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  #41  
Old 04-01-2013, 12:29 AM
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Default Re: 42" build in Virginia

Gudday Fabby
I feel you pain buddy, you are definitly betwwen a rock and a hard place.
You have the best advice here from a brick layer who can build an oven, multiple caste oven builder, a stone mason, and dejayoh( firewood entrance arch is awsome).
If anyone can talk you through this and build an arch its is those bunch.
I'm only a mug builder have a entrance with a lintle due to my poor brick laying skills. I'll be the first to say its not best practice,its prone to rust cracks from uneven expansion, all of everything that has been said, my oven continues to work however.
Be happy with any decision you make

Regards Dave
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  #42  
Old 04-01-2013, 04:19 AM
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Location: virginia
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Default Re: 42" build in Virginia

Thanks for all the tips.

Deejoohah, your fireplace storage looks better than my whole oven

I am going to remove the rest of the supports, build a better side reveal, and then try to build some sort of arch. If that gets too complicated, I do have a piece of regular steel that my brother has, (not galvanized) that I can always go back to. I am not sure I can cut my bricks with my grinder and diamond wheel to fit this space. My cuts have been crude at best

Any other tips on how to make the steel work better?
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  #43  
Old 04-01-2013, 04:27 AM
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Default Re: 42" build in Virginia

If I were to make an cast arch, is this poured out of refractory cement, or is there a refractory "mix" for strength? Would I have to pour the form in place?
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  #44  
Old 04-01-2013, 06:29 AM
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Default Re: 42" build in Virginia

Quote:
Originally Posted by fabby View Post
If I were to make an cast arch, is this poured out of refractory cement, or is there a refractory "mix" for strength? Would I have to pour the form in place?
I don't have experience with castable refractory (yet) but, the way I would make that arch would be to make a form on a table, then cast it as I would a concrete piece. I feel that you can control the quality better than casting in place, and less chance of damaging the piece when you remove the form.
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  #45  
Old 04-01-2013, 06:32 AM
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Default Re: 42" build in Virginia

Also, if you choose to build it from brick, why not make a template of the arch out of paper so you can make adjustments to your cuts without having to slide brick in and out of your form? Then just lay the template down and dry lay your brick to fit...once that is done you can mortar it all together.
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  #46  
Old 04-01-2013, 09:48 AM
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Default Re: 42" build in Virginia

I think I will try to make a form and cut some bricks with my grinder and see how that goes. I like the arch deejayoh built with the fancy cuts. Anyone try this using a grinder and diamond wheel?
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  #47  
Old 04-01-2013, 02:45 PM
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Default Re: 42" build in Virginia

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Originally Posted by fabby View Post
I think I will try to make a form and cut some bricks with my grinder and see how that goes. I like the arch deejayoh built with the fancy cuts. Anyone try this using a grinder and diamond wheel?
You can do it with a diamond wheel. It'll be messy, but it looks like your oven is out in the open, so it won't get all over your house like mine!

Build your arch support then dry fit the bricks onto the support. Draw the square on the front of the bricks. Cut them with the grinder, and then flip the whole thing around for installation...

Just remember to leave enough room for your mortar gaps
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  #48  
Old 04-01-2013, 04:37 PM
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Default Re: 42" build in Virginia

Quote:
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Anyone try this using a grinder and diamond wheel?
I never have but mainly because I like to wet cut firebrick. Even low duty firebrick are pretty hard by brick standards,so make sure you get a blade that can handle it. General purpose are fine, as long as stone is among the approved material listed...these are usually better suited for firebrick. Keep a soft brick handy, and use this to 'sharpen' your wheel...a couple passes are all that is needed to wear the matrix down and expose more diamonds (or tungsten carbide depending on brand) which will really improve cutting performance.
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  #49  
Old 04-01-2013, 06:51 PM
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Default Re: 42" build in Virginia

What size mortar gap should I leave at the closest contact of the arch? How about at the top of the arch?

I was thinking there should not be a gap at the bottom of the archs but butting them together like on the oven? The refractory cement directions recommend no more than a 3/8" inch gap?
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  #50  
Old 04-01-2013, 07:17 PM
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Default Re: 42" build in Virginia

As small as you can without creating tiny brick slivers in your arch.
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