Loading the new kiln while hubby puts up roof framework

I started mixing glazes, washes, and preparing the work for loading. It took much longer than I expected to get everything done. Used a Malcolm shino glaze without redart, a wash, a liner glaze and an accent glaze. I tried to keep a lot of the pots bare as I really want to see the soda flashing etc. the wadding was 50/50 alumina hydrate and EPK.

Most of the pieces were practice pieces I made at a workshop since I figured my first firing will be rough.

They were loaded into the kiln. It was a loosely packed partial load. I remembered to place wadding on all the pots and kiln posts.

I opted not to kiln wash my shelves. Not sure that is a good choice but I'll try it this way. Added in my test rings and a couple of cone packs.

Saturday evening we fired up the kiln, crossed our fingers, and had a beer. It ran all night on less than one psi and slowly climbed as we hoped!

As I was loading the kiln, Russ and my boys built the framework for a metal roof to protect the kiln. Firing has started and the nail biting begins...

Ironwork and remainder of chimney

The remainder of the ironwork is complete. Here's the chimney damper support:

We welded in the remaining ironwork (meaning my hubby, not "we") and took down the temporary bracing.

The chimney was extended up to about 7 1/2 feet and framed in with more ironwork.

I also layed out the wicket (kiln door). It is a double layer thick of IFB 23. These were my nice square 50 IFB that Tom kindly traded with me for some key shaped ones.

Of course we had to test the burners. As expected, they shot straight across to the wall then up the wall. To make the transition smoother I added some angled bricks in both corners to aim the flames up.

Safety shut off featured were tried and worked great! Flames ran well and gas lines were checked for leaks with some soapy water.

Here are the flame "ramps" to encourage them upwards. Simple but effective.

The silicon carbide bottom shelves were placed in and I am ready to load the Kiln!!!

Burners and gas lines going in!

So my hubby is installing burners and gas lines. He got a bunch done while I was away at the John C Campbell folk school in NC taking a class from Stephen Jepson. I came home to this:

I can't describe any of this other than to say my hubby built the burners out of stainless pipe, fittings, welding stuff... I'll get him to post a blog with descriptions of all. We did not scrimp on the safety portion so each burner has a baso valve and pilot light. For now I can only provide the pictures. The picture above is the one in front and here is a picture of the rear one by the chimney.

Here's my hubby installing it:

The burners are adjustable forward and back to adjust the distance of the burner to the kiln. Three trips to Home Depot later and it was too dark to finish and trial. :( We also need to pick up a little more angle iron to finish up the chimney support. 

IFB arch is up! and some more iron support

I opted to add a layer of 1" ceramic fiber over the hard brick arch to help seal up any leaks (and because I already have some to spare). Thank you soda fire Facebook buddies for all the advice.

Next went the IFB arch. I had to cut them down as the key shape made too straight of an arch. ;( With some finagling, I was able to cut some and use about half "as is". :) I did no fancy calculation and just eyeballed them. It is a short arch so I was able to hold them up and formed the sprung arch over the ceramic fiber without compressing it. It actually sits about 1/8" above the fiber blanket.

It took a few days of cutting and fitting but the arch is up! We ran a double layer of angle iron across the top of the door and welded into the side supports.

I used IFB to fill it in. Better explained by the pictures. This way the arch has plenty of support and it will be an easy stacking for the door. Because of the angle iron I ended up with a small gap at the front of the arch. I added a little ceramic fiber blanket covered by tin foil to fill in the sliver.

Finally a stack of hard brick to support and close it all up. Everything seems tight and well supported but I won't know how I did until the kiln is running. :)

Hubby also built a support for the burners with holes to adjust the placement.

Look at the pics and you can see where all the ironwork was welded. Some supports were just to be extra cautious and reinforce and others were to correct my sub-standard brickwork. :)The top angle work is temporary and will be trimmed off. The chimney needs another 4 feet added and the ironwork on the chimney needs to be welded on.
But...the brickwork (except the chimney) is finished!!! I kept all my fingers too!!! (That tile saw is quite the hazard!) Lol! Sooo excited!