Jim's Build for the Common Man

[GianniFocaccia]

Re: Jim's Build for the Common Man

Building the inner arch- can anyone help me understand how to determine the angle of the slope to cut into the arch bricks to accommodate the dome bricks?

Jim,

It's easy. I made two identical wood templates of the interior dome profile I wanted. The first one I used periodically to keep each course consistent with the profile. The second one I cut vertically to account for the vertical inner arch.

At the center of my inner arch form, I laid a full firebrick. For lack of a better term, I call this brick my TDC (top dead center) brick. Then I took my trimmed dome template, placed it against the top of the 7th course and made a mark (A). You can't see it very well, but it has an arrow pointed at it. I used this mark to determine the red line (B), which extends from the floor center of the dome past the face of the inner arch. This would ensure that the top of the course immediately above the inner arch would stay level all around. I think this is the angle you asked about.

The last angle was simple: just match the curvature of the template to end up with an inner-facing (down) brick angle that matches the rest of the dome on that course.

I hope this explains it. If you have more questions, just holler.

John

You can find more images here (post #34)

http://www.fornobravo.com/forum/8/octoforno-7122-4.html

[jimkramer]

Re: Jim's Build for the Common Man

I think I got it. So are the arch bricks Identical? I thought from other builds I saw that the angle cut for the dome bricks to rest on top changes. If not, that sure would make it simpler.

[oasiscdm]

Re: Jim's Build for the Common Man

Changes with each Buick from memory

[oasiscdm]

Re: Jim's Build for the Common Man

Changes with each Buick from memory

[UtahBeehiver]

Re: Jim's Build for the Common Man

It is the orientation of the plane of the angles that changes from each brick from the TDC (Top Dead Center brick) as you move down either side of the arch, your IT can help you mark the orientation of the plane rotation as it moves down the arch. Notice how one side of plane on a brick may be higher or lower than the opposite side. But the "slope" angle from the IT remains constant, just rotates.

[GianniFocaccia]

Re: Jim's Build for the Common Man

Russell's picture tells all! The easiest way to do it is to cut your TDC brick first, and then each brick to the right and left and so on. Use your IT to make a mark on the top of each brick, and use the arch form to mark the bottom. This will give you the line for each brick. I found it significantly easier to cut the taper (sides) each brick holding it my hand vs cutting it on the saw table. It takes a little practice, but you'll get the hang of it quickly.

[jimkramer]

Re: Jim's Build for the Common Man

Thanks all.

Next question: How do you calculate the bevel (the angled vertical cut on the sides of the brick) that allows you to avoid the inverted V? I know I've seen this in other posts, but didn't make a note of it for future reference.

[mrchipster]

Re: Jim's Build for the Common Man

It's time to go Vertical by RCLake
# 68 by JCG31

The spreadsheet first appears there.

[jimkramer]

Re: Jim's Build for the Common Man

Okay. It's coming along. I'm going to take a day off from work tomorrow, so I should be able to make good progress on the dome.

-I have to cut the first brick for a chain that goes right next to the arch. However, there's a corner from an arch brick that is sticking up (in first pic). It's about 2" long and maybe 1/4" high. Can I grind that down, or is it a bad idea to cause all those vibrations on the arch and dome? It would make it easier to place the brick on top if I could grind it down. Though I could also cut some out from the brick above.

[jimkramer]

Re: Jim's Build for the Common Man

A more important question than the above. I angled the sides of my bricks and they fit together very tight. When I even just butter the sides, I don't get brick to brick contact. Can I mortar just the bottom, no mortar on the sides?

[jimkramer]

Re: Jim's Build for the Common Man

So when I actually mortared them in, the bricks did not meet up well. Not sure why this happened, but beveling the edges seemed to add a level of complexity that I decided to avoid. So I went back to just angling the sides, no bevel. At least the top side edges meet fairly well. For the most part. I can't seem to get it consistent. Maybe my IT is moving around.

So due to my loosey-goosey build, some joints luck pretty good, some look dang ugly, with big gaps. But I think it will still stay standing for a good many years. At least the arch is done. It all looks pretty good from far away at least.

[deejayoh]

Re: Jim's Build for the Common Man

Looks pretty good to me. I've seen much messier. And the mortar holds the bricks apart, it doesn't hold them together. You will be fine!

Note that if you want to get better coverage with the mortar, mix it a little wetter. It will squish out and the excess water will disappear pretty quickly, soaking into the brick

[jimkramer]

Re: Jim's Build for the Common Man

Thanks, dj!

Since I'm almost over the arch I think it will go faster now. This went very slow today, especially since I removed and reset many bricks. I try to squish them down in one motion. From what I've heard it's not good to adjust them after that first squish, which is why I had so many re-do's. But the last several were better, so maybe I'm finally getting the hang of it. I think making a wetter mix will help me set them right the first time.

Here's a shout out to my friends Brian and Seth who helped me out today with labor, consultation, and moral support. Most importantly, their kids kept mine busy for a while so we could keep working.

[cobblerdave]

Re: Jim's Build for the Common Man

G'day Jim
Well its great to see your arch complete, I'm kinda glad I posted on my angle iron entrance . Mine still has not been replaced ...but I have the cut pieces in my shed for when the time comes.
The arch is the real "deal maker " with any oven, let's face it when there flashed up and full of pizza or food the entrance is the frame that people see around the food and the fire, so its good to make it special.
Keep plugging away
Regards dave

[jimkramer]

Re: Jim's Build for the Common Man

I'm above the arch! Don't look too close, it gets a little funky right above the arch. But it'll still make pizza. It still goes very slow, but I'm getting a bit faster with the mortaring. Deejay, I tried a wetter mix, and it is easier set the bricks. But doesn't that make the mortar weaker?

And I'm trying that thing (can't remember who first posted it) with scoring the brick to hold them together better.
And yes, Dave, thanks for inspiring me to do the arch instead of angle iron. It does look very pleasing to the eye. For the vent, I had been thinking of casting a lintel, which I could make an interesting shape and etch with a pattern. However, I enjoy looking at the inner arch so much, that I'm going to do it again for the vent.