Stage 1 -Building the walls and top

The 2" square weldmesh was purchased in large sheets from a local builders merchant, this I cut into the following 4 - 24x30" panels (sides) 1 - 24x24" panel (top) In the top I cut a square hole for a top flue (and viewing hole). Two holes were cut in one of the side panels for a burner and flue port.	Bisque buttons, these have been supplied by Bath Potters but can be easily made from a heavily groged clay and bisque fired. These buttons are threaded with Nichrome wire	Here you can see the kiln wall and is layers starting with the weldmesh, two layers of a kitchen foil, two layers (each 25mm thick) of ceramic fibre. These layers are secured by piercing them with the nichrome wire and tied to weldmesh (just like attaching a button to a shirt).
The four completed sides and top. To make removing panels easier and helping to remove top when firing I added handles made from some old shelf brackets.	This view shows the burner port and top side flue	To strengthen the fibre panels, Rigidiser(w) was painted on, leaving a boarder so the panels can butt up and make a compression seal at corners.

Stage 2 of building and my first firing

This picture illustrates how using 2 layers of 25mm ceramic fibre as a base(placed straight on paving slabs and a pallet) the sides would sit on top forming a seal. This base was untreated, so that the 'props' would be able to compress and form there own socket.	Bulldog clips, used to hold all corners (I found that these square topped clips worked best.You can also see the front panels handle this was a great addition to the original design.	The burner, this I placed a little away from the hole and fixed a piece of fire resistant board under the barrel, securing the hole thing with a house brick. The hose was also covered to avoid anyone tripping over it. The gas cylinder was moved as far away as possible.
All sides attached and kiln shelf in place. (a flame baffle was placed just inside the burner port to deflect the direct heat away from the pops and shelf). The top flue was covered with a shelf and later a layer of ceramic fibre was put under the shelf to make a good seal.	All ready to go - all we need is some pots !	Just like magic - These pots where made with raku clay and bisque fired to 950 degrees in my electric kiln. I used 3 glazes all purchased from 'Pottercrafts Limited' the bowl at the back was painted with brush on glaze before a white crackle glaze being applied.
She's cooking (well actually 'he's' cooking - my son Tom has nicked named this kiln 'Carl the Kiln' - my electric kiln is called 'Kyle Kiln' - she can be hot stuff . . .). As I had no way of knowing the temperature I went by the colour and the way the glaze was looking. The second firing took about 30 minutes and gave far better results over the first which was about 20 minutes.	Earth and Fire - well you can just about see the fire in this picture. I used a plain pine shaving which was dampened with water. NEXT TIME - I'll get somene to take some real action shots !	Little volcanoes, I left the ends out of the sawdust so that they would not go black with the carbon.

Stage 3 other firings

With the front of the kiln removed pots can be removed using long armed tongs.
The pots ignite the sawdust which can be very spectacular.

The first results

[HOME]