What started out as a fun past-time thought turned into a large scale project which spanned three years. We've finally completed the pizza oven and can now relax and enjoy it. I've detailed the build process as well as some rough-draft plans for anyone else eager enough to try and build one of these things.
Starting with a Plan
I put together a basic idea after scrounging around the Forno Bravo Forums and various youtube channels. Here's the only drawing I have left of the original design.
Building the Base
We began with a concrete slab of around 9" in depth with rebar embedded. We did not have much aggregate underneath due to difficulties with the slope.
Once this was complete I built a 6' x 6' concrete block cube. The front entrance to the block cube was created with a pair of steel L beams, so we will have wood storage.
Once that was done I laid down forms that were built out of 2x12s. After cutting slots partially through plywood to create a curved front surface.
Pouring the Raised Slab
To support the top slab we built a set of 2x4 framing structures. On top of this we placed concrete backer board. The viscosity of concrete was enough to prevent seepage down into the base.
The raised slab is 7" thick. Two layers compromise the pour. Normal concrete was used for the first four inches. Vermiculite is mixed in with the concrete for the top 3" to make a more insulated layer for heat retention.
Constructing the Dome
The dome was built with a single layer base of firebrick. On top of that we started to build the dome. I built a jig with a universal joint that allowed us to keep the internal radius consistent.
The first layer is vertically oriented to add some height to the dome. The rest are placed horizontally. This is the dome around 200 bricks in.
And the completed dome with 500 or so fire bricks total. There are two additional front arches that compose the flue in the front.
Finishing Touches & Insulating the Dome
We laid down a marble floor and used porcelain to construct the working surfaces around the dome.
At this point the dome required insulation layers. First chicken was bolted to the base.
Three inches of fire blanket are wrapped around the dome with the wire holding it down.
A few layers of heat-stop 50 mortar cover the dome, giving a nice hard surface.
The First Meal
Some homemade dough, fired to 900 degrees. We made margherita pizza.
PIZZA!
Perfectly thin crust and melted cheese.
