“The blue of our lakes and the white snow of our winters”
—Zachris Topelius, Poet
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Most people glorify the act of building, as in being able to transform a humble pile of building materials into a noble sauna or house or shed. I like to think that too: that my profession is a noble one, with an emphasis of craftsmanship and attention to detail that can only be honed by decades of working with fine materials. But the truth is, on any given day, on any given project, especially for on-site work, where I take my tools and materials, my truck and trailer, my lunch and my laptop and various other accoutrements, is that I am often just a professional schlepper. And I bet any other contractor reading this just now nodded his or her head.
I love doing saunas that are removed from the house, perhaps beyond the garden gates or down by the lake or out in the woods next to a pond. I like to work immersed in nature, take lunch by the water, and contemplate the finer things in life while I toil at my craft.
But, when I bid jobs like these, I have learned to think of the schlep— that is the sum total distance from truck to the site. I think of thousands of steps back and forth to carry lumber, to retrieve the pencil or glasses from the cab, of the steps I have to climb or the potential for slipping and falling with a 100 pound load on my shoulder. I have literally carried an entire eight by twelve sauna on my shoulders, load by load. Some days I count the steps and do the math—how many miles I wonder? Other times I count the load— a ton of concrete mix, how much work was that?
I don’t mind the schlep. The key is to embrace it. If I know from the start and plan for it: clear the path, remove obstacles, make ramps, then I can proceed slowly but with the steadiness of a Yoga master moving through a progression of poses. Each repeated carry is perfected in the same way a bobsled driver learns to lean through each curve.
With two or people it is a choreographed movement. Go left here, stoop here, K- turn at the end and dosey-do before we enter the door. Perfecting the movement makes it almost enjoyable.
At 60 I have to protect my body. I know my strengths and limits and my strength is knowing how to carry and move heavy objects. Always keep one hand free- you never know when you’ll have counter an off- balance step. Always be relaxed and take smaller loads— there is no race. It is amazing what you can in an hour of honest schlepping. Ironically when I do have spells of days or weeks when my back is “out” and the chiropractor is needed, it always the stupid stuff that gets me: desk work (I stand at my desk now), shoveling snow or that heroic effort to rake all the leaves in one Sunday. These are unintentional actions. Work with intention and you will become stronger. Work smarter and you will avoid injury. I really like those 60 pound concrete bags— and I’m eyeing those forty’s. At 19, everything came in 100’s.
I’ve had jobs where the schlep caught me, like the sauna-cabin in the woods where I was promised an ATV to haul everything. After the first week, 3 feet of snow put the brakes on that. Everything had to be hauled on a sled with me in snowshoes. Good thing I Loved those Jack London stories as a kid.
But then, I’ve been pleasantly surprised too- like a recent job on the lake where the haul was several hundred feet down steep stairs or a windy path. Then the owners produced a golf cart. It became my mini-truck and my morning joy as I breezed down the hill silently. There is a beauty to electric vehicles: the joy of still hearing nature as you whizz through it.
I’ve thought of offering classes on Schlepping—or even rigging—which is a specialized form of schlep that involves more weight, more dance, more cooperation. We would move things each day. And then maybe move them back again. Everyone has it wrong about Sisyphus. If the enjoyment of the act of moving becomes the goal, rather the completion of the act, then he could be seen as a master perfecting his craft. Like a cat that keeps hitting the toy away only to chase it again, a worker who carries load after load and enjoys the process will reach the goal of enjoying his or her work.
And only when a worker enjoys his or her work is
true craftsmanship possible.
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We started the year in the midst of the pandemic which made for some challenges but mostly the pandemic has meant a huge uptick in the sauna business as we all became more centered on home life and more reluctant to go out into public for things like gyms and saunas. Besides the several projects I have completed locally and around central New York I have fielded calls and emails from folks desperate to have their own saunas from as far away as Europe and Australia. I never set out to become a sauna expert, but here I am, 25 years into making them, and people are seeking out my knowledge from all over. In the process I feel like I have made many new friends. The global sauna community is alive and well. At the same time, due to the pandemic, I have mostly refrained from seeing all but my closest friends and family. It’s a strange new world but I am thankful to be connecting to so many people, if only on Zoom.
For my new friends I have designed and consulted on saunas from Maine to California— that has kept me busy when I was not getting my hands dirty. But whenever I can, I am working with my hands, either in my 3000 square foot shop, which I am ever grateful for, or I am on jobsites. It used to be that builders would simply stop in the winter and spend the dark months sitting around the woodstove reading back issues of Fine Homebuilding, but now we all seem to be out there in any weather. My cut off is 10° F; any colder and I want to be by a fire, in the sauna, preferably. Good gear helps; I’m especially grateful for my boot warmer and insulated pants.
Nothing I do is cookie cutter—I would die of boredom is life was too easy— thus the custom in my business moniker. This year I seemed to run the gamut of sauna permutations: First, a garage retrofit to a Yoga and sauna retreat, then a quiet walkout basement electric affair, then a classic one room wood burning sauna on a idyllic creek, then a more urban collaboration in Syracuse, followed by a tiny personal electric sauna in a bathroom, a rustic elegant wood burning retreat in the trees, and a distance job downstate. Currently I’m finishing up an electric sauna in a historic boathouse on Cayuga lake. I’m hoping to take it for a test drive, with a jump in the frigid water, by Christmas.
In between all of these I have sold a few of my Lämpimämpi sauna stoves and many sauna plans. DIY interests, especially in the mobile saunas which are really big now. I get a kick out seeing my designs being brought to life by many different hands. It is also fun to see all of the other builders following in my steps. The more builders, the better. There is plenty of work to go around and I encourage anyone who wants to take the work seriously to pursue it with a passion. I did offer a sauna building class this year but had to cancel; Covid has thrown a wrench into a lot of plans. But stay tuned: perhaps 2022 will be the year.
Covid also threw into a wrench into the supply chain. We’ve all heard the phrase “supply chain disruption” by now. I bid jobs in the beginning of the year only see to prices on materials I quoted go up by 250%. Some materials simply vanished from the shelves. But now things have settled down and I also started ordering and stock piling materials well in advance. I can keep several saunas worth lumber and supplies in my big shop and insulate myself from some of the inflation—another reason to be grateful for the big work space.
I’ve been working alone for most of the year, which actually suits me fine, especially with Covid lurking. Workers are hard to come by: not only are the skilled trades losing new blood, but, I think, the pandemic relief made a lot people lazy and unwilling to get off the couch. Scarlet, now my partner in everything, has been my greatest blessing. When she can escape childcare duties she has proven to be the hardest worker I could wish for. I could use a few more workers like her: eager to learn, unafraid of dust and dirt and willing to sweat. She also manages all of the marketing, so give her the kudos for the web media you see. The business feels like it wants to grow so if anyone is seriously interested in building saunas and wants to relocate to Ithaca, drop me a line.
For those of you lucky enough to have a sauna, I hope you get to celebrate the New Year in it for there is no better way to bring in the new and shake out the old. It’s been my tradition for four decades now and I hope to continue for four more.
Lately I have been thinking about the application of the foil I use in my saunas as a radiant vapor barrier. Perhaps this is because it almost Christmas and I was thinking of how we decorated the tree each year. The final touch would be to drape foil tinsel over everything; our mother would have to constantly damp down our enthusiasm by reminding us to place it carefully on each branch, not to throw it.
There are tricks to using the foil but the first and most important step is to buy the right stuff. Like the tinsel we put on the tree, the foil may actually be aluminum-coated plastic— which you don’t want to use. That plastic is likely polyethylene which, if you look it up on the material specification sheet that every product has, it has an upper working temperature of 55-120° C, meaning it will likely melt at typical sauna temps. Sauna Foil, available from any of the familiar sauna suppliers, is aluminum foil on a kraft paper backing. I used to find it with fiberglass reinforcing thread, which is helpful because the stuff tears easily. Also helpful is 4 ft. rolls, rather than 3 ft so you can do a wall in 2 passes, but I have trouble finding this too. I recently tried a new supplier selling 4 ft rolls of “sauna” foil, but upon opening it had a suspicious plastic look to it. That night I put it in the sauna and within seconds it began to distort and curl up like the polyethylene I suspected it was made of. (See illustration above)
The second thing is to design the wall correctly. I read and see a lot of misinformation that touts using no air gap with foil. The air gap is essential. The foil works by reflecting radiant heat. All “black bodies” give off and absorb radiant heat that travels in a straight line from one hotter object to another cooler one, the hotter the body, the more heat it emits. The sauna rocks radiate a “soft” heat to you, the walls, and the benches, and that is why you want the sauna to be laid out so that everyone has a view of the rocks. The fire, if seen through a clear glass door, also radiates heat— but at a higher intensity. Too high for a comfortable sauna (but great for ambiance.) When that heat hits foil, it is reflected back into the room or the backside of the cedar—if there is an air gap of at least 1/2″. If it touches the backside of the cedar the foil— also a perfect conductor—pulls the heat away from the cedar and transfers to the wall space behind.
I’ve understood this for along time. The first semester of college I took a class: Solar Design and the Energy Efficient Home. We learned all about insulation, heat transfer and basic building skills. The first day of lab, where we were building a timber frame house, I was handed a Makita 12″ circular saw. My building career started right then and there.
With the web of misinformation out there I had to think of a way to illustrate this basic principle of thermodynamics that I learned my freshman year. So, one slow day in the shop I rigged up an experiment and photographed it. (see illustration below) I set up a section of cedar wall about 18″ from my infrared shop heater and fastened 2 pieces of foil to the back, one with a 3/4″ air gap, and one with no gap. After an hour the cedar was 250°F on the front—like it is often is in my sauna. The back of the cedar was 121° F, which is impressive by itself. The back of the foil with no gap was 115°F, meaning it was acting as a perfect conductor, and the back of the foil with an air gap was 71°F: room temp. The air gap was clearly making a difference, 45° in this case.
The foil is a perfect vapor barrier rated at zero perms— meaning no vapor moves through it. But unless you layer it properly, with insulation behind it, the moisture will condense on it, or the first cold surface it hits. Even in a perfect build, there might be cold spots in the insulation (typically about the size of a mouse hole), so there likely be some condensation, but not a problem if there is air movement. The air gap behind the cedar allows air to circulate around the cedar, removing any moisture and ensuring that the wood heats and dries evenly and remains stable. Heating one side of a board and wetting or cooling the other is how you make curved boat staves.
There are other tricks to using the foil- like unrolling it and re-rolling it foil-in, or using temporary magnets when working a commercial job with metal studs, but the key is to use care. Use plenty of hi-temp foil tape and patch tears as you go and work with a partner if possible.
I suppose you could build a sauna by putting a heater in a refrigerator box- but that would last about a day and be incredibly wasteful. Cedar touching foil won’t ruin your sauna and neither will plastic melting in the walls where you don’t see it. But if you are going to take the time and bear the expense of building a sauna, you might as well do it right and so it will last generations. I guess my mother was right: applying foil carefully and not just throwing it up is the way to work.
When building a sauna the first and possibly most important consideration is the location.
With a wood-burning sauna, which is free from the tether of an electrical connection, it can be away from the house—not just for safety but also to create a separation from the electrical buzz of modern life. Simple and inexpensive solar options make it easy to provide needed lighting. It should have some of the comfort of home but be integrated into nature; near a body of water is always a good choice.
My latest sauna does all of that and more. The site is fairly close to the house but lies outside the garden gates. It all but hangs on the edge of a small gorge that contains a lively creek in its serpentine confines. Like the basswood and cherry trees that cling to the sides of the gorge, firmly rooted in the ground, the sauna is anchored to the 300 million year old shale bedrock with concrete and steel. The owners built a steep stair down to where small waterfall flows into a perfect bathtub sized hole. Descending it may be slightly perilous but that only adds to the adrenaline to rushing from the steaming of the sauna and plunging in the ever-cold water.
As I build I tweak my design to allow nature into the sauna. Framed and without sheathing I could see the perfect view up the ravine from the upper bench, suggesting the optimum location for a small candle window. The large window allows a view of the wooded hill and brings in ample afternoon light and the view down into the creek through the framing allowed me to imagine the possibility of a small square creek view porthole below knee level that would let in the ambient sound of the rushing creek. Exiting the sauna one faces the woods, not the house; a crude stair-path leads the eye up into the forest while the other leads to the creek.
The sauna is visible from the road and the house, but neither is evident from the sanctuary within. All you hear is the babble of the creek and all you feel is the relaxing heat of the sauna. Finishing a few rounds in the sauna with a dunk in the massaging water is pure bliss.
The site not only perfect for the sauna but it was a joy to work there, listening to and watching the water flow. Daily I took dips in the creek to beat the steamy summer heat. Having a site that allows me to enjoy the process of building lends means I can build a better sauna—one that is infused with the spirit of the place and connected to nature.
