Author Topic: building a pizza forge  (Read 7932 times)

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Offline sohara

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building a pizza forge
« on: May 09, 2011, 06:06:47 PM »
Hi Everyone,
I'm new here to the forum, but I have seen a bunch of posts regarding converting a weber type bbq into a pizza oven. I just procured a weber knock off and I plan to attempt to recreate the so called "pizzaforge" created by the pizza hacker, as pictured here: www [dot] charlesandhudson ( dot com) /archives/2011/02/do-it-yourself_wood_fired_pizza_oven.htm. I do have a bunch of questions about how I could go about this.

The bbq I have is a 24.5 inch circular kettle bbq. For the cooking floor/surface I was thinking of using firebricks. Every pizza stone I've ever purchased had broken almost immediately and I don't think they are thick enough to retain much heat. My only question about the bricks is whether they might be too heavy to be supported by the legs of teh bbq.

For the dome and the "walls" I plan to use some kind of refractory concrete mixture made for high temp conditions, mixed with perlite. I got this link from a previous post by one of the forum members: www [dot] boyerfour (dot come) /notes/refractory.htm. Does that seem to be a suitable material? After the concrete has set, will I need to cure it somehow? Any ideas on how to go about that?

If there's interest I'll post updates/photos on my progress.

Thanks in advance for any input.
(sorry had to mangle the links since i'm a new member and not allowed to post links/urls)
sean
« Last Edit: May 09, 2011, 06:14:16 PM by sohara »


Offline mnjesse

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Re: building a pizza forge
« Reply #1 on: May 31, 2011, 09:13:09 AM »
How did it turnout? I am planning on a making a cover for my gas grill with similar ideas to a pizza forge. I am hopefully going to get it poured this week and I will also post some pictures if it works. Good luck and I can't wait to see what your pizzaforge looks like.

Offline Tman1

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Offline mnjesse

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Re: building a pizza forge
« Reply #3 on: June 02, 2011, 09:41:45 AM »
Thanks for the advice, but I want to try something different than the MBE or LBE. Does anyone have any advice on what type of cement to use. I have seen a few different websites talk about using portland cement plus vermiculite and others talk about using castable refractory cement plus vermiculite. I plan on making it similar to the frankenweber where the whole roof is made out of the cement/perlite mixture. I bet it doesn't matter since it isn't going to be very big, but I just want to make sure that I do it right the first time. thanks for any advice

buceriasdon

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Re: building a pizza forge
« Reply #4 on: June 02, 2011, 12:58:46 PM »
I've built a couple of melting furnaces over the years using formulas such as:     http://www.backyardmetalcasting.com/refractories.html
I went to a ceramic supplier for the fireclay. Less expensive than refractory cements.
Don

Thanks for the advice, but I want to try something different than the MBE or LBE. Does anyone have any advice on what type of cement to use. I have seen a few different websites talk about using portland cement plus vermiculite and others talk about using castable refractory cement plus vermiculite. I plan on making it similar to the frankenweber where the whole roof is made out of the cement/perlite mixture. I bet it doesn't matter since it isn't going to be very big, but I just want to make sure that I do it right the first time. thanks for any advice

Offline mnjesse

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Re: building a pizza forge
« Reply #5 on: June 03, 2011, 09:42:53 AM »
Thanks for the response Don. I have one question about the mix. Do you think that it will be a good insulator like the pizza hackers ceiling on his weber grill? Thanks again for the help!

Offline mnjesse

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Re: building a pizza forge
« Reply #6 on: June 03, 2011, 09:51:51 AM »
One more question. How long should I let it cure? Should it be a room temp cure or should I throw it on the grill and dry it with high heat?

Offline mnjesse

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Re: building a pizza forge
« Reply #7 on: June 03, 2011, 09:55:13 AM »
Sorry. I promise this is my last question. What type of fireclay? There are a ton of options and I have no knowledge on this subject? Thanks again for all of the help

buceriasdon

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Re: building a pizza forge
« Reply #8 on: June 03, 2011, 11:30:13 AM »
http://www.traditionaloven.com/articles/101/what-is-fire-clay-and-where-to-get-it

Sorry. I promise this is my last question. What type of fireclay? There are a ton of options and I have no knowledge on this subject? Thanks again for all of the help


Offline Ronzo

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Re: building a pizza forge
« Reply #9 on: June 03, 2011, 11:52:02 AM »
Hey Don, based on your experience, how good is that refractory mixture at holding its shape without a restricting mold? Do you think forming a dome style oven over top of a sand mound base would work with the refractory cement mixture? Like they do with forming a temporary clay oven?
Fuggheddabowdit!

~ Ron

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buceriasdon

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Re: building a pizza forge
« Reply #10 on: June 03, 2011, 03:26:11 PM »
Ron, My limited experience as been one wants the mix to be more "packable" than pourable. Like adobe in feel. I would keep the portland cement ratio under 10% of the total. Too much water, same as any cement mixture, makes for a weak product, however, if used as mortar between bricks naturally one would mix with more water with no perlite. Many years ago I built a little Gingerly furnace and not finding a source of fire clay I busted up old red bricks, whew, now that was a messy hard job :( I should mention these furnaces have a metal casing of some sort. I would think that using chicken wire embedded in the inside, pack a layer of mix over the sand, then trimmed, overlapped chicken wire(triangle shaped) pressed into it, followed by the rest of cement would be a good idea. Reverse that if inside a kettle form.
Don


Hey Don, based on your experience, how good is that refractory mixture at holding its shape without a restricting mold? Do you think forming a dome style oven over top of a sand mound base would work with the refractory cement mixture? Like they do with forming a temporary clay oven? ,

Offline Ronzo

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Re: building a pizza forge
« Reply #11 on: June 03, 2011, 05:17:32 PM »
Your suggestions make a lot of sense, Don. Thanks for your input, sir.

Looking for a cheaper alternative to a full brick oven, but without having to worry about it disappearing in the rain like a clay cob oven.
Fuggheddabowdit!

~ Ron

Former NY'er living in Texas
http://newtexianbrew.com - http://ronlennex.com/ - http://pinterest.com/NewTexianBrew

Offline mnjesse

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Re: building a pizza forge
« Reply #12 on: June 06, 2011, 03:40:46 PM »
I picked up my fireclay over the weekend in the Twin Cities. It was pretty cheap $7.50/50lbs. I am going to pick up the rest of the supplies tonight and hopefully get it poured sometime tomorrow evening. I am going to let it dry for 1 week before I heat it up. I was going to apply a low heat to thoroughly dry it out before putting the full high temp heat on it. I will post some updates as it is being built.

Offline mnjesse

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Re: building a pizza forge
« Reply #13 on: July 04, 2011, 10:36:17 PM »
I have been a little behind, but today I finished the forms for the refractory concrete. I will get it poured this week and hopefully fire it up in a week or two. I will have some pics after I get it poured.

Offline Ronzo

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Re: building a pizza forge
« Reply #14 on: July 04, 2011, 11:33:30 PM »
I have been a little behind, but today I finished the forms for the refractory concrete. I will get it poured this week and hopefully fire it up in a week or two. I will have some pics after I get it poured.
Looking forward to your results!
Fuggheddabowdit!

~ Ron

Former NY'er living in Texas
http://newtexianbrew.com - http://ronlennex.com/ - http://pinterest.com/NewTexianBrew

Offline mnjesse

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Re: building a pizza forge
« Reply #15 on: July 24, 2011, 10:03:06 PM »
I got it poured yesterday. Now I just have to wait a few days for it to dry. I can't wait to try it out next weekend!

Offline mnjesse

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Re: building a pizza forge
« Reply #16 on: July 27, 2011, 06:36:36 PM »
I pulled it out of the concrete form today and it seems a little brittle. Will it gain some strength when it gets really hot? I am assuming that this will happen with all of the fireclay in the mixture.