Ok, enough talking, here are loads of pictures to back up my words of late
So back to square one. A clean base and this time around we went for a soldier course for the first row. In short that means half bricks on their side. Idea here is to give us more "fire room" around the edge of the oven which should make it more usable at the cost of forcing the dome to be more curved to keep the height in check.
We built from the door way bricks around so one fixed reference, these are not quite square on to the circle of the dome floor due to space issues but close enough.
First angled course goes in. Again we are cleaning up between each course with a damp sponge. The homebrew cement was great to work with. Cheated though using the rapid set cement. Meant we had about 20 mins to work with the cement so only made up a 1/2 bucket each time. Up side is the whole build was quite quick as the bricks held their place in a short amount of time so less time hanging around for bricks to "set".
Some spacer bricks now added in to avoid "H" joints. Could not get them all but certainly reduced the number from last time. Strength over beauty this time!
Cutting up the arch with a little form (again cut from the wood the bricks came on).
Shot of some of my angles. All the edged that needed to be "clean cut" had the grinder run down them. This would only go an inch into the brick though and then finished off with a chisel. Top tip was to run the grinder over the proud island of brick that appears when you split them this way. Then its easy to just chisel them off for a clean finish.
One for Terry, finished arch, powered by cider...
Filling in the tricky arch-dome transistion
Everything when a bit "egg" shaped at this point...
...so we tried to fill the gap with carefully crafted brick...it sort of worked.
Offically higher than our last attempt! Woohoo!
The iTool stopped being much use at this point so time for a change of plan. I was also working on my own at this point too so less camera time I'm afraid. First thing was to get the iTool out, the bit they don't tell you is to make sure it will fit through the doorway so you can get it out. Luckily I'd worked that bit out before hand
Notice this is the same day I finished the arch, rapid set cement for the win, actually the arch was self supporting without any grog in it so was confident.
Then I built a stand inside the dome out of bricks and another sheet of wood and chocked this up to the height of the next course of brick. Plan was to simply use wedged to on this platform to hold the bricks in place. Works a treat but was a bit messy.
Then we topped out! It was not my finest work I have to say but we did it and it held up. So much so that within an hour I took the dome support and started cleaning up (brave I know but remember I was against the clock with the wife, there are only so many weekend she will let me use up).
Inside is not too pretty up top, not my finest work but it should do:
First of 5 drying out fires so far.
You can see the effect as the bricks dry out but the mortar is still darker (eg still damp). Don't worry this one was take really early on, I didn't fire it in this state
Then blanket time! I'm on coat two at this phase. I found wrapping it around and then tapering in the side the best way. Took lots of shots of this as its one of the bit I see skipped over on the site so far, hope it helps someone:
Cable ties are great for getting some tension in the wire wrap!
Found it cut really easy with a stanley knife blade, wear gloves though as its very itchy stuff! Notice how the first layer is cut nicely so it all lays flat. Ended up with lots of long triangle bits which I used to insulate the very top of the dome.
Capping off the second coat I laid the remaining foam over the top, I wanted a one peace capping rather than lots of little bits as I had in the first layer. Carefully cut it out and stuffed it down, lovely fit.
Chicken wire time, was careful to get the bit over the arch on nice and tight (without compressing the foam though). Wired all together using welding wire! Only just had enough mess though.
Here is my top tip, use long nose pliers to twist the wire mess to tighten it up where there is any slack, worked a treat.
Finished dome all insulated.
Now time for the arch, time to get technical. Due to rain stopping play I went inside with a brick, pencil and paper and came up with my cutting list. Then transferred this onto all the bricks I'd need with the exception of the key stone which I'd cut to order to give me some slack.
Cut arch bricks going on. I had the smart idea to carve into the brick to leave a lip/step that my render could go up to. Thought it would look better. Pig to have to cut out that many though but the finish effect should be worth it I think.
Now the tricky bit, that chimney and closing the arch!
Seems I skipped taking pics during the arch keystone bit! But here is the chimeny hole from the top once done. Again notice how I've had to cut into the chimney stack bricks to keep the hole as big as I could:
Here is my chimney pot, my brothers unwanted patio heater. Though about using it as is but its too narrow for my arch so I chopped it up instead...red dust everywhere, horrid!
Finished chimney!
On with the render! Its castable cement, works quite well. Some one said it will end up looking like yoda's house...I have to agree
And then rain stopped play (and the Olympics 100m final).
More rendering tonight if the weather holds. Thanks for reading!
Pete
