Why I Oughta...

My last check-in on the oven showed the 4th chain of dome bricks rising up.  I call it the 4th, but some call it the 'soldier plus three'.  Whatever.  There are 12 or 13 total chains that are needed to close the dome, so four is about 1/3rd of the way.  Today, I'm showing off the sixth (or 'soldier plus five') chain installed.  Along with the 'anchor brick' for the next chain up. We're starting to get a real pitch on the bricks - see below: And, we're starting to see some curvature to the dome, too.  See below: Lots more to go - including the inner arch.  

Last week, I posted the first few photos of the dome 'going vertical' with the second and third (or first and second if you count the solider course as separate) being mortar'd in with high heat refractory mortar.  Today, I'm showing the next chain (the 4th - or 3rd if you similarly call the solider NOT part of the numbering sequence) going in - where we're starting to see the slightest bit of dome starting to appear with each chain of the dome hanging *over* the previous one oh-so-slightly. Below are a couple of photos showing chain four.  (or three plus the soldier....) I've been cutting the bricks with side angles to get a tight fit and that's been working well.  This chain is the first one where I needed to use wedges under the bricks to get the right top angle. Just eight or nine more to go.  With each chain getting a little bit more difficult. 

Last week, the pizza oven dome went vertical with the first chain rising above the solider course .  Today, I'm showing a few more photos of even more vertical construction.  First, I've learned from the FornoBravo community that part of mortar'ing in a chain of bricks on the dome *should* include the placing and mortar'ing of an 'anchor brick' for the next course/chain.  You can see that below - in the first photo.  I set the first brick of the second chain (soldier + 2) in the middle of the back of the dome.  I did this one evening, then let it set.  I came back the next night and was able to mortar in the bricks to the side while using this fixed brick as an anchor. Below you can see that anchor brick with the rest of the chain: From there, the dome keeps rising: Below you can see the pitch starting to be created by the IT / dome gauge.   Below is the solider + three chains.  Four in total - from the outside of the dome.   And he...

Back a couple weeks ago, I shared the latest pizza oven build project update:  I set the floor and the first chain of the dome .  I went with an isolated floor, so the first 'chain' of the dome is set at the same height as the floor.  But, instead of being set on a 50/50 blend of mason's sand and fireclay, I set the dome chain with refractory mortar - BETWEEN - the joints.   Today, I'm sharing how the dome is going vertical.  Thanks to my brother-in-law (not Equation Boy/Man, rather on Nat's side), I have an indispensable tool (IT) or dome gauge that allows me to easily set each brick of the dome at the right distance and angle.  You can see it in the first photo below.   The other thing that I did was to cut-down the Masonite template that I used to create the floor and placed it *inside* the dome to keep the floor clean from errant mortar and what-have-you.  I'll pull it out when the dome is complete.   The first photo shows ...

Moving on to building the ACTUAL oven - starting with setting the floor.  The last time I checked in, I showed how I used a 50/50 blend of Masons sand and Fireclay to create a bed for the floor to sit-on that allows for a smooth, even floor surface.  And, just a few days ago, I showed how I experimented with the medium-duty refractory mortar to learn how to set the joints and work with the stuff .   As I've talked about, I'm going with an isolated floor and dome.  That means that I've cut the floor bricks to sit *inside* the dome.  It required a few more cuts, but it is the right move, imho.  My first job was setting the oven floor and landing.  You can see that layout below.  I aimed to have the herringbone pattern hit dead center and I tried to keep larger cuts near the entry to avoid having my peel 'catch' on them: This is a BIG MOMENT for me.  20 years ago, I thought about an oven.  Six months ago, I started the project.  ...

The oven project is continuing to move head.  Last time I posted about it was the cutting and installation of the CalSil insulation board that I mounted on top of a pattern of mosiac tile .  That 4" of CalSil insulation is the base for the firebrick floor.  So, laying that insulation was the last big piece towards building the actual oven.    To get the floor in place and level, I opted to lay down a base of mason's sand (which has no rocks) and fireclay (the dried-up dust from cutting the firebricks that comes off the saw) that I combined 50/50 and wet to make a paste.  You can see this process in a few photos below.  I used a notched trowel to smooth out the paste.  Then....I began to lay the brick floor down like tile.   Next up - laying the full floor and the first layer of the dome.  As a reminder, I opted to isolate the floor from the dome with the dome bricks cut separately from the floor . 

The oven construction process has been one focused on:  planning (the foundation), building (the foundation), planning (the stand), building (the stand).  And, then more planning (for the oven).  And...now comes the ACTUAL building of the oven.  That starts with learning how to handle the wetsaw and cut out the floor.  Thanks to my VERY HANDY brother-in-law, we went with an isolated floor.  That means, we cut the floor of the oven to be 40" diameter and *then* cut out the soldier course to lay NEXT to the floor.   We started with cutting the oven entry:  Then, thanks to the jig that my brother-in-law made, we quickly cut out the rest of the floor and the soliders: We began to figure out the oven opening and how to make the transition pieces from opening arch to oven dome: And, cut out the second layer of the dome - these only with side-cuts, no tilt cuts (yet): We also built our indispensable tool (IT) or dome gauge - to help place the bricks...

Yesterday, I shared the details of a template that I cut out of Masonite and a circumference tool that will shape the form of the floor of my wood-fired oven.  In order to get the inner arch opening correct, I opted to create a second drawing jig - one that is 20.25" wide that will set the width of that opening.   The goal was to draw the outline of the oven floor, but it proved harder (for me) than I thought it might be when I started. Before I get into the process of getting the oven floor drawn, a quick mention on firebricks.  The community on FornoBravo spec's "Medium-Duty Firebricks" for the floor and dome.  After poking around online, I've come to discover that Illinois is home to the Alsey Refractory - in Alsey, Illinois.  Somewhere between Springfield and St. Louis is the Alsey Refractory ; where they've been making firebricks in the USA for more than 100 years.  A few towns over, a materials dealer - LaGrange Materials - sells Alsey firebrick...

Last week, I showed the final form of the raised hearth - after I stripped the concrete-pouring forms from the four sides and talked about how I can now move-on to actual oven building.    For me, that started with creating a template out of Masonite.  I bought an 8x4' sheet and created a little circle-drawing jig that I cabbage'd together out of spare parts I had on hand.  The sheet is just 48" wide and after thinking about it, I've decided to make a 40" oven (interior diameter), which means the outside footprint diameter is 49".  That meant that I'm going to be a half-inch shy on either side.  That's ok.   I also needed to figure out where the dome meets the inner arch.  I started by attaching the circle-drawing-jig to the center of the board and drew out a 40" and 49" circle.  Then, I started to think about my arch sizes and how the inner/outer arch differ.  I chose to go with a 20-1/8th" inner arch width.   That meant...