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| 22 June 2003- we add a four-inch-thick layer of concrete to the existing slab. This thin veneer of concrete will provide a bit more support for the masonry monster to come. Almost one ton of concrete required just for this... Notice the stack of firewood already acquired and awaiting the oven. |
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| 15 July 2003- the foundation work continues, with standard 16x8x8 concrete blocks laid in a U-shape. The open end will allow access underneath, for bracing the concrete pour for the hearth base, as well as ash removal once the oven is operational. |
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| 15 July 2003- the completed base. Next step is to establish a hearth- read on. |
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| 26 July 2003- plywood enough to span the interior is held up by 2x4 braces, and wire mesh is laid across to reinforce the hearth slab. Notice the blue chalk lines snapped on the inside of the blocks just shy of the top edge- a slurry of portland cement and vermiculite will be splooged in first (the vermiculite provides insulation below the hearth bricks, retaining heat in the oven chamber), then wooden forms will be placed around the edges to retain another concrete pour (see next photo). |
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| 26 July 2003- a crosshatch of rebar for strength, and wooden boards to retain the concrete. Notice the vermiculite layer described above, which is about to be buried under concrete. |
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| 26 July 2003- as stated above, reinforcement bars and wooden forms are set to retain the concrete (only several hundred pounds this time). Notice the wooden bit sticking up at what will be the front of the oven- this form blocks off a space for an ash slot in front of the opening into the oven. More about that later. |
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| 26 July 2003- the concrete bed for the hearth is complete. Now the ash slot is visible. Next step will be to make a sand/water/fireclay mixture, about the consistency of cake frosting, which will get spread across this concrete bed. Atop that will be... (next picture) |
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| 27 July 2003- dig the bricks, which comprise the floor of the oven itself. The bricks are carefully laid so that there is as little space as possible between. The frosting into which they're set (see previous picture's text) contains no mortar, to allow removal should a brick be damaged at some point and require replacement. |
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| 31 July 2003- now we take more firebricks and start building up again. These vertical bricks are mortared to the hearth, as they are structural members and must withstand heat and lots of weight. |
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| 3 August 2003- we've skipped a good bit of masonry detail and leapt to the finished vault. The firebrick arch was formed on a plywood arch template, one course at a time (see other shots below for similar template used to make the front arch). |
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| 4 August 2003- the federally-mandated pepper lights are visible hanging over the oven. |
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| 9 August 2003- Mary's birthday, and the project moves along. |
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| 11 August 2003- foil will create a slip layer between the brick vault and the concrete to come, allowing the two to expand and contract as needed during heating and cooling. |
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| 11 August 2003- concrete weighs a lot, and can start oozing out fast if one's wooden forms are not up to the task. Lots of wood saves the wall from ending up on the floor. |
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| August 2003- soon the pipe will cap the brick, making a chimney. |
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| August 2003- expensive insulated chimney components (one can do this part cheaper). |
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| 9 August 2003- leaping back (this should have been before the shiny space foil shot above), the arch of the vault is visible behind the arch of the facade (Mary spent her birthday building the facade arch). |
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| 13 September 2003- the first fire lit in the brick oven. |
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| 13 September 2003- she who co-built the oven gazes at the first fire lit within. |
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| 1 October 2003- metal studs and concrete backer board create a box around the oven, and will contain the perlite that will insulate the beast. |
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| 1 October 2003- eventually, this will be covered by stucco (see below). |
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| 1 October 2003- twenty cubic feet of perlite provide insulation, keeping the heat in the masonry; ultimately, the heat therein stored will re-radiate into the oven chamber, allowing baking to occur. |
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| October 2003- the oven is done, save for cosmetic details. |
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| October 2003- fire is good. |
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| 29 August 2004- did you notice the passing of a year there? Lots of baking went on in that time, but now it's time to finish the beast. Metal mesh is applied to the concrete backer board enclosure; this will provide enough tooth for the stucco to come. |
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| 29 August 2004- more of the mesh. |
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| 6 September 2004- tiles set directly into the stucco. |
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| 6 September 2004- a shot taken on Pop's birthday; the oven is stuccoed and tiled. |
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| 12 September 2004- the east wall of the oven room after the Fire Girl got hold of the paint. |
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| back to 2003- a fun shot that got out of order somehow |
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| 12 September 2004- el horno Leona is truly finished. This shot was made almost exactly one year after the first fire was lit. Many dozens have been lit since, and many hundred more await. |
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