42” Corner Build in the Shadow of Mount Nittany

[Giovanni Rossi]

A further problem about fitting a door under the arch occurs when the oven cools, the door opening shrinks against the door, jamming the door in the opening.

Well, my thought was that if the insert fits into the arch with a proper gap on the sides and top when the oven is cold, I should be fine. What surprised me was how much the wood expanded as it warmed.

The steel door normally fits flush against the inner arch. I was just going to use it the same way with the insert in place, but thought I would experiment with the gasket.

[david s]

A further problem about fitting a door under the arch occurs when the oven cools, the door opening shrinks against the door, jamming the door in the opening. It is better to just have the face of the door sitting tight against the face of the opening rather than under the arch this requires a larger rebate in the door opening, otherwise you run the risk of the oven mouth contracting against the door as it cools, jamming it so tight that the door can’t be removed without damage to either the door or oven mouth. If you have a rebate in the oven mouth it needs to be big enough to allow for this difference in expansion or you end up with a jammed door.

[UtahBeehiver]

Nice pro looking door.

[Giovanni Rossi]

Found some flush-mount pulls to aid in extracting the insert. I fit it so there was an ~ 1/8” gap on the sides and top. It fit in fine when the oven was hot but the wood expanded as it heated and after about 15 minutes, the top was starting to catch on the arch. I stopped using it and will trim some off before the next use.

I attached wood stove door gasket to back of the oven door to cover the gap between the insert and arch. The door is supplied with a probe thermometer to monitor the air temp inside the oven. That had to be removed so the door would fit against the insert.

I have a thermometer with a probe embedded in the oven wall. I’ll document the temps after a few firings next season and report the results.

Enjoy the holidays!

[Giovanni Rossi]

I had just enough CaSil board left over from the floor insulation. Before I closed the case I applied some high-temp silicone to the seams to contain any fibers that may be shed. I had quite a lot of extra FOAMGAS so I used that for the inside layer, 4” of insulation total. The case was closed with 7/8” oak (not pictured) and that side will face the inside of the oven. The unit was assembled using stainless steel screws. I hope I’ll be able to replace the oak once it chars and begins to fail. I’ll provide follow up on how this experiment works out.

[Giovanni Rossi]

First turkey! A 20 pounder. Pretty happy with the result. For those eagle eyes out there, no, the one wing didn’t get incinerated. We are fortunate to be able to buy fresh birds the Sunday before Thanksgiving from Penn State’s Student Poultry Sciences Club. We always ask for a #2 bird and this year we got one. #2’s are a little cheaper because they have a defect resulting from the students learning to butcher!

This was a new experience in firing in cold weather. All summer and fall I could get the oven to full temp in about 1.5-2 hrs. I didn’t want to push too hard to start, so the 4 hrs to get it to full temp was probably longer than it need to be. I used 1.5X the normal amount of wood.

Now, for the “last” part of the construction: I decided to do an insulated insert instead of an insulated door. I believe it was david s who commented in another thread about how oven doors were traditionally made of wood so I decided to give it a try...sort of. I started with 7/8” oak for the frame and 1” maple for the outfacing side.

[Giovanni Rossi]

Thanks Mongo,

And, thanks again for your help with the form work for the cantilevered slab.

[mongota]

I've been off the forum for a while and as a result I've missed quite a few PMs...

I just want to say congrats on your oven. You'll appreciate the hard roof over the top as the seasons go by.

[Giovanni Rossi]

I appreciate the kind words and observations spoink47

One of my goals was to provide an outline for a brick build including the supplies and techniques I used as well as those I didn't but were applicable to others. I also tried to note current best practices and some of the dos and don'ts. Since one of the hallmarks of this forum is discovery and sharing of new information, I'm sure this thread will also become dated in time. If so, hopefully it will still be a good starting point for some. I'm happy to make the effort even if just few future builders find value.

I finished my insulated door (well, more of an insert) and will be adding a few posts about that.

[spoink47]

Your meticulous attention to detail throughout this project is truly impressive! The comprehensive documentation you've shared is a treasure trove for newcomers like me trying to navigate similar endeavors.

I had to chuckle at your "cost per pizza" calculation—it's akin to my own musings about the "cost per coffee" after investing in one of those top-tier Nespresso machines. These quirky metrics always add a touch of humor to the reality of project expenses.

The insights you've shared about the project's highs and lows are incredibly valuable. Hearing about both the successes and challenges is truly enlightening. Your experiences with concrete consistency and brick cutting are invaluable for anyone starting a similar project.

Your dedication to giving back to the Forum community is commendable. It's this kind of knowledge sharing that truly enriches our collective experience.

Even though your project is already complete, your journey of research and contemplation resonates deeply. It's akin to my search for the best Nespresso machines amid countless options—thoroughness is key!

Congratulations on completing such an ambitious project! Your perseverance and the support of your wife and family are genuinely inspiring. Moments like your wife placing the keystone while you were inside the oven are what make these projects truly special.

Looking forward to seeing your future endeavors.

[MarkJerling]

Devious mind Mark! No, I hope that time capsule isn't opened for decades or longer. The plaque is really just a marker. The capsule is in the void of the block stand in that corner. Probably going to need a jack hammer when the the time comes. It contains current events, stories about our area, family, house, pizza dough and sauce recipes, pizza party menu and items that will probably only exist in museums like CDs and coins! Those interested can blow up the photos in post #12. I may PM you about the ECM.

Great stuff! I had to flick back to look at your time capsule photos. Real cool. I forgot to do that with our oven, but I did do something a little like that when we did our kitchen renovations as there was a large corner void.

[JRPizza]

Congratulations on the beautiful work - I really like how your shelter came out and how it fits into your yard!.

[Giovanni Rossi]

Devious mind Mark! No, I hope that time capsule isn't opened for decades or longer. The plaque is really just a marker. The capsule is in the void of the block stand in that corner. Probably going to need a jack hammer when the the time comes. It contains current events, stories about our area, family, house, pizza dough and sauce recipes, pizza party menu and items that will probably only exist in museums like CDs and coins! Those interested can blow up the photos in post #12. I may PM you about the ECM.

[MarkJerling]

Great write-up. I must say, I love the inclusion of the "cost per pizza" calculation! LOL Sounds like my "cost per coffee" figure after purchase of the ECM machine.
Oh, and did you put the time capsule plaque on the wrong brick just for fun?

[Giovanni Rossi]

What’s left to do?

I’m getting days of retained heat cooking so I’m debating the necessity of making an insulated door. If I do, it will probably be some sort of FOAMGAS and wood sandwich.
I will post that if I do.

Until then, I’ll wrap up this build with the following…

The questions I get most are:

1. Are you glad you built it? [Absolutely]
2. Would you do it again? [Absolutely not]
3. Does the fire go in the open space on the bottom?

Some random final thoughts:

Project duration: April 5, 2022 - September 18, 2023

Manhours consumed: 595 (Though I admit to not being a fast worker and I usually over-research and overthink things – especially those tasks new to me.)

Current cost per pizza / loaf of bread baked : $127

As with most home improvement projects, the final cost was about double the original estimate. However, I didn’t plan to build a structure and that contributed a significant portion of the additional cost.

Weight of the project:

Oven above the support slab – 3,100 lb
Stand – 14,900 lb
Pavilion – 5,375 lb
Landscaping stone – A lot

Favorite parts:

• My wife helping me to place the keystone from above while I was lying in the oven.
• Working with family when I needed help.
• The first full firing.

Least favorites:

• Laying concrete block for the footings (I’m going to need more practice with this).
• Fitting ceramic fiber blanket on the dome wearing full protective garb in 90 degree weather.
• Supporting each dome brick above course #4.

New favorite tool – angle grinder

Most of my prior skill set was woodworking and construction framing. I had to research a lot and learn as I went for everything else. So many of the parts of this build were new skills that I improved along the way such that another build would be much easier…if I were so inclined.

Most significant lesson learned: Getting the consistency of any concrete product correct takes practice and will make or break the application.

I had to cut only about 2 dozen brick along the way because I used a kit with per-cut bricks. It was certainly more challenging using an angle grinder than a wet saw, but I still wouldn’t want to cut for an entire oven. Hats off to those of you who did. Again, I am so impressed by those of you who figured out the arch layouts.

It’s important to determine final floor height early in the design process.

As you can expect, this Forum was invaluable to me.
I noted when I used advice from others.
Those I didn’t recognize who who provided insight and knowledge: JRPizza, gastagg and fhausback. Apologies to those I missed.
Thanks to those who chimed in along the way with additional content and clarifications.

As I learned more from research and experience, I’ve tried to comment on new threads to pay it forward.
My research on the Forum helped me customize the kit in ways I believe will help me take greater advantage of the heat generated from a single firing.
I researched my build for nearly two years (part of that was during COVID lock-downs). While that is an excessive amount of time, I recommend new builders take enough time to do so. I see many new builders just diving in.

Fino alla prossima volta!