The photos in this album show the process of this build and will serve as a reference for further projects. Will and myself have enjoyed this project and are now in the process of developing a Cast Oven project. Photos of our progress on this new cast project can be viewed at the end of my project world site @ https://picasaweb.google.com/waynebergman/WayneSProjectWorld
This is the 1 to 12 scale model Will and I made to show our customer the look of the oven we are starting to build them. My friend Will and I have designed this build working off of different strengths we both have from previous projects. Will has some big equipment and great skills to make his part of the build tie in nicely with the oven component. We will create a series of photos of the building process on this oven similar to the album showing my 36" Pompeii Oven.
The link to a photo album showing my own oven can be viewed at ...... https://picasaweb.google.com/waynebergman/WayneSPizzaOvenWorld#
Shown here is a jig to aid in placing the fire brick for the oven to form an igloo style Pompeii 42" oven
Unit now split into three pieces so it can come out of the oven chamber after dome complete. Should stand up for several future ovens. I will epoxy it in the next few days and hinge it at the gaps you can see left and right of center.
Will has been busy milling up the posts.
Post shown in its horizontal position is one of 6 for this project.
Stock pile of sand and aggregate.
Will on the left, Wayne on the right and Derek at the camera.
Getting ready for more fill and our gas powered compactor.
A bit of concrete today under tarp with re bar to tie together the section of foundation that will be exposed to the slope of this site. It was nice to see the sun shinning today.
Work in progress........ Blade for Will's homemade rock shear we will have up and running for the construction of the pizza stand. Thanks for the machining Steve.
More of the pieces for the rock shear.
Five down one to go!
Three inch thick granite for the ledge on top of stand. We were able to hand pick our pieces from this very cool rock yard in Coquitlam called "Bedrock Granite". Today's trip to the city maxed out Will's load limits to the limit. High heat mortar, rock, steel, & odds and ends came close to 2000 lbs.
This saw looks dangerous!
Floor protector and jig unit now complete. Epoxy treatment done and hinged so this unit can be pulled out of oven and reused after dome complete. The new RED MK brick and rock saw in the background. It will be nice to have this saw for the tapered brick cuts that are planned.
More wood for our materials pile. One more trip to the city (we have said that a few times now) and we should have all of our materials in storage ready for the build.
A nice crisp start to our morning at our local gravel pit.
Its so cold today our sand is frozen into sand balls.
Rough level on this fill of sand. Colder weather to come so after things warm up a bit we will form up our circle for the pour and rent a compactor to prep the site. We are also welding up a re bar configuration to hold the post inserts to ensure symmetrical positioning of the post work. We also want to include the rough in for electrical cable routing into the foundation so a few things to take care of in the shop before cement pour.
It was just way too nice of a day not to take this picture.
2" thick Forno Bravo insulating board. This will be used under the cook floor to keep oven tempratures inside the oven. This 2" board is equal to a 6" pour of vermiculite and portland cement for insulating oven tempratures.
compacting sand fill today
The wood is now milled. The stacked cedar shown in center is what will be used for the wood structure around and over the oven. Re bar and square tubing fabrication shown in foreground will tie in with the balance of re bar at pour. The upright component to these units will ensure a symmetrical build and an aid for its construction. Smart thinking Will!
Loading up for our foundation pour today.
Derek is on duty as well today. He must feel like spider man in there.
This went together quickly. Upright tubing and flat bar attached to re bar assembly are sitting plumb and symmetrical. These components will be fixed in this position with the pour.
Plastic tubing in place for electrical wiring. The post closest to this tubing will house the cable routing to upper part of the structure for future lighting options.
The level shown here will have 2 more inches added to its height with a facing of Flag stone. This treatment will come later in the project as we will want to protect the finished Flag surface from all our cement work still to do on the stand and oven.
Blades for rock shear have now been heat treated and ready for assembly
If testing goes good tomorrow evening this unit may be putting in its first day of work shortly. What could go wrong with a paint job like this!
Was a fun evening of testing on both brick and granite with Will's just completed rock shear. Works really well and is now in need of a name worthy of its abilities. This rock shear is either foot actuated or air driven.
This unit plowed through these samples with ease. Nice going Will!
3/8 " Aluminum stock partially cut for the start of fabrication on the cupola tomorrow.
Until the weather improves we will be getting a few things done in the garage. Although the cupola was going to be one of the last things that needed doing, it may get completed sooner rather than later. Top of the roof of the cupola will be finished in copper and the aluminum structure will be painted black. 2"x2" fir is not part of the unit but the jig for placing and clamping the aluminum components to.
Good thing I have lots of clamps!
Will made up the roof components shown here. I will seam tape both sides and epoxy resin coating on all plywood surfaces. Copper piece shown will be the lid on the upper opening. This copper piece is a mini version of what will cover the entire top of the cupola roof top.
3M Brand Epoxy Resin over all will be used with 4 oz cloth @ plywood joints.
Rock shear is breaking up this granite nicely.
Two coats of Sikkens for the under side of the inside roofing material.
I am no longer so thrilled with the number of clamps I have, what I really need is 12 hands.
Shown in foreground are the flags for the pad. These will be one of the last things to go in place. Coverage looks to be about 80 sq feet so we will have plenty to go around the oven stand on top of the foundation and a few left over for the entrance way into the storage area of the stand.
3" Granite tops for post plinths cut today in Wills shop. Looks like four very crunchy pizzas.
Four plinths complete now. Will will be directing his efforts now to prepping the Gazebo components. Steel hub for tying the rafters together will need to be welded up and the wood for the Gazebo will be somewhat prefabricated and treated with Sikkens in Wills shop before installation on site.
Copper for the roof of cupola is now waiting for its patina. We will be testing a few products in the next while for the right look. We were able to watch the fabricating of these pieces from our copper supplier and feel this step of the process can be done in house for future ovens.
Will has welded the hub up for anchoring our rafters to. All 1/4" plate steel fabrication on this component.
Rafters are now cut to final dimensions. Holes shown on the end that will be connected to the hub are for a steel T dowel that Will is machining for this part of the build.
This is a transition piece that will tie in the main body of cupola to its lid. The lid on the main body will be also made of aluminum. The lid and transition piece is structural in design and also a helper in holding back heat to the main roof of the cupola and an anchor for bolting the main cupola roof to. The angle of this transition piece is the same as the roof line, 12 machine screws will anchor the roof to this cupola frame with strength.
Posts Beams and Main Rafters
Lid is now on cupola. "Fresh Start" primer will go on next with an exterior flat black paint to follow. The last of the rafters have been given there Sikkens treatment today and if the weather cooperates tomorrow we will erect the gazebo.
Considering this is two o-clock in the afternoon....................
...........and this is four thirty in the afternoon, I thought we had a good day today. Some rain in the morning sent us home for a nap after our scafolding setup, then the afternoon sun gave us our second wind.
Our goal for today was installing the rafters complete with center hub and the first course of inside exposed 1x6 cedar roofing.
Mission accomplished! Tomorrows plans are to carry on with the inside exposed 1x6 cedar roofing. Next week to do the cedar shakes. After the shakes will come the Cupola and stand for the oven.
Day one of our Cedar Shake efforts. Our West Wing of Scaffolding is earmarked for a more professional look for our next visit. Even the Monkey tree is looking a little frightened!
Cupola is pretty much roof ready now except for the patina treatment to kick start the weathered look on the copper.
Cedar Shakes are now complete. Patina treatment on cupola is starting to blue and weather things out on Wills driveway. We plan to install the cupola in its final resting spot tomorrow and then its back to the shop for some fabricating of the forms we will be using to construct the Granite stand for the oven. Will says he has the building of these forms figured out so that's good enough for me. It will be nice to get our feet back on the ground after tomorrow and clean up all the scaffolding, ramps and ladders.
Clean up done!
For those that may be interested the link below will show a pizza being cooked in a wood fired oven. This video link below is showing the Builders own oven that was built a few years back.
The outside dimension of this wood stand will be the inside dimension of the rock stand. It will act as a form for back filling the Granite structure with mortar. This unit is built so it can be taken apart and used for future ovens. The height shown on this wood stand will be the underside height of the structure hearth that will span the Granite walls and support the oven floor and dome. The final cook floor height of 43" and the placement of the oven in relation to the stand is important at this point. The center of the vent stack for the oven based on the footprint of the cook floor placement will need to line up with the center of gazebo hub and cupola. We will be measuring twice at this stage of the game for sure!
Outside of stand is now greased up with car wax so concrete back fill doesn't stick to it. First course of stand is set with a mortar mix of 4 parts Sand, 1 part Portland Cement. The mix was kept on the dry side.
The Rock Shear shown in the foreground worked really good but was a bit of a beast to get it to the site. Will and I looked like pyramid builders getting it into the truck.
Back fill behind the first course filling in back to the form was a mix of one sand, one Portland and three aggregate. We can see today with the wind and rain we need dry weather for the stand build. The mix of hard rain and winds coming into the stand area mean tarps are in place for the overnight.
Starting to add some re bar into the stand now. Third course looking good. I am off on vacation now so Will will be watching the fort all alone.
We are up to the top edge of the back fill form now so things will sit for a few days and the arch and stand forms can be removed. We will then lay the flagstone on top of the foundation slab both inside and outside of the stand area. After this we will pour a 3 1/2" structural hearth spanning the stand to support the oven build.
For our Flagstone setting we used the "bondit" product for our mortar to key into the foundation. We also added some glue to the 4 sand one Portland mortar mix.
Flags are looking good. Once the structure hearth covers over the top of the stand this inside area will be somewhat in darkness. We may paint the inside walls to clean up the look.
Dry fitting the cook floor firebrick. Oven door shown is from my own oven but is the same size as the door that will be built for this oven. Aluminum piece up front is for a back fill of a Vermiculite Insulating pour that will but up against the cook floor insulation and continue out under the entrance hearth.
Last course of Stand Granite in place. Hardibacker and rebar shown here for the structural 3 1/2" hearth.
While this cures for a day or so we will complete the Flag work tomorrow and cook floor insulation the day after.
Forno Bravo insulation now in place for under the cook floor. A small surround pour of vermiculite insulation tomorrow and then the oven build will start.
Vermiculite pour in place. This was a mix of 5 parts vermiculite and 1 part Portland Cement and about 1 1/2 parts water. Cook floor next, which will give us a reference point to meet our granite ledge with.
Floor is set with Super 3000. Day after tomorrow it can be sanded flat before course one of the cook dome gets put in place.
Course one in place.
5th course in progress has had the bricks cut to more of a wedge shape now. This treatment of angle cutting the bricks will reduce the amount of mortar needed but also will increase the amount of fire brick needed. The fifth course and above will get this wedge cut treatment. The bricks will be set at a steeper angle as we progress towards the top of the dome, and this slope of placement is best handled with a wedge cut brick. Also pointed the inside facing of cook dome with the "Super 3000" mortar.
Looks like Lucy is sleeping on the job again. I have told Lucy she will have to hand over the keys to Baldrick (A&M's dog) for this dog friendly abode once the oven is complete.
Oven Opening Arch has had the top bricks taper cut and will be placed tomorrow. The left and right outer brickwork on the vertical component of this Arch will be hidden behind the Entrance Arch which sits in front of this one. The left and right outer pieces have only been added for extra side to side support of the vertical component to this arch work.
This is the look of two compound tapper cuts put together. Not super important down in the lower courses but will help for placing the upper section of the cook dome for sure.Shown here are two bricks from the 6th course. This treatment will also cut down on the total amount of mortar needed for this project.
Ledge work is now in place. Course 6 & 7of the cook dome in progress.
As the sixth course makes its transition to the oven entrance arch it can be a challenge to get everything to tie together in a smooth way. This layer of split firebrick will serve as a good anchor for the casting that will be poured into this area.
A series of adjustable wedges and shims used here to give the compound miter needed for the brick cutting treatment that will help with the placement of the upper rows of the cook dome. Shown here are the cuts needed for the 9th row.
Note to self..........Don't stick my finger in that extruded hole while cutting bricks. Its a nice anchor for holding the brick in place for the table slide but could be dangerous.
Duck Tape oiled up so mortar will release from it. A light application of the S3000 to help stop the MolditX pour from spilling through.
This transition from the cook dome igloo shape to the straight vertical lines of the arch way is in my opinion is the hardest part of the oven build.
Start of 8th course shown in the background. These bricks and the balance of upper dome will need to be propped up with sticks anchored to floor to hold the steep angles in place until the mortar sets.
Course 8 went good today. The extra work for the compound miter cuts are paying off now on these upper rows, if straight cuts were used instead on these bricks there would be large "V" shaped spaces at the joints that would leave large mortar gaps and would also make the bricks and the mortar want to slide out of place as they set.
Getting ready to start the arch work on the entrance way. This opening is 1 1/2" wider on each side and 1 1/2" higher than the oven entrance arch. This difference in size will give an area for the door to seat itself to.
New system for holding the bricks in place as they set. The rubber mat taped to the floor will hold my quiver of 1/4" dowels in place as they are wedged into the underside of the bricks. These last rows of brick will be tricky to cut and have them stay were they are put so we will see how this works on the 9th row.
Full scale drawing of arch work with vent pipe anchor plate in position. This will ensure the centering of the vent pipe for hub fitment and anchor plate to stucco transition. Going with the double wide verticals on the entrance and the taller facing on the arch will give this oven much nicer lines than my 36" Pompeii oven. Its tricky to get this transition from the straight verticals in the arch and its curved top to fit in with the igloo. I feel with the taller top arch at 9 inches and the 9 inch width on the verticals the overall shape of the two components will blend nicely.
Course 9 in place. All fire brick at front of archway top and sides will be faced with more firebrick cut to a one inch thickness.
Even though I inked in number 8 on that brick I am pretty sure its course 9!
10th row now in place and the vertical uprights for the entrance arch as well.
Foam shown in entrance way with its plastic lid will be used tomorrow for a back fill on the castable unit for the very top of the dome. The plastic lid will be coated with oil so it will release from casting. The Moldit-X mortar will be used for this mixed with a 2% by volume of stainless steel needles. The stainless will give the pour extra strength. This is the method I have used on my 36" Pompeii Oven which worked and continues to work very well.
Stainless Steel Needles for the casting.
Keystone will be cast from the Moldit-X and the stainless needles. The plastic lid has been secured in place from inside the oven and bits of crazy rag soaked in vegy oil have been squeezed in under the last row of fire brick to help the transition from castable to firebrick receive its pointing.
Will has returned from the City with our Copper Eaves Drips. Install went smooth and really dresses up the structure.
Looking down into the keystone pour. Bottom one inch done in the morning and given a chance to set before the last 3 inches poured in place at the end of the day. I felt pouring it in two stages lets the smaller first pour set and harden so not so much weight sits on the foam mold underneath. The keystone loads itself into the dome and kind of locks everything into place. This last piece to the dome is the key to its strength and self supporting design.
Laying out the facing on a full scale drawing to help get the cuts right and check on scale. This drawing has been very handy in planning the vent area and for checking the flow of shapes that will converge from the entrance to the igloo.
4 pieces shown in the entrance landing are for the oven vent. This is a space that will transition from a 4 1\2" x 16" rectangular shape up to an 8" circular opening.
This photo and the six that follow are of a door I have made a while back. One of the photos may look out of place as it is being used on a different oven at an earlier date.
My first oven at our home in Garden Bay
First row of Arch top shown here is the transition component from just outside the oven opening to the anchor plate and vent pipe.
Second of the three rows in total for the Arch top.
A combination of grinding some of the fire brick, cutting split bricks and the MolditX castable for the anchoring of the vent plate. The vent plate will be mortared in place tomorrow with more of a fill in with the MolditX to level out the Anchor plate.
This thick angle of Aluminum and the clamp make a nice adjustable fence for the ripping and wedging of the bricks much more predictable. All the little grains of firebrick from previous cuts need to cleaned off the bed and fence to keep things plum and on angle. Seems like you have to wash up the deck and fence on each cut or things can get a bit out of wack.
Anchor Plate for pipe is now in place. Hope to install the vent pipe, insulation, and then start the curing process with a series of controlled fires in the next little while.
Dry test fit of the half thickness fire brick for the face of the oven entrance way.
Ring for Kiln Shelf containment built with pivots so it can be slid in and out of oven opening. When folded flat it will hug the outer edges of cooking sub floor to hold it together as one unit. A mix of 50/50 fire clay and sand will level the kiln shelf pieces on top of the main fire brick floor. The purpose of this unit is to have a slightly raised cook floor for pizza. After the firing and heat up of the oven for cooking pizza's you typically rake off the wood coals and ash to the side before placing the pizza's right on your cook floor. With this raised floor it helps stop the ash falling back into the area where you are cooking your food. It has worked well on my oven so we will give it a try here as well.
Insulation now in place. Mesh is attached over top of insulation for the stucco to key into. Pipe to be installed and the start of our curing in the next couple of days. This will give all mortars a full week of cure time before the fire cure begins.
Will and Janet have done a nice job with the artwork on the Decorative Arch work. Will has carved out the relief into the brick and Janet has painted this area in a contrasting brown.
Bricks are set now and will be pointed tomorrow.
The facing on all the front decorative split brick was masked with duct tape before pointing.
Pointing done now and the masking helped keep the mortar out of the relief work and made the clean up easy. Will is shopping for a sealer to be used on the split bricks to help with future cleaning from oven smoke deposits.
The arch shapes from the ring beams take on a fluted look in the reflections given from oven pipe.
First Spark! Day one of the curing process. 300 degrees max today for 4 or 5 hours and then door up for the overnight. This curing process continues for 6 or 7 more days with each day upping the heat by 50 degrees.
Infrared Thermometer comes in handy for reading temperatures anywhere in the oven. Supposed to keep first day curing under 300 degrees so you can see I was behaving myself. Its very tempting to go for the monster fire. 7 days till MONSTER!
Wayne and Lucy
Will looks pleased as well.
Door can be propped up in this fashion for use with a working fire but is more commonly used when the fire and ash are pulled from the oven for cooking breads. With the door tipped as shown in this photo the top of arch is left open to vent smoke. When making bread and the fire removed then the door can then be set upright to oven entrance so heat can be retained for baking applications.
This unit comes in handy for spinning pizza's while working the oven. 1/4" Aluminum round in 1/2" Aluminum round inset in a spring handle. The tip is an Aluminum rivet that has been hand set to retain the pin. Once the pizza has been set on the cook floor it only takes a few seconds for the dough to crust up enough to use this tool for spinning. Much easier than spinning with the peel. Two peels are still needed for placing and pulling pizza's out of the oven but this is a handy addition to the tool kit.
A little over 3 feet in length seems to do the trick.
Curing has gone well. This morning, after yesterdays last day of fire curing the temperature in the oven had held to 350 degrees. I guess we could have cooked a chicken in there while laying our first and second coat of stucco with the retained heat from yesterday. Oven will sit now for one week while the scratch and brown coat cures then our top coat of color and texture to follow for our last day on the job.
Landscaping is complete now and looking very nice. Waiting for some sunshine now, and the last coat of stucco with coloring to take some final photo's.
Final top coat of stucco shown here. Project is now complete. Stucco can cure for a bit and then the first pizza cook. Looking forward to the experience of cooking the first pizza, should be fun.