SketchUp image of stand and hearth. I just did this for fun, basically, as it didn't really help with the design. I'm not so sure about the brick arch.
Before work began. The flagstone patio was a 2006 project.
Cement footing with 1st layer of block (pre-mortar). The footing is 16" wide by 12" deep. I left the inner 2x4 forms in place, but removed the outer ones.
Plastic wrap was used to keep the center "island" from collapsing. Hole was dug entirely by hand, 5' deep, with help from my nephew.
Wall complete, but used wrong type of half-hi block! Need to fill those holes in the second row from the top. An obvious rookie mistake.
Half-hi block holes are filled with mortar and sealed (the white stuff). Center was leveled to 7" deep. Ready to build forms for foundation slab and add gravel. The pile of leftover cement chunks was used to partially fill the block cores.
What to do with all that leftover dirt? Bald spot to right is where a huge pile of dirt used to be.
Added a 6" layer of gravel, topped with a dual layer of 6 mil plastic, then constructed forms. Everything is square and level.
Topped the vapor barrier with rigid insulation, then added 2 wire mesh panels from Lowe's. The mesh fit perfectly with no cutting (leaving a 2-3" gap around outside edge). With a few cuts, the single insulation panel fit perfectly too with no leftovers.
Added 2 courses of #4 rebar on stand-offs and wire-tied it all together. Ready for cement! The pink insulation may do nothing in this application, but it was recommended and I thought it couldn't hurt to raise the frost line a bit.
I used six 10' lengths of rebar. The 15 psi of the Foamular 150 insulation board is plenty strong enough here.
Completed slab. I'm a newbie at using an edger, but I think it turned out nice enough.
Basically smooth, with a few minor dimples!
View of the back side of our house.
Side view, with back of neighbor's house.
Mockup of first course of block.
Stand almost complete (lintel not yet mortared into place).
Lintel is supported on 2 pieces of 3" angle iron. It's heavy stuff (too heavy), but it's all the salvage yard had. Cutting those blocks was a tough job a using circular saw and angle grinder.
Looking up at lintel. Blocks were fit over the angle iron.
The end of the angle iron butts up against the middle of the corner block. I filled this hole with leftover mortar.
Lintel is mortared into place. Block stand is complete!
I filled the cores on both sides of the lintel, to lock the steel supports into place.
Starting to add supports for the hearth slab.
Skipping ahead a few steps ... the hearth is done!
Not perfect, but acceptable.
The grey stuff is Quikrete Vinyl Concrete Patch, which I used to fill a couple of low spots on the top. It can be feathered to 1/16", so I used the leftover to smooth out the front of the cantilever a bit.
Many boxes of kiln-dried hardwood I received from a friend. Almost too nice to burn!
Mockup of oven floor.
Here's the template for the oven floor and vent/landing.
I had the herringbone going the wrong way ("horizontal" orientation instead of "vertical"), so this is my corrected oven floor layout. Much better!
Looks pretty flat, but perhaps those ridges could catch a pizza peel. I can always sand them down after the floor is on the hearth.
Oven floor layout marked with a pencil.
All bricks cut to shape. The curve was a lot easier to cut than I thought it would be!
The 2 bricks to the right form the base for the arches.
This was my initial plan for the shape of the dome....
...but in the end I decided to use a full brick for the soldier course.
I tapered all of the soldier bricks, but wasn't careful to leave room for mortar. I may have to make a few more cuts, but it should fit together pretty well. The bricks in the "lower" half of this picture were moved out of alignment and twisted around; that's why they look odd. Up to this point I used up one diamond saw blade.
The curved board will be used as a guide to place the dome bricks. I still have to cut the bricks for the arch, but otherwise I'm just about ready to move everything outside!
Draft arch layout.
Arch supports completed.
Oven drawn onto insulation board. Starting to lay out the floor.
You can just make out the small hole in the center of the oven floor where the thermocouple will go.
Arch walls and soldier course mortared into place. The "door stop" (reveal) on the right is a little small, but hopefully it will work.
The bricks are uneven on the side of the entryway, but that will be completely hidden.
I left a small expansion gap around the floor.
Here's my inner arch. Not quite as nice as I had hoped, but it should serve its purpose.
My saw blade was less than perpendicular, so I think that might be why some of my bricks turned out a little crooked. I fixed that problem now, a little late!
First 3 courses are done.
Fourth course mortared into place, except keystone to right of arch.
That arch looks really lopsided from this angle! Hopefully it will serve its purpose.
My "paper floor protector" is getting all warped from the water and mortar spilled on it. Cardboard would've been better.
Another course or 2 and I'll need to tie it into the arch.
5th course done. I didn't taper the full underside of these bricks, so the mortar is thicker at the back (outside) edge.
Starting to tie the dome into the arch.
I used a "bridge" to get over the arch, because full bricks could not be cut properly to "hang on" to the lip of the arch.
View of the back of the bridge over the arch.
Ninth course done.
The ball is for supporting the final few courses.
Top-down from the outside.
Inside, looking up.
This shows the thermocouple probe sticking out the bottom of my hearth. (That's a plastic sheet I'm holding up.) The probe extends 7" up into the oven floor, into the middle of a brick. I may have to put a junction box here to protect it.
Starting to build the outer arch that will support the chimney.
Beginning the outer arch, using the same form as I used for the inner arch, plus a few paper shims.
The first 2 bricks added to the arch were partially cut at an angle to better funnel the smoke.
Complete outer arch, with the chimney base begun on top.
Looking up from below. The top brick is the chimney support.
Chimney support is complete (the steel base is not attached on top).
This is my favorite shot.
Anchor plate attached with tapcon screws.
Steel buttresses added to both sides of the arch, for support. These will not be visible once enclosure is complete.
Insulation between buttress and bricks, to prevent heat transfer.
Getting some small cracks in the dome. Nothing to worry about ... yet.
Components for a home-made door: Durock concrete board (top), insulation board (right) and a slab of maple (left).
The insulation board is encapsulated within the Durock, which was then painted with hi-temp grill paint.
Since this pic was taken, I added some fireplace gasket where the wood touches the brick. Hopefully that will keep the wood from scorching.
Will this withstand several hours at 700+ degrees? Time will tell! I may be using the maple face for firewood next week....
Insulation blanket has been added, with chicken wire used to hold it in place. The ONLY thing now visible in this picture that will still be visible when the oven is done is the opening itself. Everything else gets covered.
3' chimney attached.
First major fire. Soot burned off the dome, as it should.
The air temp is over 1,000 degrees in there!
First pizza (before cooking, obviously).
In it goes...
waiting and watching, watching and waiting...
just 90 seconds later...
Success! Best ... pizza ... ever!
Track installed to support the metal-stud enclosure walls. This was as far as I got in 2008.
Sure enough .... the door cracked.
New door. Steel face this time, instead of wood. This back side will be painted black, like the front.
Wood-fired bagels & scones for breakfast ...
... and baguettes for dinner.
And a loaf of rustic Italian bread. Looks ugly, but tastes great!
The 1st picture of 2009. Framed up the walls and roof with steel studs.
The blue box in the wall is for accessing the thermocouples. Here you can also see some Romex wiring for some (hopefully) recessed lights in the gable overhang.
Added a small vent in the back, though it may not be necessary.
The roof slope is about 32 degrees.
Added Hardiebacker sheathing to the roof and walls. None of the materials around the oven are combustible, except maybe the wiring. Here you can see I extended our stone patio to the front of the oven.
I can't close up the front until I build a final decorative brick arch at the oven opening and raise the level of the landing a bit. Here you can see that I started pouring in the loose vermiculite to insulate around the outside of the oven.
Started adding stone veneer. I picked up the stone at a quarry near Chilton, WI.
The quarry sliced the stones flat on the back side. They attach directly to the block with Type S mortar, although I did paint the blocks with a concrete adhesive for better adhesion.
That was one TOUGH puzzle!
I used just over 2 bags of mortar for all the stones and grout work. I did have to do a good amount of cutting with a masonry blade to get all the stones to fit.
The large corner stones look a little out of place, but ... too late now!
I used stones with a naturally flat edge for around the opening, so I didn't have to cut them.
This shows the grout added to the stonework. (The orange glow is from the sunset.)
I love the color of these Chilton stones.
Grout is complete.
Polished concrete shelf from a local artisan. Turned out a little more brown than we expected, so those burgundy bricks there might not work for the decorative arch.
I used 1/4" shims in the back to tilt it a bit, for runoff. I secured it with silicone.
Petrified wood. Fitting for a wood-fired oven!
We'll add some kind of tile to the curved cantilever edge.
Tile installed, sans grout.
Grout done, stones sealed, decorative arch done.
First layer of stucco is on, as well as the soffits.
Getting ready for the roof. The fascia boards look "splotchy" because I had to sand where the screw-heads are. I'll clean that up later.
This plywood will support & raise the bottom row of cement tiles
Concrete roof tiles.
Chimney flashing, pre-solder.
Still need to add hip and rake trim, and a rain cap for the chimney.
Roof is done! No more tarps to deal with.
Need to fill that white space with something interesting....
Added an exterior door (half decorative / half weather protection) and a too-small metal "sun." That trim under the roof is too light, so I'll have to darken that.
Sourdough. I didn't dock these loaves enough.
Lights finally installed, soffits painted, and wood trim darkened.