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975 pound day tank rebuild web chronicles
Day 3 - Saturday
Things got off to a slow start today. We didn't have a complete crew until about 10:00, never-the-less we got an adequate amount completed before lunch. This is the false work which Carl, one of the Studio's assistant techs, put together. I think he is a part time cabinet maker or something.
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So the next step was to finish Row 5 and bring the IFB's up to the top of R5. This shows the Tamax brick to up to that point. Note the 12" Tamax brick over the flue, basically just a nice touch.
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Here is a shot of the "superstructure" up to row 5 including all the IFB's which had to be shaved level with the Tamax - at least where we are about to lay skews.
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This is the false work installed. We set up 4 brick posts and put a couple of planks across them to support the false work frame. The whole affair was leveled with little wooden shims. Note how we used an arch brick in each corner to get the false work level.
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After one installs the skew bricks it's a good idea to have Lunch!
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After lunch we got right on the arch. It went great. One must be extra carefull that the bricks don't wander when your doing an arch. If the mortar is slightly thicker on one side than the other or if you push harder on the bottom of the brick than the top, well things go bad quick. And DO NOT forget the holes for the thermocouples.
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Another point of interest here, There is a 3/32" (or so) gap between the front and back wall and the arch bricks. This is so I can put a thin frax gasket between my walls and the arch. This allows the arch to move up and down at a different rate than the walls when the furnace heats up. The arch will never crack. Just before we put the steel back up, just to save a ton of hasle tomorrow, we put the 1/2" thick frax blanket around the base and put the aluminum up against it. This is sooo much easier now than it is after the steel is up.
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Before we can extract the false work we have to put the steel back up and put pressure plates on the skews. Between the push plate and the skews I like to put a price of the 1/8" frax paper as a kind of gasket that helps equalize the pressure into the skew bricks. At this point we are ready to pull out the false work and scrape mortar off the arch. Note - you will be making a huge mistake to leave the false work in overnight, I did this once, the next day the little wooden slats were totally stuck to the bricks and had to be chiseled off. Mortar and wood are in love.
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Well that's were we left it. If all goes spectacularly tomorrow we will be finished with all the brick work on Day 4. Unless of course we get lazy and get drunk before the end of the day - it's Sunday after all.
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