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  #11  
Old 04-19-2007, 04:29 AM
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Default Foundation

The foundation started with lots of roots and digging with an ax and pick.

It was hard work digging down through the top soil until we found undistrubed earth.

My friend had returned his loaner cement mixer to his contractor so I ended up buying and putting together a harbor freight model - this set us back a couple hours in our schedule. My brother in law was a great help putting it all together. We thought digging the foundation was tough until we started mixing concrete.

Attached are pictures of the pentagon frame (had to do it!), a pic of me bending rebar with a pipe (really not too hard - see next post - too many pics in this one), trial fit of the chain link fence in place of reinforcing mesh. There is also the obligatory picture of my brother in law resting in front of yet unabused cement mixer while I worked (BTW - he worked really hard on this in real life)

The cement mixer worked surprisingly well. We were careful at first and then started to set it up right and dump two 80lb bags of concrete mix, water it down and start it up. Made a lot of noise but mixed up really well.

More to come!!

Christo
Attached Thumbnails
Christo's Cucina-foundation.jpg   Christo's Cucina-plastic-lining.jpg   Christo's Cucina-mixing-concrete.jpg   Christo's Cucina-tying-off-rebar.jpg   Christo's Cucina-bro-law-helping.jpg  

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Last edited by christo; 08-13-2007 at 08:11 AM.
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  #12  
Old 04-21-2007, 04:46 AM
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Default Re: Christo's Cucina

Foundation is complete and block walls are getting laid.

I lost my detail plans for constucting the base out of block and minimizing cutting of the block. We gave up trying to find the plan and decided to wing it due to a few reasons: Oven was now a little larger and my brother in law thought it would be useful to have a door in the back.

We mocked up the walls, made a list and went out to buy some 8x8 block and concrete lintels. I had plenty of scrounged 8x16 block. We also bought some 4X16 block to divide the inside of the hearth and act as a permanent cross member to the hearth. Since the cores do not go through all of this material, we will stucco it later with the fiber reinforced stucco designed to make mortarless walls.

When we came back we mocked up the walls again - totally differently. Made out better with this layout. Very few cuts and nice sharp reference points on all but one corner. Turns out the door in the back allowed for an easy transistion as well. For us it paid off to play with the blocks a little before building.

For the lintels - they did not have any large ones at the concrete supply company near my house. But we came across some knock out blocks - these blocks have a cut down the center - I thought the cuts were for angle iron. The slot is there to make it easy to knock out the center webs to allow conduit to be placed in the wall. We bought some big angle iron, too.

We cut the knockout/lintel blocks to fit and lay them upside down on the driveway. We inserted the angle iron and filled the cores with concrete to make sure the blocks did not rotate when we placed them on the block wall the next day. They worked out really well and not overly heavy for two people to lift into place.

Christo
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Christo's Cucina-foundation.jpg   Christo's Cucina-block-foundation.jpg   Christo's Cucina-lintels-place.jpg   Christo's Cucina-bend-rbar.jpg  
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Last edited by christo; 08-13-2007 at 08:11 AM.
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  #13  
Old 04-21-2007, 02:11 PM
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Default Re: Christo's Cucina

Hearth pour was fun. We learned alot about the cement mixer and handling 80 lb bags of concrete.

We also learned that duct tape does not stick to wet form board or concrete block. We ended up putting duct tape along the inside of the form and using a staple gun to attach it to the form to seal any block to form gaps. Sealed all the concrete leaks really well.

We drilled holes in the block and inserted nails to support the 2x6 form made form the foundation forms. We shimmed it level but had to hang block from all corners of the form to keep it level.

Christo
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Christo's Cucina-hearth.jpg   Christo's Cucina-hearth1.jpg   Christo's Cucina-hearth2.jpg  
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Last edited by christo; 06-17-2007 at 03:51 AM.
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  #14  
Old 04-21-2007, 07:54 PM
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Default Re: Christo's Cucina

Any orange slices in those Blue Moons?
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  #15  
Old 04-22-2007, 04:01 AM
Il Pizzaiolo
 
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Default Re: Christo's Cucina

Nice progress Christo....and I like the shape!
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Tiempo para guzarlos.....
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...enjoy every sandwich!
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  #16  
Old 04-22-2007, 04:54 AM
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Default herring bone floor is finished

We mixed up fireclay and applied it to the new hearth with a notched trowel. We were going to apply a layer of foil over the clay to create a moisture barrier between the hearth and the iso board, but it had rained the night before and the iso board was soaked (and heavy). We opted out of the foil and placed the board on the clay. The board became very stable.

As the board was wet we decided to try the notched trowel and clay on the isoboard. This did not work at all.... The wet Iso board still sucked enough of the water out of the clay that the firebrick would not press down - even with some hammer taps.... We scraped all the clay off the isoboard and put down dry clay. My brother in law and sister did a nice job on the herringbone floor while I cut bricks and continued to mock up the dome.

This is where we ran into some of the same problems that Dave talked about when he built his Oven. Huge gaps all over the place. It looked much better during our trial assembly on the driveway. At the end of the head scratching, we adjusted the diameter of the dome 1/2 inch and things started to line up rather nicely.

As expected from Dave's advice (but still not totally understood why), the bottom row needed to tilt in a bit and there was a gap most pronunced with the half hexagons. Instead of trimming the pieces to fit, we added a little bit of extra mortar to one end of the first row of half bricks.

Clamps - lots of clamps came in handy. Orange slices in the beer and wine were optional, but Ibuprohen was mandatory at this stage.

Christo
Attached Thumbnails
Christo's Cucina-first-trials.jpg   Christo's Cucina-troubles.jpg   Christo's Cucina-have-plan.jpg   Christo's Cucina-mortar-time.jpg   Christo's Cucina-some-clamping-required.jpg  

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  #17  
Old 04-22-2007, 04:56 AM
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Default Re: Christo's Cucina

It was a late night but the first two rings were completed.

Christo
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  #18  
Old 04-22-2007, 05:18 AM
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Default Re: Christo's Cucina

Christo, that is coming along great! - thank you for posting your progress pictures
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  #19  
Old 04-22-2007, 03:32 PM
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Default Re: Christo's Cucina

More of the dome is complete. So far no cutting of preassembled pieces, but we did have a joint that was hitting the max of 3/8 inch. We fussed around with that one for a while and tried to minimize the size of the gap. We got into a situation where there was not room for clamps and switched over to using sticks to support the pieces.

I stressed out my brother in law by getting a little over confident with the mortar. I was taking out supports less than 15 mins after we placed the polygon - no tragedies this day.

We assembled all the preassembled pieces - and a few of the individuals. Washing the bricks after install was a pain - lots of water and sponges but it looks really nice when finished.

At the top is the hole for the pentagon - I thought that would be the last piece. But it looks like we will work down towards the door.

I'm having a really bad hair day and hadn't shaved - but I left the picture in there anyway....

Christo
Attached Thumbnails
Christo's Cucina-second-row-start.jpg   Christo's Cucina-oven-morning-2.jpg   Christo's Cucina-2nd-day-end.jpg   Christo's Cucina-individual-triangle-time.jpg   Christo's Cucina-end-day.jpg  

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Last edited by christo; 04-22-2007 at 03:40 PM.
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  #20  
Old 04-23-2007, 08:43 AM
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Default Re: Christo's Cucina

The rest of the dome build went fairly smoothly.

The oven looks very high off the ground, but we are putting in a patio and 8 inches of gravel sand and brick will level it off to a nice height.

The last triangle to go in was custom cut to fit into the hole as I had evidently lost a triangle or miscut one somewhere else. It was about 1/4 inch wider on one end than the other triangles. Over all very pleased with the level of sub assmebly we did and the piecework with triangles at the end. I am getting out very easy as the second time around build!!!!

Almost fell off the front of the opening while working inside the oven on the last few pieces.

More to follow!!!

Christo
Attached Thumbnails
Christo's Cucina-last-triangle.jpg   Christo's Cucina-door-support.jpg   Christo's Cucina-helper.jpg   Christo's Cucina-success.jpg   Christo's Cucina-big-inside.jpg  

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Last edited by christo; 04-23-2007 at 08:46 AM.
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