We're renovating a 60-year-old tile roof. This time, some veteran carpenters came to help us. First, we'll install cedar bargeboards. Mizutani-san: Cut it straight! Murataka Kazu
Foreman Carpenter He’s making adjustments because the angles didn't quite match. The existing bargeboards were thin and had worn down considerably, but... the new bargeboards are thicker and will be covered with sheet metal, ensuring they can withstand wind and rain. Screw the bargeboards to the rafters and purlin with nails and screws, completing the eaves board replacement. Didn't this roof look sturdy? However, it has had to be maintained many times due to misalignments caused by typhoons and other factors. And the biggest concern is the possibility of collapse due to earthquakes. In a previous episode, the tiles and soil were removed by tile craftsmen. We're replacing them with flat tiles that don't require soil, reducing the roof's weight by about 3,600 kg. This significantly reduces the risk of collapse during an earthquake. Next, the carpenters will remove the old "ura-ita" (roofing boards), "hirokomai" (eave extensions), and eaves boards to prepare the foundation for the new tiles. They'll reconstruct the foundation to lay the new tiles. Kazu-san wants to use "sumi" (ink) to install the hirokomai straight, but the senior carpenter is relying on his "intuition" to install the hirokomai. Mizutani-san: Cut it straight! In general, carpenters do not wait for someone to tell them what to do. The site takes shape rapidly without someone giving detailed instructions. However, in critical situations, the foreman needs to raise his voice to provide clear direction. Carpenters often rely on their visual judgment as they work. But just to be sure, Kazu is using a string to double-check the alignment. As a result, they decided to remove and redo the previously installed "hirokomai." The rafters, which have borne the weight of the tiles for 60 years, had become warped, making visual alignment challenging. The installation of the new "hirokomai" has slightly reduced the overall rafter deflection. We’ll replace damaged rafters that have been compromised by water leaks. To cut the rafters, they partially cut the roof board Cut the rafters on the purlin that is receiving them. These rafters supported the second-floor ceiling beams. Using a circular saw, he cut the rafter to match the height of the existing ones. Mizutani-san
Master Carpenter They check the rafter deflection to ensure that the eaves won't sag under the weight of the roof. Hiroshi-san
Master Carpenter While replacing the rafter, "hirokomai" arrives. With work progressing rapidly, there's no time for confusion or hesitation. Shimizu-san
Master Carpenter They use screws to pull the rafters from above the "hirokomai." After aligning the front of the rafters, they secure them to the beams and purlin. Finally, they reattach the "men-to-ita" (eave panel), completing the rafter replacement. After attaching the "hirokomai," they will proceed to install the "shinaita" on the bargebords. We purchased a HiKoki circular saw and decided to use it for the first time on this site. This is the moment when Makita enthusiast carpenter uses Hikoki for the first time! In areas where the circular saw blade couldn't reach, we
used a multi-tool. No one is wearing helmets right now... What's going on now? Kickback.
Shimizu-san: Hahaha! We cut off the defective knots in the boards we're installing. Even though these knots won't be visible from below, The top part is cut by applying the piece and tracing it. The installation of the “shinaita” are complete. We have finished replacing damaged rafters, hirokomai and sinaita. Next, we'll install the decorative boards and cedar eaves boards on the backside of the roof. Traditional houses in this area have a "naka-kyoma" layout, which is wider than the typical "kanata-kyoma" but narrower than "kyoma." As a result, standard 6-foot materials are often too short, leading to significant material waste. While the four carpenters continued to make progress, I struggled to move around on the scaffolding and rafters. Until now, I couldn't shoot properly, but with the roofing boards in place, I could finally walk on the roof. The carpenters have been moving back and forth on the rafters freely from the beginning. Even Shimizu-san, who is over 60, is no exception. The installation of the roofing boards is now complete. Mizutani-san: Shouldn't we nail down the sheathing now? If we put the blue sheet on now, it will only add extra work. Shimizu-san: How about using softwood and putting on felt (roofing)? Kazu seemed a bit uneasy. Once we remove the blue sheet, there's no turning back; we have to go with it. With little time left, we're pushing through. We have about two hours of work left, and we'll attach the sheathing and roofing felt in one go. Many carpenters love RYOBI (now: Kyocera) circular saws. Come to think of it, this circular saw is... a bit different. This time, we're nailing structural plywood onto the existing sheathing with 50mm nails. We could roll it and replace it, but we prioritize workability. Of course, if the existing sheathing is heavily damaged by termites or rot, it's a different story. It might look like they're nailing randomly, but there are hollow spaces inside. They aim somewhat and confirm the nail grip while nailing. As I mentioned earlier, this house is built in the "naka-kyoma" style, so we can't just attach plywood directly. Also known as "sanroku-kan" or "Fukui-kan," it's mainly used in Aichi, Gifu, and Mie prefectures. We can't attach plywood directly; we have to cut all the plywood, which takes more time than usual. The sun has already started to set, so we hurry to finish the other side. The average age of the carpenters here is probably around 50. I'm sure they're quite tired by now. The older gentlemen are working hard, not letting the younger ones outdo them. Remodeling involves a lot of irregularities, so it's mentally exhausting as well. Yocchan, you're up! Yocchan
Camera, Narration, Female Carpenter? With just a little bit left to finish attaching the plywood, Hiroshi-san starts laying the roofing felt. We're almost there. We have to finish no matter what. Working at a high pace on a steep roof like this, they must be exhausted. The foreman cleans up everyone's tools before it gets dark. We finally finished the base for the main roof. Next time, we'll be working on the lower roof, tile work, and sheet metal work. Thank you for watching.
