Beyond The Build

Luxweld
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Welcome to Beyond The Build, where we help Australian volume builders, architects, and installers eliminate skylight defects and reduce warranty risk. Most skylight suppliers cut corners. We don't. Each episode breaks down the real cost of preventable defects, the five brutal ways skylights fail, and the exact framework for turning liability into an asset. From silicone joint failures and rivet risks to bad product selection and poor installation, we cover what's keeping you awake at night. Join Jono Anderson, carpenter and builder, as we explore defect prevention, installation standards, bu

Episodes

  1. Aug 17

    Roofer Reacts to Viral Skylight Installations

    Book a builder consultation to review your skylight design and flashing detail before it becomes a callback 👉 https://www.luxweld.com.au/pages/contact Most builders have heard the same line, there are two kinds of skylights, the ones that leak and the ones that will leak. But that isn't a fact. It's a planning, product-selection, and water-management problem. In this episode, Jono reviews real skylight and roofing installations to show what separates a risky roof penetration from a reliable design feature. From thermal performance and custom triple glazing to insulation, water run-off, tape sequencing, and hose testing, he breaks down the details that need to be resolved before the roof goes on. You'll learn: ◼️ Why the myth that skylights always leak still persists and what actually causes the failures ◼️ How changing building-code requirements make thermal performance and careful skylight selection more important, especially in colder climates ◼️ What a properly planned high-performance skylight detail looks like, including insulation around thermal gaps ◼️ Why triple-glazed and custom skylights must be planned early instead of ordered when the roof is ready ◼️ How upstand height, roof offsets, wraps, and a clear drainage path protect a skylight from water ingress ◼️ Why bottom-to-sides-to-top taping and secondary sealing layers matter when integrating a skylight into the roof ◼️ The value of hose-testing an installation before handover ◼️ Why you shouldn't rely on silicone to fix a detail that wasn't planned properly from the start ◼️ The simple water-management principle every builder needs to remember: water is heading downhill, so create the path Timestamps 00:00:00 Introduction: 00:01:36 Reaction 1: Why Builders Assume Every Skylight Will Eventually Leak 00:01:47 Breaking the Myth: Skylights Don't Leak When They're Treated Right 00:02:12 Reaction 2: Thermal Performance, Leaks, and Changing Building-Code Requirements 00:02:35 How One Builder Solved a 20mm Thermal Gap in a High-Performance Skylight Detail 00:02:54 Why Insulation, Planning, and the Final Finish Need to Be Considered From the Start 00:03:19 Reaction 3: A Custom Triple-Glazed Skylight on a Five-Degree Roof 00:03:42 Triple Glazing and Lead Times: Why You Can't Leave Custom Skylights Until the Last Minute 00:03:58 XPS Insulation, Pre-Installed Wraps, and Diverting Water Away From the Skylight 00:04:20 The Details That Matter: Upstand Height, Roof Offset, Water Path, and Code Compliance 00:04:31 Taping the Detail Properly: Bottom First, Then Sides, Then the Top 00:05:06 Why a Hose Test Should Happen Before Handover 00:05:22 What This Installation Gets Right Before the Roof Even Goes On 00:05:53 The Most Unique Skylight Detail Jono Has Seen: The Barbecue Tray 00:06:18 Old Way vs. Better Way: Letting Water Pond or Giving It a Path 00:06:40 Why Water Flow and Planning Are the Key to Keeping a Roof Dry Follow Jono Anderson & Luxweld: Facebook: https://www.facebook.com/profile.php?id=61556448458026&sk Tiktok: https://www.tiktok.com/@luxweld LinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/ Instagram: https://www.instagram.com/luxweld.au

  2. Aug 14

    How I Built A Product That Stops Skylights Leaking, Permanently

    Book a meeting to review your current skylight flashing standard before it ends up on your defect list👉 https://www.luxweld.com.au/pages/contact In this episode, Jono takes you behind the scenes of how Luxweld was built. From standing on a roof watching the same failures repeat themselves, to being told by every manufacturer that nothing was wrong, to travelling to Japan to understand what it means to build something that truly lasts. This isn't a product story. It's a story about what happens when you refuse to accept that "good enough" is good enough. You'll discover: ◼️ Why Jono couldn't keep installing skylight flashings he knew were failing (and what that moment of frustration started) ◼️ How every manufacturer denied the problem, dismissed the evidence, and told him "that's how it's always been done" ◼️ Why the industry said fully welded flashings couldn't be done (and how a young engineer named Dave Gardner helped prove them wrong) ◼️ The research behind Luxweld's materials, welding technology, and manufacturing process designed to remove weak points instead of patching them ◼️ What a trip to Japan revealed about defect rates, manufacturing mindset, and building products for the next generation ◼️ Why Australia's acceptable defect rate of 2% would be considered a crisis in Japan (and what that means for how we build) ◼️ The philosophy behind Luxweld: products built with respect for the builder, the installer, the homeowner, and everyone who lives under that roof ◼️ Why "it'll get us through the warranty period" is the wrong standard to build to Timestamps 00:00:00 Introduction: 00:00:45 Standing on a Roof Watching the Same Failures Repeat Themselves 00:01:30 Why Jono Couldn't Keep Installing Flashings He Knew Were Failing 00:02:15 Going Back to the Manufacturers: "We Don't Believe There's an Issue" 00:03:00 Being Gaslighted by the Industry: Photos, Videos, and Still No Accountability 00:03:45 What the Manufacturers' Response Really Revealed: Profit Over People 00:04:30 The Challenge: Build the Product the Industry Said Was Impossible 00:05:15 The Team Behind Luxweld: Engineer Dave Gardner and 40 Years of Installer Knowledge 00:06:00 Deconstructing Everything: Materials, Welding Technology, and Manufacturing Process 00:07:00 Designing for the Installer, the Builder, and the Homeowner (Not for Ease of Manufacture) 00:07:45 The Trip to Japan: A Different Mindset on Defect Rates and Product Quality 00:08:30 Australia's 2% Acceptable Defect Rate vs. Japan's 0.002% Standard 00:09:15 Building for the Next Generation: Not Just to Scrape Through the Warranty Period 00:10:00 The Philosophy Behind Luxweld: People Matter 00:10:45 One Piece Welded Construction: Removing Weak Points Instead of Patching Them 00:11:30 Two Choices When You Know a Problem Exists: Cover It Up or Build Something Better 00:12:15 The Takeaway: Don't Accept "That's How It's Always Been Done" as a Good Enough Reason 00:12:45 Summary: Skylights Don't Need More Band-Aids. They Need Better Products Follow Jono Anderson & Luxweld: Facebook: https://www.facebook.com/profile.php?id=61556448458026&sk Tiktok: https://www.tiktok.com/@luxweld LinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/ Instagram: https://www.instagram.com/luxweld.au

  3. Aug 11

    I Tested 3 Skylight Flashings, Here’s What Happened

    Book a meeting to review your skylight flashing standard and eliminate defects before they hit your defect list👉 https://www.luxweld.com.au/pages/contact In this episode, Jono Anderson breaks down exactly what we found so you can make the right call before it ends up on your defect list. From riveted flashings to spot-welded systems to fully welded solutions, discover why the smallest part of your project shouldn't become your biggest risk. You'll discover: ◼️ Why riveted flashings look great when they go on the roof but have the highest risk of failure (and the shortest warranty) ◼️ The hidden problem with spot-welded flashings that gets exposed during powder coating (and why silicone isn't the answer) ◼️ How the wrong flashing choice can turn 0.002% of your build cost into 50% of your defect list ◼️ Why lead time and availability shouldn't be your primary decision criteria (and what actually matters in 12, 18, and 24 months) ◼️ The three questions every builder should ask before specifying a skylight flashing ◼️ How fully welded flashings eliminate weak points and remove the defect risk that's costing you callbacks ◼️ Why warranty length is a big indicator of what manufacturers expect their product to actually last ◼️ The real cost of saving a day on flashing selection vs. the cost of a callback Timestamps 00:00:00 Introduction: 00:00:40 The Three-Year Testing Program: Same Criteria, Same Conditions, Same Scrutiny 00:01:30 Why You Don't Find Out About Flashing Failure Until It's Too Late 00:02:15 What Actually Matters: Testing Criteria That Affect Real Projects 00:03:00 Flashing Type #1: Riveted Flashings (The Most Common on the Market) 00:03:45 Why Riveted Flashings Have the Highest Risk of Failure 00:04:15 The Problem With Pinholes and Silicone Joins on Riveted Flashings 00:04:45 Riveted Flashings: Speed vs. Risk (12-24 Month Warranty) 00:05:30 Flashing Type #2: Spot-Welded Flashings (The "Smarter" Option) 00:06:15 The Hidden Problem: What Happens During Powder Coating 00:06:45 Why Spot-Welded Flashings Still Rely on Silicone (And Why That's a Problem) 00:07:15 Spot-Welded Flashings: Stronger, But Still Vulnerable (5-15 Year Warranty) 00:07:45 Flashing Type #3: Fully Welded Luxweld Flashings (No Silicone, No Rivets) 00:08:30 Why Fully Welded Flashings Eliminate Weak Points 00:09:00 Lead Time vs. Reliability: The Trade-Off That Matters 00:09:30 Marine Grade Aluminum: One Flashing for Coastal and Bushfire Properties 00:10:00 The Real Question: What's Your Flashing Going to Look Like in 12, 18, and 24 Months? 00:10:30 Heavy Storms, Australian Summer Heat, and Debris Buildup: What Happens on Your Roof 00:11:00 Why Volume Builders Need Standards, Not Just Quick Fixes 00:11:30 Warranty Comparison: 12-24 Months vs. 5-15 Years vs. 20 Year Warranty 00:12:00 Don't Let 0.002% of Your Build Cost Become 50% of Your Defect List 00:12:30 The Three Questions Every Builder Should Ask Before Specifying Flashing Follow Jono Anderson & Luxweld: Facebook: https://www.facebook.com/profile.php?id=61556448458026&sk Tiktok: https://www.tiktok.com/@luxweld LinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/ Instagram: https://www.instagram.com/luxweld.au

  4. Aug 7

    Why Most Skylights Leak … and How To Avoid It

    Stop accepting "good enough" from suppliers. Eliminate these risks from the start. Book a builder consultation with Luxweld and get ahead of defects before they start. 👉 https://www.luxweld.com.au/pages/contact In this episode, Jono breaks down the 4 key failure points behind almost every skylight defect, and the exact standard top builders use to eliminate leaks and callbacks for good. You'll discover: ◼️ The 4 key failure points that cause almost every skylight defect, and how to eliminate each one ◼️ Why "skylights leak" is a myth, and what's actually going wrong (it's not the skylight itself) ◼️ The product selection mistakes that set installers up to fail before anyone gets on the roof ◼️ Why the flashing, not the skylight, is your real line of defense against water ◼️ The exact questions to ask an installer to know if they actually understand the system ◼️ How to build a maintenance plan that doesn't rely on your homeowner remembering anything Timestamps 00:00:00 Introduction: 00:00:40 The 4 key failure points builders need to get right 00:01:15 Why "skylights leak" is a myth: selection, flashing, install, and maintenance 00:02:00 Failure Point 1: Product selection and why it sets everything else up 00:03:30 The racing slicks analogy: matching the skylight to the roof 00:05:00 Failure Point 2: Flashing selection, your main line of defense 00:06:30 A real job gone wrong: the wrong flashing on the wrong pitch 00:07:45 Why Luxweld built a welded, silicone-free flashing system 00:09:00 Failure Point 3: Installation and why complexity increases risk 00:10:15 The questions to ask before choosing an installer 00:11:30 Why consistency matters more than experience alone 00:12:15 Failure Point 4: Longevity and maintenance done right 00:13:45 Why silicone-reliant systems put the burden back on homeowners 00:15:00 Reviewing your current standard: the questions every builder should ask Follow Jono Anderson & Luxweld: Facebook: https://www.facebook.com/profile.php?id=61556448458026&sk Tiktok: https://www.tiktok.com/@luxweld LinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/ Instagram: https://www.instagram.com/luxweld.au

  5. Jul 29

    Top 1% Of Builders Assess Their Materials Like This

    Stop losing money on defects. Book a builder consultation to see how Luxweld can help eliminate defects on your next project. 👉 https://www.luxweld.com.au/pages/contact In this episode, Jono shares the framework that separates builders who never get a callback from the ones stuck fighting defects for years, and the leak investigation that first showed him why "cheaper" materials almost always cost more in the end. You'll discover: ◼️ Why choosing materials on price alone is quietly costing builders their margin and their reputation ◼️ The real story behind a failed flashing system, and who was left to clean up the mess ◼️ What Japanese roofing manufacturers get right that most Australian suppliers don't ◼️ The 3 non-negotiables top 1% builders check before price ever enters the conversation ◼️ Why a supplier who answers the phone when something goes wrong is worth more than a longer warranty ◼️ How warranty exclusions are quietly written to cancel out the warranty itself ◼️ Why a $200 "saving" can turn into a $3,000 problem, and cost you ten referrals Timestamps 00:00:00 Introduction: Why Price Alone Is the Wrong Way to Choose Materials 00:00:40 Meet Jono: Building Australia's Most Advanced Skylight Flashing System 00:01:15 The Leak That Wasn't the Skylight's Fault 00:02:15 What Japan Taught Jono About Building for Generations 00:02:50 The Carpentry Lesson: Do Your Best Work Where No One Sees It 00:03:10 20 Years of Product Failures: What Actually Separates Good Suppliers 00:04:05 Why Velux's Support Beats a Longer Written Warranty 00:04:35 How Warranty Exclusions Quietly Cancel the Warranty Itself 00:05:05 The $200 Saving That Becomes a $3,000 Problem 00:05:40 You're Not Just Buying a Flashing, You're Buying a Reputation 00:06:00 The Three Questions: Will It Last? Will They Stand Behind It? What's the Price? Follow Jono Anderson & Luxweld: Facebook: https://www.facebook.com/profile.php?id=61556448458026&sk Tiktok: https://www.tiktok.com/@luxweld LinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/ Instagram: https://www.instagram.com/luxweld.au

  6. Jul 20

    How THIS Skylight Gets You More Repeat Business

    Book a builder consultation to see if Luxweld can eliminate skylight defects on your next project 👉 https://www.luxweld.com.au/pages/contact In this episode, Jono shares the story of how one honest conversation, one bold guarantee, and one builder willing to challenge conventional wisdom transformed skylights from a liability into a competitive design advantage that's helping them win nationally recognized awards. You'll discover: ◼️ Why most builders have written off skylights as a liability (and why that belief is costing you repeat business and design opportunities) ◼️ The power of one honest conversation to change an entire builder's trajectory ◼️ How a bold guarantee built trust and proved that skylights don't have to leak ◼️ Why natural light is one of the most powerful selling tools in residential design (and buyers don't even know why they love it) ◼️ How turning a liability into an asset became a point of difference for a nationally recognized builder ◼️ The real problem isn't skylights. It's poor design, bad product selection, and products that aren't built to last ◼️ How challenging conventional wisdom and taking things back to first principles creates the biggest opportunities in the industry 00:00:00 Introduction: The Builder Who Swore They'd Never Install Another Skylight 00:01:15 The Turning Point: From Zero Skylights to 16 Per Home 00:02:30 The First Honest Conversation: "Don't Even Bother" 00:03:45 Understanding the Builder's Fear: Years of Defects and Callbacks 00:04:30 The Bold Guarantee That Changed Everything 00:05:15 Ten Years Later: Still Waiting for That Callback 00:05:45 How Skylights Became a Design Feature (Not Just a Liability) 00:06:15 The Emotional Impact of Natural Light on Home Buyers 00:06:45 From Local Builder to Nationally Recognized Multi-Award Winner 00:07:00 The Real Lesson: Challenging Assumptions and Conventional Wisdom 00:07:30 Taking Things Back to First Principles: Design, Selection, and Product Quality 00:08:00 How to Turn Liabilities Into Competitive Advantages 00:08:30 Summary: One Conversation, One Guarantee, One Bold Decision Follow Jono Anderson & Luxweld: Facebook: https://www.facebook.com/profile.php?id=61556448458026&sk Tiktok: https://www.tiktok.com/@luxweld LinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/ Instagram: https://www.instagram.com/luxweld.au

  7. Jul 14

    5 Brutal Ways Skylights Can Ruin Your Reputation

    Book a builder consultation to see if Luxweld can eliminate skylight defects on your next project 👉 https://www.luxweld.com.au/pages/contactMost builders spend years managing projects without realizing their biggest liability is sitting right on top of their roofs. The construction managers who actually build defect-free homes and protect their reputation aren't working harder than you. They just have a different strategy. One that starts at the design phase, not on the roof.In this episode, Jono breaks down the exact framework for eliminating skylight defects, reducing warranty claims, and turning a massive liability into an asset that protects your margin and your reputation.You'll discover:◼️ Why one bad silicone joint can wipe out a huge chunk of your margin (and what happens at the molecular level during powder coating)◼️ The hidden risks of rivets on modern, flat metal roofs and how poor installation by under-trained trades is costing you thousands◼️ How bad product selection leads to mold, leaks, and voided warranties (the $2M build that went wrong)◼️ Why "creative roofing" and unqualified installers are your biggest liability and what to look for instead◼️ The one strategic move that saves you a fortune: bringing your roof plumber and installer into the design phase before the roof goes up◼️ How to turn skylight liabilities into assets and sleep easy knowing you won't get a callback in two yearsTimestamps:00:00:00 Introduction00:01:15 The $10M Apartment Block Story: How Silicone Joints Deteriorate After 12 Months00:03:45 The Molecular Truth: Why Powder Coating Destroys Silicone Seals00:05:30 Problem #1: Silicone Joints and the Risk You're Carrying as a Builder00:07:00 Problem #2: Rivets, Under-Trained Trades, and Flat Metal Roofs00:08:45 Problem #3: Bad Product Selection (Velux FCM vs. EFS vs. GLS Which One Are You Using?)00:10:15 The Mold Risk Nobody Talks About: Choosing the Wrong Skylight for Bathrooms and Showers00:11:30 Problem #4: Poor Installation and "Creative Roofing" That Leaks00:13:00 Problem #5: Bad Design (The $1.5M Build That Got It Wrong)00:14:15 The Design Phase Solution: Bringing Your Team In Early to Eliminate Risk00:15:45 How to Pick the Right Product for Your Roof Pitch and Water Flow00:16:30 Why Planning Saves You a Fortune vs. Fixing It After the Roof Is Up00:17:00 Summary: Turn Liabilities Into Assets and Build Homes You Can Stand BehindFollow Jono Anderson & Luxweld:Facebook: https://www.facebook.com/people/Luxweldau/61556448458026/#Tiktok: https://www.tiktok.com/@luxweldLinkedIn: https://www.linkedin.com/company/luxweld-pty-ltd/Instagram: https://www.instagram.com/luxweld.au

  • 7 Episodes

About

Welcome to Beyond The Build, where we help Australian volume builders, architects, and installers eliminate skylight defects and reduce warranty risk. Most skylight suppliers cut corners. We don't. Each episode breaks down the real cost of preventable defects, the five brutal ways skylights fail, and the exact framework for turning liability into an asset. From silicone joint failures and rivet risks to bad product selection and poor installation, we cover what's keeping you awake at night. Join Jono Anderson, carpenter and builder, as we explore defect prevention, installation standards, bu

Information

  • Creator
    Luxweld
  • Years Active
    2026
  • Episodes
    7
  • Rating
    Clean
  • Copyright
    © Luxweld
  • Show Website
    Beyond The Build