A new Folly at Full Moon Farm-- build thread

[UtahBeehiver]

Nobody looks inside the oven after it is done and you are are cooking. They are more interested in what comes out..............

[agrasyuk]

Transition area of the inner arch is probably the most complex task in this project. As with all things practice makes it better, but not being a pro I sure know where I could improve on that if I ever to build an oven again. As such no one on here going to grill you to much so you could have easily posted your pictures.

[rwiegand]

I'm writing a bit tongue in cheek, but people have way better examples to look at than mine on this site. My respect for the other builders who did such beautiful work has gone up dramatically, having now tried it.

Now to get my outer, more visible arch to be beautiful.

[Gulf]

The "engine" is looking just fine. And, I'm sure that what ever "chassis that you place it in will look mighty fine too!. All that said, they won't see nothing but the "mouth of the dragon" when you fire it up .

[rwiegand]

Speaking of the mouth of the dragon, I just (10 min ago) finished a sketch for the proposed exterior. I've been wanting to use that dragon tile someplace for a long time, I made this to share with the potter to talk about colors and how he might do the bottom half of the circle.

[rwiegand]

Two more courses today. Going surprisingly well given the steep angle now. I'm not sure at what point I'll need to rely on a physical support to hold the bricks up until a ring is complete.

The angles required at this point are much steeper and the brick count much lower than the spreadsheet would suggest. I'm going to jump a course for the next round to try to get a better side angle. It doesn't help that the HF brick saw flexes so much in use. I'm just gritting my teeth to get through this, telling myself I'll probably never have need again for protracted use of a wet saw. For every other purpose I long ago gave up on buying cheap tools, this saw is constantly reminding me why that was a good choice.

[ubcpsyc]

Looks great! I ended up using an exercise ball and putting a garbage bag on top.. I know others have supported a round piece of plywood from below.

Good luck!

[agrasyuk]

You will not need to support bricks if you do your mortar right , even on the very last row. Tap them in, hold in place for 5-10 seconds and they will just magically float in the air defying gravity.

As for the saw, try to push it less perhaps and give the blade a chance. HF saw is of sufficient quality for the job. Maybe a luxury even, many here built with an agle grinder and I seen some chisel-hammer builds .

[rwiegand]

We have an oculus! Unfortunately it is too big for a two brick plug so I'm going to try to fashion two pieces that hit most of the angles then a wedge in the middle to lock everything in place. Cutting a conate heptagon ought to be an interesting challenge. I decided to take it on first thing in the morning rather than when I'm tired.

(Yes, I cleaned up the inside of the dome before the mortar set, after I took that picture)

[rwiegand]

Forgot to mention, I ended up using only the IT to place the bricks in the final rings. Worked like a champ. I played with an exercise ball, but the shape was wrong, it was bouncy and kept moving, and didn't really keep the bricks where I wanted them. I had no problems with slippage using only the IT, just as Anton suggested.

[rwiegand]

Lots of activity today. Closed in the dome, which feels like a major milestone. Began building the vent hearth. On to arches tomorrow.

Ordered stone to clad the exterior ("New England Blend Ledgestone) yesterday. Begun reading up on steel framing for construction of the enclosure. Lots of help on non-structural steel framing and from amateurs with more enthusiasm than sense building "little houses", but surprisingly difficult to find guidance on joining techniques for structural steel framing. I'll go visit someplace that sells the stuff this week and see what I can learn. Watched really scary videos of guys in Cambodia welding steel framing with no eye protection.

[UtahBeehiver]

Congrats on completing the dome. Are you talking about actual structural steel and not steel studs? There have been a number of builds on the forum who have used steel studs. One builder did suggest to use a higher gauge stud vs what you see the the big box stores. Do a search on the forum.

[rwiegand]

Yes, steel studs. In the trade the 25 ga ones they sell at the big box stores are referred to as non-structural, for use only in non-load-bearing construction. (They are used extensively for internal walls in commercial steel and concrete buildings.) The heavier gauges of steel studs (20 and 18 most commonly) are referred to as structural and can be used in a load bearing wall.

Since I'm planning on a slate roof and potential for substantial snow load I'll need a pretty beefy structure.

[agrasyuk]

It feels like milestone because it is quite a milestone. I'd say it thist point you are half way done. And there is a very noticeable dent in the pile of firebrick .

Joining steel is either rivet, weld or bolt. Unless you own a welder chances are you will be drilling and bolting things together. But honestly I feel like it would be way way of an overkill.

[rwiegand]

A busy day cutting bricks today, and yet another trip to the stone yard for bricks and mortar. Wish I could estimate better! I hope this will be the last batch.

It's a bit of a struggle to make the vent area big enough. I think I'll come out with a vent of about 60 in² feeding a 50 in² pipe.