39/42” Corner Building in Brisbane

[cobblerdave]

G’day
Well done a wet saw!
Don’t even think about using fire brick for external stuff. It just absorbs water even out of the air. And plain firebrick looks pretty dull. Use ‘commons’ the solid bricks without the holes. My entranceway and chimney are all commons no problems.
regards Dave

[Delta]

Well spoke to soon about the brick saw and didn’t get it.
Not wanting to delay any more, I decided to cut them all by hand.
lots of noise dust and thirst.
Managed to cut all of third course and the tapers for the arch bricks.
Tool quite awhile to assemble and space them all to be acceptable.
I figure they will mostly be hidden.
Now have to just mark and cut the back end of the arch which should be a piece of cake compared to the tapers.
Todays question is, should I mortar in and complete the arch, or assemble it as I lay each individual course?

[cobblerdave]

G’day
Start each course at the back of the oven. This is were it pays to be careful. This is we’re you want the gapes not to line up. The front of the oven can’t be viewed when complete except by getting on your back and sliding into the oven.... not going to happen.
regards Dave

[Delta]

I might be rough but I am slow.
Made a new IT scribing Tool, figure I only need it to mark the arch so doesn't need to be fancy.
Took the inner radius (500mm from the top of the first course and marked the inner vertical faces of the arch bricks, then took the outer course radius and scribed across the top of the arch.
If I draw a line from inner to outer, then that is one cut, and if i draw a line from inner to the inner arch template intersection, then that is the second cut.
From the photos does this look correct?
Cheers

[Delta]

Well just realised that I shouldn't cut all the back to the Arch template,, that would be too deep.
Maybe just back to where the base arch brick meets the dome.
Hopefully the photo indicates my intention?
Cheers

[cobblerdave]

G’day
Even with a 125mm angle grinder and diamond blade you can’t get a full cut. I tended to cut then used a brick bulster to snap the rest through. A pair of saw horses with a plank between lets you get a sand bag up to a better level and can be moulded to hold the brick so you’ve got 2 hands for the cut.
Dust is a big problem. A very big problem. Letting the firebrick soak in water will minimise it, but not eliminate it. A mask is not good enough you’ll really need a cartridge respirator and replace the cartridges.
Tried a large metal chop saw with a stone cutting blade when covering my oven with brick 1/2s. OMG.... took the dust to an unmanageable level. Covered my yard and the neighbours as well with a layer of dust. Had to hose down both yards, every tree and bush got dusted. The masonsry blades don’t last long either. Went to the brick bulster only cause my original 125 mm angle grinder had sucked up too much dust and killed it.
Anyway hope this helps in some ways. Not trying to put you off by any means you’ll still get a workable oven by any means....
regards Dave

[Delta]

Thanks Dave,
I think I have done most of the heavy duty cutting now but will keep an eye out for another saw.
What do you think about my markings for the arch cuts?
do they look ok?
Cheers

[cobblerdave]

Thanks Dave,
I think I have done most of the heavy duty cutting now but will keep an eye out for another saw.
What do you think about my markings for the arch cuts?
do they look ok?
Cheers

G’day
Yep they look to be the goods. Not my area of expertise usually as my entrance intrudes into the oven.
Some of those cuts are larger and might be deeper than an angle grinder cut even when cutting from 4 different directions they might not meet in the middle
regards Dave

[Delta]

Yeah well the lateral cuts on the arch bricks I did with a diamond blade in a 7" circular saw, a bit rough but will be filled with mortar anyway and will not really be seen?
It will also be ok for cutting half bricks and the bevel to get rid of the inverted V I can do with the grinder.
Hoping to start mortaring the third course today?

[Delta]

Bit the bullet and went and got a new Wet Saw, SE Qld builders watch this space for space for Wet Saw sales
Took awhile to work out the Arch transition of the first couple of courses but I think I have done it.
Would appreciate it if I could get confirmation I am on the right track.
I am using a small laser level to see if I can keep things level as well.

Cheers

[MarkJerling]

Bit the bullet and went and got a new Wet Saw, SE Qld builders watch this space for space for Wet Saw sales
Took awhile to work out the Arch transition of the first couple of courses but I think I have done it.
Would appreciate it if I could get confirmation I am on the right track.
I am using a small laser level to see if I can keep things level as well.

Cheers

That looks very tidy. Well done.
For interest sake, what's the size of your door opening and the diameter of your oven? I don't know if it's the photo perspective but, to me, your door seems quite small.
(Edit added) From the other photos it looks wider, so not a critique, I'm just interested!

[Delta]

Hi Mark, Oven is 500mm Radius.
Door is 480 mm at the base

[MarkJerling]

Aha, thanks! I figured it must be the perspective of the photo that makes it looks smaller on the one image!

[JRPizza]

Looking good! Keep an eye out for any droop around the arch - that is where it happens.

[mongota]

What do you think about my markings for the arch cuts?
do they look ok?
Cheers

I think they look fine.

I prefer to mortar the arch first, then go course by course upwards to cover the arch.

Your first two lines for cutting the arch bricks, the outside oven radius (on the top face of the arch bricks) and inside oven radius (on the inside face of the arch bricks) are pretty standard markings.

The underside line (on the bottom face of the arch bricks), some folks go with the inside dome radius, some go with the spot where the arch brick meets the arch template. Your arch template does sit a bit outside of the dome, so using the interior dome radius makes perfect sense.

The brickwork is looking nice!