Mike's Northern Virginia Build

[UtahBeehiver]

Re: Mike's Northern Virginia Build

Making headway, should be okay with slightly wider joint at center, your bricks are tapered and not going anywhere. Most of this arch is hidden any with the soot, chimney vent, and outer arch. Probably no need to skim coat inner arch since they will be covered by the dome bricks, but no harm, no foul. Making nice progress. I used 7" Selkirk since on a 42" since I found the pipe at a clearance store for $10 but if I were doing it again, I would have gone with 8". I can't remember what size oven you are building.

[Mdog91]

Re: Mike's Northern Virginia Build

Thanks! I went ahead and attempted the arch. I think it turned out pretty good. The slope matches up to the angle of the brick at TDC when I have it on the IT, so I think it should marry up pretty well.

I got bold and CAREFULLY removed the form about 30 minutes after the last brick was set to clean the underside of the arch and wall seemed fine. I Carefully put it back just to be safe.

I kind of "skim coated" the back side since I had a few blemishes from the saw and angle grinder as I tried to get it right.

I will insert the additional support bricks on the sides tomorrow.

Should I have any concern about the slightly larger mortar gap in the center?

Also, I am going to order my chimney set up on Tuesday, should I go with a 7" or 8" duravent? The oven opening is 19" wide and 12" high. I think 7" is good, but I have never heard of anyone complaining about being over flued.

Thanks!

[UtahBeehiver]

Re: Mike's Northern Virginia Build

You can go either way on the arch, but joints have a way of growing as you build then you have no room to spread changes over several bricks if you build as you go. Just make sure you keep the arch ahead of the course bricks, much easier to tie to the arch. IMHO, I would build the complete arch first. Make sure you leave yourself some form release and save the arch template for your oven door,

[Mdog91]

Re: Mike's Northern Virginia Build

Some good progress so far. I am up to the 5th course. My neighbor Rob made a Chipster style jig for me, to cut the angle and bevel. It works great! I have been trying to avoid the inverted V. I think it has been fairly successful so far. I may have actually over-beveled a little. They are not perfect, but I am learning and getting better as I go. I also got a little overzealous with the grinder trying to cup the inner face of a brick or two (back right) oops! I'll see if i can smooth that out tomorrow. I also need to pay a little closer attention to the joint bond and making sure they do not line up.

I have my arch bricks tapered and ready to go. I hope I didn't make a terrible mistake though - a full size brick would not fit in the saw to make the taper, so i cut the brick to 3.5 inches and then tapered it. They are still full length so i can match them up with the angles of the dome. I don't see any problems with them being 3.5" but I guess time will really tell...I will see how the tie in goes soon enough.

Is there any problem building the arch as I build the dome? or should I just build the entire arch and then the dome?

Pics of the Chipster Jig, 5th course, and the 3.5" high tapered arch bricks....

Thanks for your time and advice.
Mike

[the_dr_masuess]

Re: Mike's Northern Virginia Build

It is looking great so far. Love the expansion gaps and the tapered inner arch is definitely the way to go in my opinion. Granted I haven't done it yet but that's what I am shooting for too. Good luck. Wish you the best this weekend

[Mdog91]

Re: Mike's Northern Virginia Build

Thanks for all of the replies and info. I hope to make significant progress this weekend.

I feel better about my arch choice with your reply Cobblerdave. The oven opening is 19" wide and the vent will be 20.5" wide to give me a .75" reveal all around, it will also be a brick and a half deep. I think this should work well to funnel the smoke and prevent stains on the front.

I think I have my head wrapped around the design and tie in of the arch to the dome thanks to the link from Utahbeehiver. That link and the one GiannaFocaccia posted about Gene's oven in the same thread really do a nice job of illustrating it.

I will post pictures of my progress.

Thanks again,
Mike

[GarnerAC]

Re: Mike's Northern Virginia Build

Very nice start! Anxious to see how it ends up!

[UtahBeehiver]

Re: Mike's Northern Virginia Build

Mdog,

Now that I understand what type of arch opening you are doing, here is a link for doing a tapered inner arch similar to what you are doing. It is an efficient why to tie your dome to the inner arch.

http://www.fornobravo.com/forum/8/oc...tml#post119582

[cobblerdave]

Re: Mike's Northern Virginia Build

Gudday
No,as smoke naturally goes to the highest point most of the smoke will go to the middle. I would still make your vent opening as wide as possible to catch as much of the smoke present when you first flash up a cold oven.
Regards dave

[Mdog91]

Re: Mike's Northern Virginia Build

G'day
So you thinking about a rectangular entrance? I did a rectangular entrance and it's not as easy to tie into a dome as you think . I have since helped to build an oven with an arch entrance and it was a walk in the park compared to mine .
The secound thing to consider is that an arch shape naturally concentrate the smoke to a mid point. With a rectangular entrance its spread out. I have a rectangular brick chimney as a result. My oven has no smoke stains at the entrance, which I can't complain about . But if you plan a smaller steel chimney remember you'll have to slowly funnel that smoke into a smaller and smaller space to enable it to work .
My oven works well and I'm quite happy with it. So basically I'm saying, be aware of the pitfalls and the chimney shape that is possible.
Regards dave

I don't mean a true rectangular entry with angle iron. I mean a sprung arch, at least I think that is what it is called. The straight sides and arched top like Les' and K79's builds. I think it give more access and view of the fire, and my wife likes it better. Do your statements about the smoke and such still apply to this type of arch or is it just for true rectangles? I plan on using a 8" duravent chimney. Thanks!
Mike

[UtahBeehiver]

Re: Mike's Northern Virginia Build

Nice tight brick joints.

[cobblerdave]

Re: Mike's Northern Virginia Build

G'day
So you thinking about a rectangular entrance? I did a rectangular entrance and it's not as easy to tie into a dome as you think . I have since helped to build an oven with an arch entrance and it was a walk in the park compared to mine .
The secound thing to consider is that an arch shape naturally concentrate the smoke to a mid point. With a rectangular entrance its spread out. I have a rectangular brick chimney as a result. My oven has no smoke stains at the entrance, which I can't complain about . But if you plan a smaller steel chimney remember you'll have to slowly funnel that smoke into a smaller and smaller space to enable it to work .
My oven works well and I'm quite happy with it. So basically I'm saying, be aware of the pitfalls and the chimney shape that is possible.
Regards dave

[Mdog91]

Re: Mike's Northern Virginia Build

Thanks UtahBeehiver, I appreciate you following my build and providing advice. I have tried to pour through your and many other's build(s) to learn from.

I leveled the floor with sand and fireclay today and mortared in the first course. I only mortared the brick sides for this course. I am using heatstop 50, it seems to be easy enough to work with if the bricks are moist and it is mixed to a peanut butter consistency. I put a strip of cardboard between the floor and first course. I cut and dry stacked the the second course as well.
Tomorrow I will cut the plywood template so I can remove it upon completion, and tape the gap to prevent mortar from falling between the wall and floor. I will lay the second course and cut the third. Is there any problem with laying more that one course in a day? Should I let it set for 24 hours before going "up"?

I am planning on a "rectangular" type arch opening and am undecided if I should build it as I go, or build the arch before the dome. I plan on trying to tie it into the dome like K79's build that UtahBeehiver advised on as well.

Time to study K79's arch for the night. Thanks again to all on here, I am having so much fun doing this. I can't wait for pizza time......

[UtahBeehiver]

Re: Mike's Northern Virginia Build

The gap is good, acts as an expansion joint between floor and dome. Be sure to cover the gap with duct tape during your dome build to keep mortar from falling in and defeating the purpose of the expansion gap. Nice job on floor and first course.

[Mdog91]

Re: Mike's Northern Virginia Build

Thanks UtahBeehiver.

I pulled the plastic and forms today, and am satisfied with the hearth slab.

I laid out the plan on the slab and then put down the FB Board. I trimmed the FB board and drew the layout on it as well. I decided to put the floor inside of the dome walls so I laid out the floor pattern and cut the floor. I was also able to get the first course cut and in place. I tapered the both sides of the bricks. My neighbor Rob has been a big help with calculating the brick angles and other general assistance.

I have about a 1.5" gap in the course that I imagine will be taken up by mortar, if not I will cut a small brick to fit and place it near the front out of sight.

I have a few little gaps between the floor and the first course (first time cutting bricks) Most are within 1/8 of an in or so. I don't imagine they will be a problem and will ultimately fill with ash.

I also played with the dome profile. It will be just like the FB plans. 36" oven, 18" high with a 19" wide 12" high door.

Tomorrow I will pull all of the floor bricks (I numbered them), mix the clay from todays cuts with sand and level the floor. (it is not too bad now).

Please let me know if I am am overlooking something important! (the arch form is not properly aligned in the picture)

(edit) - sorry for the sideways pictures, I don't know why that happened....
Thanks,
Mike