Involuntary Bathroom Remodeling Part II

In my last post, I discussed the suddenly urgent need to completely redo our downstairs bathtub/shower, and the accompanying demolition.  With everything demo'd to dry wood, I had to contemplate rebuilding everything to support the new tub and shower enclosure.

The first order of business was figuring out what tub to put in the space.  The old tub was a 60" jetted "drop-in" that, you will recall, (1) didn't have working jets, (2) wasn't properly supported by the framing, and (3) didn't fit into the 57" space--the tub protruded three inches into the closet in the adjoining room.  Kendra and I decided we would buy a 54" tub instead, which is harder to find than a standard 60" tub.  We finally settled on a 54" tub at Menard's, primarily because it was available without special ordering.

This still left us with a size problem -- a 54" tub to go in a 57" space.  The best solution I could think of was to build a three-inch shelf out at the top of the tub.  This meant more carpentry (ugh)* but seemed very doable.  Since 2x lumber is actually 1.5", that means I just needed to nail a couple 2x8 to the framing to create the shelf.  It all seemed very easy, until Kendra mentioned that she'd like to install shower doors in the finished space, instead of a shower curtain.  Now, my simple shelf project turned into a new wall projecting three inches out from the old wall.  Ugh, more carpentry.

*The reason I say "ugh" is not because I hate carpentry, it's just that I'm really bad at it.  Driving a nail usually is a two- or three-take process for me.  Which makes me hate carpentry.

I set to work reconstructing the space so that we could set the tub.  First, I needed to reinforce the floor joists, which had significant (although not catastrophic) water rot, so I sistered some 2x8s to the existing joists.  Underneath the bathroom is crawlspace, which made the work more difficult in that I was flat on my back the whole time, yet also easier in that I didn't need to reach straight over my head to work.  Due to the bathroom being located on an exterior wall, I was able to rest one end of the 2x8s on the sill plate, which should make them hold better (I think).   After reinforcing the joists, I cut a piece of OSB board to fit the opening in the floor and screwed it to the joists.

After a little bit of framing to correct the hole in the wall the old tub was shoved into, and then installing two 2x8s to create the proper width for the tub alcove, it was time to install the tub.  I cut and fastened a 2x4 ledger board on the back wall to support the tub.  Then  I enlisted Kendra's help to lift the tub into place.  It took quite a bit of coaxing, shoving, and pushing, but we finally got the tub set on the floor.  I doubt we had a quarter-inch of space to spare.  I used some shims to level the tub, and then we were set.

The tub snugly in place.  You can see the new framing at both the right and left-hand sides of the tub.

After getting the tub in, I turned my attention to the new, 3" deep wall I would need to build out to accommodate our future shower doors.  I decided I would attach horizontal 2x4s to the existing studs, then attach vertical 2x4s on top of that to run the length of the new "wall."  This successfully narrowed the tub alcove from 57" to 54", and resulted in a plumb-enough new structure for installing the cement board.

The cement board was surprisingly easy to work with, although there was some drama along the way.  First, I needed to clean up some of the wiring by removing the switch and wires that worked the nonfunctioning jetted tub.  In the switch's place, I installed a GFCI outlet, located in the same electrical box as the switch for running the exhaust fan.  It doesn't really makes sense to have an outlet in that particular spot, but I didn't know what else to put in the box.  I guess this will leave a power source in case we want to put in a 42" TV right across from the toilet.

After the wiring, I called and had Cooter's Plumbing come over and replace some of the old PVC pipe that ran to the tub and shower with PEX pipe.  They also installed the new shower valve and made the drain connections.  With the wiring and plumbing done, it was time to cover the walls.

I attached 4 mil plastic sheeting on top of the lathe board to act as a waterproof barrier to the framing underneath.  I decided to install the cement board on the long wall first, because it would require the least cutting and let me practice my technique before moving on to the more delicate pieces.

One wall down, two to go!

I found the board easy to cut and work with, but my efforts were not without problems.  After hanging the first piece--the one on the top in the picture above--I realized I had forgotten to cut out the opening for the exhaust fan.  Luckily I was able to punch out an opening with the use of a utility knife and cold chisel.  It added some work, but not an ungodly amount.

Yesterday, after a couple weeks of no progress, I was finally able to hang the rest of the cement board.  Here are a couple shots; this picture shows a straight-ahead view:

And here is a photo showing the new 3" wall:

As of today, we are almost ready to start tiling.  I still need to mortar the cement board joints, and finish the perimeter with joint compound.  And we still don't have the tile yet, although it's supposed to come in this week.  After two months of no downstairs tub, and I'm guessing 40 hours of labor, we are getting close to finishing this project.