David Hendley on thu 28 apr 11
Thanks to all for the suggestions for fixing my electric kiln top, which
broke into many pieces when the perimeter band rusted away - the lid
fell off the prop hinge and onto the kiln.
Mel called on the phone soon after I sent the message to Clayart. He
encouraged me to rebuild the broken lid rather than build a new
one - said he has done it and I could too.
Then Rogier Donker e-mailed and wrote the same thing - that anyone
who has built several kilns could rebuild a broken top. He also offered
to send a stainless steel band for the rebuild and specific suggestions
and steps.
The lid is now rebuilt and drying. As per Rogier's suggestion, I built a
36" X 36" slanted plywood work surface. There is a 2 X 4 under
one end of the surface, to raise it, and another forming a ledge at the
other end.
First I arranged the broken pieces back in the proper order on a work
table, Then, starting at the low end of the work surface, I reassembled
the lid by quickly dipping each piece in water and then in mortar cement
on the edges to be joined.
A couple of times, half way through the re-building, I got out my pipe
clamps and gently snugged the already-cemented bricks together. Once
all the bricks were laid, the band was installed and tightened around the
perimeter.
The best feature of the slanted plywood surface was that I was
able to fill in small voids on the top of the lid with mortar, trowel it
smooth, then easily stand up the lid and plywood work surface up
on edge, and then gently remove the lid from the plywood surface,
still standing upright.
I then cleaned up the plywood and the bottom of the lid, rotated the lid
and lifted it back on the ledge, and lowered both back down with the
bottom of the lid now up. I could then fill in and smooth off the bottom.
Next, I stood up the lid and plywood again, lifted off the lid and gently
clamped it in 2 pipe clamps, standing vertically, so both surfaces will be
free to dry.
It will take a long time to dry, but a week in the Texas sun should do it.
I will, of course, wait a week for that, to first let it slowly set up.
I am thinking of setting the lid on the kiln upside down for the first
firing,
to better harden the cement on the top of the lid. I will then turn it
over and attach the hinge and prop arm for the next firing.
Thanks again for all the replies last week - they gave me many ideas to
consider for tackling the project.
David Hendley
david@farmpots.com
http://www.farmpots.com
http://www.thewahooligans.com
Dannon Rhudy on fri 29 apr 11
Excellent, David. I knew you could do it. If
I can, anyone can. It just takes time and a
bit of thought; and it's important not to rush
anything.
Best, and I bet it lasts a looooooooooong
time.
regards
Dannon
David Hendley said:
Thanks to all for the suggestions for fixing my electric kiln top, which
broke into many pieces when the perimeter band rusted away - the lid
fell off the prop hinge and onto the kiln.
Mel called on the phone soon after I sent the message to Clayart. He
encouraged me to rebuild the broken lid rather than build a new
one - said he has done it and I could too.
Then Rogier Donker e-mailed and wrote the same thing - that anyone
who has built several kilns could rebuild a broken top.
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