After years of dreaming I've finally started - now finished

[mm289]

Looking very impressive - well done

MM

[markmckenzie]

Thanks - I appreciate the kind words.
Another layer on today using an exercise ball as a support.
Had to take care not to over-inflate this as the dome could easily be pushed apart from within.
The bricks are used to adjust the angle of support by the ball to the dome layer.
Hopefully the 2 finishing layers will go on tomorrow to be followed by the top plugs once it's dry enough to take out the ball.

[markmckenzie]

Today I did the 7th and 8th rings of bricks for the dome - all that is left is to either cut 2 full bricks down to plug the top hole or cast the plug in-situ with castable concrete.
I've cleaned the inside of the dome while the cement was still soft and will let it all dry for a good few days now.
Trying to keep the staggered bond was very difficult as the dome got higher! I'd give myself 7/10 but it is my first attempt.
Hopefully moving on to the flue gallery next weekend.

[markmckenzie]

Top hole plugged and former for front arch installed.
Front arch bricks also cut to allow flue fitment.
Hopefully, more progress at the weekend.

[oblertone]

Closure ! What a lovely feeling. Excellent work. What sort of flue are you contemplating ?

[markmckenzie]

Thanks - does feel good to close off the dome. Getting in there to clean it was very awkward.
Flue will be a 1 metre stainless 6" internal diam insulated flue from MIFlues sitting on a connecting plate with an anti-downdraft cowl on the top. I'm guessing that the top of the cowl will be about 9 feet in the air.
This will be supported by a brick outer skin back-filled with loose vermiculite - you'll only be able to see the top 8" or so of the pipe.
Next job is to fill all the gaps with castable high-temp mortar (1600F from kilnlinings) and then start the brickwork to the sides of the front entrance. Once the entrance walls are as strong as possible I'll fit the outer arch.

[oblertone]

Unless you've already bought the high-temp mortar then could I suggest a little cost saving by using 'Homebrew' ? Your WFO will only ever get to around 550c max and therefore using the high-temp stuff on the outside is overkill and more expensive.

Homebrew = Sand/cement/clay/lime in ratio 3-1-1-1 by volume.

Whatever you choose,this has been a 'template' build and will give many years of service.

[markmckenzie]

Thanks for the tip - though I already have the high temp mortar.
Starting the bricks that cover the suspended slab this weekend - which will allow me to then start the bricks around the entrance arch.

[markmckenzie]

Grabbed a few hours this morning to set the bricks around the oven and work out spacing for outer brick arch etc.
Tomorrow I hope to fill all the gaps in the dome and , possibly, lay the first 2 courses of the outer brickwork. I think I'll do the first 2 layers in blue engineering all the way round.
Fingers crossed.

[markmckenzie]

Few more hours today.
Filled the gaps in the dome brickwork with Kilnlinings 1600F castable concrete/cement - messy stuff to work with but it's just there for strength.
Then I filled and pointed the joins in the slab bricks.
Cut some templates for the outer brick dome and vermicrete outer surface.
Dry laid the first course of blues - all these will need trimming if I want to avoid big cement joints.
Still a long way to go!

[simonh]

Impressive work.

[markmckenzie]

Thanks Simon,
Hoping to do some more work tomorrow and Friday with the aim of completing the flue gallery by Sunday.
Can start curing fires after that.
Regards,
Mark

[truckcab79]

Very nice work.

Is the entire outer skin going to be in the blue bricks or are you rendering?

[markmckenzie]

Outer skin will be all brick - 2 base layers in blue and the rest in reds.
Hoping to make a start today (if the rain stops).

[markmckenzie]

Long day today with a late start and finish - ended up cleaning the brickwork and pointing joints in the dark with a head torch on.
Should be able to cement in the outer firebrick arch this Friday and insulate most of the dome with 5cm of high-temp blanket.Then I hope to build the flue gallery over the weekend.
A few pictures - forgive the terrible brickwork (pictures taken when it was still light) - it looks a lot better now.