Greg & Karen's 42" Deck WBO in MI

[glindhout]

Re: Greg & Karen's 42" Deck WBO in MI

I didn't get as much done as planned yesterday since we had parent/teacher conferences and a high school soccer banquet.

But I managed to get the indispensable tool welded together, ground down the floor bricks with a diamond cup wheel (it's REALLY smooth now!), and cut and assembled the first row of bricks...

I can't remember who posted the suggestion that I read (sorry), but I decided to cut the bricks on an angle to minimize the grout lines between. Attached is a drawing that I used to determine the size/angle, and a YouTube video (next post) showing the cuts using a simple wooden jig on the HF saw. It worked great, and hopefully I'll be able to use this method on the first couple of rows. Any advice on how many rows I'll be able to build with these half bricks??
.

[glindhout]

Re: Greg & Karen's 42" Deck WBO in MI

Here's the YouTube video showing the brick cutting... of course, I cut them in "bulk" before changing the jig each time...

[ThisOldGarageNJ]

Re: Greg & Karen's 42" Deck WBO in MI

Nice video, I like the way you worked that out....

wow Pics and video...

Very Cool
Mark

[glindhout]

Re: Greg & Karen's 42" Deck WBO in MI

I got the entryway walls cemented together, and the inner arch bricks cut today. I also got enough angled bricks cut for at least two more rings... If I get motivated, I may crank up the heater and head back out to work tonight.
.

[ThisOldGarageNJ]

Re: Greg & Karen's 42" Deck WBO in MI

Cmon Greg,

Get the heater going.........

[jmhepworth]

Re: Greg & Karen's 42" Deck WBO in MI

I had my arch bricks all lined up the way you did and even cut one for a keystone. Then when I actually laid them, I ended up with enough more mortar between them that the keystone needed to be re-cut. Did anyone else experience that, or am I the only really poor brick layer?

[kebwi]

Re: Greg & Karen's 42" Deck WBO in MI

Just had the same problem yesterday jmpehworth. Measured and cut my inner-arch bricks to a fairly tight tolerance. Kept my mortar gaps very small and made every attempt to keep the bricks aligned with the protractor drawn on my arch form. Nevertheless, the last brick wouldn't quite go in...or might have, but would have had no mortar gap at all and would have pushed the other bricks, breaking their bonds...not that I didn't break most of them before finishing anyway (the RIGHT way to do this is probably to set one brick (per side of the arch) per day...UGH!). Anyway, I'm obviously going to shave that last brick before placing it.

...and since several of the bonds broke many minutes after initial placement (as subsequent brick-placements shifted them), I question the long-term strength anyway, regardless of recutting the keystone. It'll have to rely on true arch-mechanics to stand up!

[mfiore]

Re: Greg & Karen's 42" Deck WBO in MI

Looking great, guys! At this rate, you'll be done before the deep freeze.

[Dino_Pizza]

Re: Greg & Karen's 42" Deck WBO in MI

I'm with Joe: Even though I made my entry-arch mortar "soupy", I could not squeeze in my top 3 bricks. I had to remove them and re-cut them so my keystone had some mass to it.

Nice job on the 1st course Greg. Good job planing your cuts as well. As you go up, make small adjustments every other row or so since it's so hard to keep the interior joints (horizontally) at zero since some mortar usually gets in there and adds 1/64"-1/8" and it may throw your final height dimensions off a bit.

Say, you can use your heated "pizza-hut" tent you've got going for ice fishing later when you're finished with the oven! kidding...Dino

[DaveW]

Re: Greg & Karen's 42" Deck WBO in MI

....

But I managed to get the indispensable tool welded together, ground down the floor bricks with a diamond cup wheel (it's REALLY smooth now!), and cut and assembled the first row of bricks...

Greg, I am thinking of grinding my surface also. Any tips on doing this? Did you keep the surface wet? Was it difficult to avoid swirl marks or digs? I am unhappy with the unevenness of my floor but I am also a little nervous about making it worse.
Thanks, Dave

[glindhout]

Re: Greg & Karen's 42" Deck WBO in MI

Dave,

I installed the soldier course and the entry bricks before I did the grind so that the floor bricks couldn't move around. Even though the bricks are relatively soft, it still took awhile to grind smooth--even with a brand new 4.5" diamond cup wheel. I probably should have done it with a wet surface, but I kept it dry. It creates a HUGE amount of dust and fireclay, so make sure you wear a good respirator.

The key is to make sure you keep the grinder relatively level and move quickly. You shouldn't have a problem making a gouge in the bricks. If you're nervous about using a diamond wheel, you could always start with low-grit polishing disks and take your time -- you can't possibly mess up with those!

Greg

[Dino_Pizza]

Re: Greg & Karen's 42" Deck WBO in MI

Like Greg said, move quickly and use deft hand (which will come in handy on that odd brick in a row that is somehow taller than the ones next to it later on in your build)

That said however one of the pro's on this forum said to me to always take a pizza peel and slide it in and out on the floor first. You will be surprised at how well the herringbone pattern works to resist anything catching. Then, I only took down the 6-8 highest EDGES and left it at that. However, a really smooth floor is beautiful thing to look at. -Dino

[DaveW]

Re: Greg & Karen's 42" Deck WBO in MI

Thanks Greg and Dino. I kept the hose on the bricks so airborne dust was minimal. However the results were not good. To see my frustrated explination see here...

http://www.fornobravo.com/forum/8/da...html#post71305

I wish I had read your replies before I dove in! Anyway, the plan at the moment is to replace the floor with new bricks. And if I end up with a high spot I will go at it with a sanding disc.
Dave

[stonylake]

Re: Greg & Karen's 42" Deck WBO in MI

Greg, how far along are you? I keep thinking that I should have just continued after i built my hearth, but it is Michigan. I'm going to set up a wet saw in my shop this weekend, and hopefully cut some brick over the Thanksgiving holiday. Did you buy insulation board at Industrial? What was it?

[glindhout]

Re: Greg & Karen's 42" Deck WBO in MI

Stony,

I have been stuck on the fifth ring for over a week, despite the nice weather because we've been really busy at work, etc. I'm hoping to continue working as long as I can with my heater, but I'll have to give up for the season as soon as the snow starts accumulating on the "pizza hut".

I bought my insulation board at Industrial Brick -- it's 2" Duraboard RGLD board, milled one-side (rough on the other) -- it's cheaper than the milled 2-sides and works great -- I used 3 sheets of 24x48", which gave me a small piece leftover for my door eventually. The total cost w/out tax was 377.28 ($15.72/sq ft).

They also have boxes of 1/2" insulating blanket available as mill-run end cuts (about 40" x 40") from their die cutting service. It's only $50 per 100 sq. ft., so I'll probably use that around the oven when I'm ready to insulate.

I bought hydrated lime and 250 fire bricks at Spruit Bros. for $1.22 each. And got a 50 lb bag of fireclay at Belden Brick for $18.00.

Greg