Begining dome construction

[Hendo]

Originally Posted by dmun

The leveling layer is designed to level off the rough surface of a vermiculite concrete pour. You may not need to do this - I didn't, just left the bricks sit on the insulation board.

I found that my bricks were not dimensionally identical, and I ended up with some minor height differences where the peel could catch. Hence the dry fireclay (which stayed dry) to pack between the low bricks and the insulation sheets. Those bricks that were OK were, like David's, placed directly on the insulation.

I didn't find that numbering and removing all the bricks was a great hassle, and I think it would have been harder to remove only those bricks that needed adjustment. And when they went back, I knew they'd be staying there! Very satisfying.

Paul.

[rlf5]

I think i'm just going to go over the floor with a belt sander after everything is locked in. Most of the floor seems to be pretty dang smooth.

[maver]

I used a spare firebrick as a 'plane' to grind down the few minor elevations - it worked very well and avoided risking heavy equipment on my carefully laid brick. It also was more selective on the bricks that were ground down so that I could avoid ruining the factory finish surface on the bricks that were ok.

Marc

[RTflorida]

I chose the belt sander approach, worked great.
I actually did the entire hearth floor because the firebricks I used were 'wire cut'; having the texture of 60 grit sandpaper on all sides as well as being dimensionally challenged. The belt sander gave them all a finish as smooth as a baby's bottom.
By all means where a good mask if you choose the belt sander approach, it does create quite a cloud of dust.

RT

[wlively]

I second the belt sander approach. It does give the floor a very smooth feel and appearance.

[Les]

What grit on the belt worked best? I'm assuming they were trashed pretty quick, so did you use the least expensive ones?

Les...

[wlively]

I used 60 grit and if my memory serves, only took 2 belts.

[RTflorida]

I used 1 each of 80 grit and 120 grit. Bought them at Lowes. Not sure what I paid. The inside of the belts say GatorGrit brand, made in the USA

RT

[rlf5]

Started mortaring the floor/wall bricks in today. You can see my technique improved with the later ones...much less mess. I was originally going to use all tapered bricks for a perfect semicircular dome, but I think I'm going to make a solider course on top of the floor, and then go back to the tapered bricks for the rest of the dome. That way I'll have more height clearance on the inner perimeter of the dome.

[rlf5]

Finished the rest of the floor bricks. I hope to get the soldier course done tomorrow.