The Badger Build

[asudavew]

Re: The Badger Build

The transition is tough. But from the look of your build, you will figure it out.
I must admit, that is the hard part of the build. .... although the back wears out the higher you get.

[thebadger]

The Badger Build (tying into the arch)

Gang,

On my fifth row and I?m already pretty steep ~50 degree angle! I?m going to have to use a ball on row 6+. I?m hoping for an 18? height, right now I?m at 13 1/2.? Lower would be fine as long as I get to at least 16?. My front arch height is 11? at the highest point.

So far working the row into the arch has been real easy! This is the one part that caused me the most apprehension /angst. I think the trick is ? where you put your arch. To far out and you won?t have anything to support your row. To far in the dome and you have the same problem. I think you just have to eyeball your arch placement to where you?ll end up with your row so it will ?lay? on top.

I used a cheap HB grinder with a masonry cut off and just started cutting away at my arch to get my bricks to fit! ? In all honesty it really was easy!!! I just have two more bricks to work in and I?ve officially cleared that hurdle. btw - I plan to fill in the row/arch area transition gaps with some angled bricks once I finish the dome...

Dick

[james]

Re: The Badger Build

Very nice Dick,

Taking a grinder to the entry arch makes a lot of sense. Keep the HF grinder, and you can use it with a polisher at the end to smooth out and polish your arches!

It is go green in your neighborhood. It looks great. You just don't see that much natural grass and foliage in CA -- even in the spring.

James

[gjbingham]

Re: The Badger Build

Good looking build Dick. I've forgotten. What kind of bricks are you using. It appears that you're alternating rows of standard and firebricks. Kinda cool looking! So one else will ever see it, of course.

[Frances]

Re: The Badger Build

I know I'm always saying this, but I think those last archway pictures and the explanation should go in the picture gallery, so they're easy to find for future builders.

The reason being, when I was at that stage, that's where I looked and didn't at that time find much that really helped an archway-challenged (or angle iron-challenged) builder like me.

Reading your explanation made me think that maybe I could have tied in an archway to a dome after all... specailly the placement of the archway a bit back from the first row of bricks. Obvious when you think about it and maybe I'm just thick, but still good advice to have for before you start building....

[thebadger]

Re: The Badger Build

I'll post my pictures in the picture section as welll - once I finish...

George,

I actually scored some "red" fire bricks... The place I bought my "yellow" ones had about 30 leftover so picked them up!

Dick

[thebadger]

The Badger Build (finished tying into the arch)

Gang,

Finished tying the 5th row into my arch. What a relief - I've thought about how I was going to tie in for a long time and debated between angle iron and an arch. Again, it was way EASIER than I thought. I hope the vent/rest of the build goes as well. Remember, placement of the arch is critical! You then get a cheap angle grinder and cut away what you don't need from the arch to tie in your row.

Not perfect but I'm happy with the results.

Thinking ahead - I tried to see if a big ball would work for my last rows and wasn't having much luck. Instead I built a platform (which I assembled - so I know I can un-assemble it through the arch) which I raised up to hold a sand mold for the top of the dome. I'm hoping I'll be able to put up the last rows fairly quickly without "rushing" of course.

Thanks
Dick

[Frances]

Re: The Badger Build

Thats looking really nice! Can't wait for the keystone - not long now...

Makes me wish I could have another go...

[thebadger]

The Badger Build (Finished the Dome)

Gang,

FINISHED THE DOME!!!

The original plan was to do course 6-8 then finish the last few rows/keystone next weekend. But using the sand form really sped things up. I don?t think I rushed things (at least I hope I didn?t). Definitely not perfect? toward the top I had one row than sort of ended in a swirl but I was able to tie it into another row. I mainly used ? bricks on the last 2 rows. I didn?t do any intricate triangle cuts like others have done. I have no idea how things look from the inside as I haven?t take down my support/sand form. I?m not too worried about the structure integrity as I did pretty good job keeping a constant angle on each row. BTW - the keystone just happened to be a leftover brick I had cut that worked out perfect. Also, I never intended to use so much HS50 on the outside. I wanted "cleaner" joints as I wasn't looking for the extra thermal mass - oh well...

Don't think I get to work today - a) it's Mothers day and b) looks like rain all day.

Here are some pics ? I?ll get a better one of the whole dome.

Questions:

1. Wait and cure now or should I construct the vent/front arch then wait and cure????
2. Getting low on HS50 ? From this point ? where do I HAVE to use HS and where can I use regular mortar?

Thanks
Dick

[thebadger]

Re: The Badger Build

Update,

I was able to sneak out an get the form/sand out

The only issue is there's A LOT more HS50 that "oozed" on the front of the bricks on each row. I tried scapping it off but it's dried in place

I don't think it will be an issue other than aesthetics but at least rows 1-5 look good!

I just need to get in and fill in some of the gaps.

Dick

[Frances]

Re: The Badger Build

Oh wow, congratulations! You look pleased...

Looks lovely, beautifully shaped dome there.

About your questions: I was advised to build the arch/vent bit before curing, because otherwise you'd have to cure a second time when the vent is in place...

Question two: the higher up, the hotter it gets... so I'd guess that the sides of the entry arch would be ok with regular mortar, while top of the arch and the vent would benefit from the heat resistant stuff. Any other opinions on this?

[PizzaJNKY]

Re: The Badger Build

Congrats Badger! Looks really nice. Any plans for the finish? Igloo or framed?

[Ken524]

Re: The Badger Build

Nice work, Dick. Looks great!

Definitely build the vent/arch before curing. Those components will need to cure as well. I would be concerned about them being connected to the oven and curing/drying at a different rate as the dome.

[asudavew]

Re: The Badger Build

looks great.
And so fast!

i agree with ken, build the arch and vent first.

You can use poor man's mortar to finish the rest if you are out of heatstop. But you need a high heat mortar for the vent and entry.

Congrats
Dave

oh yeah.. my keystone.. same thing!

[thebadger]

Re: The Badger Build

Thanks for the kind words.

It's really not pretty in there after the 5th row... But I know I'll get over it and not too many people will put their head in the oven, especially with a fire in it.

I will wait to cure after I finish the front arch/vent.

How do you attach the "duravent" chimney plate to the bricks? Do you drill holes and use concrete screws??? I still haven't worked out how I'm going to construct the vent/chimney yet.

I am planning on doing an igloo...

Thanks
DIck