Table of Contents
- Materials Needed are;
- STEP 1: BUILDING THE BASE
- STEP 2: COVERING THE BASE
- STEP 3: Making the countertop of the oven
- STEP 4: ASSEMBLING OF THE OVEN
- STEP 5: INSTALLATION OF THE CHIMNEY FLUE
Materials Needed are;
• A Concrete mixer or a large tub in which concrete can be mixed
• Big trowel and small cement trowels
• 1 or 2 Grout bags
• A welding machine
• A Circular saw
• Safety glasses and rubber work gloves (these are must have)
• A Shovel (perhaps two if needed)
• Measuring tape
• 8-inch cinder-blocks (Concrete Blocks)
• Exterior grade plywood
• Iron angles
• Brick Tile
• Oven kit
**The oven kit we use consists; 5- base components, 2- dome components, metal door with temperature measuring system, flue manifold of 6-inch interior diameter, arch, thermal insulating blanket or thermal insulating materials, refractory mortar**
STEP 1: BUILDING THE BASE
A cement pad should be laid first, on which all other constructions will be done. We’re going to be using Concrete Blocks or 8inch Cinderblocks. Start off by building the L shaped structure, this helps as a support for the oven and will provide counter space.
According to the picture above, since we already know the height we wanted to achieve, we make use of the height of four(4) cinder-blocks put together. Place the bricks such a way so the holes face upwards. The holes can be filled with concrete later on. This will strengthen the bricks to withstand enough loads.
STEP 2: COVERING THE BASE
Once the construction of the base is done, make the structure look attractive by using stones or brick tiles. As seen in the picture above, we have used brick tiles because they make the structure durable. We have used a combination of flat bricks and corner pieces.
The quantity of mix mortar or cement required for this depends on the requirements of the manufacturer. Apply a good amount of the material to the back of the tiles and press firmly onto the base.
STEPS TO FOLLOW:
•Mix the mortar or cement
• Using a trowel, apply a good amount to the back of the brick tile and press onto the cinder-block base
• Use spacers to make sure the bricks are evenly placed. The spaces we used is a half inch (1/2”) pieces of scrap wood
• Let it dry completely
•Use a small trowel or grout bag to fill all the areas with an additional cement mixture.
STEP 3: Making the countertop of the oven
Once the bottom has been done, we are going to need a durable countertop for the pizza oven to sit on. To make it look better an iron frame is made for the countertop edges. Exterior-grade lumber might be used for the edging of the frame, cut a chunk of ply-board measuring the size of the countertop. Weld the frame around the ply-board.
If you’re using a wood border, attach the outside grade wood to the plywood from the bottom using glue and galvanized nails.
If you’re using a metal frame, smooth corners with a metal grinder then use black-hammered paint to provide it good finish.
• Now lay the plywood frame on top of the base and lay rebar on top of the plywood in a crisscross pattern. (Rebar will support the concrete and prevent cracking or separating.)
• Attach the rebar using wire ties
• Pour concrete mix into the frame making sure no air gaps are present in the frame.
• With the help of the large flat trowel or the wood board even out the concrete and give it a smooth finish. Let it dry for a day.
STEP 4: ASSEMBLING OF THE OVEN
The oven we bought came in several pieces. We have had it put together and made a solid Oven.
See the installation guide provided by the manufacturer. The following is ours:
- Do a dry installation first. Just place it where you want it to be. This includes the arch as well. align the oven on the concrete slab, mark an outline of the oven with chalk. Remove the oven once done.
- Open the refractory grout bucket which holds fluids. You see there is water on top of it. Save it by pouring it into another container. Once done transfer the grout in large container. You may use a 5 gallon bucket for that, should be enough. Pour the liquid in the grout until it is the consistency of a creamy peanut butter. Save the leftover water for future use.
- The base of the oven should be installed in such a way that the smooth side is facing up since it is the cooking surface. To achieve this, start with the small rectangular floor element which is found in front of the oven. On the underside of each tile put three individual globs of grout, set them up and level them.
- If any tile isn’t level pull it up and add more grout so the tile is firmed up and will prevent any accidental shifting. Once done pour back the remaining water to the grout, replace the lid and store it in a cool, dry place.
- Enough grout should be put in a pastry bag, then apply the grout to the seams (middle) of the tiles. The grouted seams should be lowered to avoid peeling off from Pizza or casserole when placed on the oven floor.(Secrets of a fine Pizza)
- The upper vault(roof) overlaps comfortably which requires little grout. (Do not grout the upper vault’s element to the floor elements(refractory pad).) Apply grout only the female groove on the vault’s elements with a 3/8-inch bead of grout, place the male dome element, support with grout, then followed by the female element with a little-grouted groove. After the upper vault is done, if you look inside there will obviously be a gap where the floor meets the dome walls. (The gap is needed for expansion because floor tiles expand when exposed to high temperature.)
- A strip of the refractory grout must be applied from the outside of the upper vault and not from the inside of the oven.
- Finally, apply a little dab of grout on the bottom and excess amount along the backside of the vault that touches the oven. Set it properly and hold in place.(In replacement of grout, another material such as stone, granite, tile or brick can be used.)
Take a little dab of grout on the bottom and sufficient amounts on the back of the arch which touches the oven, set and held in place. You can try other materials as well such as stone, granite, tile or brick.
STEP 5: INSTALLATION OF THE CHIMNEY FLUE
The chimney flue comes in two different parts. The flue with the smaller connector is placed on top. Put enough grout at the base of the chimney and connector.
Finally, you may contact a mason to provide your Oven a pleasant stucco end and make sure you wait the suggested period of time for your oven to completely set before use, normally about twenty(20) days.
More outdoor Pizza Oven DIY projects:
For more ideas you check out the following resources.