This is totally off subject but I just know someone will find this link and go WOW !!!! thats what i was looking for.
http://www.darleyrefractories.com.au/castable-use.html
the website explains heaps about castable cement and who what why when and how...
Tuesday, December 29, 2009
Friday, December 11, 2009
9 steps to finishing the oven
Just 9 more work days till the oven is finished and I thought i'd detail the end process here.
You really need to read the previous post first to have this one make sense. these steps will also be expanded on in coming posts with images.
day 1) cut the "drop" bricks to size, what i will be doing is cutting there edges so they fit properly on an angle and create a good seal. Create a small arch template, this is for the small 1/3rd bricks on the side. Fondue "drop" bricks into place with last of the front of oven bricks using the "L" metal to hold the bricks over the oven door. Cover the whole section in fondue to make a good seal.
day 2) Clean up the inside of the drop with angle grinder and remortar any holes. (see previous post of the dome clean-up)
day 3) Mortar/build chimney section including part that overlaps the "drop" . build the dome sides wall wooden borders that will hold the concrete/fondue mix that will hold the sides together and insulating and provide a nice even outside surface to render. Place the insulating wool and chicken wire over the dome and drop ready for the concrete/fondue mix ( I may be adding vermiculite in that mix as well.
day4/5) this will be a LONG day, fill the sides with concrete/fondue covering the wool UP TO when the dome stops being vertical and starts its arch section THEN sitch to a concrete/fondue/vermiculite and clay mix to cover the dome top. There are 2 reasons for this change in mix, the first is I want the sides to be SOLID and the weight of whatever i put on top will natutally push the dome sides OUT, the second it that heat rises so most of the heat and thus insulating should be at the top of the oven, thus the vermiculite and clay, the clay is simply because its good to use but also I have ample supply in the backyard so why not use it !!
This will seal the entire oven back to front up until the chimney begins, my chimney is a decorative OLD chipped brick so i want it to be seen.
day 6) remove the wood holding the concrete together and hope it all worked ! complete the top of the chimney with the flue going through the roof of the outdoor area ensuring the smoke escapes. hopefully my front pavers will arrive by then and i will create the front paver "level" so i can set them.
day 7) Lay the front pavers, I need to let them set so this will be an easy day, I will then build the front arch another day as I really need the pavers to be solid as a rock, but i have other small projects to do so no big deal.
day 8) build front arch, as i am doing a double brick side which will be very stable I shouldn't have a problem with the dome weight but it would be better to wait after building the vertical before doing the dome.
day 9 ) add extra vermicullite/clay mix to top of oven if I feel it needs it. by the time i get here i would have done some firerings of the oven and would have got it to a good temperature so it will depend on how hot the oven gets.
During this whole process I will also be creating the oven door and tools to use in the oven, more on that later.
You really need to read the previous post first to have this one make sense. these steps will also be expanded on in coming posts with images.
day 1) cut the "drop" bricks to size, what i will be doing is cutting there edges so they fit properly on an angle and create a good seal. Create a small arch template, this is for the small 1/3rd bricks on the side. Fondue "drop" bricks into place with last of the front of oven bricks using the "L" metal to hold the bricks over the oven door. Cover the whole section in fondue to make a good seal.
day 2) Clean up the inside of the drop with angle grinder and remortar any holes. (see previous post of the dome clean-up)
day 3) Mortar/build chimney section including part that overlaps the "drop" . build the dome sides wall wooden borders that will hold the concrete/fondue mix that will hold the sides together and insulating and provide a nice even outside surface to render. Place the insulating wool and chicken wire over the dome and drop ready for the concrete/fondue mix ( I may be adding vermiculite in that mix as well.
day4/5) this will be a LONG day, fill the sides with concrete/fondue covering the wool UP TO when the dome stops being vertical and starts its arch section THEN sitch to a concrete/fondue/vermiculite and clay mix to cover the dome top. There are 2 reasons for this change in mix, the first is I want the sides to be SOLID and the weight of whatever i put on top will natutally push the dome sides OUT, the second it that heat rises so most of the heat and thus insulating should be at the top of the oven, thus the vermiculite and clay, the clay is simply because its good to use but also I have ample supply in the backyard so why not use it !!
This will seal the entire oven back to front up until the chimney begins, my chimney is a decorative OLD chipped brick so i want it to be seen.
day 6) remove the wood holding the concrete together and hope it all worked ! complete the top of the chimney with the flue going through the roof of the outdoor area ensuring the smoke escapes. hopefully my front pavers will arrive by then and i will create the front paver "level" so i can set them.
day 7) Lay the front pavers, I need to let them set so this will be an easy day, I will then build the front arch another day as I really need the pavers to be solid as a rock, but i have other small projects to do so no big deal.
day 8) build front arch, as i am doing a double brick side which will be very stable I shouldn't have a problem with the dome weight but it would be better to wait after building the vertical before doing the dome.
day 9 ) add extra vermicullite/clay mix to top of oven if I feel it needs it. by the time i get here i would have done some firerings of the oven and would have got it to a good temperature so it will depend on how hot the oven gets.
During this whole process I will also be creating the oven door and tools to use in the oven, more on that later.
The oven drop
How to do an oven drop.
everything i'll write about here relates to this starting image.
So what you see here is the dome and front bricks to close off the oven, that thin piece of metal marked by the red arrow is going to be placed from the oven to the front arch to stabilise the structure forward of the oven, from back to front it goes oven then chimney section then front arch, they do not intertwin much so placing a rod across them all it will give strenght.
The metal rods around the dome area marked by the lime green arrow, are there until I do the side walls reinforcing, they presently are not doign anything as the dome is solid by itself but they did help until the mortar had set, i'm just keeping them there to make myself feel better !
The front area marked by the blue arrow is where the front terracotta pavers and cream front arch will be built, the pavers haven't arrived yet and they are not going to be "brick height" so i will need to "build that area up" , i have a few options but haven't decided yet, i think but i will lay a small slab to the correct height.
The area marked by the orange arrow is where the chimney bricks will go, they are located outside of the oven dome ....after the "drop" and before the front arch, the plan is that the drop will force the smoke down and out of the oven and the chimney will suck the smoke up so NO msoke reaches the front cream arch and it remains clean !! big hope? we'll see.
The lightblue/aqua arrow is a bit difficult to see what i mean but it is where the drop starts, but it is actually going to be a third of a brick wide with a full brick infront of it, it will then be an arch 1/3rd of the way into the centre that reaches the full drop bricks. HARD to explain but I intend to fully detail the process with images as i go as it has taken me loads of time to work it out as there is little quality info online i can find.
The thin yellow horizontal line will be a metal "L" bar to rest the bricks on, the squiggly angled yellow lines represent the slanted brick "drop".
Next post I will detail the steps I will take to complete the oven.
Another before and after/now
Just thought i'd show you the progression
this is way back in March 2009
Here we are at December 2009, remembering that its only been a lazy sunday project its really starting to show some promise, The white rods you see is a temp structure so i can sling a tarp up on hot or rainy days.
The stack of bricks at the back are for the next stage which is the smoker oven and "4 burner bbq" area which will be where the red trolley is in this image.
The blue tarp is covering the buffet/herb area, you'll see what i mean once its finished and its looking great, i'll do a seperate post on that alone once completed.
this is way back in March 2009
Here we are at December 2009, remembering that its only been a lazy sunday project its really starting to show some promise, The white rods you see is a temp structure so i can sling a tarp up on hot or rainy days.The stack of bricks at the back are for the next stage which is the smoker oven and "4 burner bbq" area which will be where the red trolley is in this image.
The blue tarp is covering the buffet/herb area, you'll see what i mean once its finished and its looking great, i'll do a seperate post on that alone once completed.
Wednesday, December 9, 2009
Dome bricks cleaned
The next week I reground the filled mortar and its as hard as a brick which is GREAT.
It looks fantastic , I am doing the front "drop" section this week and that will complete the oven internally, this time I will be using heaps of mortar to make sure there are no gaps and then simply angle-grind them flat later.
The drop section is trick as its hard to get the bricks all lined up. I'll explain that next post.
It looks fantastic , I am doing the front "drop" section this week and that will complete the oven internally, this time I will be using heaps of mortar to make sure there are no gaps and then simply angle-grind them flat later.The drop section is trick as its hard to get the bricks all lined up. I'll explain that next post.
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