Acoma 42" Tuscan

[Acoma]

Re: Acoma 42" Tuscan

RC, and others that are to do the tie in of the dome bricks to arch. I did my first ones today. I found it time consuming for these bricks becuse they were not merely straignt cuts, angled, to tie in the two parts. The next will likely be easier though.

For this course 5 brick tie in, I started with foam blocks from an art store with the same dimensions as the fire bricks. Then I shaved the foam to desired shape. Once this was done, I mirrored the foam bricks to that of the fire brick as best as possible. I used the wet saw for bigger cuts, then shifted to detailed cuts, and the fine tuning using the grinder.

I plan to do half of course 6 this afternoon. Hopefully that gets accomplished, then I will finish 6 tomorrow.

[Acoma]

Re: Acoma 42" Tuscan

Today I finished 17 of the 29 pieces needed to completed course 6. The angle of 6 is really showing off the dome as well. I still have 12 bricks to modify angles with. I will attempt to get 6 of the 12 done tomorrow evening, and hopefully, to finish 6 Tuesday evening.

With the 5th course behind me, and the experience of tying into the arch, I feel great about the 6th course tying in. I also don't have to deal with as many angles to make that happen which is nice.

My fingers feel raw after many days, evenings with no break. I thought 6 would be done, but we woke up to 5 inches of snow, strong winds, and modified cuts to be done outside with the wet saw.

I notice that each course requires a more agressive beveled angle from top to bottom with each brick. Also, the inside dome face of the bricks are getting tighter, not as wide due to the courses moving inward. Boy the lessons of each course amazes me. We learn with each course, each brick, each step.

[gjbingham]

Re: Acoma 42" Tuscan

...and the gaps underneath the new row get larger and larger against the previous.

Fun, huh? Enjoy your sore hands. They will heal quickly. These few days will be but a memory before you know it.

Hang in there Rob.

[Frances]

Re: Acoma 42" Tuscan

Yep, building the dome is fun! And a really intense experience! Sounds as if you're enjoying it Acoma.

...So how about a few pictures?

[Frances]

Re: Acoma 42" Tuscan

OK, I just saw the pics...

Its looking really good, beautifull work!

[Acoma]

Re: Acoma 42" Tuscan

Thanks Frances. It is great to know that a few of you are observing the progress, and are contributing your views. I am curious as to why some of the other veterans to the forum have been quiet recently? Knowing that one is not alone while working through the cold snowy, rainy winter, but has others contributing to the process truly helps with motivation.

[asudavew]

Re: Acoma 42" Tuscan

I've been enjoying watching your progress.
And I agree with Jim.
You are really taking your time and doing an outstanding job.
I wish I would of waited and bought the HF saw, and really took my time.

I may be up for a redo this summer.

Keep posting! I'm reliving the experience through you!!


Great work so far.

Dave

[RCLake]

Re: Acoma 42" Tuscan

RC, how was tying in the bricks to the arch on 5 for you? I have one brick left per side to tie in and I am nervous. Then on to 6. BTY, it is truly coming together This hard, cold, exhausting work is starting to show in great ways

Tying into the arch has been quite interesting. I'm afraid it may be one area with the greatest weakness. Wish I knew of a "super mortar" to reinforce this area. Both row 5 and 6 for me have the same issues. You want straight up a farther distance than I did.
The weather had been cold and rainy until today. So this weekend I cut the brick angle and bevels in the garage. The first three seemed to fit nicely so I cut the entire row.
Started mortaring down the 6th row today and I had to make adjustments to the whole row. Almost finished but still have to tie into the arch. Next row I'm doing each brick cut individually , get a dozen done and then mortar them in. Then repeat and repeat.
You're are right it is coming together

[Acoma]

Re: Acoma 42" Tuscan

RC, I totally agree with you about doing brick by brick now. being that we want to avoid the triangle gap. I did a course pre cut, and found myself doing more angle afterwards to avoid the triangle. I got lazy and used the grinder for my last 3 that were done. It was a pain in the but. I am going to do the last 12 tomorrow because I have 2 sick children, and a wife that had school all day. I will adjust each brick as I finish.

RC, do me a favor and take a photo of the tying in of the bricks to the arch. I will do the same for all courses. I want to see how we differenciate since we are going at the same pace.

I have not started the front of the arch, but I came up with an idea and tell me what you think:

Finish course 6.
Do end bricks of the front arch, then finish course 7.
Do next two bricks of arch, then 8
Same until finished with arch, continuing with dome.

I figure this will get me complete with dome and arch at relatively same time.

[Acoma]

Re: Acoma 42" Tuscan

RC, as for the dome and arch, I strongly suggest an inch of cladding upon completion of the dome to get a strong bond to the bricks everywhere, and for extra insulation. This may avoid cracks.

Canuck Jim, you have done plenty of ovens now and your method will be what I apply, so what can you add to this? To apply the cladding before curing?

[gjbingham]

Re: Acoma 42" Tuscan

Robert,
Sorry the others are so quiet. Must be a winter thing. I gave up on my thread. No responses time after time. No big deal. I can easily live without the comments. Everyone's watching. No one is saying anything.

Cladding? Do you like making bread? That is the question. I love making bread. I had no heartache about adding cladding. If you're not a bread baker, maybe just a little couldn't hurt. I sure didn't see any major flaws in my cladding after the curing fires, though there were some circumferencial hairline cracks about 2/3rds of the way up the dome. A little is not going to signfiicantly change the wood required to heat your dome. Remember though, I used the portland cement/lime/fireclay/sand mortar mix vs. Refmix or similar products. Those may be different.

[Frances]

Re: Acoma 42" Tuscan

I can't really help here, as I opted fot the angle iron doorway... That was quite enough of a challenge as it is! I've seen the pics, but I still don't really understand how the arch ties into the dome.

But about the cladding, if you want it for structural reasons, it certainly won't hurt, but don't listen to George about retained heat . I love baking bread, but even without cladding the oven retains more heat and for longer than you will know what to do with.

Actually what I really think, is that it doesn't matter either way. The ovens seem to work fine with or without cladding. Serously, after reading all the posts I could find on the subject (and there are quite a few) that's about what it boiled down to.

Right, and now I'm going to find George's thread and write something there as well!

[jcg31]

Re: Acoma 42" Tuscan

RC, I totally agree with you about doing brick by brick now. being that we want to avoid the triangle gap. I did a course pre cut, and found myself doing more angle afterwards to avoid the triangle. I got lazy and used the grinder for my last 3 that were done. It was a pain in the but. I am going to do the last 12 tomorrow because I have 2 sick children, and a wife that had school all day. I will adjust each brick as I finish.

Robert,
Sorry an unexpected trip at the end of last week and family over from the weekend has kept me away. Your progress looks outstanding, sorry for the sick kids.

After course 5 I grew weary of running back and forth to the saw and began cutting my courses (one course at a time) all at once using the bevel cuts outlined on the graph I did for RC (http://www.fornobravo.com/forum/atta...vel-chart3.jpg) and the fit was nice and snug. And, like RC did all in the comfort of my garage. Of course this could be disturbed by some errant brick placement in any of the courses below, but based upon what I am seeing you won't have that problem.

The numbers on link above are for a 42-inch oven and will differ with different size ovens. If I remember correctly you were going larger than 42. If you post your diameter, I will send you the angles and bevels for your remaining coarses. Also, if you know it, send me the slope of your current course.

Hang in there, winter is ahead.
Jim

[Acoma]

Re: Acoma 42" Tuscan

Thanks Jim. I have the wet saw right outside the tent, and believe that I can cut the halves, then bevel one side front to back for all. The part where I believe I will need to do each brick, or every few is the beveling from top to bottom on one side. It is somewhat time consuming, but that is one of the smiles I will remember once done....patience, perfection (as an amateur) and invitation of friends and family to share great food.

Kids are pretty sick. I am still committed to getting bricks cut this evening, and mortaring some if possible. I may have to finish 6 tomorrow.

It seems wiered but true, we value feedback from those finished, and always will. I want to thank every one of you that contributes.

[Acoma]

Re: Acoma 42" Tuscan

Versachi, Les and Ken? You guys ok this winter? Been fairly quiet guys......