BenjaMia Bakehouse Project

[DrakeRemoray]

Re: BenjaMia Bakehouse Project

Wow this is going up in record time and looking great!
Drake

[SpringJim]

closing in....

almost done the dome.....it's been interesting with the teardrop shape!

My son-in-law is in the canvas business so I have a nice tarp to cover the dome while it's resting....

[SpringJim]

Arch failure

Well I broke my new oven arch.. ..my fault for two reasons....

I didn't shim it well enough and removed the form too early.....the premix mortar in the broken joints was still soft since the masonry mass was so moist!

Good news is it broke into three blocks....so I reset the end block and waited a day to place the other two blocks back in place. It was an easy rebuild and only a minor setback....bruised ego....

nobody likes fallen arches!

back in business

[SpringJim]

Re: BenjaMia Bakehouse Project

another chain....

[SpringJim]

Re: BenjaMia Bakehouse Project

So far it's a freestyle build.....doin' what feels right, but I have not reverted to forms.

I buttressed the bricks on the side of the arch, built the arch and cut the entrance blocks to give a lot of room on the landing. The outer arch is going to be more of a challenge since it's larger. I have to think about what that will look like....maybe buy some new bricks.

Laid up the next ring of bricks. ...And it is getting more interesting!

The homebrew is portland based so the mortar bag needs to be cleaned after use.....but it keeps the mortar mix moist while you need it. I use the premix on the inside of the bricks next to the dome and let it set up, then I come in and fill in behind and finish by smearing the mortar on the backside of the dome. I keep it moist and give it a wet brush as well.

Drake, I have a bag of castable and will try to cast the transition vent to fit the opening I've created.

I also took a stab at beveling the arch blocks for better exhaust flows.

so far so good....

[asudavew]

Re: BenjaMia Bakehouse Project

Hey Jim!

Just curious... Did you cut a pattern to guide you as you place each course? Or are you using some other method? Ken's string trick worked well for him. Have you come up with something different?

Anyway. I was just wondering.
And I'm nosy.

Dave

[Modthyrth]

Re: BenjaMia Bakehouse Project

Jim--
Does the mortar bag keep the mortar fresh and workable indefinitely, like an icing bag would when making cakes? I love the idea of using the premix and the homebrew for separate applications, but would worry about one drying out while I was fussing with the other.

[DrakeRemoray]

Re: BenjaMia Bakehouse Project

Arch-smarch! Cast a vent for better draw and easier construction. Since the front is going to be in the enclosed bake house, good draw is going to be important...

Drake

[asudavew]

Re: BenjaMia Bakehouse Project

Looking good Jim.

It's about to get a bit more challenging.

Good luck on the arch. Have you got it figured out in your head yet?
That part about drove me nutz!
Not sure if I have it in my head YET........

[SpringJim]

Doming

I mix the homebrew refractory in big batches to infill the bricks and joints using a mortar bag and trowel.

....then smear the remaining mixture over the dome for strength and some additional dome mass.

Now I need to do the arch and some additional buttressing!

[SpringJim]

Re: BenjaMia Bakehouse Project

Finally put in the cardboard floor protection. Since the first course was set the cardboard was just pushed into place against the soldiers.

Laying the second brick course....I'm using a premix refractory to set the brick with the shim and then filling in with the homebrew refractory.

[SpringJim]

Re: BenjaMia Bakehouse Project

The first skew course in in place and the floor still clean!

[SpringJim]

Perlite stucco

Here is the after and before shot....

I had some perlite mix left over so I filled the holes in the stand....was surprised that it worked so well!

[SpringJim]

Re: BenjaMia Bakehouse Project

Dave, it's a technique I've used when doing stucco work on concrete walls. You're always spilling a bunch of the stucco.

It's so nice to lift up that ratty wet dirty nasty mushy cardboard and have a clean floor underneath.

I'll get right on it!

[asudavew]

Re: BenjaMia Bakehouse Project

I know, I know.....

That's what I said....then spent many hours kikin myself in the crack and cleaning up mortar,