MarRi Design

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Put A Lid On It

Building the Gas Kiln |
Episode 10 of 10

And finally on this last post, I’m putting a lid on it.

We raised the roof – with some winching and a little wincing (from my mother). But let’s get to making this roof beam.

In the original designs from Andrew Holden in the Self-Reliant Potter, some original resources are no longer available or technologies have improved since as it was written nearly 40 years ago. There were certainly subs we had to make. For the roof beam we turned again to kiln cement which we adapt to any formation we needed. When my Dad made my kickwheel about 30 years ago now I remember being so excited to see him mold the flywheel. It was so massive, so heavy, wrapped with plastic sheeting like this and garden edging. Super rudimentary materials but somehow if feels pretty spectacular. In this case, note the exhibit below: the humble subflooring and plastic sheeting.

This is well for the top of the chimney box (to exhaust the heat).

Making a void in the top beam.
Again, packing wire mesh. Leftover cattle fencing, just enough to stabilize the cement to give it tensile strength.
Putting the camera down for a bit, I moved in to help compress the cement. Because it was quite a big piece and August gets mighty hot in Central NY, we needed to move pretty quickly.
The cement was covered with plastic and sprayed with water from time to time to give it a nice, slow drying time to prevent it from cracking. Oh the waiting…

One week later (another Saturday) we popped that baby out of there. A little bit of cleanup of residual stuck insulation board but relatively clean.

Slight detail finishing work, and surely that right-hand side where you can see less compression is probably on account of me not being girthy enough to push it down. 

To compensate for some areas that weren’t compressed well enough, the sides were wet again and cement added to smooth it out. This created a clean edge so I’m not cutting myself as I’m reaching into the kiln with delicate pots.

Five days later, the cement top was cured. A cradle was made to hold and lift the roof beam. The kiln is quite tall, and the caulk does set up enough that it was worth having it overhead and held and lowered evenly. It’s a heavy piece on its own.

Once lifted and situated in place, more Kaowool caulk was run across the top lip we made in the last step.

Without much fanfare, the kiln is done, albeit the lid that nests against the roof beam. That was made with the ceramic fiber while I returned to a freelance assignment in NYC and didn’t get to record that detail.

A peep hole will be made as well to view inside the kiln.

Testing the burners

Looking back, this day was as exciting as every other step. I love watching this as this is so typical of the exchanges between my parents.

My mom worried about everything going wrong, and my dad, cool and collected.

If you are just coming to this series of the gas #powerkiln and want to read through the build from the beginning, you can click below. I’m happy to answer what questions I can. Anything extremely technical I will do my best to get you the answers you need. Calculations such as the burners and your final design size is best discussed with Ward Burner. To compare refractory material you can look at Sheffield Pottery in Western Mass which was my closest supplier.

Mary Ritzel

Craftsman / Humanitarian / Conservationist / Materials Girl

Designer and artisan practicing traditional and historic crafts in the Mohawk Valley of Central New York. I’ll always prefer raw materials to create a more conscious, considered and thoughtful world.

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