#11  
Old 03-24-2011, 07:25 AM
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Default Re: Strength vs Simplicity

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Originally Posted by BeanAnimal View Post
Do you see an issue with dry fitted vertical joints?
I didnít see an issue with it. I thought of it as an advantage. With all the expanding and contracting going on, I felt it would minimize cracking. I have no clue what is happening at the back since itís covered.
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Originally Posted by BeanAnimal View Post
Are you the only builder who has used no mortar in the vertical joints and instead dry fit them?
I am not aware of any - I know a few have come extreamly close. I think if someone had the right saw and time you could dry fit the entire oven other than the entry.
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Old 03-24-2011, 08:14 AM
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Default Re: Strength vs Simplicity

I had thought that a total dry fit would work as well, but the angles just get so complex. I have laid out the entire dome in autocad and can see that one would need a CNC machine to cut anything after about the 4th chain. Even the bottoms of the 1st-3rd chains would need a bit of easing to flit perfectly flat.

I am going to go ahead and attempt to work with dry fit sides and attempt to taper the tops and bottoms for a cleaner fit with mortar.

Is that 4" of FB board you used on th hearth?
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  #13  
Old 03-24-2011, 08:40 AM
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Default Re: Strength vs Simplicity

Yes, I used 4 inches of board under the hearth. You mentioned a CNC machine. I think the ticket would be a water jet.
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Old 03-24-2011, 09:46 AM
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Default Re: Strength vs Simplicity

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I think the ticket would be a water jet.
For the cost of water jetting 20 different styles of bricks in two planes you could buy multiple modular ovens.
Really, look into tapered firebricks. They're worth the cost if you're going to cut that third plane for perfect fit.

Harbison Walker has a branch near you. Call them before you commit yourself to months of work. Everyone's time is worth something.

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Old 03-24-2011, 11:14 AM
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Default Re: Strength vs Simplicity

I used the large saw to make rough tapered and/or compound cuts and then used an angle grinder on each brick as I went along laying them. Not precise, but it minimized joint gaps on the inside surface. I left the gaps large on the dome exterior and filled them with home brew mortar.
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Old 03-24-2011, 01:13 PM
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Default Re: Strength vs Simplicity

I have contacted Harbison and requested sizing and pricing information for their medium duty fire bricks. The other local supplier lists their bricks as 8.75 x 4.25 x 2.5 so not ideal, but $1.30 each.

Harbison also carries many blanket and board products so I will get pricing and data sheets to see what is suitable.

I am very excited to get the planning finished and start the foundation (will create a build thread in the proper forum when the work starts).
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Old 03-24-2011, 05:40 PM
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Default Re: Strength vs Simplicity

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For the cost of water jetting 20 different styles of bricks in two planes you could buy multiple modular ovens.
I totally agree with you David. I'm just saying that if you had access to one, it would be a fun project to build an oven that way.
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Old 03-27-2011, 03:35 PM
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Default Re: Strength vs Simplicity

As to the brick cutting: I got a used 14'' saw off of craigslist and have not replaced the blade yet after a lot of cutting (oven and kitchen project). As stated here before, the key is to have a good water pump and not force the bricks and your blade should last a very long time.
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Old 03-27-2011, 05:01 PM
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Default Re: Strength vs Simplicity

I think I will buy the $99 14" chop saw and retrofit it with a few water sprays and a diamond blade. That way I can set the 10" HF saw up for the angle cuts and the 14" for the bevel cuts.
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Old 03-27-2011, 06:26 PM
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Default Re: Strength vs Simplicity

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Originally Posted by dmun View Post
We've learned that the best commercial oven builders in Italy only trim the inner edges of the bricks so that they appear to fit on the visible side, and fill the outer gaps afterword.
I was considering cutting perfectly shaped bricks for minimal joints but after seeing the work of some traditional Italian builders decided it would make negligible difference in the end. If you want a good finish on the inside with minimal joints you only need to taper the bricks vertically.

Actually, I found it harder to get the mortar into the joint if I also tapered the bricks from front to back.

And you will still end up with some flat V-shaped mortar joints on the tighter chains because the circle is not actually a circle but a series of straight lines.
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