I’ve only just finished repairing the slow combustion heater in the Old School classroom in preparation for the coming winter, when Janine points out that the fire brick in the wall of the wood fired kitchen slow combustion stove is all cracked and spalled away. The metal casing of the cabinet is showing through. We can’t light it again like this. Being over 40 years old, there are no spare parts available. I will have to improvise – as usual.
I have no real options here. I don’t want to take the stove apart completely to re fit a new home-made fire brick into the wall, so I do a patch job. I use some of my homemade ceramic fibre glue and fill up all the cracks and spalls with ceramic fibre high temperature insulation.
This will have no chance of surviving the intense battering of logs thrown into the fire box. But I have a cunning plan. I find an old piece of kiln shelf down in the pottery that is just about the correct size. So I cut it and shape it with the angle grinder until it fits the bill.
I wedge it into place with a few off-cuts of similar ceramic kiln shelf material and it all locks into place. Only time will tell how long it will last? However, I am confident that it will protect the fibre insulation stuffed in behind until it cracks or breaks.
On close examination, I see that he curved fire brick just inside the stoke-hole door is cracked in half. This is a home-made, hand-built, custom-shaped fire brick which we made from a hand-made mould that we cast back in the 70’s. I made 3 spares at the time. I can see that I will have to make a few more now, as we have used them all up over the 40 years of constant use. It needs to be special shape, with recessed corners that interlock with the other fire bricks, so that it can just slide into place and be held securely, but not too tight, to allow for expansion.
Janine finds the mould after almost 25 years, stored away in the third chamber of the climbing kiln that we don’t use anymore. I knock one out with a rubber mallet to get good compression. One down two more to go. The first three that I made lasted 25 years or so. So this lot should last me until 2045! I’ll be well into my 90’s and won’t be cutting too much fire wood by then.
Last year I repaired the other side of the fire-box, the heat shield that protects the oven from getting too hot. That cast iron plate had completely disintegrated. I replaced it with a home-made kiln shelf that we made in 1976. We still have a lot of them left. I didn’t think that it would last very long, but gave it a go. It has one crack in it after 18 months of use and still going strong. Very pleased, but.
Nothing is ever finished, nothing lasts and nothing is perfect.