Hammerhead Stoneworks

Up to this point, every time I’ve cut a stone using feathers and wedges, I have done so in a straight line. I decided to trying cutting a S shape out of this particular slab of sandstone paving because it was just too large for the walkway under construction; it would unbalance the whole composition. I wanted a sinuous line to accent the rolling shape of the path and to avoid creating a uniform, tiled feeling with long straight lines and square stones.

I drew the line over a few times, trying to get the right shape. I wanted a subtle curve, figuring it would be easier to accomplish. The X’s indicate where the drill holes be, evenly spaced. This is the back of the stone, so my scribbles and drill marks will be unseen.

I drilled six holes. Why six? Because that’s how many complete sets of feathers and wedges I had at the time. More would have been better. The holes are fairly shallow, about two inches. The stone itself is only three inches thick. I was careful to not punch the drill bit through the stone, as it would have created ugly knockouts.

I placed the wedges so that they turned along the line. This ensures that the force applied pushed the stone apart along the desired line. They look like soldiers marching.

Ah, so close. The actual split wandered from the desired line at the very bottom of the stone. Looking at it now, it’s clear that the split followed the path of least resistance. Another wedge even closer to the edge might have helped this, as would have reorienting the line so that the desired line followed the path of least resistance. Tracing the desired line with a chisel might also have been helpful.
There’s a lot of surface flaking where the feathers are set. I believe the wedges are a fraction to big for the drill holes so that they bind at the top and cause the stone to pop like this. This was a secondhand set of wedges that I have since replaced. Another reason to do this on the bottom of the stone.

Here are the cut stones in the pathway. The two big, rust-colored stones to the left side of the image are the cut stones flipped and set. Note the ‘dog paw’ pebbling just above the gray stone, to honor Dixie, a regular visitor to my lunches during the project.

The second issue of the Hammerhead newsletter The Daily Sledge is now available. This issue focuses on dry stone patios and pathways. I created it specifically for my DIY flagstone classes at the Arboretum.

On Saturday, I led the first DIY Flagstone class of the season at the NC Arboretum. Ten people took part in the workshop which started at 9 and lasted until 4. In the morning we looked at several samples in a slideshow and discussed the stones, tools and structural elements of a good drystone patio. Just before lunch, we reviewed the safety concerns we might encounter working together. After lunch we headed outside to the ‘Stone Classroom’, a corner of the Arboretum grounds where they have built a gigantic sandbox for paving projects. After a couple of demos, people worked in teams of two to build their own section of flagstone patio. People had fun and did some great, creative work.
There’s a second section of the Do-It-Yourself Flagstone Paths and Patios workshop now registering via the North Carolina Arboretum’s website. The next class take place on Friday, September 4th. Come join me for a fun day of learning and playing with stone.

I don’t always get to see the work I’ve built after it’s been landscaped and finished. Right now I’m doing the second phase of a new front yard. The first part, completed over the winter has grown in nicely. I took these photos this morning, after a night of steady rain.

This project was designed by Tony Hauser of Ambient Design Group.

I have been busier than the recent blog postings would suggest. The chimney is 99% done. I’ll photograph it after the scaffolding comes down. The Rube Goldberg qualities of the scaffolding have discouraged me from taking any pictures of it.
Currently I am working on a walkway and short stack of steps in a north Asheville neighborhood. At right is my tent workshop. It’s a ten by ten canopy that I set up when the sky got particularly threatening. When the downpour did arrive, there was an area about the size of piece of paper in the middle of the canopy that didn’t get wet.
A particular challenge with this section of the walk is the fact that the concrete driveway drops five inches over four feet. The band of bricks at the very end helps me to accommodate that slope without leaving a trip-lip. The brick band is a repeating feature that will appear in the upper sections of the walkway.

The cabin chimney is steadily growing, now seven feet high and rising. I am using a FireRock modular system, thinking it would save money and effort. I think I’m wrong on both counts, but in for a penny… I am building the liner as I go because of the limited scaffolding options. I don’t have any of my own yet, and real scaffolding wouldn’t fit in the space anyway.

This is the third chimney on this cabin since it was moved to this spot by oxen in the 1850’s. I am reusing much of the stone from the most recent version, perhaps earlier versions as well. Some pieces are blackened and smell like fire when I work them. Technically, this is a veneer but I am laying my stone in its bedded plane, easier because I gave myself a minimum of eight inches to work.

Stylistically, I am drawing from the original chimney and the other stonework I see around. I drive through Mars Hill College to get here and they have old buildings there in the local vernacular, which is rough and lumpy, a lot like the stone and the landscape here. As seen in other posts, the fireplace is tighter and more formal. With the chimney I am fighting my own impulse to overwork everything. As it grows, I like it more and more.

As grows the chimney-slow and steady, so goes the new website. I have recently added portfolio pages that feature samples of my work with Unturned. The Hammers page is complete and yesterday I added a page and slideshow about the Flagstone Classes I offer. I just checked the list on the wall and I only have another fifteen pages I’d like to add.

In April I led a class on creating do-it-yourself flagstone paths and patios at the North Carolina Arboretum. It was a perfect day for it. We started with a classroom presentation that covered the basics of setting flagstone as well as aesthetic choices and safety issues. after lunch we went outside to the Arboretum’s Stone Classroom and played with some Tennessee sandstone. Flat and easily worked, sandstone is a good starter stone for DIYers. People worked in teams of two and laid small areas of flagging.

In this picture I am apparently demonstrating the proper technique for making sure your stones don’t float away while you are working them.

Photo credit: Mac Franklin of the NC Arboretum. Mac and his crew built the classroom, including the gigantic sandbox I used for the class.

We have scheduled two more classes for August and early September. The dates will announced to Arboretum members soon. If you are interested, e-mail me for details: marc (at) hammerheadstoneworks (dot) com.