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  #11  
Old 03-18-2014, 10:02 AM
deejayoh's Avatar
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Default Re: 42" Started in Fountain Hills, Arizona

My $0.02...

Low duty bricks work fine. Don't worry about that at all. $3.89 is robbery! hope you paid much less.

As for the fireclay - take back what you bought. Start cutting the bricks for the floor and then clean out the saw tray. You are going to end up with so much of that stuff you will be wondering where to put it all... The brick cuttings in the tray are basically fire clay and will shed most of the water pretty quickly. Mix them 50/50 with dry sand and use that for leveling.

Try to find fine sand - not mason's sand - which has bigger particles in it. You can usually get a range of sand types at a concrete/masonry vendor.
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  #12  
Old 03-18-2014, 10:06 AM
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Default Re: 42" Started in Fountain Hills, Arizona

You've got it right about the "fun finding materials" part - that's part of the unique experience with this project.

You'll be perfectly fine with the Low Duty brick - if that is what you purchased. If pricing in your area is anything like mine $1.44 would have been pretty good. I paid $1.77 for my dome bricks but $15/sqft for my hearth slabs (which I believe to be Medium Duty). If I were to do it over again I would use the cheaper low duty brick for the hearth too. Medium and High Duty bricks might actually be more challenging cooking surfaces - like soap stone. If you had to pay $3.89 for you dome bricks..my sympathies to you…all I can say is that it will all be worth it in the end.

In regards to the underlayment, I can’t comment as I did not use any (I scarfed any High spots I found on my insulating brick with a knife until I was satisfied that my hearth was level). Using 2 sqft slabs helped too. I didn’t have to “scarf” much but an underlayment would probably be quicker anyway.

Look forward to seeing more pictures.
Good Luck
AT
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  #13  
Old 03-18-2014, 11:17 AM
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Default Re: 42" Started in Fountain Hills, Arizona

I personally prefer low duty brick, and have used them in most of my builds. The lower conductivity is especially helpful at high temperature, when burning the crust is more of a challenge to prevent.
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  #14  
Old 03-18-2014, 11:26 AM
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Default Re: 42" Started in Fountain Hills, Arizona

Also, some people have mentioned having difficulty with 1:1 ratio of fireclay:sand for the leveling the hearth brick. You can make a leaner mix with no ill effects, the clay is there to add some adhesion when setting the brick, little more.
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  #15  
Old 03-18-2014, 12:55 PM
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Default Re: 42" Started in Fountain Hills, Arizona

gordy,

a dry mix of 50/50 fire clay and sand under floor and on top of CF board will work fine for leveling if you really need it. I found my CF flat enough not to have to place it Do "NOT" mortar down floor brick perimeter, you want it to float during thermal expansion.
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  #16  
Old 03-19-2014, 09:06 AM
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Default Re: 42" Started in Fountain Hills, Arizona

Love the start of your build! What will you be using your gas line for on that left side?
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  #17  
Old 03-21-2014, 09:47 AM
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Default Re: 42" Started in Fountain Hills, Arizona

Thanks for the reassurance on the low duty firebrick.......it was bothering me a bit. I ended up paying $1.24 per brick after they sensed my irritation of misquoting me over the phone.....and the 80 mile round trip. The regular price for the LD brick was $1.60.......contractor price $1.44........torqued-off oven builder price $1.24!!! Now I just need to make the trip again to return the fireclay.......joy. At least it is on my way to Marjon ceramic supply where I can get fireclay.

Good eyes Maseuss, yup that is a gas line. I had to relocate it from the back left corner of the oven. When I built the house I buried a 250 gal LP tank in the fron yard and ran gas lines where I thought I might need them. This one was for a gas BBQ years ago, haven't used it since getting my Big Green Egg. I decided to come off the existing valve with an elbow and stub it out in the front of the oven. I did not want to unscrew the existing valve since I had no way to keep the innerwall pipe from turning....hence possible gas leak!!! I formed out around the valve to keep it accessible. Probably never use it.

OK, no mortaring of the floor whatsoever......good point, that would screw up the expansion capability. I'll just try and avoid small pieces, at the cost of altering the herringbone pattern a bit.

I am shoehorning this 42 inch oven into the available space. It will only leave 3 inches from the uninsulated dome to the house wall, but only at two tangency points. Plan on at least 3 inches of ceramic blanket, but might double it since it is cheap.......$35........pick-up price. The house wall is 1/2 inch stucco over 1 inch styrofoam and then the structure is urethane core structural panels.....so, shouldn't be an issue. The depth of the slab was limited to 63 inches because of the window. So I am left with 12 inches from the face of the inner arch to the edge of the slab, should be barely enough, but still laying things out.

Thanks again for all your replies.

Gordy
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  #18  
Old 04-07-2014, 12:35 AM
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Location: Arizona
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Default Re: 42" Started in Fountain Hills, Arizona

Great to see another build in Arizona! I'm in Glendale, and I wish I had your view to go with my oven! I was going to recommend Marvel...they did right by me. I bought the beige firebricks from them for my floor and so far they work well. I bought my powdered fire clay there too. I wish I had some advice to help with your build, but I went with an old-school cob-style oven. You'll find lots of great advice here...can't wait to see yours when it's done!
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  #19  
Old 04-07-2014, 06:53 AM
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Default Re: 42" Started in Fountain Hills, Arizona

Moovebuff,

I've finally assembled all the materials to get me through the dome phase. Like so many others I have other trumping obligations. Lately I have been helping a good friend complete some of the woodwork in his new restaurant he will be opening in a few weeks.

The view will be very complimenting to the oven location. I fretted forever trying to decide where to locate it. I briefly considered the back patio but didn't think there was enough room. Finally it just seemed like the best place for a lot of reasons. It will be a squeeze, and I will be tight on clearances to the house but I will take all the insulating steps to insure safety.

My current mind occupying decision is the dome shape. I pretty much want the 21" high with the 12" opening but am waffling with to soldier or not to soldier. Complexity/ geometry is not an issue, since there is tons of info/experts here to help. I'm going to build the dome and then the accompanying entry/vent.

My Italian friend with the restaurant has had some good input on my design considerations. Mostly the decision to completely face the inner arch with steel for durability. Many here have said the bricks are easy to chip at the entry arch. I am looking to go for a much larger exposed face than the common 1 inch. So, the inner arch and face will be completely covered by a steel weldment, maybe stainless. Upon reading many of the threads describing what many would do different, I have decided to eliminate any firebrick in the entry since they stain easily, or at least the floor. I'm thinking a custom cut thick piece of granite would be nice. Gee, and I thought I was just going to BUILD an oven. Many facets to the journey.................not just having a finished oven.

Take care!

Gordy
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  #20  
Old 04-09-2014, 08:42 PM
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Default Re: 42" Started in Fountain Hills, Arizona

It can be as simple or as complicated as you want. I am not sure about a solid steel lining around in the inner arch (if that is what you mean). Others may know better but it may create some issues with metal heating at a different rate than the masonry.

I am sure that someone here will know for sure. I like the KISS theory myself.
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Last edited by Greenman; 04-10-2014 at 01:19 AM.
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