Casa90 Build

[Cdubs]

Re: Casa90 Build

Here are some more pictures since you can only fit 5 per post.

[SableSprings]

Re: Casa90 Build

Wow! I'm really impressed you got the entire outside vermicrete layer in place in a single day-great job! (I hope you rewarded yourself with your favorite adult beverage.) It took me 3-4 days with my slower "ring at a time approach". I did have to come back after the first layer had cured (and my hands had healed) and put on a second layer of perlcrete for "smoothing/rounding/shaping" prior to the finishing brick facade I used. How are you going to finish the dome -brick or stucco or ...?

[PlanoPhil]

Re: Casa90 Build

Confused. I am going to be at the install stage for my Casa90 very soon and don't understand why you are applying a vermicrete layer. The instructions don't call for this and I haven't seen where James says it is necessary. Did I miss something?

Phil

[SableSprings]

Re: Casa90 Build

No, you didn't miss anything Phil. Adding a layer of perlcrete/vermicrete over the ceramic insulation blankets is not necessary. However, having an additional layer of rigid insulation over the blanket has a couple of advantages. Of course it adds more insulation (always a good thing), it contains the "bad fibers" in the blankets (think asbestos & fiber glass...), protects the blankets from critter & weather & other physical damage, and lastly it provides a better substrate (IMO) for the final dome enclosure/facade.

Yes, it is extra work. Yes, it is more expense. Yes, it is not absolutely necessary...but it does have some advantages to consider...relax and do what feels right for your build.

[PlanoPhil]

Re: Casa90 Build

Thanks Mike
I think I'm gonna just do several layers of stucco and call it a day. No enclosure for now.

If my replacement hearth pieces (broken in shipment and or warped) would just get here I could get started.

I think I'm gonna cure first and then add the blanket followed by the stucco layers.

Phil

[Cdubs]

Re: Casa90 Build

Mike - Thanks, it took me 5 hours hours but it was worth every band-aid. I literally did it by hand and not with a trowel. I started doing it the traditional way but it just wouldnt stick. Probably not the smartest idea but these are the things we will do for our fornos.

Phil - Mike is right on the target. Even though applying the vermicrete is not suggested I would hihjly recommend it. I do feel like extra insulation can't be a bad thing but I really did it to keep the ceramic blanket debri to a minimum. After you work with it you will see what we mean - it is nasty stuff.

Here is my daily update - Today was a huge milestone in my WFO journey - I finally started a fire!!!! The sight of the first flame was absolutely amazing and almost brought a tear to my eye. I obviously didnt want to go crazy but I started the curing process!!

[Cdubs]

Re: Casa90 Build

Sorry Mike I forgot to answer your question. I am planning on building a stone house. Right now I am struggling with colors and different brand stones. I just put in a gray patio and dont know what colors would go well with that. I'm afraid that if I go with something other then gray it won't look right. Thoughts anyone?

[SableSprings]

Re: Casa90 Build

I wish I would've thought to mention this earlier, but if you do cement work by hand you'll notice not only the extreme wear and tear on your skin but the burning and itching caused by the caustic mixture. One trick I found really worked for me is to wash your hands liberally with vinegar after you've cleaned up for the day. The weak acid in the vinegar neutralizes the cement & mortar caustic (lime) components and really helps your hands recover more quickly. Also, get a pair or two of the cheap rubberized gloves made for masonry/cement work...they are really worth it!

Great to have your first fire, isn't it? We invited about 20 people to our house for the evening and then it took about 1 minute to burn the recommended small crumple of newspaper...I just never thought of how quick it would be over. (It's good to have not only adult beverages and snacks but lively, enthusiastic friends to help fill in the slack or the remainder of the evening.)

I suspect you'll find a color or type of stone for your enclosure that just "rings your chimes" this spring or summer. That's a really nice feature of the forum photo galleries...lots of pictures of good ideas and views of how different colors and textures work together (or not). I think that the "finishing part" for your oven will be a while from now (I certainly wanted to work with my oven a bit when the actual fire curing process started...I was sick of mortaring!) My guess is that you'll develop a strong feeling from working with the oven for a while as to how it "should look" and that will guide you on the final enclosure choice(s)...Zen and the Art of WFO Building?

[Cheesesteak]

Re: Casa90 Build

Here is my daily update - Today was a huge milestone in my WFO journey - I finally started a fire!!!! The sight of the first flame was absolutely amazing and almost brought a tear to my eye. I obviously didnt want to go crazy but I started the curing process!!

You'll never be the same - and your family will never want to order out for junk pizza again. Welcome to the club!

[Cdubs]

Re: Casa90 Build

Thanks Cheesesteak. I made my first flatbread while curing the oven and it was amazing!! I do have a question - During the last few days of curing I have noticed an excessive amount of smoke. I can't imagine this is normal, and to be honest I feel bad for my next door neighbors. Does anyone have any ideas what could be creating so much smoke?

[Les]

Re: Casa90 Build

Does anyone have any ideas what could be creating so much smoke?

What kind of wood are you burning and is it cured? Also, the hotter it gets, the less smoke you will see.

[Cdubs]

Re: Casa90 Build

I believe it is kiln dried oak. The amount of smoke just does not seem normal.

[Paul in Rockwall TX]

Re: Casa90 Build

As Les mentioned, the hotter it gets, the less smoke there is. When it's near full temp, there is no smoke whatsoever coming out.

I'm new to this as well, and just finished curing mine a couple of months ago. I too was very concerned with the amount of smoke and smoke coming out the front on a windy day. I thought it wouldn't draw. But have no fear, that's only at low temps - especially if there's a breeze.

Also, I was concerned about the smell. When the dome is blackened with soot and then you have a hot fire, there is a distinct smell that occurs when the soot burns off. I've smelled it before in really hot fires in a fireplace. almost a creosote type odor. but it goes away as the soot is burnt.

[Cheesesteak]

Re: Casa90 Build

Thanks Cheesesteak. I made my first flatbread while curing the oven and it was amazing!! I do have a question - During the last few days of curing I have noticed an excessive amount of smoke. I can't imagine this is normal, and to be honest I feel bad for my next door neighbors. Does anyone have any ideas what could be creating so much smoke?

Les and Paul have covered it. If the smoke is only coming out of the interior of the dome / chamber - you just need to make sure your wood is dry and not "sappy." I'm not personally familiar with "kiln dried oak," I use oak seasoned for at least two years - and have experimented with different types of oak as well.

Did you cure the oven?

[james]

Re: Casa90 Build

Hey Cbuds,

The smoke you are seeing is the moisture from the oven curing. You are slowly baking a lot of water out of the oven castings, mortar, etc -- and it will go down significantly after your oven is cured. Water and heat just don't go together.

You will see a big difference after the first 5-6 fires; it will be as though your oven wants to just leap forward when it is fully dry.

James