Texman Build

[texman]

Re: Texman Build

5th is in. I bought a laser level, so i will see if i can figure out how to use it on the 6th course. All is level and round best i can measure so far. I only got to work Saturday and had honey dos on Sunday. I had to cut all these bricks numerous times, just didn't go smooth. Probably a sign of things to come as i am sure it does not get easier.
I just pushed mortar in the joint that was void with fingers, seems ok to me. I melted my old worklight and had to get a new one. I was trying to use aluminum foil on the old lite to keep the glare down and melted the thing. I have had my first curing fire.
Tracy

[Gulf]

Re: Texman Build

I set the level up in the back of the oven directly across from the arch. I had only about 3 completed rows so I was able to set the level in side of the oven. I could have set it up just outside the oven the way I tied the arch in, though. By that I mean that I began racking back. I layed the first of these rows just a little more than half way around each side toward the rear. I felt that this was far enough to keep everything stable. I racked back one bond on each row until I cleared the dome. Doing it this way allowed me to keep the level far enough back that the beam shown on both sides of the arch at the same time allowing me to get reference points to level from. Placing the level just outside of the dome would work as long as you leave enough brick out at the rear of the dome on that row to have a line of sight for the level. Just finish tying that row in to the dome before you complete that row in the back or you will loose that line of sight.

If you meant "how" it is mounted, I just set it on some full brick which I stacked up to use as a temporary base for the level. My level has a few inches of vertical adjustment built in to it. I just kept adding a brick to the stack on each row and the did the fine tuning with the built in adjustment dial on the level.

I only took a couple of pics while I was doing this and none of the wide angle shots showed the beam. That was probably because of the flash. That one pic that did turn out was a staged shot. In reality that row underneath would have been completed half way around and another brick layed on bond (not visible in this close up) would have been used to get the reference point.

[Lburou]

Re: Texman Build

Tracy, I believe you are too hard on yourself. In my view, the 'errors' in cuts are so minor as to forget them in a month, and you will. Compared to my cuts, yours belong on exhibition in the National Museum of Art.

[deejayoh]

Re: Texman Build

Tracy

Looks very good

On those joints, I had that issue too. What I did was take some of the mortar that oozes out of the back of the brick, the stuff that is a little dryer, and forced it into the joint with my finger. You are not going to get the whole thing filled, but you can get quite a bit into the joint

[Amac]

Re: Texman Build

Every time I set the bricks next to the arch, i have to make myself trust the IT because it just doesn't look right

The only problem with the IT is it doesn't reliably get the height correct, and mine at least, could tilt slightly also.

i don't get where you mount it?

I asked Gulf about it and he said he set it up at the back of the oven. Maybe gulf will jump in here and clarify that.

As for the mortar - given that there are a few mortarless or near mortarless attempts on here I don;t think it is any problem. It is a very thin jont compared with mine. I can't remember if you are using homebrew. I would say if you do as you suggest and use a wet mix and a toothpaste tube or an icing bag you should manage to grout it up.
My attempts at grouting with a plastic bag with the corner snipped off were a waste of effort. I ended up grouting using a small pointing trowel, some wooden ice lolly sticks and the rubberised gloves till I wore holes in them

[texman]

Re: Texman Build

Amac
I know what you mean by "fool" you. Every time I set the bricks next to the arch, i have to make myself trust the IT because it just doesn't look right. Even then i purposely give it a slight turn up on the arch side. I want to try the laser, but i don't get where you mount it? I can't tell from the pics where the laser is actually mounted.
I was cutting bricks and cleaning up a bit and noticed this. See pic. Not sure how i managed to do this. Probably too aggressive on the spray bottle with water to clean and washed the mortar out. What should i do with this? The brick is solid and set but the mortar is gone on the vertical joint. I can slide the trowel about 3/4 of the depth of the vertical joint and about an inch into the bottom joint. I was thinking of forcing wet mortar in with trowel and fingers or maybe use an old toothpaste tube to try and force it in there. I thought about taking the brick out, but it is set and i don't want to cause another catastrophe.

[Amac]

Re: Texman Build

Looks good Tracy. It's at about this point that the bricks connecting to the arch start to dip a little. If you have a laser level use it like gulf did to keep those bricks on the level. Even if you have a toy laser I would tape it to a level because these bricks will fool you and you will have some unnecessary work later managing an egg shape.
Here is gulfs pic - I didn't do it and I had a small egg shape to contend with:

[Lburou]

Re: Texman Build

Tracy

It looks good to me! If you could see my dome/inner arch transition, you would get a big head

[texman]

Re: Texman Build

i think i am back to the point i was at post #71 and the "event"
Going well i think the second time around. Doing better this time on the bond. I still have to use small bricks, but don't know what else to do in those places other than cut all the course the same.
i plan to use the grinder on the inside inner arch and make it pretty once i get above the arch top.

Tracy

[deejayoh]

Re: Texman Build

Looking good Tracy! I started my arch the same way you are doing it. Seems to have worked out fine.

I don't blame you for outsourcing the bar work. That's a lot of bricks.

[texman]

Re: Texman Build

I reset the floor again and got better results. I had some corners that did not align as good as i wanted.

I built the arch first and then I did the first two courses and started the 3rd course which is where i began my dome curve. I used probably 3/4 of a full firebrick next to the arch on the 3rd to hopefully add some strength and get the bond correct.

I started using a hawk(board to put mixed wet mortar on) and that seems to help me. I can work the mortar easier and load the trowel better. I am mixing in a sawed off 5 gallon bucket that is about 5" deep. The alsey mortar needs to be set withing 15 minutes of mixing. I mix about 8 oz. at a time. I can usually get that used in 15 minutes. The mortar can not be retempered, so you have to mix small batches.

I cheated on the brick on the outside of the bar and paid to have it done, but, it is done. I can set my bar top now.
Tracy

[texman]

Re: Texman RE-Build ReThread

I went ahead and leveled the vcrete layer with fireclay and set the FB board and leveled it with another layer of fireclay. Got the floor tiles reset and the first course laid out and got the arch close. Not bad for a Monday evening. I need to recheck all the layout, but it seems close. Seems like i have been here before.

[texman]

Re: Texman Build

Vermicrete 5:1:1 (vermiculite, portland,sand) is in. Poured it Saturday, the pour had shrunk away from the forms about an 1/8", so i removed the forms sunday afternoon. I wish i had packed the vcrete against the forms more to avoid voids, but other than that it went well. I mixed 1:1:1 (vemiculite, type S mortar and fireclay) and slopped it on the outside edge to fill my voids and hopefully give it some edge protection. Threw a little fireclay on top to start leveling in the pics.

How long should i wait for the vcrete to cure before I set the FB board on top and set the oven floor? I have read 3 days and also wait for full cure of 28 days. Also, i think i should be cautious with this since the FB board might wick moisture from the vcrete.

I just read some post this morning about letting the first course of dome float with no mortar. I must have missed that in the fb plans and everywhere else.
Does the first arch brick float as well? So no mortar between oven floor and walls and the arch?

I guess i am glad i am on the second try, because i mortared all this the first time.
Tracy

[Mike D]

Re: Texman Build

I did a 6:1 (I don't know why).

Mike

[GianniFocaccia]

Re: Texman Build

Tracy,
I did my vcrete just like Mike using a hoe in my wheel barrow. Stir carefully and it will fold together quite easily. I read of ratios here from 5:1 to 12:1, so I went right down the middle, 8:1, and topped it with 2" of fiberboard. The lower the ratio (5:1) the more more portland and less insulative value, but a slightly stronger finished product.

I put insulation under my oven floor and entryway. If your oven bricks touch your oven entryway at all, this will cause a thermal bridge and lead to residual heat loss. The entryway insulation should help to reduce this.
John