Category Archives: the fire

A Free Kiln ?

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I have been given an old electric kiln that is 44 years old. The frame is still in OK condition, but the ceramic fibre lining has collapsed, it is all cracked, shrunken, and falling to bits. The fibre in the roof and back wall has sagged, broken up and half of it has fallen in. Most of the element rods are also cracked and broken. It looks like it has had a hell of a life. I was told that it was once in use in a school, but I don’t know where it was originally from or it’s history before that. But it ended up being last used to slump glass. We were given the kiln when it finally became unworkable and the glass artist, (a relative of Janine), retired. And, I believe, spent its last years laying on it’s back and used as a top loader.

I’ve been given lots of things that don’t work in my time here, especially since the fire. I’m used to it. People say. “Steve, your handy. I’ve got this thing that doesn’t go, but I’m sure that you will be able to fix it. You can have it!” And occasionally, I can actually fix it! I surprise myself sometimes!  

Most things only need a different way of thinking to get around the huge problem of built in obsolescence. To find the creative alternative. It doesn’t have to look like new or be perfect. It just needs to work. Our pottery is full of old gear that I have rebuilt like this. In fact, there are less than half-a-dozen items that were bought ‘off the shelf’, as it were, brand new. We just don’t buy new stuff very often. Even my recently purchased ‘new’ electric car, was actually a used car, but new to me.

That is how we survived financially all these years, we rarely buy anything new. Only 2nd hand stuff, that no one else wants, or is less desirable. Second hand car, second hand house, second hand tools and equipment, we were always being offered stuff cheaply, or free, because it needed repair or just didn’t go anymore. However, If nothing turned up, I just built things from up scratch, using recycled material, or re-purposed from another job. The first two pottery studios that we built here, were made from re-cycled and scrounged materials, mostly wood. Tragically, they both burnt in fires. So no more building with wood for us. It is only this last studio that we built using a metal frame, but we spent a year scrounging sufficient old recycled corrugated iron to both clad it and line it, inside and out. Along with 2nd hand fittings and doors.

I decided to include a big arched window for the South wall of the new pottery facing the house. I wanted it to reflect the arch window that I made for the house back in the 80’s. No chance of finding something like that on the side of the road, so I welded one up out of marine grade aluminium for just a few hundred dollars. It actually turned out OK. I’ve never done that before. And can’t see myself ever needing to do it again. I never seem to get any good at anything much, as I only ever seem to do these jobs once, or maybe twice, but a couple of decades apart, just after I’ve forgotten how to do it.

The first thing that I did to get this old freebie kiln on the mend, was to make some new element mounting rods. As far as I’m aware, no one makes these ceramic kiln rods anymore in Australia. They are not hard to make, just time consuming. But I guess that you do need to know what you are doing. And in this case I just happen to know just enough to to it. That is to say, that I have had a go at home made kiln furniture/home made refractories about 50 years ago.

I needed to get these rods made early, as the only kiln that I now own that can fit in 650mm long ceramic element rods, is the big wood fired kiln. I can only fire the wood kiln in the cooler months, avoiding summer for obvious reasons. So I needed these rods made back in March, last year, so as to be dried out and ready to fire in May/June. As I was planning to do the rebuild of the electric kiln over this last summer break. I got a lot done, but it has taken me a long time. Principally because I don’t really like doing kiln work. I’m over it!

I mixed up a small batch of 10kgs of refractory clay body suitable for use as element rods. I used some old refractory ‘Puggoon’ kaolin, along with 3 sizes of high alumina grog. For years, I used to make all our wadding for the big wood fired kiln out of ‘Puggoon’ high alumina kaolin from Gulgong. I still have one big jute sack of it left in the barn. This special High Alumina wadding (HA) that I made up, after firing to stoneware, wasn’t just rubbish to be thrown out, but instead, I had created very useful, high value, HA grog. Converting what would normally be any one else’s waste product into a valuable asset worth over $6,000 per tonne.

I can also crush a very good quality HA fire brick down to dust in the rock crusher to make excellent grog.

This is not just re-use, re-cycle, but rather up-scale and value-add as well! Over a year, it’s amazing how much wadding/grog you can accumulate. A very long time ago, way back in the 70’s. Janine and I managed to buy 12,000 mixed fire bricks for a few hundred dollars, from a metal bath tub enameling factory that was being de-commissioned. This meant that we were able to build a very large 3 chamber wood fired climbing kiln. The biggest problem we faced at that time was that kiln shelves were so incredibly expensive. Without kiln shelves we couldn’t fire the kiln, so I taught myself how to make our own kiln shelves and props. Most of which, I still have! I developed a reliable recipe using crude ‘Puggoon’ HA Kaolin 50%, mixed with our own home made HA grog 50%. Our own crushed wadding and fire brick grog gave us a range of sizes straight from the crusher, coarse, medium and fine, It proved to be a good blend of sized aggregate. I learnt this technique when Janine and I worked with Harry and May Davis in New Zealand way back in the early 70’s.

My recipes and pictures of me making the kiln shelves and props were all illustrated in the book ‘Handbook for Australian Potters’ published in the early 80’s. Pages, 206 to 212. Below, I’m shown in my youth, in these images, taken by Janine, of me making kiln shelves, fearlessly declaring my independence and learning to be self-reliant. I’m a lot older and fatter now, but nothing else has changed. I’m still enthusiastically practicing self reliance!

These home-made kiln shelves weren’t very good. But they worked, and were good enough to get us going and in business, because we certainly didn’t have the money to buy enough of them to fill such a big kiln. So I taught myself how to make refractories way back then out of necessity. Now I’m financially secure enough to afford to buy element rods, but as a Nation, we don’t make anything in Australia anymore. Such items may be available from China? But I know how to make my own, So I do.

The refractory clay and grog mixture is so non-plastic and short, that it doesn’t hold together much at all. The clay is naturally short, crumbly and non-plastic, and when mixed 50/50% with fine grog it is, not too surprisingly, totally short, crumbly, floppy and useless. A bit like working with sand castles. I can’t extrude the rods vertically, they just snap off under their own weight. I have to extrude them down an inclined stainless steel ‘V’ shaped ramp, lubricated with a little used engine oil brushed on to it to ‘lube’ the process. The clay has to be pushed down the ramp to keep it compressed and avoid hair line cracks. If it can slide easily, it will distort, stretch, weaken and break. The thick engine oil, allows the clay to slide, but is sufficiently viscous to stop it from sliding easily. I use the thin stainless steel ‘V’ angle slide to carry the soft rods to the drying table.

Once dry, the rods have to be carefully carried and placed in the kiln very gently. The clay body is so ‘short’ that they snap so easily. It has NO dry strength. NONE! I broke a couple packing them, even taking care. Once fired to stoneware, they are more resilient. The final strength is achieved when they are used in the kiln. Each firing to stoneware, helps to develop the matrix of primary mullite crystals in the body that gives it high temperature strength and thermal shock resistance.

Now, with the element rods in stock, I recovered 2 rolls of ceramic fibre that went through the fire, (completely unaffected, but just a bit blackened, and now without their cardboard boxes), a box of 2nd hand refractory insulating bricks, slightly burnt, blackened and box-less, and a box of recycled and charred ceramic anchors, that also survived the fire. I only needed to buy some new stainless steel bolts to hold the anchors in place. 

The largest expense in rebuilding an old kiln like this is my labour, so I’m saving a lot of money there. The other big expense is the cost of the bulk Kanthal wire, so that I can wind up a new set of electrical heating elements on the lathe. I have done all the calculations and decided to design the new elements to use the best grade Kanthal A1 resistance wire, and run the whole thing at very low ’watts per sq. millimetre’ rating. This requires using more of the most expensive wire, but gives a set of elements that will last a very long time and make the kiln more or less maintenance free. The wholesale cost to me to purchase the bulk wire is close to $900!  Before spending time to wind them on the lathe and form them into hairpin element units.

I once had a phone call from a kiln maintenance guy who’s job was to go around the Schools, Colleges and Art Schools servicing pottery kilns. He told me that he had been doing this job for over a decade and had seen my kilns sitting there in the various kiln rooms, and he had never been asked to look at them. Constantly working on other kilns in those facilities. Apparently, my kilns had never needed any servicing.

It’s pretty unheard of for a pottery kiln like that to go for 10 years, fired 2 or 3 times a week, and not need any elements replacing or other work. He asked me directly, “What are you doing?” “How come they last so long?” I was pleased to hear that he was so impressed. I told him that I simply used the best material available and plenty of it, and did the best good job that I could. I don’t want to be going out doing maintenance. I want the things to last forever. There was one brand of kiln that had the reputation for having a certain degree of built in obsolescence. Those were his bread and butter, he told me. He loved the fact that they were rubbish,

I built around 300 kilns in my time over the 50 years. When I started my kiln building business decades ago, and rang the ‘Kanthal’ wire distributor, to order their best quality A1  high temperature wire. I often got the message that they would have to order it in, “as no one uses that wire in Australia very much, so we don’t carry very much in stock!”  I’d have to wait up to 2 months for the next shipment. It opened my eyes to the fact that other kilns being made here at that time, didn’t have the best grade of wire in their elements, possibly ensuring a certain degree of ongoing maintenance calls into the future?

I don’t actually like doing kiln work. I did it out of necessity. It was one of the ways that we found to earn the extra money that we needed to pay off the mortgage. Making pots was so much more fun, but financially unreliable. However, although I didn’t enjoy the kiln work. I found ways to make it more mentally challenging, by always looking to do things a different, or better way. I developed all my own designs. Got both a gas license and an electrical license to keep it all legal. Taught myself how to weld both stainless steel and aluminium, using a sophisticated solid state, AC/DC, pulse, TIG welder, and do all the sheet metal, as well as the electronics and learnt CAD design software. There was always something challenging to learn to keep it ‘alive’ and interesting. So although it wasn’t my first choice,  it was better than all the other alternatives. Like packing the shelves at the supermarket, being a delivery driver, or becoming a full time ceramics teacher. I was happy to just go into town one day a week to teach my special subjects at the Art School. I really enjoyed that. But it was only one day a week. I could cope with the driving once a week. I couldn’t see myself doing it every day. It was a 2 to 3 hour trip each way. A waste of my life if I was to do it full time. I couldn’t bear the thought! 

So we found half a dozen creative ways to cobble together a risky, uneven, slightly stressful, but fully committed and involved creative life. It turned out that we ‘got away with it’!  We managed to get through life without ever having to get a ‘real’ job! I was never on the dole either! Completely independent. Most of the other potters that we knew had a partner who had a full time job to smooth out the economics. But we were one of only a few couples, who survived working together with no one earning a safe ’salary’. We were both fully involved in this erratic, ceramic based, artistic engagement with self reliance and creative mini-capitalism. It taxed our inner resources both physically and intellectually, but was ultimately very rewarding in exact proportion to the effort that we put into it! I’ve never been motivated by the desire for money in itself. It’s necessary for a basic level of comfort, but after that it consumes people. Someone once told me that money is like manure. It has a great fertilizing effect when spread evenly, but stinks when it’s piled up in great heaps!

So all this life experience has now come in handy in the refurbishment of this ‘free’ kiln that was destined for the tip. Is anything ever really free?

I laid the kiln over onto it’s back, so that I could take out the broken and collapsing roof fibre and replace it, without the whole brittle ceramic fibre roof collapsing down on me. I only replaced the hot face and the 1st of the damaged back-up layers of fibre. However, I changed the overall layout of the ceramic anchors to triple the number. It was the lack of sufficient anchors that lead to the roof sagging and collapsing. Next, I stood the kiln up and added another hot face layer of 1400oC ceramic fibre on top of the shattered and spalling existing back wall. Best not to muck around with old fibre where possible, so I just covered it with a new layer. I also added double the number of ceramic anchors to support it. Plus, the extra 25mm of hot face fibre that I added will make the wall more thermally efficient.

I made a set of tools to do the fibre work. I made a special little plunger out of fruit tree pruning wood, to hold the stainless steel bolts in place while being installed. Its a gorgeous little home made improvisation to make a fiddly job a lot easier. I took the trouble to make a tapered mortise joint to hold it together. Sweet! No one knows it exists, just me. I know how beautiful such an unimportant tool like this can be. I enjoy the fact that it exists, that’s enough.

I added another layer of fibre to the floor, but didn’t touch the side walls, as they are intact, and well supported by the element rod support brackets. They will last for a while yet. 3 of the element rod support hooks are broken off. As these where custom made, and are no longer available, rather than go back to basics and make a new set from scratch. I will make 3 small support blocks to hold the rods in-situ in those spots.

I was lucky that we found a few old re-cycled ceramic anchors in the ashes and rubble after the fire. Janine and our friend Trudie hunted around for them at some point when I was fully occupied doing something else during the chaos. She knew that they had a value and might come in handy in the future. Now 6 years later, they have. Thank you Janine and Trudie ! Some are chipped and have a bit broken from the rim, but still perfectly functional, if used with care.

I have wound the new heating elements on my old lathe. I bought it 4th hand. It was at one time in use at the naval shipyards in Sydney harbour – a very long time ago. It was actually made in Melbourne by McPhersons, most probably in the 50’s or 60’s? So it’s as old as me!. That’s old! But very solid and reliable. (it, – not me!)

The next job was to renew the door seal, to create a secure tight fit during firing to protect the metal around the door frame. Once that is done I will use the oxy torch to form the heating element coils into ‘hair-pins’, I get them red hot , so that they become pliable, then I can bend them over and double them up into ‘hair-pins’. I can then fit them into the kiln on the ceramic rods, with both terminal ends sticking out the back of the kiln where they can be linked up to make full circuits.

New door lining and door seal installed

Forming the ‘hair-pin’ heating elements from the straight coils.

Heating and bending the rear element ‘tails’ into paired ‘loops’, so that I can link them together to make heating circuits of pre-calculated ampage and resistance to give precise heating of the kiln.

I have all the stainless bolts that I need, but I realised that I didn’t have enough of the correct stainless steel washers to do the connections. So I made some! As you do!

I’ve cobbled together this refurbished electric kiln for a little bit over $1100 for parts only. It is a bit less than 400 litres with a packing space of 320 litres, or 12 cu. ft. in the old units. I’ve upped the power from 16 to 20 amps x 3 phase, and used the very best quality Kanthal A1 element wire.

I have seen new kilns of this size for sale online for over $20,000. Quite a saving. This is how we survive, by the generosity of others, to whom I am eternally grateful, plus some good luck and a lot of scrounging.

I consider myself so lucky to be given this ‘free’ kiln. I have had to dig deep into my past skills and recover them from memory. I haven’t made kiln elements since before the fire, maybe 8 years ago, when I retired from building electric kilns. I am very lucky that my ancient old lathe survived the fire! Lucky, because it was in the old barn that burnt in the fire. Fortunately, because I stayed to defend, I was there and able to put most of the fire out, and control it to some extent, so that only half of the barn burnt. I said lucky, because the lathe could have been in the other half. What I lost was a lot of dried ceramic materials in paper ply bags.

I can’t remember the last time that I made kiln elements. But it’s all coming back to me, bit by bit, as I think about what the next step is. Luckily, I haven’t made any drastic mistakes!

My last job was to link up the element tails at the back of the kiln with stainless steel bolts and washers to complete the circuits. That done, I was able to pug it in and give it a run. My ‘tong’ tester revealed that I made a very slight error in my calcs, as the ampage on each circuit turns out to be 21 amps rather than the 20 that I had calculated. No problem. The kiln will be 4% more powerful.

This kiln isn’t beautiful. It just has to work! And as of now it does. Time will tell. I have had this ruin for a couple of years now. I didn’t do anything with it for the first year and a half, as I didn’t really need it. However, Now that I’m keen to make big, round, fat, pots inspired by Moon Jars. I need a larger kiln. This kiln has a 600 x 600 floor, and 750mm high. So plenty of scope to make a larger, fat, round jars.

I’ve out grown the small 450mm x 450mm. cubed electric kiln that Len Smith gave me to help me get re-started. I have been using it for the past few years and it works just OK, but is worn out and struggles to get to cone 8. I have purchased new element wire for that kiln, but I haven’t got round to making the new elements yet. I had to re-wire the old lathe after the fire burnt out the barn, so I’m working on lots of projects all at once. But now that I have the lathe back in working order. I can proceed on to the next job, which is Lens old kiln.

Nothing is ever finished, nothing lasts and nothing is perfect.

Nothing is affordable, nothing stays new, and nothing does exactly what you were promised that it would in the add!

More rain and tasting cider

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It’s been raining again quite heavily. We now have 4 different little streams flowing across our land, where the dams overflow, and the front lawn is under 25mm of water, like a slow moving shallow lake gently flowing across our kitchen vista.

We had 65mm of rain at one point. I thought about what to do for a while and came to the conclusion that it was probably best if I decided to do all those glaze tests that I had been meaning to do for a while. I certainly didn’t want to do any outside work. So I spent a day rolling out slabs and pressing out grid-tiles from my standard plaster grid-tile mould. This ensures that all my test tiles are the same size and shape, so that I can compare them at any time with tests made years before if needed. Tragically, I lost 3,000 glaze tests in the fire, so I’m starting again.

Weighing out glaze tests can be quite boring, especially when it goes on for days. However, it keeps me gainfully employed in the warm and dry pottery studio. I put on a CD while I work. It takes more than the length of a CD to fill one test tile with the infinitesimally small gradations of ingredients in the logical progression of the recipe. Each tile is 8 x 4 squares = 32 weighings and recordings.That’s 288 tests made in this sitting. Enough!

When I was doing my PhD, I did every test in triplicate, so that I could fine them in oxidation, then reduction and also in the wood fired kiln. As each kiln gives its own variation to the test. Having done that very thorough exploration, I’m over it and these days I only make the one series of tests, and fire them  in the kiln that I think will deliver what I’m looking for.

It fills 10 pages of my glaze note book this time around. I have to keep detailed records of what I do and why I’m thinking that it might be a good idea. Sometimes, it takes so long to get the firings done at the temperature that I’m imaging will be best and in the atmosphere that I want, and in the kiln that will give me those ideal conditions, so that If I don’t write everything down in detail, then I can forget what I was thinking and why I went to all the trouble. Hopefully, it will help me to understand both the results and more about myself in a few weeks time, when they are all fired, and I can decode the results! 

Each tiles takes about one hour to complete. After two days of this, I’m pleased to do the last one – for the time being

When there comes a break in the rain, I get out and pick vegetables for dinner. This time is leaks, broccoli, Brussel sprouts and carrots. I’m planning baked veggies with a mustard infused béchamel source for dinner. I make a quick and warming lunch of pasta. I tried to steal the spaghetti from the supermarket, but the female security guard saw me and I couldn’t get pasta!

🙂

We decided to try is years cider with dinner. We made this batch of cider back on the 11th of February and bottled it on the 11th of April. So now it has had 4 months to settle down. It will be good to see how it has turned out.

See my blog post; ‘Autumns rewards,  Posted on 11/04/2025’ 

Janine thought that we should do a vertical tasting of the last 3 vintages. What a good idea! 

As we still have a few bottles of the 2012 vintage. This was the last vintage from the aged 40 year old apple trees in the previous orchard. From 2012 onwards there was a severe drought, so intense that we didn’t get to harvest any apples from 2012 through until the fire in 2019. So no cider was made. In 2015, our friend Val had a good crop of apples on her trees in ‘Lagan’, 2 hours drive, south of here, so she drove up a couple of washing baskets full of her apples. We were able to make a small batch of cider from those apples. We re-planted a new orchard in 2020 with different varieties of apples.

We opened 3 bottles to see and compare the difference. The older 2012 vintage was still very lively with good spritz, but a darker colour from its age, more akin to a beer in colour. It has a medium nose of sultry notes and a good firm cider flavour, just as we are used to. Completely dry on the finish. The 2015 from Val’s apples is medium in colour and flavour, and similar to above.

The 2025 is very pale with floral notes, a delicate palette and a dry finish, however, not very effervescent, because, as it is the first vintage from all the new apple trees in the new orchard, all planted since the fire, and this being the first year that we had a decent crop. I made the decision to cut the amount of sugar added at bottling, to ensure that there wasn’t too much pressure in the bottles. I don’t want to experience any exploding bottles. 

We make a completely ’natural’ cider here from our organic orchard apples. Nothing added at all except yeast. I have always used Moet and Chandon champagne yeast, as it has alway worked well for us. Back in the 70’s, you couldn’t buy cider yeast here in Australia, so i chose champagne yeast, as it is closest to what we wanted to make – a sparkling cider. These days I can buy any number of cider yeasts form the brewers supplies shop, but I stick with what works. 

I always leave the cider in the fermenter for 2 months to make sure that it has completely fermented out all the available sugars and is ‘dry’. Over the past 4 decades, I learnt to add one spoonful of white sugar to each bottle at bottling. This is the standard champagne bottling technique. This is to allow it to re-ferment, just enough to make a sparkling cider. Because these are all new trees and therefore an unknown fruit. I played it safe, and only added half a spoonful of sugar at this first bottling. So this batch has only a gentle spritz, but this is better than too much. 

After this test run, next year I’ll be brave enough to add the full amount of sugar.

I’ve never been brave enough to go with the wild ferment of naturally present yeasts that are on the skins of the fruit. When we had a small vineyard of 100 cabernet and 30 shiraz vines. I tried making one vintage of a macerated, whole bunch ferment. The wild yeast that was dominant on the skins at that time was very vigorous and resulted in a rather unpleasant distasteful wine. I didn’t like it at all and threw the whole lot out. So I lost a whole vintage. it’s nothing to do with money. It’s all about the investment of time and effort, and the expectation that there will be something interesting and delicious at the end, even if the amount is very small. For instance, we only make 30 to 36 bottle of cider each year, just enough to fill one fermenter. It’s enough.

Nothing is perfect, nothing is ever finished and nothing lasts. Good cider doesn’t.

First cabbage of the cool season.

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We have just harvested the first cabbage and first broccoli of the autumn. I planted a range of brassica seeds on boxing day. The first batch were all dug out by the blackbirds, so when I re-planted the 2nd sowing, some time later. I also covered the bed with bird netting to stop a repeat of the blackbirds scratching out the seeds. Blackbirds don’t want the seeds, they just like to scratch into freshly worked and composted soil looking for worms. This little hiccup set me back a few weeks, so our first cabbage is a bit late arriving.

I have now repaired all the melted sections of the plastic netting over the vegetable garden. Almost total replacement at both ends that were worst hit by the fire, then applying patches to the large holes in the other walls, and finally stitching together the small 50mm to 100mm holes that are scattered all over the enclosure walls and roof. I purchased a commercial size roll of 100metres by 10 metres of netting over 30 years ago to cover the vineyard at harvest time. The netting that is over the veggie garden now is all that is left over from that time. It had a 10 years warranty against going brittle with the ultra violet light. So I’m very pleased that it has lasted so long. However, it is getting very brittle and the galvanised steel netting is all rusted through in places. So a total rebuild is in order, but I’m not too sure that I can manage that big a job these days, or if it would even be wise to attempt it at my age, having just turned 73, I shouldn’t be up and down ladders for days on end.

I made an Australian version of oka-nomiyaki pancake. Of course it is not really an okonomiyaki, as I don’t have mountain-potato starch, or almost any other authentic Japanese ingredients, but I do the best that I can with what I have. The super-fresh garden ripe cabbage makes it really fresh, crisp and delicious. The broccoli goes into a veggie stir fry along with all the other garden delights of the current season and some tofu for protein. Vegetable gardening, which mostly involves a lot of weeding, mowing and watering, suddenly becomes so worthwhile when you are harvesting such beautiful produce each afternoon, freshly picked ready for dinner. Our food has carbon metres, not miles!

I have also planted another 4 different varieties of seed garlic in the garden, just to see if any of therm are well adapted to grow here in the future.

In the pottery, I have been throwing some sericite porcelain stone bodies. This stuff is so short that I have to make the wall bases thick to hold the form up. That then means a lot of turning to get the pot thinner again. This weird stuff tears and rips as the turning tool cuts into it – unless it is turned quite firm and almost dry. But then there is the dust to contend with, so I like to do it while it is still a bit damp, but then it chips a lot. It becomes a two stage process. Roughing out the mass of extra thickness, drying some more, then final turning. I get to do a lot of slaking and re-cycling of turnings.

I have built an extra-large tray for my shimpo, but with this porcelain, I still fill it very quickly. This image is of the trimmings from just 15 small 150mm. bowls.

It all goes into the mixer pug and is recycled, ready for throwing again the next day, although leaving it to age a little bit and ‘recover’ would be even better, but because I use a dozen different mixtures and recipes, it is easy to loose track, with too many small packs of different clays hanging around. So I prefer to use up each batch all in one go as soon as possible.

The tyre on the old wheel barrow went flat last week. I took it to the tyre place to get a patch or a new inner tube, but they told me that the tyre wasn’t worth working on and I’d need a new tyre and a new inner tube – at a cost of $78! As the old metal rim is quite rusty, I decided that I might just as well buy a whole new wheel unit from the big hardware chain for $32! But then I remembered that I had a complete wheel off a buggered trolly that I picked up off the side of the road on council clean-up day. It is 25mm smaller in dia. but still holds air pressure well, so I had to change the shaft size and make some new brackets to hold it on, out of scrap tin plate. 20 mins later we are all back in business and good to go. It’s not perfect, but it works. Recycle, reuse, repurpose!

The Japanese have a word ‘Mottainai’ – too good to waste!

A botched up job that will keep all of this useful material out of the waste stream and land fill for another decade. I actually picked this whole wheel barrow up off the side of the road in the village some years ago on Council clean-up day, when the owner decided that it was just junk, because the tyre was flat. I took it home and just pumped it up. It worked! And has been working hard here for all those years of reprieve since then – and now still continues to be useful. Waste averted, Mottainai!

Nothing is ever finished, nothing is perfect and nothing lasts.

Our re-built old wood splitter

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This last few of weeks, We have been teaching weekend workshops each weekend. Working in the garden and orchards in between time, but in particular, I have been re-building and restoring my formally beautiful hydraulic wood splitter. This machine was brand new and only used twice before the 2019 catastrophic bush fire. Our Lazarus wood splitter in the Phoenix Pottery Workshop. I need to get it going again, for our wood firing weekend workshop.

It used to look like this. All new and shiny.

Then after the inferno it looked like this!  Just the RSJ column of the splitter standing in a clearing in the burnt out forest, that used to be our kiln wood shed.

Today, with a lot of effort by my friend Ross, who rebuilt the hydraulic ram and other bits for me, it looked like this.

The 2nd hand tyres went flat every week and continually needed pumping up. I finally took them off and got inner tubes put in them. 

I replaced the burnt-out hydraulic control lever. This is the gadget that makes the ram move up and down. 

Then I turned up an adaptor unit on my metal lathe, made from some old aluminium irrigation pipe off cuts that I used for the new orchard netting frame. They were roughly cut to over-size with the angle grinder, then machined to exact tolerances. Finally I re-worked an old 3 HP electric motor that Ross gave me, making an improvised power adaptor/converter.

The last job was to give it a coat of zinc primer paint.

It is now functional again and running on sunshine, instead of petrol. So much better for everyone.

A damaged, but reliable, solid and still working, thing of beauty.

A self portrait! – without perhaps, so much beauty!

Repair, reuse, recycle.

Tea bowl exhibition in Seoul, Korea

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I currently have one of my bowls in a tea bowl exhibition in Seoul, South Korea.

This bowl was fired at the front of my wood fired kiln. During the firing the ash glaze ran just a little bit too much and stuck the bowl to one of its pieces of wadding. Luckily, I was able to chip it off without breaking the bowl. I repaired the damage using the ancient Japanese technique of ‘kintsugi’, using gold to repair precious pieces of ceramic.

Using pure gold to repair a damaged pot shows respect for the item. It honours the piece by giving it time and resources, and finally finishing it off with a coating of pure gold. By showing it respect, I choose to give it a greater value than it would have had, if it had come out of the kiln intact.

The pot is damaged, but it is still beautiful. It has Value, and it is Unique. It is Honoured even though it is Damaged. It’s possible that repairing a damaged thing can make it more beautiful and precious than if it hadn’t been through its ordeal.

I see these damaged and repaired objects as self portraits. I went through an ordeal and although I was damaged, and am not the same, I am still working. I’d like the think that I’m also improved by the experience, although I’m not too sure about that. My pots that I repair are certainly more beautiful, interesting and valued.

And then the rains came.

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We have been going through a very dry time recently, with the onset of the summer heat and reports confirming that we are entering another el-nino period.

All a bit glum really, but then the rains finally came. We had about 150mm. that’s about 6 inches in the old money. I had recently spent a few days pumping water from one almost empty dam up to another, slowly accumulating what was left of our water in the 4 dams, all eventually up to the one small dam near the house, where we have both a high pressure, petrol driven, fire fighting pump, and a small electric pump that is mostly used for watering the garden.

I managed to get that little dam about 1/4 to 1/3rd full. not a bad effort. That would have been just enough to see us through the first half of summer.

Before the rains.

After the rain.

But now, since the down pour, we have 4 dams all about 3/4 full. The little house dam that started from 1/3rd full, over flowed down into the next dam in the series. A lot of that water I pushed up hill 2 weeks ago flowed back. A waste of a couple of gallons of petrol. I still buy petrol for the pumps, the chain saws, the mowers and diesel for the tractor. So we are not fully weaned off the dirty oil economy. I worked out recently that I spend a little bit more money on the fuel for the mowers and chain saws, than I do putting petrol in our Plug-in hybrid car, simply because we make sure that we keep the car fully charged off our solar panels, so we rarely ever need to put petrol in it. About $30 every 3 months, where as I spend about $100 twice a year filling up the fuel drums for the garden appliances.

We have recently bought a solar charged electric push mower, plus a whipper-snipper thingy, and a solar charged electric chain saw. So I expect that my visits to the petrol station will decrease accordingly. I still need diesel for the tractor and petrol for the ride on mower.

Since the weekend workshops of the last two weekends, Janine and I have spent a good part of each day during the week in the pottery consolidating our sgraffito skills and developing a few new designs, to include in our next batch of work. I would have liked to spend more time in the pottery, being creative and self absorbed. Once you start to draw and decorate the surface, the time just flashes past and it gets late so early. We  have to stop to do the watering. There will be more time tomorrow to get a bit more done. There is always enough time for everything. We just have to learn to allocate out time and and as we age to allocate our limited energy. 

There is so much to do around the garden and orchards. We have had to start watering by hand again since the rains stopped and the temperature has been going up – just touching on 40 degrees today. Even hotter in the west. Hand watering all the gardens and orchard trees. It takes us both over an hour to do a quick once-over, just to keep everything alive. It takes a lot longer to give specific beds a really good soak while we are at it.

We could probably buy vegetables much cheaper from one of the rip-off, price gouging supermarkets. But they wouldn’t so clean, fresh, healthy, organic and immediately delivered straight from the garden and onto the plate. There is something so very, even intensely, powerful in growing your own food. Not just the self reliance of it, but the intimate nature of the activity. It grounds me here in this place. I’m intimately here and now on this ground. This has become my little all-encompassing environment. My statement of belonging. I’ve sculptured this place into being as what is is now. It’s peaceful, abundant, pretty, and very functional as a home art space and garden.

We are just coming to the end of ‘the hungry gap’. That time of the year when most of the winter food in the garden is coming to an end, but the new spring planted summer crops haven’t started producing yet. We have been eating the last of our carrots, beetroots and cabbages, and have just picked the last of the broad beans along with the first of the new season zucchinis. Tomatoes have set on the bushes, but are still very green. It is always a challenge to get one ripe red tomato before Xmas. 

maybe not this year, due to our being away and not getting that head start early on at the end of winter, or the first weeks of spring.

One very nice treat for this time of the year is the summer fruit crop. We are harvesting strawberries, blue berries, peaches, nectarines and plums. That equals fruit salad for breakfast for the next month.

I love the summer garden, but I don’t like the 40 degree days, or the potential for bush fires that are always in the realm of possibility when the wind picks up from the west.

Bush Fire Water Management

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The first Open Studio Weekend is over. One more to go! 

We had a very slow day on the Saturday, as it was raining hard on both sides of us in Picton and Bowral. So visitors were reluctant to leave home, and few and far between. We had just a few brave people venture out. One visitor from Picton had gone to an Open Garden event, but it was so miserable in the pouring rain, that she gave up and decided to come and visit us for some indoor, dry and warm, entertainment.

The Sunday Open Studio was much better, quiet in the morning, but it picked up after lunch and we were almost busy dealing with a steady flow of visitors in the afternoon. We hope for better weather and more visitors next weekend. However, if it is going to rain, I’d prefer it to pour down, flood the gutters and stream down into the dam.

Of course, as usual, it didn’t rain here at all, just a few light passing showers throughout the day. Our top dam, the one closest to the house, that rely on for irrigation and fire fighting water is bone dry. The foot valve for the pump is sitting high and dry on top of the caked and cracked mud. This dam still had a very small amount of water in it when we left for our time away in New Caledonia and then Brisbane. However, we got a call from our lovely neighbour one day to tell us that she had tried to water the garden for us, but no water was coming out of the hose. I knew knew why. I expected it to run out and dry up at any moment. but there was nothing that I could do at a distance.

Starting on the Monday morning, with the news of so many houses burnt down in the north of the state in the terrible bush fire there. I wasted no time in preparing ourselves for the next bushfire – whenever it happens. Maybe sooner than later? With the bushfire season now upon us in earnest. I was straight into action working on all those jobs that I had put off during the recent three wet years.

We have 4 dams, built in a key-line system. I moved the high pressure, petrol driven, fire fighting pump, down into the bottom dam, which is nearly empty, but still has some water in it, right at the bottom. I built a jerry-rig, improvised system of poly pipe lines to convey the water from this little bottom dam, up to the larger, middle dam. A day of running the pump moved most of the water up the hill to the next dam. I left just 300 mm of water in the bottom of that dam for the yabbies, to keep them safe over summer. If it does dry out completely, they will bury them selves in the mud.

From the bottom dam, up to the middle dam. This larger middle dam also has next to nothing in it, just 300mm deep in the middle, but every drop counts in summer. Especially when a bush fire is in the offing.

Neither the bottom dam or the middle dam, has a functioning pump on them at the moment, so moving all the available water up to the top dam, where I have both petrol and electric pumps installed gives me access to whatever water is left to us over the hot dry summer for fire fighting. Also, concentrating all our water in one place minimises the losses from evaporation. 

Once the bottom dam was more or less empty. I carried the petrol pump up and into the middle dam, re-arranged all my Heath Robinson, improvised piping and began pumping from the middle up to the top dam. I’ve been on my very own personal, localised, ‘Snowy Hydo 2′ project here for two days now and all the water hasn’t been relocated yet. It’s a slow job, moving thousands of litres of water, up hill through a 40mm dia pipe. I hope to finish it off tomorrow.

From the middle dam up to the top dam.

The little top dam is now half full with all the accumulated water from the other dams, it will keep us safe into January. Then?

While all this was going on. I was also working on the new fire fighting sprinkler system along the verandah and roof of the new pottery building, and also rebuilding the burnt out sprinkler system on the barn. It worked perfectly during the fire, and saved the barn for burning, but when the power failed and the electric pump stopped, the plastic pipe system melted. I will be installing a petrol driven, high pressure, fire fighting pump in this system when I’ve finished pumping all the dam water uphill.

The roof and wall sprinklers all rebuilt and up and running again now.

Nothing is perfect. Nothing is ever finished, and nothing lasts.

However, I feel safer knowing that I have water in the system available to use to fight the next fire, 

and a reasonably functional system in place that I hope will be able to cope with whatever nature throws at us

I make sure that I use the fire pumps often over the summer months to irrigate the garden and orchards. 

In this way, I always know that the pumps are in reliable working order, then if one of them gives some trouble with the irrigation, I can step in and fix it well before there is any emergency, when there is no time for fixing things. Everything must work perfectly and immediately.

Since the last fire 4 years ago, I have installed 45,000 litres of tanks in front of the Barn, dedicated to the fire pump for the pottery and barn system. I have also installed 30,000 litres of new water storage tanks on the old Railway Station and car port with its own fire pump.

We are much better prepared now than we were 4 years ago. This is self reliance!

Our first weekend workshop in the new pottery

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We have just completed the first weekend workshop in the new pottery.

We invited the potters and ex-students who had helped us clean up the mess from the catastrophic fire that cleaned us out in November 2019. We only have 8 potters wheels in the new throwing room, so our numbers were limited to the first 8 potters to get in touch with us.

Regrettably, we had to turn a few lovely people away. However, there will be other workshops coming along in the pipeline. I’ll be announcing them here on the blog as they become reality and when we have set firm dates. This first workshop was a ‘freebie’ as our thank you to those volunteers.

To help us out on this first workshop we invited or friend and collaborator Warren Hogden to join us. We started off with throwing mugs, cups and beakers.

The pottery was buzzing, with every one being busy. Janine, Warren and I all gave a demo of our throwing techniques, so everyone got 3 different approaches demonstrated, so that they could choose something to concentrate on for the day. 

Each lunch time, we asked our son Geordie, who is a ‘hatted’ chef, to come in and cook lunch for us – a very special treat.

We set up the hand-building room as our lunch room, I made a table out of a very large slab of wood from one of our trees that was killed by the fire. And rather than waste it. I couldn’t bear to see it bull-dozed, chopped up and burnt, so I hired a portable sawmill for 3 days and we milled the trees into all the planks and slabs that we needed to build the new pottery.

This solid table is one big slab of timber that can seat 12. We use this room for functions, dinner parties and openings. Our house is small, so if we need to sit more than 6 guests, we move out into the pottery where we can seat 12 to 14 at a pinch. It’s a large bright, well lit room with loads of practical, flexible space, so it has become an extension to our house in some ways.

On the 2nd day we all demonstrated turning our pots, then making and applying handles. We kept everyone busy all day for both days.

I demonstrated pulling handles from simple hand rolled coils, as well as my somewhat crude, but easily made, twisted-wire handle ‘blank’ extruder.

These ‘blank’ billets of proto-handles are applied to the pot and then ‘pulled’ in the traditional way to make an elegant, smooth, curved handle.

Janine demonstrated turning the base of her pots on a leather-hard clay ‘chuck’.

I couldn’t help by notice how things have changed over the years. These days everything is videoed on mobile phone for later reference.

Warren demonstrated the use of a ‘caulking’ gun to extrude the basic handle shape. He also demo’d the use of a plaster mould to press mound handles.

Everyone appeared to enjoy them selves. It was certainly an intensively productive 2 days.

We farewelled everyone with a very tiny taste of Geordie’s latest venture as the head distiller at ‘Renegade gin’ in Mittagong.

We had a bottle of his Australian Native Plum Gin. I served it in very petite antique Japanese porcelain sake cups. I didn’t want any one to get booked on the way home, so just 1 or 2 mls. It’s really delicious stuff. So intense, fruity and concentrated, just superb!

Winter, Everything is dormant – except us

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We have had our new chickens for 5 days now, so this afternoon I let them out for a little wander around the garden for an hour before bed time.

They had no hesitation in running straight out onto the lawn and practised running very fast and flapping their wings. First in one direction and then back again. 

I’m thinking that it is the first time in their life that they have been outside, with unlimited space to run and flap about.

They stayed close to their house all the time. They only had a passing interest in watching me load compost into a wheel barrow and wheel it into the garden to mulch fruit trees.

At 4.30, they put them selves to bed. 

Each day, I’ll let them wander a little bit further and for a little bit longer.

Since the fire we haven’t had any cherries from the burnt out Chekov orchard. I think that most of the tiny, tender fruiting spurs on the cherry trees got roasted in the fire. They don’t regenerate, it seems. The trees can grow new fruiting spurs on mature 2nd year wood, but they haven’t so far. So I only pruned them very lightly last year and not at all this winter. That should produce the possibility of 2nd year mature wood for new spurs next year? 

But all the new wood is right up very high reaching for the sky. These are old trees now so the new shoots start up at 3 metres+  and go straight up. That means ladder work to pick the fruit. Not good. It’ll all go to the birds I suspect?

Just in case, I ordered 7 new, dry rooted, cherry trees for this winter. They are all grafted onto dwarf rootstocks and also bred for low chill warmer climate conditions. Perfect for me to maintain into my older age without needing ladder work. All transplanting of deciduous trees is always done in the winter months while they are dormant.

I mowed, then weeded and dug over a suitable strip along the back fence of the netted veggie garden. This reduces the area under cultivation, making the garden smaller and better suited to my diminishing capacity to maintain the larger space of intensively cultivated plots.

We should start to have some more cherries in a couple of years from now.

I noticed that the first early peach has started bud burst in the stone fruit orchard. So I dropped everything and got stuck into the pruning. I should have done it at the end of June, but time slipped by. In the past it took both me and Warren 2 days to prune the old established 40 year old fruit trees in the previous orchard. This time, with all the new dwarf trees. I got it all done in one 3 hour session on my own. That’s so much better.

The first of the early blueberry bushes has also broken into flower. It’s almost as if its spring already and we are only half way through winter.

While I was at it, I made a full weekend of it and also pruned the almond grove. It has not flourished since the fire and I had to prune a lot of dead wood from the trees. I’m not too sure if they will survive? They don’t look very vigorous. We have had quite a number of very big eucalypt trees die this past year. They survived the fire and shot out new branches and were looking OK, but 3 years on, they just turned up their toes and are now dead. They’ll need to be felled at some stage to make the garden safe, otherwise they will start to drop branches.

I was doing a bit of a clean up, mowing and weeding in the veggie patch, while prepping for the new cherry trees, suddenly a glint of red, I discovered yet one more self seeded stray tomato bush. So this must be one of the latest harvests of ripe, free range tomatoes that I have ever done!  The seasons seem to be coming around faster and faster, or am I just getting older?

While I was doing all this tidying up I also took the time to pick a red lettice, some red radiccio, chicory and the last of the endive. This mixed with a green onion and some chervil. I made a lovely little bitter salad for lunch.

Winter Solstice and the First Truffle of the Season

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We are well and truly in the months of winter now. We had a week of crackling frosts, then they were driven away by a week of freezing winds. That didn’t help me to get out and about in the garden at all, so I stayed inside working in the studio, out of the wind.

We celebrated the winter solstice with a dinner here in the big decorating room in the pottery, at the big work bench, converted for the day into a refrectory table. We can seat a dozen pretty comfortably in there. It is such a big, almost empty space, that it doubles up very well as our entertaining area. It is huge and uncluttered, as opposed to out house, which is small and compact, and none of the rooms in the house were designed to seat 12 people for a meal. We have however, had over 30 souls in there for a house concert, crammed in cheek and jowl. But that was only for listening to music, not a sit down meal.

On this occasion, I cooked pizzas for everyone, as it is cold outside, it was a good time to light up the old wood fired pizza oven and crank out a few pizzas. 

I try and stay clear of the usual suspects. My favorite this time was wilted spinach and oven roasted pumpkin from the garden, with a few olives. I prepared everything before hand, picking, washing and wilting the spinach before everyone arrived. I spent the morning in the kitchen prepping. The pumpkin was finely sliced, diced and roasted in the new solar electric oven, with olive oil salt and pepper and some finely diced garlic, also from the garden. These crunchy little gems melt in your mouth and smell and taste delicious.

We have been enjoying the first truffle of the season for our breakfasts this last week. We buy only one truffle each winter. It’s a special indulgence. They are hard to buy around here directly from the growers, who prefer to sell in larger amounts directly to restaurants. Luckily we have a son who is a chef and has access to the trade, so we order one each season through him. We take what ever comes. I only ask for something less than $100. At $1 a gram, it can quickly add up, but usually we get something around $30 to $50 worth. However, this year, the price has gone up to $1.50 per gram, and what turned up in our order is a beauty! 50 grams. That is about 50mm dia. and the biggest that we have had the privilege to enjoy so far. 

This is a 4 or 5 meal truffle!

We store the truffle in a container with the eggs for tomorrows breakfast and a cup of rice that will be the next nights risotto dinner.

The best way to enjoy truffle in my opinion is just simply grated over very soft scrambled eggs.

We spent the weekend cutting and splitting wood for the kiln and house. These are logs still sitting in the yard, left over from the bushfire clean-up.

Yes, We are still dealing with the aftermath of that horrible event. It’s still all around us, in the dead trees still standing, but on this occasion, we are cleaning up logs still sitting on the ground from burnt tress that were felled for safety reasons by the State Government clean Up squad that came through after the fire to ‘make-safe’ the area where people might be living and working around their houses.

Some of the logs were particularly straight grained, so were ideal for splitting very fine for the side stoking of the 2nd chamber of the new wood kiln.

Others were gnarled and knotty with many forked branches, so I cut these short for use in the house stove. You can see the new pottery up in the distance. We are clearing up further from the core area around the house now, So we are making some progress.

It was a full day and by the end of it I was conscious that I was very tired and needed to stop before I ended up hurting my self. I have damaged my hand in the splitter years ago, by working on into the gloom in the evening, just trying to get the job finished in one day. 

As the shadows lengthened. I called it quits. I will finish the job another day.

What started the day as a 3 big piles of twisted logs and butt ends, ended with several small er piles of split timber kiln fuel. 

49 years ago, when we started out together on this creative journey. All we had was a two metre long, ancient, two man cross-cut saw and a block buster hammer. My, how things have changed! I still have the big cross cut saw, it hangs up on the wall in the barn. I still have the block buster head too, however it has had countless wooden shafts, broken and replaced since then. My days of swinging the block buster are numbered, but it still gets some sporadic use for small jobs that are too small to be bothered getting out the tractor and hydraulic splitter. It’s a bit like kitchen gadgets that take more time to clean up than the time saved using them. I still admire and appreciate many old things and ways of being, but splitting wood with a hammer is not one of them.