Neill’s Pompeii #4

[nissanneill]

Just discovered that I put the other 3 threads in the wrong forum. If you want to see the first 3 with pics, go to the Pomoeii oven construction forum.

The weather is very much against me at the present, constant rain and more rain. For those not in the know, South Australia is very much in the need of rain as we are on water restrictions.
This however did not stop me as I set up a small tarp over the oven and carried on regardless. Mixing the poor man?s mortar was an experience. 3 parts sand, 1 hydrated lime, 1 fireclay and 1 portland cement, was sticky and quite difficult to mix in the wheel barrow. I couldn?t be bothered using the mixer as I was only mixing enough to put in the base layer of soldier bricks and the bricks holding the steel arch oven frame. Three rows later, I had used it all up. Great to work with as it is exceptionally sticky and really grabs onto the bricks, very handy when working on chains 3 and over with very sloping bricks.
I cut and installed the hearth this afternoon and redid the arch and another chain of the oven tonight. Will post these pics next time as I only finished 2 hours ago in the dark, in fact did them with the aid of the flood light and a double fluoro.

Neill

[nissanneill]

Re: Neill?s Pompeii #5

What a day. It started out with beautiful fine sunny weather and when I was ready to mix the mortar, it rained and continued for the rest of the day. I commenced by putting in the sand dome in for the top chains. It went in well and compacted to the point where I decided not to mix cement in the top inch or so. I made a pattern out of some high impact styrene, which was lying around and got it all ready to brick in to closure after lunch.
As the chains got higher, I had to cut bricks so as not to have larger mortar joints. Even with great care, there is always those bricks which do not want to line up, The inside of the dome shows that once I put in the final 2 key bricks and immediately removed the sand dome. I then climbed inside to remove the trapped mortar and see what sort of a mess I had ended up with.
It wasn?t so bad, didn?t have to do any serious modifications, rather leave it than interfere with the setting mortar and disturbing the bricks. I don?t even need to use the angle grinder with a diamond blade on any bad or protruding bricks.
Cleaned up inside the oven and called it a day.
Next week I will put on the insulating blanket, the chicken wire and a good thick layer of cement/vermiculite. All that remains then is the vent/chimney, the tiling of the vent and the cast iron doors. I will get into them during the week and get them cast once the patterns are done. Guess I can start my first fires in it next week to commence the drying out. Not in a hurry to get cooking, so will take my time, but everyone who sees it has invited themselves over for the inaugural feast.
I will post the next pics when something new has happened.

Neill

[Hendo]

Re: Neill?s Pompeii #4

Neill,

Fantastic effort, especially given the lousy weather lately! I?m really impressed at what you?ve achieved over the last two days. It?s looking great, and I?m sure you can smell that first pizza already ?.

Good to see another ?deep throat? (!) design ? my design for a deep vent chamber is similar, forced on me in a sense by my layout. I think your oven should draw very well.

I like the idea of the channels for fibreglass rope seals ? can you post details of sizes of channels, seals and supplier? While I?m going down the route of a firebrick arch, I could always incorporate a rope seal into the door when I get to that stage.

Finally, how did you rig up a tarp over your work area? Any chance of a photo? I haven?t ventured outside since the rain started, so things are slipping badly and I need to weather-proof my oven area so I can get going again.

Congratulations!

Paul.

[nissanneill]

Re: Neill?s Pompeii #5

Hi Hendo,
just went outside in the mist and took a pic for you.Very primitive but the small tarp is JUST big enough and it is really quite good to work under. I will leave it up to help dry the dome for the next couple of weeks.
The fibreglass rope seal was purchased in 2 metre lengths from Castworks, 8 Roosevelt Street North Coburg Vic for $15 + postage. Phone (03) 9354 4668.I had it delivered 2 days later. Very efficient people. They specialise in wood fired ovens and accessories i believe. Got onto them by Consolidated refactories.
I ordere 2 packs but only need one. The one I chose was their 18mm but it is available in 3,6, 9,12, 15, 18 and 25mm ropes
The track that I used is simply a piece of scrap stainless that I bent to an 8mm w x10mm deep channel and welded it to the frame. I have a stainless sill to put into the edge if the hearth and will wels a leg under it and high temp sealed into a groove cut into the brick edge. The vent floor is to be tiled and will provide the 8mm gap for the rope. I plan on putting a similar channel onto one of the cast doors to seal between the two when closed. It will be too difficult to include this in the casting of the doors.

Neill

[james]

Re: Neill?s Pompeii #4

Neill,

You get extra points for surviving a wet early winter. All I can think is how happy you are going to be when your oven is done and cooking great pizza -- and spring is coming to Australia six months from now. Right when those of us in the north who are just falling back into winter.

I like the way the two keystones in the top of the dome mirror each other. Nice touch; and some great cuts.

Well done.
James

[nissanneill]

Re: Neill?s Pompeii #5

Thanks james,
Yes, the oven is coming on nicely. I try not to let the elements distract me from my goals and if you are prepared to work around them, well you can proceed. If it is raining, put up ashelter, if it is cold, put on a jumper or work harder, if it gets dark, set up lights. You know what I mean! Nobody else is going to do the work for me and i am not one to pay someone to do something that I feel capable of doing. In fact i prefer to do most things myself as I know that they are done properly and the self satifaction says it all.
Our winters are relatively mild when compared to some of our northern American members, but cold none the less. A cold day here is around 6 to 8?C but rarely lower. I am just south of Adelaide in the foothills just below the top of the hill, so we always get gully breezes but because we are cut into the high side of the road, our back yard is quite sheltered.
The neighbours are taking an interest in the oven construction and came in for a look last night whilst I was inside it cleaning off the bricks and excess mortar. They commented on the steam that was coming out from it. I commented that it was me. Everyone was complaining of the cold but I was sweating, keen to get it finished for the weekend. My glasses were fogging up and making it difficult to see properly. I can now see why the ovens hold that necessary humidity for good pizza cooking.

Neill

[Bacterium]

Re: Neill?s Pompeii #4

Good work Neil...... yes its been quite wet.

Great work with the photos, its always good to see someone else chipping away at it.

[nissanneill]

Re: Neill?s Pompeii #6

Friday 8th June, fine sunny day and I?m off to Bunnings for some gear to continue with the oven. I collected the thermal blanket and another 300 litres of vermiculite on Wednesday and need some chicken wire and also some perforated drainage hose for the back of the oven where it is dug into the garden. I cut the 25mm blaket and carefully secure it to the igloo dome with gavanised clouts, just into the mortar just enough to hold it in position. I then had to cut and shape the chicken wire over the blanket for the vermiculite to grip when rendered.
Time to mix some vermiculite, 5 parts to 1 of Portland cement and the careful rendering of the igloo. Started where it was easy at the top and worked my way down and around the base. It was difficult to get it to stay in place especially on the vertical surfaces but care and persistence prevailed. The first 1? coat is on and I will put the second one on tomorrow, with the final one on Sunday. It is then only a case of plastering the vermiculite and then the final tiling.
I have started the cast iron door patterns and will move into them if the weather is poor, in readiness for casting, hopefully next week. I have designed some special brass pivot hinges which will allow adjustment for the doors against the rope seal.
I found a potentially good disk for surfacing the hearth bricks today and will put it to the test later in the weekend. I have included some pictures and details of the disc.
The stainless steel vent will be cut and folded over the weekend if I can with the small bender that I have. I have not thought much as to the flue size but will check out the available stainless sections available through the fireplace depots here in Adelaide.
The end is getting closer and I plan on starting the curing fires early next week.

Neill

[ihughes]

Re: Neill?s Pompeii #4

Nice work.
Do you plan on using a spark resistor at the top of your flue? If so I'd be interested to know if you come across any on your flue search.
We had bushfires to the edge of our street last year so I want to make sure I don't set any off.

Glad it's good weather down Adelaide way. Cyclonic conditions here in Sydney - no building for me this weekend

[nissanneill]

Re: Neill?s Pompeii #4

Saturday 9thJune
Very easy day, at work this morning and mixed 3 loads of vermiculite/cement and laid another inch layer over the igloo. Still having some trouble getting it to stick to the vertical surfaces so I tried mixing 1/2 bucket of fire clay with 1 cement and 5 vermiculite. Much stickier and worked well
iHighes
At this stage, I hadn't thought of a spark arrester, but one will be very easy to manufacture. They are simply a woven steel mesh which is rolled into a sleeve/cylinder/drum and inserted at the top of the chimney directly below the cap. The place where I normally buy my 304 and 316 grade stainless steel tubes/pipes has numerous offcuts for sale at very reasonable rates. It will be a simple task to roll one to the final flue size, tack the ends and and weld it onto the top flue section.

[CSWolffe]

Re: Neill?s Pompeii #4

The spark arrester sounds like a great addition.
could you give a more detailed description of construction?

[nissanneill]

Re: Neill?s Pompeii #7

Sunday 10th June
Another fine day, well until drizzling rain set in at 4:30pm. Mixed up 4 mixes of vermiculite and put the final third coat on the igloo. Went and picked up some platering sand and a couple extra 20 kg cement and mixed enough render to clad the vermiculite with a ¾” coat. It was then time to clean up all of the tools and the area as all of the dirty construction is now complete.
I also cut to shape a very hard and heavy black granite slab that one of my students had left over from a sink cut-out when he was a worker in granite headstones and bench tops. A very nice slab for rolling our the pizza bases. I can almost smell them already. I start the fires tomorrow and also fold up the stainless vent. I may as well make the most of the last public holiday until October.


CS Wolffe
Thanks for interest in my oven construction. The spark arester is as explained in a previous reply. The wire is woven in a plain or tafetta weave and a length around 10-12" high is rolled onto a cylinder to the diameter the same as the flue and inserted at the top just below the cap. All smoke and sparks will be forced through the mesh and kill any sparks that might go up the chimney. Will post some pics when I get there. Keep watching.

Neill

[nissanneill]

Re: Neill?s Pompeii #8

Monday 11th June
A wonderful blue sky and a few clouds, so it was up early and into the oven flue. Dragged out the remaining sheet of stainless and marked out the vent components. Cut it with my little angle grinder and 1mm cutting blades – fantastic for this type of work provided you don’t force the cut. Folded up the sides and welded them together. Found some galvanised flue laying around, 8" but plan on using stainless for the final fitment. Still have a few things to finish before putting vent in permanently. A couple of fittings and it is ready for installing. It can just sit in place for a couple of months until I can demolish the existing pergola and replace it with a new curved/rolled steel unit with polycarbonate and colour-bond which is still on the drawing board.
I lit the first fire and all went well. A little smoke out front but when the kindling caught, all was fine. Plenty of heat but not too much to cause trouble.
When the fire died down, I drilled the hearth bricks and installed the stainless steel sill and temporarily put the rope seal in place for the picture. I used some copper wire as the plugs for the screws to grip in the screws holding the sill plate in position. All other materials will either burn or deteriorate with the heat expected in the fire bricks.
Made the adjustable brass bushed for the cast doors but ran out of time and will progress with the door patterns during the week whilst increasing the fires. Pizzas are looking like on the menu for next Sunday night!

Neill

PS To continue these threads, please go to:

http://www.fornobravo.com/forum/f21/...10-a-2119.html

[md_massimino]

Re: Neill?s Pompeii #4

Love the arch and opening design with the steel.

So your spark arrester is a strip of woven steel about 10" wide by about 6 feet long, then rolled to the diameter and stuffed into the top of the pipe?

[nissanneill]

Re: Neill?s Pompeii #4

md_massimino

So your spark arrester is a strip of woven steel about 10" wide by about 6 feet long, then rolled to the diameter and stuffed into the top of the pipe?

It is actually expanded aluminium mesh, but being up so high, it doesn't get quite so hot and has lasted and looks like lasting many more years.
I have had some serious fires in the oven with flames rushing up the flue but never seen any sparks out the chimney top.
The oven and doorway with the 'floating steel surround and arch' is working well with no cracks at all. It also gives a great support for the adjustable hinge pivots which allow the cast aluminium doors to well seal the oven.

Cheers.

Neill