The Southern Appalachian Highlands Conservancy, a repeat client of Charlie Norman's, needs a reliable shelter constructed for weary hikers and campers trekking the Appalachian Trail. Drawing from the techniques used to build old barns, Charlie and his crew erect a pavilion -- but not without taking a break to visit the weathered cabin of a long-ago hiker.
A ramshackle barn in Piney Flats, Tennessee, holds within its poison oak-covered boards an original two-story log cabin the owner would like to reclaim. Charlie gets to keep the barn boards if he and the crew can claw through the weeds, avoid critters and take down the beast all while keeping its treasure intact.
Charlie Norman and his crew take a trip into the mountains of Banner Elk, North Carolina, to retrofit a modern home with a rustic timber frame interior. With the house already built though, it takes some finessing to get the 1,500-pound beams into place. Two new faces join the team to help tear down a barn, and Charlie gets a few antiquated boards out of the deal.
Jack, an expert craftsman, is giving Charlie Norman a lesson in hewing logs the old-fashioned way, using simple hand tools and a lot of elbow grease. Then the team gears up to finish a lengthy home remodel in Mendota, Virginia, by trimming the kitchen with worn wooden beams, but the three-man crew soon realizes these beams are bigger than they bargained for.
Charlie Norman and the crew travel deep into the hills of Sandy Mush, North Carolina, to disassemble a 100-year-old cabin on a compound time forgot, but trouble seems to follow them at every turn. One crew member's goofing off leads to a trip to the hospital.
Just when his inventory is beginning to run low, Charlie Norman receives an unusual call from a man offering a barn full of disassembled barnwood. After replenishing his stock, Charlie goes to the aid of a childhood friend, Sarah, whose cabin has acquired a bad case of rot. It's nothing a little cosmetic construction can't fix, though, and Charlie might even teach Sarah his tricks. Charlie also takes his wife, Beth, on the job to build an antique mantelpiece for his eighth grade English teacher.
In Church Hill, Tennessee, Vaux has a 100-year-old barn that's rotting from the ground up thanks to a wood foundation. Unwilling to tear it down completely, he brings in the log cabin crew. This is a new challenge for Charlie Norman, who must raise the barn and install a new foundation in order to keep the structure sealed from the elements for years to come.