Since the overhead structure was already in place, itwas crucial that I situate the kiln right, for the chimney to go through the roof in the right spot later on.In my focused attention, I seem to have forgotten to take a picture of this! So, the pictures of the floor only start once we have three courses laid (and some extra eyes and hands around). oops.
But basically here is what I did:
I dangled a plumb line from the trusses in the roof to determine the centre of the chimney and traced out from there. Once I had the blue-print for the whole kiln, I laid a layer of cinder-blocks underneath the ware chamber and chimney (the elevated part of the floor on the picture above). The cinder blocks don’t exactly add up to the width/length of the chamber, so there are little gaps between them (no more than 1/4 inch). The first layer on the firebox area (front of photo) is soft brick (IFB 2300), with an outer edge of hard-brick. My logic was that the soft-bricks would offer better insulation, thus preventing the concrete floor from cracking. The second layer (still only in the firebox) is basically the same (soft-brick inside with a hard-brick edge), but laid in a cross pattern from the course below. Except for the channel that will be the ‘mouse hole’ floor, which was made of hard-brick. The photo above shows the third layer (with the channels that will be the mouse holes).
We still followed this arrangement (soft-brick inside with a hard-brick edge) for the first course over the cinder blocks in the ware-chamber area (see photo above). But the front half of the fourth course (firebox floor) is all hard-brick (photo below).
Anyhow, it is done!
The firebox floor:
finished, with the
Next: the walls (and a couple more courses on the ware-chamber floor)…