All Change

27 May 2020

I have finally decided to replace my plastic baseboards because of the continuing problems with expansion.

I have replaced the bridge over the patio with a concrete lintel. Where the triangular junction sits in the soil I will use concrete. I am rebuilding the remaining part with timber.

I have found some rot at the edges of my curved baseboards. I think they will last at least another year while I redo the junction. Then I will try using the plastic as planks spaced to allow for expansion and supported by timber beams.

This shows the concrete lintel with ducting on one side for cables. More ducting will be needed on the other side. The first replacement concrete starts at the end of the lintel under the point. This all needs final fitting. I have reduced the curve to the right to 5'6" radius allowing me to remove the previous kink at the end of the bridge. The track is temporary while I try the new alignment.

Further round to the right I have replaced more plastic with concrete. Beyond that I will use more conventional wooden baseboards because they are not buried in the ground.

Latest delivery received from Wickes today after a 3 week wait. That included a piece of OSB3 to complete the baseboard top. It is now just begging for track but I ordered the wrong felt so it will have to wait for a shopping trip to exchange it.

5 October 2023

The felt on my curves has shrunk along the edges and the baseboard top is rotting from the outside in. I am experimenting with a cast concrete replacement. Here is the first attempt at a mould. The sides are intentionally over long because the next board will be slightly longer.

I gave it a month after pouring the concrete and turned it over to reveal this.

The base and outsides of the mould were made from recycled plastic and melamine faced chipboard. They came away from the concrete without any problems. However the 2 x 1 and OSB board on the inside were very difficult. Next time I will use recycled plastic on the inside and chamfer the edges to make it easier to remove (I hope). 

Here is the result ready to replace the wooden board above. 

The result is very heavy. For the next board I will reduce the depth of concrete from 3 1/2" to 3". The well underneath will also be reduced a little bit by virtue of using 2 layers of 18mm recycled plastic instead of 2 x l on 18mm OSB. Hopefully that will still be strong enough as it will also be a few inches longer than this one.

16 October 2023

Here is the board in position, temporarily. On the left is the mould awaiting modification to fit the next board. Once I have cast that board I will have to decide how to arrange the supports. I am favouring either building a mould under the joins and filling it with concrete or a concrete beam sitting on top of the existing legs. I will probably finish up with one or two of each. The existing legs are described here. 

18 October - 15 November 2023

Here is my adaptation of the mould for my second baseboard. It is slightly longer and the angles of the ends are slightly different. I have also reduced the depth from 3 1/2" to 3" and replaced the centre well with 2 layers of 18mm recycled plastic chamfered at the edges. Hopefully that will make it easier to remove the mould once the concrete has cured. Now I'm waiting for a break in the weather to pour concrete before the frosts arrive.

I poured concrete on 22 October.

I removed the mould on 15 November by unscrewing the base board and easing the inset chamfered section with a little encouragement from a putty knife and flat chisel. I turned it over to avoid ice collecting in the centre well and will wait for another couple of weeks for it to fully cure. It showed no signs of breaking up during this process so, hopefully, all will be well.