Re: Strength vs Simplicity
I have no plan to shape the bottoms to eliminate the horizontal vees. That is where the CNC waterjet would come in...
The local harbison distributor has not responded with prices and a catalog yet, so I will call them again Monday. I am anxious to see what tapers the brick come in.
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Re: Strength vs Simplicity
Originally posted by dmun View PostWe've learned that the best commercial oven builders in Italy only trim the inner edges of the bricks so that they appear to fit on the visible side, and fill the outer gaps afterword.
Actually, I found it harder to get the mortar into the joint if I also tapered the bricks from front to back.
And you will still end up with some flat V-shaped mortar joints on the tighter chains because the circle is not actually a circle but a series of straight lines.
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Re: Strength vs Simplicity
I think I will buy the $99 14" chop saw and retrofit it with a few water sprays and a diamond blade. That way I can set the 10" HF saw up for the angle cuts and the 14" for the bevel cuts.
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Re: Strength vs Simplicity
As to the brick cutting: I got a used 14'' saw off of craigslist and have not replaced the blade yet after a lot of cutting (oven and kitchen project). As stated here before, the key is to have a good water pump and not force the bricks and your blade should last a very long time.
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Re: Strength vs Simplicity
Originally posted by dmun View PostFor the cost of water jetting 20 different styles of bricks in two planes you could buy multiple modular ovens.
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Re: Strength vs Simplicity
I have contacted Harbison and requested sizing and pricing information for their medium duty fire bricks. The other local supplier lists their bricks as 8.75 x 4.25 x 2.5 so not ideal, but $1.30 each.
Harbison also carries many blanket and board products so I will get pricing and data sheets to see what is suitable.
I am very excited to get the planning finished and start the foundation (will create a build thread in the proper forum when the work starts).
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Re: Strength vs Simplicity
I used the large saw to make rough tapered and/or compound cuts and then used an angle grinder on each brick as I went along laying them. Not precise, but it minimized joint gaps on the inside surface. I left the gaps large on the dome exterior and filled them with home brew mortar.
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Re: Strength vs Simplicity
I think the ticket would be a water jet.
Really, look into tapered firebricks. They're worth the cost if you're going to cut that third plane for perfect fit.
Harbison Walker has a branch near you. Call them before you commit yourself to months of work. Everyone's time is worth something.
Buncher Industrial District Michael Stillwagon
Ave. B Bldg #14-A
Leetsdale, PA 15056-1390
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Re: Strength vs Simplicity
Yes, I used 4 inches of board under the hearth. You mentioned a CNC machine. I think the ticket would be a water jet.
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Re: Strength vs Simplicity
I had thought that a total dry fit would work as well, but the angles just get so complex. I have laid out the entire dome in autocad and can see that one would need a CNC machine to cut anything after about the 4th chain. Even the bottoms of the 1st-3rd chains would need a bit of easing to flit perfectly flat.
I am going to go ahead and attempt to work with dry fit sides and attempt to taper the tops and bottoms for a cleaner fit with mortar.
Is that 4" of FB board you used on th hearth?
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Re: Strength vs Simplicity
Originally posted by BeanAnimal View PostDo you see an issue with dry fitted vertical joints?
Originally posted by BeanAnimal View PostAre you the only builder who has used no mortar in the vertical joints and instead dry fit them?
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Re: Strength vs Simplicity
dmun,
Thank you for adding the very important safety precaution that I overlooked when mentioning using the dry saw. Silicosis is not a pleasant ailment and certainly dry cutting brick, concrete and/or pavers is certain to release very fine dust laden with silica! I spent many years working in the mining industry, some of it in rock mines. I spent a great deal of time drilling in limestome mines (roof bolting) and it was not uncommon to see guys drilling without water and without respiratory protection!
Do you see an issue with dry fitted vertical joints?Last edited by BeanAnimal; 03-24-2011, 04:56 AM.
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Re: Strength vs Simplicity
You mention numerous blades? Are new fire brick really that hard on the blades? WOW!
put a diamond blade in one of the cheap $99 14" cut-off saws.
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Re: Strength vs Simplicity
LES:
I had wondered if the dome bricks could be cut to dry fit well and in essence only mortared on the outside. It would make the vertical cuts MUCH easier due to the simple single angle that reference the center point of the dome. Attempting to create touching vertical joints on the dome side and a constant 1/4" gap on the outside introduces odd angles that don't reference the center point of the dome and change for each course.
Are you the only builder who has used no mortar in the vertical joints and instead dry fit them?
To the other experienced builders: Thoughts on this method? I sure like the way Les's dome turned out.Last edited by BeanAnimal; 03-24-2011, 04:06 AM.
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Re: Strength vs Simplicity
Originally posted by BeanAnimal View PostLES:
I don't follow. You ONLY cut the sides and left the top and bottom parallel? So in effect you reduced the vertical joint size and decided to live with the larger horizontal joints. I presume due to the limitation of the saw's depth of cut as well?
Also, I recall going into my third blade (cheap ones). I was cutting paver's as well and they will eat up a blade a LOT faster then the fire brick.
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