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  #11  
Old 01-16-2012, 02:56 PM
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Default Re: 40" WFO in the New Orleans

I brought myself a Harbor Freight 10” wet saw over Christmas. As you can see, HF changed the color on the wet saw from orange to blue. However, everything else seemed to be pretty much the same.

I built a table stand for the wet saw using pressure treated wood. HF’s table stand for the wet saw was available but I didn’t like HF’s design because I have to move the wet saw with the table over a slope grass which would be hard with HF’s table stand. So, I decided to design my own table stand for the wet saw. I incorporated a HF’s hand truck into the table which allows me to move the table stand with the wet saw around easily. The wet saw is bolted and secure on the table. I use a scrapped 2.5" L angle iron to lock the hand truck to the table stand. If you need to use the hand truck for something else, you can just remove the angle iron. I am so glad that I did this because of my minor back problem and the idea of carry the wet saw every time I need to use it for this project is not good. This is my contribution to make life easier for whoever is planning to build a WFO with HF’s 10” wet saw.
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40" WFO in the New Orleans-img_0391.jpg   40" WFO in the New Orleans-img_0392.jpg   40" WFO in the New Orleans-img_0393.jpg   40" WFO in the New Orleans-img_0395.jpg  
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If you feel lost with building your WFO, just pray to St. Stephen who is the patron saint of bricklayers.
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  #12  
Old 01-16-2012, 08:17 PM
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Default Re: 40" WFO in the New Orleans

Good Idea to get the saw back and forth to the site. I was fortunate enough to be able to set mine up under a nearby shed/one day to be a shop (no covenants in the sticks where I live) The 30$ blade that I got from HF has cut a cr_p load of brick. Keep that tray cleaned out and save all the contents. You may want to use that source of fire clay.
I am following your build closely since you are near my area and in my favorite city. There is no place like "New Awlins".
I am glad that I did not have the foundation issues that you have faced. Also, I will was planning to hold off to the very end for the "reveal" to name my oven. (There is a thread on this site which covers this subject, http://www.fornobravo.com/forum/f30/...-if-17069.html (Have you named your oven, if so, what is it, posts a pic too.) which was started by Brickie). Since you are the real deal, I will wait atleast until you have keystoned your dome. By that time you will definately have an idea.

Also on a personal note: I feel your pain. From one member of the who dat nation to another IT SUCKS
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  #13  
Old 01-16-2012, 08:25 PM
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Default Re: 40" WFO in the New Orleans

There are only three type of fire brick from three manufacters that is being sold here in New Orleans Area. First, there is low duty firebrick from Elgin Butler (Texas) which is about $1.65 per brick. DON'T USE THE FIREBRICK FROM ELGIN BUTLER BECAUSE IT IS VERY SOFT AND THE CLAY IN TEXAS IS NOT IDEAL FOR FIREBRICK FOR WFO. Then there is another low duty firebrick from Whitaker Geer (Ohio) being price at $2.35 per brick. This particular firebrick has alumina content around 27% which prefect for bread baking. Finally, there is a meduim duty brick produce by Alsey Refractory (Missouri) and it has alumina at 37.5% which is prefect for pizza or flatbread. Firebrick with higher aluminum tends be more conductive, therefore, transfers heat to bread or pizza at a faster rate. However, bread usually has more mass and it takes a lot longer to cook than pizza. Higher alumina firebrick usually cause the bottom of the bread to burn before the bread is completely done. Firebrick with alumina between the range of 25% and 30% would be perfect for bread and it is also would work for pizza as well but meduim duty should give pizza a better result. You may use medium duty brick to bake bread as well but the result won't be as good as a low duty firebrick.

Therefore, I will be using low duty firebrick from Whitaker Geer for my cooking surface and medium duty for my dome/vent area. I like bread just a little bit more than pizza. As for the dome, arches, and vent area, I am going with medium duty because it is stronger and supposed to handle better as well.
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If you feel lost with building your WFO, just pray to St. Stephen who is the patron saint of bricklayers.

Last edited by banhxeo76; 02-14-2013 at 08:00 AM.
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  #14  
Old 01-16-2012, 08:54 PM
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Default Re: 40" WFO in the New Orleans

Gulf,

Giants' victory over the Packers just put more salt into the wound since we "could of, should of, would of" host the NFC Championship game in the Dome. Now that the Saints is out of the playoff, I have more time for this WFO. Anyway, don't forget about 2009 season!! However, it would be nice to get another.

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If you feel lost with building your WFO, just pray to St. Stephen who is the patron saint of bricklayers.
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  #15  
Old 01-16-2012, 09:05 PM
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Default Re: 40" WFO in the New Orleans

If you have a pu truck and can drive a few miles, call Columbia Block and Brick in Hattiesburg and/or Columbia, MS. They have a wire cut (medium duty) brick that I was able to get for $1.45 each. They were talked down from $1.65 each since I new that I would need at least 300. Some of them are a little curved but was able to sort out plenty that were straight for where it counts. They are good enough for the dome since most dome bricks are halves and less. My floor bricks were $1.87 each from Boral Brick.

This may be a little to far for you to drive to make up the difference for the gas costs, but at least price some outlying areas such as maybe Slidell. Bricks are cheaper in the Hattiesburg, MS area where I am from. I believe that there may be a better deal out there for you in some of the outlying areas from New Orleans.
Geauxe Saints!
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  #16  
Old 01-17-2012, 01:44 AM
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Default Re: 40" WFO in the New Orleans

Nice progress! I like the cantelever design of your heart. What are you using to fill the center void?
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  #17  
Old 01-19-2012, 06:11 PM
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Default Re: 40" WFO in the New Orleans

Quote:
Originally Posted by sharptailhunter View Post
Nice progress! I like the cantelever design of your heart. What are you using to fill the center void?
The center void (only 4.5" deep) will be filled with 2" of insulation ceramic board, 5" of firebrick (two layers of 2.5" firebricks). However, the first layer of firebrick will flush to the same height of concrete countertop which I will place one layer of fire brick on part of the concrete countertop for the vent landing area to even thing out. There is no insulation under the firebrick in the landing vent area. I know that I am going against the grain with most people who have built their ovens on this forum. I just don't see the need for insulation under the firebrick around landing vent area because I believe the heat supposed to rise up through the brick in this area and then through the vent (if heat even transfers that far).

Only time will tell if I make the right decision.
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40" WFO in the New Orleans-img_5066.jpg   40" WFO in the New Orleans-img_5063.jpg   40" WFO in the New Orleans-img_5073.jpg  
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Last edited by banhxeo76; 01-20-2012 at 09:17 AM.
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  #18  
Old 01-19-2012, 09:04 PM
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Default Re: 40" WFO in the New Orleans

Okay, I think I pretty done with the main design for my WFO. I will be building a hybrid dome, meaning that my dome will not be too high or low. At first, I was planning to do a flare out openning vent. After I laid some bricks to do some mock up, I decided to just go straight vent opening because I believe straight out vent provides more solid structure than a flare landing vent.

Of course, my diameter will be 40".
Dome height will be 17.5" high (close to 63% ratio to door height)
Inner Arch opening will be 11" high & 19 " wide
Landing Vent will be 23" x 13.5"
Outter Arch will be 12.75 high x 23" wide

I am thinking about extending the fire brick layout all the way to the edge of the counter top. My other option is to increase the countertop by using the premix concrete countertop w/ color and leveled it with the fire brick which stop at the landing vent floor. However, I can decide on this a few months from now.
Attached Thumbnails
40" WFO in the New Orleans-img_0369.jpg   40" WFO in the New Orleans-img_0387.jpg   40" WFO in the New Orleans-img_0386.jpg   40" WFO in the New Orleans-img_0388.jpg   40" WFO in the New Orleans-img_0396.jpg  

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If you feel lost with building your WFO, just pray to St. Stephen who is the patron saint of bricklayers.

Last edited by banhxeo76; 01-20-2012 at 11:38 AM.
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  #19  
Old 01-20-2012, 12:19 PM
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Default Re: 40" WFO in the New Orleans

As soon as the weather gets better on the weekend, it is time to mortar them bricks together. I am going with homebrew rather than premixed refractory mortar due to cost. I was vacationing in DFW area during Christmas and saw a few posts by Lburou in regard to ciment fondu (which is a Cal. Alum. Cement) and he used the ciment foudu for his homebrew. I brought a bag of ciment fondu (90lb for $75) and a bag of fire clay (100lb for $25) from Wesco Refractory (those guys at Wesco were great) and drove home to New Orleans. No masonry vendors in New Orleans area sell fire clay anymore because nobody makes their own homebrew for fireplace anymore. Everybody is selling the wet mix which is a big "NO, NO" for outdoor WFO. I brought some fine sand from local hardware store and I have to say that Quikrete’s fine sand is very similar to the Quikrete’s play sand, if not the exact same thing. I went ahead mixed some homebrew and did some test on the scrap bricks to test it out. Dried brick really absorb the moisture out of the mortar very fast and make it impossible to work with. Then I used soak the bricks (for a good 15 minutes) before mortar them and it seems to be more workable. Peanut butter like consistency is an idea mix but it seems to be very hard to work with even with a wet bricks. Running toothpaste like consistency is more workable but the strength of the mortar won't be as strong as the peanut butter consistency. I guess I will have to follow DinoPizza’s suggestion by using the running toothpaste consistency for the inside and fill in later with the peanut butter like consistency on the outside.

This WFO project is soooo much fun. I just love it.
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Last edited by banhxeo76; 01-20-2012 at 12:22 PM.
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  #20  
Old 01-23-2012, 06:57 AM
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Default Re: 40" WFO in the New Orleans

Little bit more progress over the weekend. The mock up inner arch looks better than I had anticipated. I just hope that mortar up inner arch will look just as good as the mock up after I have done mortar them together. Hopefully, I can mortar some time brick this week.

I have to clean up all the tapered bricks before I can mortar them. If I don't clean them brick, the mortar won't stick on the brick as well as it should because the dust on the brick will act as released agent which is a bad thing. I hate cleaning but it is necessary.
Attached Thumbnails
40" WFO in the New Orleans-img_0404.jpg   40" WFO in the New Orleans-img_0406.jpg   40" WFO in the New Orleans-img_0410.jpg   40" WFO in the New Orleans-img_0411.jpg   40" WFO in the New Orleans-img_0413.jpg  

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Last edited by banhxeo76; 01-23-2012 at 07:08 AM.
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