Pizza Oven build

[shanesmith80]

And so it begins...


And hopefully one day gets finished.
Thought I wouldld show some progress of my build.
I realise its probably not the best way to go, but like with most things I build I have a rough plan and then just work out the rest as I go.

So I picked an area for the oven, got approval from the boss, and started digging and pulling up pavers.
426794Discovered a drain pipe running from the back yard out to the front so had to build form over that. Over all wasn't too much work. Put down some road base, borrowed a mates compactor, laid down just a little reo:U

426793and ordered a minimix truck to bring the concrete. Was a bit worried that It would take a while to unload and have to pay exorbitant waiting time fee, but got 12 barrow loads of in 10 minutes. Missus helped shovel it to where it was needed. For first time doing anything other than setting a pole in concrete was fairly happy with result.
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Next came the block laying. Was hoping to just dry stack and core fill. Would have probably worked but blocks weren't very even so had a go at laying with mortar. I think I was just trying to lay them with too little mortar wanting to keep the joints close, which was causing frustration with trying to keep them level. Finally got the first coarse down and wasn't too bad from there.

Chopped up some rebar and went back to the wheelbarow and mixed up about 18 loads to do the core fill. Since the last photo have filled the remaining cores with road base because I have heaps on hand.
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Will knock up the form for upper slab in the new year, and was going to just mix that myself but am leaning to getting a truck back again.

cheers
shane

[cava]

Think I will pull up a chair for this one. Looking good.

[Uncle Al]

I don't think that will fall down any time soon. Nothing like a bit of hard yakka in the middle of summer, especially where concrete is involved. Keep well hydrated, and enjoy the pizzas.

Alan...

[NCArcher]

Your dog is really good at writing his name :D

[FenceFurniture]

Would have probably worked but blocks weren't very even so had a go at laying with mortar.Home-made slab is dead flat, but the machine made blocks are out.

Uh-huh.

Looking good though Shane. Mine's a thin crust vege with a shot of Pepp.

[jimfish]

Good luck with the build Shane, it is a thoroughly enjoyable process and well worth the effort. And once it’s done the trial and error of cooking in the oven is quite addictive . Ours has been finished for around 12 months now and we use it every chance we get.https://uploads.tapatalk-cdn.com/20171229/9ced7d208bcfa4959e8a3f92a1941192.jpg

[shanesmith80]

Looks good jimfish.

A few quwstions..
Looks like you used fire bricks for the base? What about the dome, did you use clay bricks like what looks like for the flue.
How thick is you suspended slab? Did you use any other insulation?

cheers
Shane

[crowie]

When will the pizza's be ready please Shane, :roll:
There's a hunger line up behind me!!!:o :U

[jimfish]

Looks good jimfish.

A few quwstions..
Looks like you used fire bricks for the base? What about the dome, did you use clay bricks like what looks like for the flue.
How thick is you suspended slab? Did you use any other insulation?

cheers
Shane

Shane, I used firebricks for the base as I didn’t think the second hand clay bricks were flat enough. ( probably should have forked out for 300 x300s but they work fine)Used the clay bricks on the dome with airset mortar. Slab is 100 mm thick which I think is plenty. One error I made was stopping the underfloor cal sil insulation board at the dome and not running it under dome bricks as I get a bit of heat transfer from the dome bricks into the slab which caused some minor cracking to the slab. Once I finished bricking the dome I wrapped it in 4 layers of ceramic fibre insulation blanket( cost $50 for a box full of offcuts from our nearest boiler and kiln manufacturer.) then I troweled on about 100 mm of perlite render to give a total of around 200 mm of insulation and finished with acrylic render to seal it all. If we have pizza at night the oven temp is around 160 c at around midday the next day which is great for slow roasting ribs etc. I’m by no means an expert but if you have questions feel free to ask here or pm if you like.

[jimfish]

I hope this is not viewed as stealing your thread but here’s a selection of progress pics showing how I went about the buildhttps://uploads.tapatalk-cdn.com/20171230/988d66326b24b386085d76de9806c3d6.jpghttps://uploads.tapatalk-cdn.com/20171230/bd6f5a3c23bcc167f2abcc5ccce504a2.jpghttps://uploads.tapatalk-cdn.com/20171230/b1f0875da699dba90496bc55519fd17a.jpghttps://uploads.tapatalk-cdn.com/20171230/c10ea8f859b0935aa5486dbf584f6545.jpghttps://uploads.tapatalk-cdn.com/20171230/cd8e5b7ad018eaf8ddac0a9e8dac7e21.jpghttps://uploads.tapatalk-cdn.com/ used a board and sand to support the last few courses
20171230/763a9bed8703dd356a138ad0e6edbee4.jpghttps://uploads.tapatalk-cdn.com/20171230/8f2ab505cf85a5021663b72aead0581e.jpghttps://uploads.tapatalk-cdn.com/20171230/6154f695936617299bea72fe4328b7a4.jpghttps://uploads.tapatalk-cdn.com/20171230/297751d53fbbe01b74b7b59bfc1109d5.jpghttps://uploads.tapatalk-cdn.com/20171230/d225e972cf37261272366f8a5c313eb7.jpghttps://uploads.tapatalk-cdn.com/20171230/499140937e699f2ef956dd54190e6ff3.jpghttps://uploads.tapatalk-cdn.com/20171230/1bfa2ee7d21fbfbdab9dd577a1f4be2a.jpg

[shanesmith80]

Thanks jimfish.

Good tip on the calsil board, i'm planning on using that too and i'll keep that in mind about going under the dome.

I'm was going to go the 300x300 fire bricks for the base, then just clay bricks for dome. Seems a bit overkill to spend that much on fire bricks for dome. Have found a couple of supply places in Sydney which i'll have to check out and decide on a mortar. I think one does have the one you used.

Might have to try someone who has offcuts of ceramic blanket because thats stuffs expensive.

Am working on getting the rest of the paving in first to try remove a few trip hazards.

Thanks again.

cheers
shane

[jimfish]

I was also given the use of a mates brick saw which was invaluable. I think I would of really struggled using the grinder and diamond blade once I got to the transition from opening arch to the dome.
Enjoy the build
Jim

[shanesmith80]

Slow progress..

Decided to finish up the paving first to eliminate a few trip hazards. Started cutting to size with grinder and diamond wheel. Although not too hard :sweat: just very dusty, picked up a secondhand brick saw:hpydans: heaps easier.
428393 428394


Got the formwork up ready to pour the top slab.

428395

cheers
Shane

[NCArcher]

Nice job on the paving Shane. :2tsup: Pizzas in no time now.

[shanesmith80]

Making progress.

Go the slab done.
431071431072


And have started on the dome. My mortar work is a bit messy, but getting there.
431073431068


Working out the cuts on the arch took a bit off thinking.
431069431074


made up a jig to cut the bricks at a compound angle to try reduce the mortar joint.
431070

[jimfish]

Looking good shane

[shanesmith80]

Starting to look like an oven.
432342 432343
As of yesterday the last brick went in the dome.
432344432346
Got in and done a bit of cleaning. Not the most fun job.
432345
Now trying to work out the landing. Its now I realise that I should have set the oven back a bit further, but oh well.

Am thinking of keeping the bullnose bricks following the curve of the slab, but not sure how it looks. Will have to let it sit for a few days and see. Opinions.

432347432348

If I do my plan would be to use some concrete polishing pads like these, https://www.ebay.com.au/itm/16Pcs-4-100mm-Diamond-Polishing-Pads-Wet-Dry-Granite-Stone-Concrete-Marble/361909105562?epid=573195837&hash=item544376b39a:g:cfMAAOSwbYdaoPom

to shape it a bit better. Question is my grinder is one speed, flat out 11000rpm I think. Most of these pads say use at 6000rpm max, once again I think. If i put these on my grinder will they just fling off?

cheers
shane

[Skew ChiDAMN!!]

Well done on getting the keys in so neatly!

Wish I could've done 'em so nicely on my last 'un, but the access was too small to 'play mechanic.'

[FenceFurniture]

432345JACQ! QUICK! Drop the camera because NOW is the best chance you'll ever get! I would suggest tickling his feet or inner bits with a feather. You can have the satisfaction of knowing that any head injury will be self inflicted - he could choose to stay still.



Bullnose is good.

[FenceFurniture]

432345Close-to-middle-age Mutant Ninja Turtle anyone?

[fletty]

432345




That’s it! From now on, your screen name is Donatello .... or maybe Raphael?

[rob streeper]

If I do my plan would be to use some concrete polishing pads like these, https://www.ebay.com.au/itm/16Pcs-4-100mm-Diamond-Polishing-Pads-Wet-Dry-Granite-Stone-Concrete-Marble/361909105562?epid=573195837&hash=item544376b39a:g:cfMAAOSwbYdaoPom

to shape it a bit better. Question is my grinder is one speed, flat out 11000rpm I think. Most of these pads say use at 6000rpm max, once again I think. If i put these on my grinder will they just fling off?



Go slow with the diamond pads and don't push them too hard, they'll break down very quickly if you turn them fast or push hard on them. I use a variable speed Bosch grinder set slow with these things.

[shanesmith80]

JACQ! QUICK! Drop the camera because NOW is the best chance you'll ever get! I would suggest tickling his feet or inner bits with a feather. You can have the satisfaction of knowing that any head injury will be self inflicted - he could choose to stay still.



Bullnose is good.

I often suggest tickling the inner bits..

[ian]

Brett

JACQ! QUICK! Drop the camera because NOW is the best chance you'll ever get! I would suggest tickling his feet or inner bits with a feather. You can have the satisfaction of knowing that any head injury will be self inflicted - he could choose to stay still.
you are positively evil

[Christos]

....432345....

I love it when I can comment on something that is just not usual(strange) but for some reason this photo just does not have a nice image. :C

Beside others have already taken a swipe to this. :U

[shanesmith80]

SO its pretty much done.
433877433875
Got the flue arch and front landing done. Still need to put in a chimney. Haven't finalised the chimney design yet though.

3 layers of ceramic fibre blanket topped of with some perlite concrete.

Then a very little ceremonial fire.
433876
First real curing attempt the other day using lump charcoal. Thought while its going we can at least cook some fish and baked potatoes.
433874 433873
Have had a bit of trouble maintaining consistent temps. First firing was going nicely at about 200'C, started to drop so threw on some more coals, and up she went, my temp gauge was of the dial at 280'C and the bricks were reading from 250'C to 450'C going up the dome. No internal cracking though, but a few on the perlite. Not worried about that though, its more or less there just to finalise the shape before final render coat.

Another fire tonight with some more roast veg and pork.
433872
Temps a bit more consistent tonight sitting around 200'C air and 250'C to 300'C wall. Although did get some nice flames early on. Looked pretty cool.

The hopeful plan is to really fire up on Saturday night for the first pizza.

[FenceFurniture]

That looks the goods Shane! Great job mate! I got my lump charcoal from a place in Mt Druitt - good charcoal, good price. The stuff I got from the local harware was rubbish by comparison, and significantly more expensive.

There is a BBQ forum (https://www.aussiebbq.info/forum/) which was very helpful when I was deliberating about my Weber purchase. Not as much traffic as here, but really good info. I'm sure they'd be mightily interested in your build, and would be a great souce of ideas for recipes and so on.



The hopeful plan is to really fire up on Saturday night for the first pizza.Mate I'm sorry, but I don't think we'll be available. :D

[FenceFurniture]

Here you go:
Charcoal - Emberpak Pty Ltd. (http://emberpak.com/charcoal/#lumpcharcoal)

I would suggest that your oven would work well with some large trunk and standard lump (which is what I use in the Weber).

I think you may good very good value out of one of these:
https://www.weberbbq.com.au/weber-accessories/rapidfire-chimney-starter/

They get the charcoal going much much quicker than if it's just in the Weber itself (which has a lot of air around it) so I imagine that it may be even faster in your enclosed jobbie.

[shanesmith80]

Cheers Brett, will have to check out their charcoal. Although I'll probably mainly use wood for the pizzas. Was using the charcoal for curing to try and keep the flames down a bit. But a mix could be good.

I have my own bodgy chimney starter. Drilled some holes in an old Milo can with some wire cris crossing at the bottom. Maybe one day I'll lash out and buy the real thing. The milo cans are starting to deteriorate.

[Christos]

I do not own a Rapidfire just looked at them a little while ago. One of the thoughts that came to mind was that this was more suited for an open grill type fire. Where you tilt the Rapidfire and the contents land in the BBQ. I don't know how easy it will be to put the contents in a pizza oven/dome type BBQ.

[FenceFurniture]

I think you'd just tip into the front and then push it to where you want it.

Edit: Actually, just looking at the opening of Shane's oven it looks like there's enough height to slide it in and then tip it over.

[shanesmith80]

There is certainly enough height to slide it in. 320mm. If your tough enough or have good enough gloves you can quickly throw your arm in and tip them out. Also helps keep arm hairs at a respectable length.

[FenceFurniture]

Hmmm. 305mm high, 190mm dia. Have you got 305mm clearance at 95mm either side of centre?

(it wouldn't be hard to cut it down a bit with an angle grinder)

[FenceFurniture]

If your tough enough or have good enough gloves you can quickly throw your arm in and tip them out. Also helps keep arm hairs at a respectable length.Nah, it's not hot in there when you put it in (unless it's a refill).

For arm and leg hair length I am forced to use clippers or I itch like all getout.

[shanesmith80]

For arm and leg hair length I am forced to use clippers or I itch like all getout.

Had it firing full boar last night. If it's hair removal you need, I singed most mine off trying to readjust dishes in the oven. Not sure of the exact temp of in there, but the gauge was off the dial at 300 and the bricks were in the 400 - 500 range.

Cooks pizza in 15 seconds.

[FenceFurniture]

Ok, perhaps a tad less timber/charcoal required?

[FenceFurniture]

Welder's gloves might be a good idea (seriously) - you know, the blue half-arm jobbies. I have a pair that I don't use very often, but like all tools, when it's the one you need, it's the one you love having on hand.

[Christos]

......Cooks pizza in 15 seconds.

Quick Fired Pizza........I think that slogan has been taken......:U

[yoboseyo]

Had it firing full boar last night. If it's hair removal you need, I singed most mine off trying to readjust dishes in the oven. Not sure of the exact temp of in there, but the gauge was off the dial at 300 and the bricks were in the 400 - 500 range.

Cooks pizza in 15 seconds.


yikes

how exactly do you control temperature in that thing?

[shanesmith80]

yikes

how exactly do you control temperature in that thing?

After a few goes you start to get the hang of it.
I basically fire it up till it gets to about 500'C on the dome, then push the fire to one side or the back and let it cool down until the floor temp is around 350 and is just a pile of glowing red embers off to one side. Can easily cook 10 pizzas at this stage. Will throw a log on the embers to keep some flame going up over the top of the dome to help with radiating heat. If cooking more just keep adding wood or move the fire to another position and cook where the fire was after the floor cools a little.
In saying all that I still really haven't got the hang of it but its always fun trying.