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Dan Melby kicks and shoves a stubborn but well measured vertical beam into place. Each piece is labeled for reassembly in Idaho.
Pat Christman / The Free Press


The cabin’s facade is littered with ax marks like these, first cut when the original cabins were built in the late 1800s. The new exterior is required to be authentic in every way, so the cut marks of modern machines must be masked using old-fashioned tools.
Pat Christman / The Free Press


This 28-by-52-foot cabin uses the wooden beams from three cabins that are themselves between 117 and 137 years old. The 44,000 pound structure is being put together in a Mankato warehouse before being de-assembled for transportation to Coeur d’ Alene, Idaho. Two flatbed semis will carry 15,000 feet of lumber.
Pat Christman / The Free Press


Published January 05, 2007 12:02 am -

Authentic cabin more than the sum of its parts
Three smaller buildings provide lumber for single structure

By Dan Linehan
The Free Press

MANKATO

A crane jolts noisily to life overhead while electric drills drive metal spikes into planks of wood.

But listen closer and you may hear an ax chopping, or maybe an oversized mallet banging away. This isn’t because these traditional tools are any better. They’re not.

This may sound at first like a modern construction site, but — and this part is important — this building will look nothing like anything built during the last 100 years.

That means there will be no thin, precise cuts that are the telltale marks of modern equipment. So that ax you may have heard wasn’t chosen for its chopping properties, but because its crude, wood-splintering incision can mask modern cuts.

If there is one word to describe this log cabin, it has to be “authentic.”

The entire exterior won’t bear the clean hole of a power drill or feature a surface smoothed by a planer.

When an Idaho resort was looking for a company to find old lumber and build an authentic cabin, it turned to Terrasol Restoration and Renovation, a St. Peter company.

And this is Terrasol’s specialty, but it has never built a cabin this large. Its second-biggest effort was barely a third this size.

This 28-by-52-foot structure required that three smaller cabins (one each from New Germany, Beauford and Osseo, Wis.) be disassembled to provide the 44,000 pounds of wood necessary. The cabins were built between 1870 and 1890.

But another problem quickly comes to mind: How, exactly, does one transport a large building 1,110 miles?

It will leave Mankato on Saturday as individual pieces of lumber, traveling on two flatbed semis. Each piece of wood bears a simple notation that will tell the crew in Idaho where it goes.

The entire schematic, of course, is anything but simple.

“I’m the puzzle maker,” says Jared Groebner, a project manager with Terrasol. He estimates he’s spent 300 hours on drawings that detail how the cabin should be assembled.

On Thursday afternoon, a crew of about a dozen was busily thrusting lumber into place, drilling holes and working on other tasks indecipherable to a reporter. Work was planned to continue until midnight and continue in the morning if necessary to meet the deadline.

“Nothing like pressure,” Groebner said.



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