First layer of hard brick.

Why did I decide on the kiln design I am doing? First of all I was going to do a 7-10 square foot kiln. I wanted something small both for build cost reasons, cost of running the kiln, and so I didn't have monster size loads to get ruined while I experiment. Soda firing is new to me and I know I will have plenty of loads that won't go so well as I get the kinks worked out. The idea of losing a smaller load of work rather than a larger load sounds better. At the same time, I am planning on becoming successful at this so I want a kiln that will be functional once I have everything going as planned. I enjoy making large pieces and I'd like them to actually fit in my new kiln! Anything less than about 15 cubic feet and the design for Matthew's back yard soda kiln is the only way to go. Initially this was the design and size I was leaning towards but I decided I needed it just a little larger and I got all those "key" shaped IFB that would easily make an arch. Joe Finch's design for a small kiln is straightforward and with his brick layout, about 15 square feet is as small as it can go. What I decided to make is closest to this design.
As I build the kiln I'll try and explain why I made some of my choices.
Here's a quick picture of my son putting in the last cinder block for me on the base. LOL, he said since he carried them all over from the other side of the yard he should get the credit for building the base! I'm just glad he is willing to help with the massive amount of heavy lifting building this kiln takes.

We got the ceramic fiber blanket layer down. Not sure it matters how the blanket was laid so I pieced to use it as efficiently as possible. I am hoping to have enough left to add a layer on the arch at the top of the kiln.

Next came the first layer of hard brick. I drew out brick placement by layer on graph paper at least through the firebox level.

The rain came and hasn't stopped so the build is on hold until the weather improves. Threw a tarp over to keep everything dry. I am planning on building a cover too.

Kiln base

First I have to admit that I messed up the base size. My hubby was so nice to weld up a steel frame in the size I gave him, and I gave him the wrong size! Airhead me but I think we can compensate. :) I dug down and leveled the area (5'x5') when I meant to do 5'x6'. Because my IFB is "key" shaped I will have to lay them sardine style which combined with the layer of hard brick will make a much thicker wall than usual. We dug in and leveled a steel square made of scrap steel. It was then backfilled with dirt then paver base (sand/gravel) and topped with some sand. The cinder block was going to sit inside, but due to my poor measuring skills, they will now sit atop.

It is level and firmly compacted. Then came a layer of recycled cinder block and a layer of solid 1/2 block. 

The only thing I am unhappy about is the 2" overhang off the metal frame where the chimney goes. It seems to be well supported and stable but wish I had done my calculations better. My hubby offered to weld a small outcrop piece if needed but we don't think it is necessary. It did cost me the price of some new cinder block to get it all the way I needed it. sigh...

Here is the level base for the kiln building to start. A layer of 1" fiberblanket (kaowool) will go down first then a solid layer of hard firebrick which will serve as the base of the kiln. (I found a new box of 50 square feet kaowool 1" thick ceramic fiber blanket on Craigslist in Atlanta for $60 from a person who decided not to build their raku kiln.) I'm just glad I have a teenage football/rugby playing son who will move all the brick for me as his "weightlifting" for the day!

Starting with design and supplies

I started by doing a ton of research, asking tons of questions, reading, and reading. Here's my favorite book list:
The Kiln Book by Frederick Olson- referred to for everything, repeatedly. Hubby used it for burner construction data and I used it as a reference when I had a questions about anything. Very in depth but a lot of info to take in at once. On occasion I found it overwhelming.
Kiln Building-A Brick by Brick Approach by Joe Finch: Great straightforward book with clear plans and explanations. I had the honor of exchanging a few emails with Joe and greatly appreciate his feedback and info. The kiln I have decided to build is closest to his design for a small kiln The diagrams in here are very helpful.
Salt Glazing by Phil Rogers: A great book to keep you motivated when building your kiln!
Soda Glazing by Ruthanne Tudball: Wow! I flip through this book again and again. Keeps me moving forward on the build. :)
For those out there looking for professional kiln build consulting for a fee, William Baker is friendly and knowledgeable too.
The web is of course a great resource starting with the Facebook Soda and Salt firing site. Here I had the pleasure of "meeting" Mathew Gaddie who generously shared his Backyard soda kiln design (innovative and super simple in concept and design) and Denise Joyal who shared her thorough master thesis where she also built a soda kiln based on Mathew's design. Online I also got in touch with Scott Cooper, from St. Earth Pottery in Indiana, who sent me info on his small soda/salt kiln. Wonderful people happily and freely shared their experience and information! It is because of the help and encouragement I got from all these people that I am now starting this blog to record and share the building of my soda kiln and hopefully it will  help someone else with their similar pursuits.
Before finalizing my design, I also started gathering supplies. Somewhere I read that your kiln should be made out of what is available as well as the best design. Of course cost is a huge factor and I am a bargain shopper so I knew this would be an adventure, and it has been! Searching on Craigslist, I ended up in a cow pasture in SC getting used cinder block for the kiln base. These were 50 cents each. :) and the cows were pretty friendly too especially this cute calf.

Having mentioned my pursuits on Facebook, I was lucky enough to meet someone looking to rehome some used hard firebrick, thank you Glenn! I found out that 288 hard firebrick is the maximum we should carry in our Chevy Avalanche even when moved as far forward as possible, with tires slightly over-inflated, and a 3 1/2 hour drive. They are now waiting in my yard for me to get the kiln built.

The IFB (insulated fire brick) was my priciest item and hunting them down was a feat! I found some on ebay and was willing to drive to New Orleans to pick them up but by the time I set aside the money for them, they were already sold and gone. I stumbled across a pallet of K23 IFB on Ebay at a super reasonable price but they were "key" brick, angled as for an arch. They were only a 7 hour drive away in Ohio...could I make it work? They were EXTREMELY reasonable but he was selling it as a whole pallet. Yup, you guessed it, I'll find a way to make them work. (and by the way, he still has quite a few pallets available but only K23 and "key" shape). 

We did manage to fit in a whole pallet in the Avalanche!!!

But, we couldn't have fit in any more! We found out these brick came out of a manganese alloy manufacturing plant, Eramet, in Mariette, OH. We decided a quick trip to check out the closed plant was necessary.

The bricks are now safely stored in our garage.

Last week I started leveling the area for the kiln and building the base. 

I've never done a blog, but my son tells me this is what I want to do if I want to record, post, and update my pottery kiln building experience. It all started a few months ago when the rec center I do a lot of my pottery out of was offered the opportunity to participate in a soda firing at a nearby university. I LOVE the effect that can be produced by soda firing and I was super excited while I waited for my piece to get fired. Unfortunately I had no input, control or participation in the firing...
It was hideous!!! My piece was a pukey grey putty color, just awful! So, like anything I do, I started some more research. The color came out like that due to the way it was fired, kiln conditions, etc. So...I need my own soda kiln to experiment, learn, and produce the kind of pots I love. The adventure begins..