be hard
to get out cuz the cut won't be right
through, will it?
>> No.
Very soft motor though. And thinking
about this in bed last night as as as a
lot of tradesmen do. Just things just
come to them when when they're a bit of
peace and quiet
instead of taking the ceiling down in
there.
We're not going to have much room to
patch up this beam filling.
So, um I'm thinking of taking the um the
brick work up another two courses on the
outside, [snorts]
which I mean we just um rebuild it with
two courses of blocks
and just gives us more room to to attack
all this beam filling and get it all
done properly.
Um, yeah, it's it's extra work on the
outside, but it'll be quicker in the
long run instead of we really struggled
on the last show trying to trying to be
fill from up in above the ceiling. So,
we're better off just opening it up on
this side. We're on the scaffold and
everything's like nice height.
So they this this this panel to come
down now and then
Oh, keeps getting me that bit.
We've cut all that down. We didn't need
to, have we? Should have been the same.
Should have left that bit in.
>> Ah,
>> yeah. Just thinking we've done the
inside wrong. We haven't done the inside
wrong. We've done the outside wrong.
That cut did not need to go all the way
down to the bottom. left that panel bit
working
which is damn annoying but
it's it's it's not a not a big deal.
This should come down pretty quick now
because the further down it gets further
the closer you get to the cut. It's gone
right through.
>> Yeah, it's tough motor.
>> The soft motors above. It's like it's
that classic um what the uh the hard car
is feeling like on the day and how much
cement like putting in cuz that bit
soft.
Yeah. Annoying that should be should be
left in but it's too late now.
Look at it block work.
>> Bless you.
>> Thank you. [snorts]
Right. Time to load out. Blocks came
yesterday.
I think it's six wide. It's definitely
four high. I think we're going the same
height as that one. I'll have to double
check the customer.
So, um, and it's double skin, don't
forget, as well. So,
that's that's half a pack. And then
you've got the pillar this side to build
up.
Yeah. Let's get tidied up and loaded
out.
[music]
There's a good hour and prep work that
you never allow for when you're pricing
a job. It never even comes into your
head that you got to do all that. So,
um,
got our damp course down for the
internal leaf. External leaf. The damp
co is there below that. So, we're not
putting another one in. So, it's
straight onto that block work. Put these
couple of pieces in that brick. All
loaded out. We've moved as much stuff
out as possible that we don't need in
here now cuz obviously there's a it's
going to become a window. So, we're
going to be in and out that door then.
Going to keep that to a minimum. So, not
rushing working through the house.
So yeah, we're ready to go. Just going
to have a quick break. Line's up. Mix is
on and we'll get cracking. Right. Oh,
right. Alex is just getting the mix
knocked up and bringing it round to load
up the two spotboards. We're ready to
get rock and roll once that door's out
the way. Of course, that door definitely
doesn't fit anymore.
Right,
let's get me line set up.
[music]
I tell you what, I wish we were um Do
you want to hop in? Just pass some
batteries out. I wish we were rebuilding
the back of the house to be honest
because
look at that. There's where the sun is
and it's like 10° cooler here than is on
the front. Very nice. See? So,
I've just spoke to the customer and it
told him we're going to take some more
out of that. Take it up another two
courses. We can fix all the beam filling
properly and we can put two course
blocks straight back in.
>> It'll work then. It's just um I just
there's no way we can patch all that.
That's all going to fall out as soon as
we take that lintil out. And there's no
way of catching it.
>> Cats can do that.
So the plan is to get this all framed
out and then get the get it boarded up
tonight temporarily. Then tomorrow the
block work will have gone off so we can
push the concrete lint over that we
forgot to take in before we built the
wall. And it needs it needs 300 cutting
off it.
>> Yes.
>> And we need to bring the wheels to wheel
it round.
So yeah.
>> Yeah. We found the wheels. I put them in
the house so they wouldn't just leave
them out and we left them in the house.
>> And I looked at them twice and thought,
"Don't forget them wheels, but don't
forget to put them in the van."
>> I like how you pointed.
>> So I did.
>> Yeah, that's what I'm just showing what
I did in the kitchen.
>> I'll superimpose a picture of the
wheels. I'll put the There's the wheels.
>> So, um yeah, I've got three pieces to go
in.
Yeah,
I've got the uh line set up so I'm not
messing around plumbing. Nice plum line
straight down from the window
and putting a screw tie in every course
and two tie wires in every course. So
that's going to be rock solid. And then
Alex is following up with the internal
tooththing in as he goes
and bonding onto that.
Nice solid job.
Not going as fast as I'd hoped, but this
it's it's deceiving how much work is in
it.
And I don't want to rush it and do it. I
want to do it properly.
That's a big old lump of lint. That
said, it's a shame you couldn't just
push it over. That'd be great if we
could do that.
Might be a bit too much weight on it.
Anyway, um I'm going to get the patches
changed over. I'm going to finish my
little bit here once I've got me more
mortal. [music]
Right,
bit of a progress update. I finally got
that part leveled up. Nice.
>> So, I've just got this part to do now,
the pillar. And dad is currently set up
over there. He's taking out another two
course of brick.
Look at this work of art.
>> There's no way we're going to be
patching that above our heads off a hop
up
>> through a hole in the ceiling. So
>> although it's extra work,
>> we can do the get the thing done
properly. And we've also got this block
exposed. We can take the cavity tray up
to a flat piece of wall.
>> Put nail it straight into that.
>> We'll take all these out and we'll put
pieces of block in. seal it all up.
>> Nice proper job. Obviously once the um
concrete lintle's in.
>> So we've um once Alex's got that bit up,
I need to hop down for me and get
organized boarding this hole up with the
uh%
>> OSB
uh which is I was I asked for 19 mil,
but that I think that's 22 mil maybe
thicker. It's heavy stuff that
lightweight stuff for boarding up, but
that's what arrived.
So, um, yeah,
>> I might put a screw through them. I
don't think it needs it, but
>> yeah, I will actually to keep them
holding together. We've got some long
screws, some I've got to pick some
150 mil screws for trying to keep these
in position, but um,
like I say, it's plan B now. So, we're
taking everything out up to the block
work. Block work sits on the joists sort
of. Once we've propped them, they will
have to put a few wedges and stuff in
there. Maybe a bit of slate.
>> So, none of this drops.
Basically, it while [clears throat] Alex
is sorting that little bit out. I've got
plenty to do here. Sorting this lot out,
making it safe. Look at that blood.
>> So, I've currently done these two these
two acros have been moved while this is
um
This is held up on here at the moment.
So, I've just got these three seven
bricks to take out and relocate this to
about here.
Yeah, basically where it is, but higher
up.
Like I said, the
the um our cavity only comes to here cuz
the lint only comes to here. So, we have
plenty out there. We might take a couple
extra out there just for the tray with
it being up so high. So, I'm going to
get these out and I'm going to start
packing up these joists so this none of
this block work falls.
>> You have to stop talking soon. Bonnie's
on.
>> Oh, yeah.
From the grave.
Yeah. Bonnie's had a dad today. I think
it's 9th of July.
>> Thank you.
Banana anybody?
Let's
talk about these joists.
>> That one's not too bad. That one is wo
That one is a bit I don't know. I think
what I think I might I think I'm going
to put screw these together just to give
them a bit of um
strength, whatever. But um like I say,
we're going to beam fill them as well.
It's going to have um a solid piece of
block in there, same as they all are.
So, I'm packing these up tight so the
blocks can't fall. And once they're
packed tight, I can take this waste of
space out.
Doesn't take much.
the old one YouTube tube.
What that is? Bit of plaster there.
And then this packing up is going to
fall down
as we take the lintle out. But then
we'll just repack it onto the um onto
the new block.
So that's packed. Those three are done.
So, I'm just I'm working my way along
here while it's just getting that
finished.
So, just getting I I had this thing in
my head where I think I'm how long
something's going to take and that's
that's why I'm so bad at cuz I'm never
right.
I honestly thought we'd have this all
done today. But, like I say, the there's
a lot of extra work been added on which
is it's just it needs to be right. Can't
walk away and leave it as it is.
So, um, right, let's get this last
right.
>> I'm finally done. Took me ages, but
>> I'll just show you my bit first and then
I'll hand you into Alex. That really
shows up how wonky these joists are now.
Now you can just see the joist on their
own. The, um, the bad brick work kind of
took your eye off the bad joinery.
So, um, stop saying so. Um, yeah, it's
all clear. That is ready for that lintil
to come out. on. There's nothing loose
that's going to drop from above it. All
the block work above is now packed down
onto the joist which is packed down onto
the acros. So, we can take that out, put
our concrete lint in tomorrow, and then
brick up underneath. So, it'll be the
concrete lintil, a course of
well, there won't be a course of bricks,
so we haven't got any concrete bricks.
We'll cut some coing
fiber lights and then we'll we'll fill
these holes completely.
>> Got some thermal lights. Yeah. You want
to use any of them? You'd be easier.
>> They're only 3 in. Not yet.
>> They're only 75 mil block them. They're
not 100. Don't you can't even get them
anymore. Probably special order anyway.
Yeah. Um so it'll be a concrete lint a
piece underneath underneath the joists.
And then
these holes filled in. And we'll
probably just fill that in with um I'll
put a couple of screws in them just to
secure them. Stop them twisting anymore.
And um probably
just stuff insulation in between them.
>> There's gonna be some open piece.
There's gonna be an open piece on top of
this concrete, isn't there?
>> Yeah.
Yeah. So, that's ready to come out in
the morning. I just need to patch this
little corner up. So, we've got a nice
solid seating for the limple. that uh
that split there,
that's going to have to be changed in
the morning, isn't it? Maybe take the
split and the brick off and put a piece
of block in instead.
But we can't do that now cuz that's
currently holding the lint up.
>> Maybe bring a piece of concrete uh block
back.
>> What?
>> We bring a concrete block back for that.
>> Yeah.
>> Just a piece, isn't it? So,
>> so it is Alice.
>> Yeah.
Took me long enough.
There you go.
If that's
pillars up. Obviously, we've left that
part blank cuz seeing concrete in pour
on it later. But there you go. That's a
doorway
moved over that way and turned into a
window.
Beautiful.
So, what's left now is to tidy up, clean
up,
and get gone. Get ready for tomorrow.
Right, we're complete. We are ready for
tomorrow.
Alex is all done.
Loads of tie wires in there. And it's
all stripped out.
And I've got the seating ready for the
little tomorrow. Bit of fetal on the
back, but we can't touch that yet cuz
it's currently holding the lintle in
place. But yeah, um that shouldn't be
too much of a job to get that out in the
morning. Yeah, it's going to be heavy,
but probably not as heavy as the
concrete one that's going to replace it.
Yeah. So, um
that's it really. Tidy up and head home
for our little birthday party with
Daisy.
So, I'll leave Alex to tidy up around
here and I'll go around sort the mixture
out to the front. But, um yeah, the
sun's around now. We're um it's going to
be on us very soon.
But it's still not ridiculously hot.
We're very lucky. We're up northwest 4
be on the
west coast near the sea. So it's quite
breezy, quite cool. Right. Anyway, shut
up and go and get tidied up.
I'm going to do a generic sign out here
for dad to use at any point because when
it's big jobs like this, we always
forget to do a sign out [clears throat]
and then the video just ends quite
abruptly. So this is your your stock
sign out for a little bit.
So, thank you very much for watching. If
you enjoyed, be sure to give us a thumbs
up. And if you're new to the channel,
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Any [snorts] other support that you do,
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all of it. It helps the channel grow.
So, we appreciate all the interaction we
get. Thank you very much. This has been
brick clean with Steve and Alex on our
ongoing
big project and [music] we'll see you in
the next one.
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>> [music]