My Old Kentucky Dome

[Hendo]

Re: My Old Kentucky Dome

I'm placing a thin strip of flattened corrugated cardboard cut from a box between the soldier course and the edge of the floor bricks. This is so I get a nice clean gap for thermal expansion.

I used a 2? x 4? strip of vinyl from our old kitchen floor to achieve a clean gap - it worked a treat, but fortunately I was able to remove it and proceed to the next lot of perimeter bricks (I didn't lay a soldier course, and my perimeter bricks were level with the floor). A cardboard flavour is one thing ....

Rather than just let the gap fill up with ash (or more likely mortar from subsequent courses!), I filled it with dry firebrick dust from my brick cuts. Hopefully this will permit a little movement if it stays dry.

... when the dewpoint hits in the morning everything gets covered in moisture.

I had the same problem before my floor went down - the Cal Sil sheets were covered with plastic sheet, but I overlooked the condensation factor. Result - the insulation sheets had a big moist patch in the middle of the floor area which was particularly difficult to dry (with a fan heater). To overcome this, I?ve since elected for a double layer approach - see pic. The tarp also lets me work on the dome in inclement weather.

Cheers, Paul.

[Ken524]

Re: My Old Kentucky Dome

I have the same problem. I have bricks over my boards and when the dewpoint hits in the morning everything gets covered in moisture. Thats fine when the day gets back up to 90F but the boards that are covered in brick don't really get to see that heat, and so they stay moist.

What kind of boards are you using? About two hours after finishing my soldier course today the sun dried everything out and the boards were again very rigid and sturdy.

I think that once the oven is finished out and protected from the elements, it won't be an issue. Any moisture that makes it's way into the floor from humidity will be driven off when the oven is fired. Once the dome is in place, we won't have anything heavier than an iron skillet or two on the bricks. Should be fine. Seems to be working for others!

[rlf5]

Re: My Old Kentucky Dome

Thanks!


Actually, I'm most worried about keeping this darn Kaowool insulation board dry. It's a pain. Even slightly damp and it gets a lot mushier than I'm comfortable with.

I have the same problem. I have bricks over my boards and when the dewpoint hits in the morning everything gets covered in moisture. Thats fine when the day gets back up to 90F but the boards that are covered in brick don't really get to see that heat, and so they stay moist. Well I was standing on the oven floor yesterday and the bricks would sink slightly into the board! This didn't happen when they were dry. So now of course I'm worried.

[jwnorris]

Re: My Old Kentucky Dome

<snip> I'm most worried about keeping this darn Kaowool insulation board dry. It's a pain. Even slightly damp and it gets a lot mushier than I'm comfortable with. <snip>

This is an interesting comment about the insulation board.

James and I found the SuperIsol board about the same time - I ordered my about a week before he offered it at the FB Store. A side comment is that I spent a couple of dollars more once freight was factored in to the equation than I would have if I had bought from FB.

Anyway, the SuperIsol board, when damp or wet from normal WFO construction, does not seem to get soft.

When I set the floor and attempted to mortar it in place, the SuperIsol board sucked up so much moisture from the mix that is was impossible to continue. Ultimately I figured that teh weight would keep it in place and set it dry.

J W

[Ken524]

Re: My Old Kentucky Dome

Looking awesome Ken!!
How bout some dimensions on your opening.

Thanks!
The door jam is 19"w X 12"h, the opening will be 20"w X 12.5"h. No magic to these numbers. I found them here:
http://www.fornobravo.com/store/Meta...r-p-16240.html


I'm not using the FB door, but I figured the size should be right.

What are you most worried about now?
I think I'm most worried about the dome to entry arch transition. Take lots of pics when you get there!

Actually, I'm most worried about keeping this darn Kaowool insulation board dry. It's a pain. Even slightly damp and it gets a lot mushier than I'm comfortable with. If I had it to do over, I would build an island of vermiculite concrete (and save $250). Every day I have to throw a tarp over the whole project in case of rain.

I have the transition worked out in my head. I'm just going to do it one course at a time and make it happen.

[asudavew]

Re: My Old Kentucky Dome

Looking awesome Ken!!

How bout some dimensions on your opening.

What are you most worried about now?
I think I'm most worried about the dome to entry arch transition. Take lots of pics when you get there! Help a fellow out!~

Keep up the good work.

and take your time!
enjoy!

cuz i have a feeling we will both miss looking forward to building our oven.

[Ken524]

Re: My Old Kentucky Dome

Fri, Sat, Sun progress:

Started by first mortaring the sides of the entry arch and a soldier brick on each side. Then started slapping soldiers into place.

The only thing I'm doing differently (at least I haven't read it anywhere) is that I'm placing a thin strip of flattened corrugated cardboard cut from a box between the soldier course and the edge of the floor bricks. This is so I get a nice clean gap for thermal expansion.

My first attempt with the cardboard strip was wide enough to stick out so it could be removed (it can be seen in the interior pictures). I soon discovered it got in the way of my trowel and sponge. My strips are now narrow enough that they can't be seen or removed. Once the oven floor goes above 500F the first time, the strips will burn away (So that's why the pizza tastes like cardboard!).

Although my soldiers were all trimmed for a fairly snug fit, I got in a hurry yesterday and set two of them twisted slightly out of alignment. I discovered it too late and had to compensate with a couple of fat, ugly joints (overhead picture, 3 o'clock position). Oh well. When it's all done, I'll be the only one that knows. Message to self: "Slow down, have fun... slow down, have fun."

[asudavew]

Re: My Old Kentucky Dome

Dang bosses....

Would make me think twice about inviting them over for pizza.

[Ken524]

Re: My Old Kentucky Dome

Get much done over the weekend?

I started some mortaring yesterday, but my employer rudely interrupted me and I had to clean up and go to work (they don't understand the importance of pizza ovens). I plan on getting some work done today. Hopefully I'll have some pics.

[asudavew]

Re: My Old Kentucky Dome

Get much done over the weekend?

New pics?

[Ken524]

Re: My Old Kentucky Dome

Moved the insulation and floor bricks out to the "site" today. I am very fortunate (and lucky) to have a virtually flat hearth slab to work on. The Kaowool boards laid down almost perfectly. No leveling necessary.

The floor bricks were almost as easy. I used my bucket of reclaimed fire clay to level the bricks. I troweled/sprinkled it on dry under the low spots and tapped the bricks in place. This worked extremely well. I only had one or two bricks that wouldn't cooperate and needed re-cutting or replacing. I probably used only a handful or two of the fireclay (Is a "handful" a metric unit of measure?)

And keep those pics coming, because I'm learning from you!

Uhmm.... I've never done this before. I'm making it up as I go. Are you sure you want to learn from me?

[asudavew]

Re: My Old Kentucky Dome

Looks like you are having fun!

Looking good. Keep it up.

And keep those pics coming, because I'm learning from you!

[Ken524]

Re: My Old Kentucky Dome

You are right Dave! Here are a few pics...

I finished cutting the bricks for the soldier course and arch (sides and top). I also tinkered with the profile of the dome. I think I'm settled on that. It will be 20" high (I like round numbers ). I'm to the point now that I need to move everything out to the block stand, cut out the insulation board, level the floor and start mortaring.

And I meant to ask... How are you gonna finish the sides of the stand and around that awesome brick arch?

Right now, the plan is to use an earthy toned stucco; like you would find in the American southwest. All plans subject to change!

[asudavew]

Re: My Old Kentucky Dome

Ken!

I was checking out your spreadsheet.......

You bought more bricks a couple days ago, and heat stop!

I'm thinking we are gonna get some dome pics very soon!

I wish I lived close by I would enjoy helping out.

Let me know how it goes!

The floor is looking good.

And I meant to ask... How are you gonna finish the sides of the stand and around that awesome brick arch?

Man, I can't wait to buy some bricks.
Maybe next weekend.

[Acoma]

Re: My Old Kentucky Dome

That truck is a great idea. It would be nice to see more of this option with the cement companies.