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Bathroom project - slow progress, but progress

Basil

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For the past several weeks I have been in the midst of a complete master bathroom remodel. Our existing bathroom left much to be desired. It has a nice cast iron tub that is still in perfect condition, but the vanity, sinks, toilet and shower fixtures, as well as the shower tiling, were at best "builder grade," meaning the cheapest carp the builder could get away with. The floor was half tile and half carpet. Originally it was all carpet (stupid!!) so about 10 years ago I took out half the carpet and tiled the area around the toilet and tub. Now, I want to take out that previous tile and remove all carpet and re-tile the entire space with large format tiles. After months of planning and looking at different tile options and different vanities and sinks and shower fixtures, late summer I decided it was time to begin the project in earnest.

The first thing I did was to replace the old inefficient toilet with a modern, low flow Toto Drake toilet. I actually did the toilet replacement last year (now I had to temporarily remove the new toilet in order to facilitate re-tiling the floor.)

Next on the list was to replace the large, aged window in the shower. I decided I wanted to eliminate to regular sliding glass window with a slightly smaller (but still large) glass block window. I designed the window I wanted on paper and had a company in Ohio build the window. I had to contract out having the old window removed, building down the opening (the original window was 48" x 36" but I wanted the block window to be 48" x 32" (4 inched less tall)):

My Glass Block Window Design. The dark/light grey blocks are alternating clear wavy glass and frosted glass 4"x8" blocks with three 8"x8" colored blocks in the center.
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This was the finished glass block window when it arrived from the maker. They captured exactly what I wanted;. I was quite happy with how it came out. Note I had them pre-install a vinyl frame to facilitate installation.
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This is a shot of the "before" bathroom as seen from standing in the doorway of the walk-in closet behind me. (The new Toto toilet is seen)
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Things get serious when I started tearing out the old shower tile and backer board. I had to take all the old tile and backboard off, exposing just the studs in the shower/tub area. This was not a fun task. You can see the old copper plumbing, which as you will see, I replaced with Pex.
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The next step was to replace the window with the new Glass block window. Because the new window weighs nearly 200 lbs, this was one task I decided to contract out. Between the cost of the window, shipping and the contractors, this brought the total cost for the new window to around $3800.

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Now that the window was installed, I needed to "shim" all the studs to ensure they were perfectly plum and straight before installing the "Go Board" (a waterproof backer board on which the tiles will be cemented). I used a combination of drywall shims and ripped wood shims to get the studs all perfectly plum and straight. This is critical, especially when installing large format tiles.
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Here I have replaced the plumbing with Pex (except after this picture I decided to replace the tub faucet drop-down and "faucet stub-out" with new copper as I'd read in several places that it was not recommended to use Pex for this part of the system).
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Finally all the Go Board is installed. Note also that I eliminated the popcorn from the ceiling immediately above the tub - I plan to eliminate all the popcorn from the entire bathroom ceiling before it's all said and done. (Whoever invented that horrible stuff?)
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Finally the tiling begins. Note the use of "leveling clips" to keep all the tiles in alignment. Normally they don't recommend a 50% overlap with large format tile like I'm doing here. However, when I tried other layouts (straight side by side or 1/3 stagger), I always ended up with some very thin, weird looking small tile cuts that would have looked bad, so I decided to do 50% overlapping tiles and try my best to keep the tiles level with the clips. In the end I was quite happy with the results and had almost no "lippage."

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Next came the grouting of the tiles and installation of the shower / tub fixtures. Also, I was originally going to trim out the area around the window with the same tile, just cut down to size, but then I decided to use "FlexStone" to waterproof and trim the window. The FlexStone is a vinyl product that looks like marble but is much easier to work with and I really liked the results. You can also see here that I have installed Schluter Coated Aluminum corner shelves to have places to put shampoo, soap, etc.
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Now that the shower is essentially done, it's time to turn my attention to the floor. I'm doing the floor in a lighter 12x24 tile that complements the darker shower tiles. First step was to tear out the carpet and use an air chisel to remove the old tile. Then I am using a 7" Makita grinder I just purchased (whole separate thread about that debacle) with a diamond wheel and a special HEPA vacuum to remove all the old thinset and carpet glue, paint etc. This is still a work in progress. I have the old vanity removed and will install the new vanity and sinks once the floor tile is done.

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Here I have all the old tile up and all the old thinset removed. As you can see, I have a crack to repair, then still need to remove the rest of the carpet adhesive. Once that is done I will be using a Ardex Flexbone decoupling mat on the floor, before laying down the new tile (you can see one of the floor tiles in the below picture). I decided to use a decoupling membrane instead of tiling over the bare concrete in case the concrete cracks more in the future, then decoupling membrane will prevent (or at least minimize the chances) the crack from migrating to the tiles. Progress is slow but steady and I'll still have a lot of cleaning up and trimming out around the edges when I'm done.
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I'm surprised a person of you years did not put in a walk in shower.
 
Basil - that is the most detailed and comprehensive step-by-step post I've ever seen here. Bravo!

(Is there a crack in the concrete floor by the tub?)
 
Nice!
I’m thinking of replacing our glass corner shower with a walk-in shower. Maybe next year.
 
I'm surprised a person of you years did not put in a walk in shower.
Whatchoo talking' about a "person of your years?" By the way, we are putting in a walk in shower in the guest bath (next project), which currently also has a tub/shower. Also, I am going to be installing a couple of grab bars in this master bath/shower. But we both wanted to keep the tub because it's nice to just soak sometimes.
 
Basil - that is the most detailed and comprehensive step-by-step post I've ever seen here. Bravo!

(Is there a crack in the concrete floor by the tub?)
Yes, if you look at the text above the last picture, you will see that I point out the fact there is a crack (that I am going to repair) and that I'm using a decoupling membrane between the concrete subfloor and the tile to isolate the subfloor from the tile; thus, if the subfloor cracks any further in the future, the cracks won't (in theory) transfer to the porcelain tiles.
 
Nice!
I’m thinking of replacing our glass corner shower with a walk-in shower. Maybe next year.
This is a project I had been threatening to do for many years. I kept saying "maybe next year" until I finally decided that, at my age, it was now or never! LOL.
 
This is a project I had been threatening to do for many years. I kept saying "maybe next year" until I finally decided that, at my age, it was now or never! LOL.
I understand completely. I rehabbed my deck last spring. Installed a concrete pad, built new stairs and installed new facia and new railing. Projects always are bigger and more $ than planned.
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I understand completely. I rehabbed my deck last spring. Installed a concrete pad, built new stairs and installed new facia and new railing. Projects always are bigger and more $ than planned.
Definitely more $$ than planned. By the time I'm all done, Ill probably have close to $20k invested in this bathroom, and that's with me doing most of the work (only hade to pay contractor $1000 so far for the window replacement). But OTOH, I know I'll have saved at least that much over having the whole job contracted out.
By the way - nice job on the deck - looks great!
 
Definitely more $$ than planned. By the time I'm all done, Ill probably have close to $20k invested in this bathroom, and that's with me doing most of the work (only hade to pay contractor $1000 so far for the window replacement). But OTOH, I know I'll have saved at least that much over having the whole job contracted out.
By the way - nice job on the deck - looks great!
Pride in doing it yourself is priceless
 
Pride in doing it yourself is priceless
So true. A few years ago, I pulled up all the carpet throughout the house and installed 3/4" solid oak flooring. Had to first lay down 3/4" plywood onto the concrete slab, then installed the oak planks over it. Did one room at a time, and the main hallway until all the rooms (except kitchen and bathrooms) were done. The whole thing took over a year, but when I finished I was quite proud of the result.

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BCF Command Center.
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looks great boss - well done!
 
Well done. Those tile jobs aren't for the faint-of-heart! I did all tile for floors in the hovel but for two "spare" bedrooms. They are relegated to office (Herself) and storage of all things household. Bathroom and shower done with flooring and wall tile in the walk-in shower.

And as of yet, NO STINKIN' GRAB-BARS anywhere! Maybe put those in the Elans for the crotchety old passengers. :devilish::p
 
Well done. Those tile jobs aren't for the faint-of-heart! I did all tile for floors in the hovel but for two "spare" bedrooms. They are relegated to office (Herself) and storage of all things household. Bathroom and shower done with flooring and wall tile in the walk-in shower.

And as of yet, NO STINKIN' GRAB-BARS anywhere! Maybe put those in the Elans for the crotchety old passengers. :devilish::p
I remember your pics when you did all the work. I installed blocking in the shower 35 years ago knowing that “one day” I might need to put up grab bars. Not today, not today.
 
well we dodged a bathroom reno bullet this week. Had the coldest weather in a few years of decembers and the pipe froze to the upstairs bathroom (175 years old) - managed to get it thawed today and it doesn't appear to have fractured the pipe (phew) - just some time with the heat gun in the crawlspace. :cheers:
 
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