morticcio
Full Member
"The problem with internet quotes is that you can't always depend on their accuracy" - Aristotle
Posts: 371
|
Post by morticcio on Nov 2, 2015 11:20:32 GMT -8
Here are some photos of the 6" batch box I started in Italy last week.
Planning permission was hard to get (my wife isn't convinced it will work) so I have to keep the existing stove in-situ until the RMH is ready to light!
Checking door and firebox fit before installation. Doors are from plans from Peter and Erik. Firebox is cast using plans from Peter.
 
Laying out the base
Stove sits on 80mm Ytong blocks on a tiled floor. Firebricks are 220mm x 110mm x 60mm. At €1.00 each they are under half price of the ones back in UK. The flue exits the bell at the back left hand corner with a cleanout and door on the front.
A few more courses...
Checking door frame fits
Used 5mm ceramic paper around the door frame and inner face. 
Door frame installed
 
25mm HT Superwool wrapped around firebox and stuffed into gaps. I cut some IFBs to insulate the 45° rear of the riser. I will lay thin hollow bricks to cover the superwool
Work in progress...
I'm on the left. Andy (who helps with the doors) is on the right.
Slate lintel and door fitted. Robax glass and rope seal will be fitted last.
 
That's it so far as we ran out of time. Will finish off in the new year. It will have a clay-based plaster finish with either local brick or Maiella stone tiles around the base. |
|
|
|
Post by dustylfc on Nov 2, 2015 12:02:59 GMT -8
Very well done love it
|
|
|
|
Post by ericvw on Nov 15, 2015 13:05:44 GMT -8
Nice work, morticcio ! Glad to see you're getting that Italy job done! I've been gone for a while, I don't even know if you've moved yours from the shed into the house?! I still I didn't build mine yet.... Just had double hernia surgery a few days ago.... Awaiting more pics! |
|
|
|
Post by dustylfc on Nov 15, 2015 13:26:34 GMT -8
Ouch !!!!
|
|
morticcio
Full Member
"The problem with internet quotes is that you can't always depend on their accuracy" - Aristotle
Posts: 371
|
Post by morticcio on Nov 15, 2015 14:38:43 GMT -8
Ouch...hope you have a speedy recovery!
This is a new build - new door, new casting etc.
First batch box (in the UK) has been taken apart so will post some photos of the insides soon.
|
|
|
|
Post by AlexHarpin on Jan 18, 2016 12:35:26 GMT -8
Hi Mr. Morticcio! Very nice start on the built! What material the door is made of? It look very neat! I would like to built one like that for my stove, my dad tell me that if its made of iron it will bent when heated...
|
|
morticcio
Full Member
"The problem with internet quotes is that you can't always depend on their accuracy" - Aristotle
Posts: 371
|
Post by morticcio on Jan 19, 2016 8:42:31 GMT -8
Hi Alex Thanks for the feedback :-) Door is CNC cut from 4mm steel plate. I hope it doesn't bend!  |
|
|
|
Post by AlexHarpin on Jan 19, 2016 10:59:02 GMT -8
It seem a little thin to me,I hope it dont bend! anyway time will tell!  I will visit a foundry next week, see if he can produce a door at a resonable prices. |
|
|
|
Post by paramick on Feb 19, 2016 4:09:03 GMT -8
Nice(and clean) work morticcio !!!
Did you notice any compression of the Ytong slabs after putting so much weight on?
It would be at least alarming to see cracks or compression marks at the finishing stage.
What recipe did you use for the casting material?
Is a vibrator table mandatory for casting?
Cheers
|
|
|
|
Post by satamax on Feb 19, 2016 23:26:22 GMT -8
Paramick, i don't know what morticio has to say about ytong (air entrained concrete) But i have tried it, and i'm not keen at all! Cracks, doesn't support heat well, crumbles etc. may be for flat load bearing insulation it's ok. Or contained both sides. But nothing better is to be expected by this stuff.
|
|
|
|
Post by paramick on Feb 21, 2016 11:54:49 GMT -8
Thanks Satamax.
|
|
morticcio
Full Member
"The problem with internet quotes is that you can't always depend on their accuracy" - Aristotle
Posts: 371
|
Post by morticcio on Feb 21, 2016 17:10:58 GMT -8
Hi Mick,
Thanks for comments.
Blocks - the Ytong blocks are insulating the tiled floor and have a layer of standard firebrick on top so the load should be spread evenly. I had stacked the bricks on the blocks for 3 months beforehand and no visible cracking or compression occurred. I will check again when I return to finish the stove.
Also the firebricks on the floor of the bell aren't going to get hot enough to degrade the Ytong blocks underneath. This design worked in previous stoves so it should be okay on this one!
Castable Recipe - this was bought in premixed so no recipe as such. Had to stick to adding water as per the manufacturer's datasheet otherwise too much weakens the mix.
Vibrating table - you need to get the air out the mix so whatever you use it is essential. I used a vibrating table and a Makita 18v cordless poker.
|
|
|
|
Post by paramick on Feb 22, 2016 10:35:29 GMT -8
I recently had my wife's OK to build a PvdBbb (better written than pronounced)in the living room.
The experimental model is in the backyard and looks like "the firebrick and barells flying circus",but the output is enough to kill
any bitter comments (thanks Peter).
So,posts like yours are full or resources and inspiring.
Thanks morticcio.
|
|
|
|
Post by mkrepel on Apr 24, 2016 14:00:59 GMT -8
Very nice Morticcio. I am willing to bet your wife will want to get rid of that old stove when she sees how the new one works. Sometimes our better halves have to be brought along slowly, but they tend to always be in our corners and end up cheering louder than anyone when we succeed.
|
|
morticcio
Full Member
"The problem with internet quotes is that you can't always depend on their accuracy" - Aristotle
Posts: 371
|
Post by morticcio on Nov 1, 2016 6:30:41 GMT -8
Finally got time to do some more work on the stove!
All the bricks were laid with a fireclay/sand/ash mix (3/1/1 by volume). We were very careful laying the mix which paid off as there were no leaks. The cap was made with refractory castable 60mm thick in 2 pieces. This was sat dry on a strip of 5mm ceramic paper. The ceramic paper was also between the vertical joint of the two halves. Unfortunately I didn't get any photos of this.
We didn't have time to finish the flue so it is just a single skin pipe at the moment. This extends by 4m into the existing 6m chimney. It didn't have any negative effect as the draw was excellent from the start. Once the building work was finished we left it for 48hrs to dry out.
    
Lighting up time...(and with my granddaughter once I'd checked for any leaks!). Slow burns to start with then gradually increasing them once it had dried out. The stove & door worked perfectly with no leaks from around the frame or the door seal. No indication the door is warping either. The glass is great - watching the fire is far better than Italian television!
  
We were woken on Sunday morning by a tremor from the earthquake in Norcia (120 miles to the north). We heard a low hum and then the whole house 'wobbled' for approx. 5 seconds. After safely evacuating the house and checking friends and neighbours my first thought was how was my stove! There were no cracks and no leaks!
Drying out nicely 
Door seals
Firebox after a burn - no soot 
The old Sideros stove did sterling service but is now redundant. I'm guessing the new stove has been approved by planning control as it was she who told me to move it to the garage! I would ask for written confirmation but I don't want to push my luck!
|
|
