Paving Tiles and Wood Heater Repairs

We were busy last weekend with a bunch of friends paving the court yard area around the new, almost finished, wood fired kiln.

I still need to finish laying the last of the floor bricks in the chamber, I would have finished this small job a couple of weeks ago, but when the court yard flooded with 70mm of water sloshing around in there. It wasn’t very appealing to be kneeling done and doing the bricklaying. Then all that water was sucked up into the floor bricks like a wick and they became saturated so that any new mortar wouldn’t stick in place. Finally, they have now turned green with algae. I’m sure that they will dry out – eventually!

This severe weather event, although not life or property threatening for us, like it has been for our friends and relatives up on the North Coast. It has been a good warning and trial run for what we can expect in the future as Global Heating increases unchecked. No one in government seems to be taking this seriously, so what can we expect for the future? Well my guess is more of the same, only much worse. We’ve been warned.

So this extreme weather event has been a great warning to us as to what we can expect in the future. I have learned from it and and I’m taking actions now to limit the sort of damage that very heavy rain fall can cause. To start with we have paved the kiln area with a significant fall away from the kiln and out into the open. I have also ordered some more steel batons and some more poly carbonate roofing sheets to wall in half of the courtyard directly behind the kiln. With contour drainage to take the water to the edge of the retaining wall. Although the pottery didn’t flood, it has become obvious that we need to create a dish drain around the front of the building to carry all the excess ground water away from the front of the building, because another event will eventually be worse. 

This is a start

Back at the kiln, I also need to fabricate a stainless steel firebox lid and a stainless steel chimney flame tube incorporating a spark arrester. I planned to have started this job already, and 3 weeks ago, I ordered the Stainless steel sheets and some Stainless steel wire mesh for the spark arrester. The sheeting is here, but the couriers have lost the SS mesh. The supplier won’t replace it until he knows what has happened to the first order. The courier company won’t pay out to replace it until they know what has happened to it. So I’m stuck in a catch 22 situation. I can choose to wait it out until the original order is found and delivered, or buy a second sheet of stainless steel mesh and get on with it, but it’s not cheap stuff, so I’m waiting and continuing to write emails of enquiry.

We had a great weekend with our friends laying the paving tiles. We also met two new people who volunteered and turned up all the way from Newcastle, who will surely become friends now. They were a great addition to the group. The stayed over night with us and we got to know each other over a home grown meal from the garden. I had previously made a big pot of tomato passata from the last of our tomatoes, so we had an easy meal of pasta. Dan and James are environmental campaigners and organisers, so we shared a lot in common. James took this image of Dan, Janine and me standing on the new paving.

Dan, Steve and Janine. image by James Whelan

  

This is all great progress and I’m really happy to see so much getting done.

Janine and I started the levelling and paving earlier in the week. As a trial run, to make sure that everything would work out the way that I planned. As we haven’t done any paving since we built the last pottery shed in 1983, I’d completely forgotten what to do and had to re-educate myself and get my skills back up to date. It’s not rocket science, but does need concentration and quite a bit of back bending work. I decided that at my delicate age, I should not do so much bending and instead get the knee pads on and work down on my knees to keep my back straighter. This worked out much better. But then getting up became a bit of an issue.

Starting the paving, getting our levels sorted out and learning how to space the pavers to allow for all the different sizes to fit together evenly.
the courtyard paving complete

As we are in Autumn now and the weather is getting cooler and the days shorter, we have thought that we may need to light the fires in the kitchen and lounge room soon. The slow combustion heater in the lounge has started to wear through and rust out in the top fire box steel sheet. A crack started to appear at the end of last season, so I made a mental note to repair it once it cooled down, during the off-season, well that time is running out now, so it has to be dealt with as a matter of urgency. I decided to attack the problem by fabricating and new roof for the firebox out of a scrap piece of 2mm thick stainless steel sheet.

The new Stainless steel fire box roof sheet ready to install
The new firebox top bolted in place

Rather than try and weld it in place, which wouldn’t really work very well , as stainless and mild steel have different rates of expansion and contraction. I decided to bolt it in place with stainless steel bolts through over size holes and oversize washers. This should allow for the differences in expansion. The 2mm thick stainless roof should last as long as the 4 mm mild steel walls and whats left of the old top sheet. Time will tell. The stove is about 30 years old, so it has proved it’s worth. I’ll continue to work on it and preserve its life for as long as I can. We bought our slow combustion kitchen cooker over 40 years ago now and it was 2nd hand then. I’ve managed to keep it going all this time with home made adaptations and ingenious improvised repairs. I’m proud of that achievement and I’m hoping to extend it to 50 years if I can.

While I was at it, working on the lounge room heater. I also made a new front door frame seal. Afterwards, we went out into the paddock and spent an hour together with chainsaws cutting bushfire devastated and blackened logs. We cut them to stove lengths and stacked them in the wood shed ready for splitting. This will be about 1/4 to 1/3rd of the fire wood that we will get through the coming winter months.

My 11th book published

This week I received a box in the mail from Korea. It contained copies of my latest book translated into Korean.

I was such a poor student of English at school. I’m somewhat surprised that I have become a published author of multiple books in 3 languages!

Even my English teacher from High School was surprised, to the extent that when I met him 10 years after leaving school, at a reunion, he didn’t believe me when I told him.

I don’t blame him.

My work building our wood fired kiln continues. This last week I have finished the chamber arches with Janine’s help. 

Adding their second layer of insulation bricks and welding on the steel bracing.

I also started work on the chimney with the help of my good friend Warren on the weekend.

The chimney is almost at the height that I can’t build anymore courses until I cut a hole in the roof to allow it to go through. 

This will involve fabricating some specialised pieces of galvanised sheet metal ‘flashing’, custom fitted to the brick courses just above the tin roof to keep the rain out.

I hope to complete the chimney this week. More ladder work! 

I have declared myself an honorary 59 year old for the past week to allow me to keep climbing ladders 🙂

We have now picked nearly all the apples and I cooked another apple and almond flan tartin for our weekend guests. 

I also made the first batch of baked quinces, as the birds had decided that it was time to start eating them, dropping a lot of them onto the ground with just a few holes pecked into them.

They need to be dealt with pronto, or the damage soon spreads and they go bad quickly. I wouldn’t mind so much if they ate the whole thing, but they just peck a hole into the fruit to get to the seeds inside. If the fruit drops, they just watch it fall and start on another. At least the rabbits eat some of the fallen fruit. Quince fed rabbit sounds pretty good!

I wash the fluff off the skin, then peel and core, chop into 4 pieces for small fruit, or 8 pieces for the larger ones. I simmer them for 20 mins in a sugar syrup of 120 grams of sugar per litre of water. This syrup is less than half strength of the recipe ! Use enough water to cover the volume of fruit. Add a few cloves, star anise, a cinnamon stick, and half a small bottle of maple syrup. Once softened a little, transfer to a large baking dish and bake for 2 hours in a low oven at 160oC until nearly all the liquid has evaporated. Remove the aromatics and bottle in sterile jars while hot from the oven. I think that they are ready when they start to catch just a little on the tips and have turned a beautiful reddy/orange colour.

The fragrance is spectacular and the taste is amazing. Can be eaten just like this, or can be enhanced a little with the addition of some pouring cream, plain yoghurt or ice cream.

I also managed to find just enough zucchini and squash flowers, both male and female to make up the numbers, so that I could make stuffed zucchini flowers for dinner. I wasn’t expecting to find so many suitable flowers this late in the season, so wasn’t prepared with suitable quantities of cottage or other suitable cheeses. Instead I used a tub of left over risotto from the fridge. extended with some boiled lentils and a few olives. It made up the distance.

This last week also brought a little bit of excitement into our dull, plodding, Post Modern Peasant lives. The State Government Funded green waste clean-up program commenced, for all the dead and damaged trees in people yards that were created by the 2019 Black Summer catastrophic bush fires here in the Southern Highlands.

We had a team of half a dozen blokes here for two days, lopping, topping and chopping dead trees. Some were completely removed and the stumps ground out, but most were pruned back to make safe habitat trees for wild life.

They shortened and made safe 15 trees and took down 3 or 4 smaller ones in the immediate vicinity of our back yard orchards, where we work and mow.

The purpose of the exercise is to get most of the smaller dead branches down out of the canopy so that it is safe to walk around underneath them in our garden. We had already dealt with the most pressing and difficult problem trees in our front garden 2 years ago at our own expense. I wasn’t prepared to survive the fire and then be killed by a falling branch.

It’s only taken 26 months for the State Government to implement this emergency safety solution into place. I wonder how long it takes them when they take their time 🙂

We still have 3 acres, or one and a bit hectares of dead forrest that is continually dropping dead branches. We just don’t go there, and if I have to, I wear a hard hat. 

It’ll be unsafe for the next couple of decades as the dead branches slowly rot and fall. But what can you do? It’ll cost many thousands of dollars to get them all pruned safely.

We’ll just have to live with it.

After The Fire – 2 years on

Now that the pressure is off for taking part in the Open Studio events, we can relax a little. We were lucky. We managed to get sufficient glazed work finished to put on a reasonable show.The next big job is to re-build our wood fried kiln, so that I can make the work for the PowerHouse Willoughby Bequest commission. As we are in need a bit of a rest after two years of constant work and anxiety about finances, materials, parts, Local Council regs, electricians and final inspections. It’s good to have this time before Xmas to do a lot less.

Janine is spending a few hours each day back in our lovely new and very comfortable pottery studio, making a few orders from the Open Studio weekends, but principally because I have promised to make a bathroom vanity sink for our neighbours new house. As we were fully occupied recovering from our own bush fire ordeal, we couldn’t help them rebuild their house very much. So making them a bathroom basin is my best gesture towards recovery.
The basin is too large for our tiny electric kiln, so will need to be bisque fired in the bigger gas kiln. We can’t afford to fire the kiln with just one pot in it, so Janine is making work to fill the kiln and make the firing more economical  We are not pushing ourselves, just taking it slowly. A few hours a day is enough. There are so many other jobs that need our attention, just to keep the veggie garden and orchards in good nik and under control. Mowing is the main job these days, as it keeps on raining and getting warmer, so the grass grows quicker.

While Janine enjoys the luxury of the new pottery. I am out in the maintenance shed welding together a pile of pressed metal ‘C’ purlin off-cuts. joining them together to make useful longer lengths. I am joining up to 7 small bits into one 6 metre length that is more useful. I will bolt these ‘recovered’ lengths back to back with some new material to make a composite ‘H’ section. These will make very strong uprights and purlins for the new wood kiln roof.

I don’t particularly like working with steel. It’s heavy, sharp, noisy and dangerous stuff to move around, but it surely does a great job of being strong and resilient  These thin beams will span great distances. The specific thing that I love about steel is its ability to be welded back together to make it larger and stronger. I’m told that a 25mm weld can hold over a tonne. That’s strong. And if I accidentally make a mistake and cut a piece of steel too short. Well, if it were a piece of wood, it would be wasted. I would have to use it up in another job where a shorter length was needed. You can’t join timber back together. However in the case of steel. It can be welded back together and the joined pieces can be stronger than the original – if its done properly!So I have saved all the off cuts from the pottery shed frame that the builders threw onto the rubbish pile. I put them aside and Janine later stacked them carefully so that now they can be put to good use making the kiln shed frame and roof. Reuse, recycle, up-cycle  waste not want not. etc. I take a great deal of pleasure in being able to forestall waste in this way with this kind of ‘thrifty’ building work. It has been being self reliant like this that has got us to where we are now in life on our small income from our creative endeavours.
In the mornings we work in the vegetable garden, clearing out swathes of overgrown weedy stuff that has more or less finished its productive life. 

Then when the sun gets up higher, we have lunch and stay inside for the afternoon doing our ‘inside’ jobs until the heat of the day has subsided. Sometimes this heat culminates in a thunderstorm, two days ago we had hail with the thunder storm. This is something like the summer weather that we used to get decades ago. Possibly the last time that we had strong La Nina conditions?
If I have to be stuck inside at these times, I spend time making something useful that will improve our lives. Today it was some garden bed edging that I cut and folded out of scrap galvanised sheet steel that had been laying about since the fire. We have decided to shrink the garden beds a little bit to make them narrower. This will result in making the garden paths wider. Once this is completed, we will be able to drive the ride-on mower through the veggie garden and save hours manhandling the whipper snipper around the current narrow paths which is becoming quite tiring work for me these days. Especially as it needs doing almost every week.

Everything that we have done since the fire has been oriented towards making our future life here easier. Building the new pottery on a cement slab floor for the first time, so everything can be on wheels – possibly including us in our dotage! We have chosen all dwarf root stock grafted fruit trees for the new orchard, so no more climbing up step ladders to prune and harvest fruit. We planted these dwarf grafted whip-sticks in August 2020. These trees are now 16 months old and in their second summer. Some of them are doing really well and have set plenty of fruit. So much so that I had to go around a month ago and pick off half of the crop and compost it before it drained the vitality from the young trees.  I picked off over 100 small apples, peaches and necturines. I also did a summer pruning of some of the tallest leggy shoots to keep the trees in a sound open vase shape to promote good growth and development in the future.

Even though I thinned out the crop, we were still able to pick about 40 peaches and twenty necturines this last week.

We are also picking loads of blue berries at the moment. Half a kilo every second day. We have to find ways to use them up, as there are too many to eat as fruit salad in the mornings now. We preserve some and I have started to make blue berry tarts now, as the youngberry and logan berry crops are more or less finished. They never make it past Xmas. But this year in particular the constant rain and the hail really ruined the usual large harvest. Who’d be a farmer or an orchardist?
Two years on we have worked ourselves into a really good place. It can only get better. The past is the past. We are not looking back. Everything is in place to create some beautiful and meaningful moments in our life.

3 firings in one day. Preparing for our Open Studio Weekends

Yesterday we had all three kilns firing at once. A bisque in the little electric kiln, a stoneware reduction glaze in the big gas kiln and another stoneware reduction firing going on in the old relocatable mini wood fired kiln. I recovered it from the ashes of the fire. As it was built from a stainless steel monocoque frame with insulation brick lining, it mostly survived the fire, because it was stored out on the verandah and didn’t get too badly burnt. It just needed some cosmetic TLC on the frame and a new set of castor wheels. Lucky!

It was designed and built as a possible dual fuel kiln to be fired with either wood or LP gas from BBQ bottles. However I had never fitted it with burners and only fired it with wood previously. Now is the time to finish fitting it out with burners. I spent a day making shiny new burners and gal steel mountings. I chose to only pack and fire the bottom half of the kiln , as it is designed to be in two sections. A bottom half with the fire box opening and burner holes – which ever is chosen to be used. Then a top half composed of a removable ceramic fibre ring and lid. The ring can be removed and the lid placed on the base section to make a smaller half sized kiln. Which is what I did yesterday. As it was the first test firing of the kiln, I thought it best to go small for a first firing.

After an initial tweaking and tuning, It worked perfectly and fired to stoneware in reduction easily in 2 1/2 hrs. using less than one 9kg bottle of BBQ gas. I had 2 set up ready with a change over switch just in case, but the 2nd bottle wasn’t needed. I also set them up in a tub of water that can be warmed. In this way I can fire them to dead empty without them freezing. But none of this was necessary yesterday.

I’m a bit more confident about our local rock glazes now after 3 rounds of test firings. The hares fur/teadust tenmoku is a little more stable.

Both Janine and I have been investigating the use of colours over tenmoku.

and I have managed to stabilise the local Balmoral dirty feldspathic stone and wood ash opalescent Jun glaze.

Janine has made some slip decorated lidded boxes.

The stone fruit orchard is looking great after a wet start to the spring season and everything is green and luscious.

The almond grove is also very lush and green. All these mature almond trees were burnt and transplanted into this area that was formally a native garden. We have decided to keep the more flammable native bush at a much safer distance from the house now.

The pottery will be open this coming weekend, the 13th and 14th of November as part of the Australian Ceramics Assn. Open Studios weekend that will operate nationally. We will be open in conjunction with Megan Patey in Colo Vale. Megan makes beautiful Majolica and Smoked Arab lustre.

click on the QR code to find your local potter.

Janine and I will be also open on the first two weekends in December and the Southern Highlands Artists Pop-Up Open Studios group.

We will be open on the 4th/5th and in conjunction with Sandy Lockwood, on the 11th/12th of December.

We look forward to being able to show you around the new pottery on one of these 6 days.

We will be following the government recommended COVID19 safety protocols. So please come if you are double vaccinated and have your vaccination certificate. There is our Service NSW, QR code poster on the door for login

We have a covid-safe plan that includes keeping the space very well ventilated and limiting numbers to 4 sq.m. per person.

Please don’t bring dogs, as we have recently had both wood ducks and brown ducks hatching clutches of little ducklings that waddle all around the property with their parents feeding on the lush grass. These are timid wild animals and we have no control over where they wander. So please keep a respectful distance if you are walking around the garden.

These last two photos by Janine King.

The Gallery Room is Finished

This last week, we have been working on getting the gallery room finished. This is the last big dirty job to get out of the way. Once this is done we can really start to clean the place up and get ready to make some pots. There is of course loads of other jobs to complete before we can fire anything, but they can wait. They will get done in good time while our first pots are drying.Some of these other jobs will include getting the kilns ready for firing.
However, in the meantime we have cut the huge pine slabs that we milled 20 months ago. I have sawn them into rectangular planks 3 metres long and 750 mm wide and 80mm thick. Not too many people can afford to use timber like this in their gallery. We can’t! It would be completely out of our reach if we had to buy it.


We can only do this because we grew the trees our selves. We got the dead pine trees that were killed by the fire, felled professionally, as they were right up against the house. We then hired a portable saw mill to cut them up into big slabs for bench tops and planks for lining boards. They have been seasoning for the past 18 months.
I had to build an extension bar for my small hand pumped hydraulic crane on the truck. An extension of 3 metres is a bit far, but it worked quite well. I took the first lift very slowly to test that it wouldn’t bend under the load. A few weeks ago, I had a friend come and help me lift and shift these massive slabs onto the ute. But we are now in total COVID 19 lock down statewide, so another solution had to be devised. This way, I can do it all myself.


The huge slabs needed to be cut to have parallel sides and squared off ends, then planed, and sanded a few times with ever decreasing grit sizes of 40#, 60#, 80# and 100#, finally washed to raise the grain. After drying, the rough raised grain texture was again sanded with 80# and then 100# to get a fine finish. There are so many hours of work in getting a massive surface like these slabs from a very rugged chain saw finish, to glassy smooth. I’m not a wood worker, so I don’t have access to any large wood working machinery. All this had to be done with hand held tools. I have to thank my very good friend Len Smith for giving me all his Makita power tools. I need 4 big slabs for the bench tops and 24 planks of 2.4 metres to be dressed like this to make the shelving. It’s taken me over a week.
Once the slabs were finished, I needed to shorten the crane arm to lift them onto the truck to drive them up to the pottery.


I needed to weld up a suitable steel frame to support all this wood.



We’ve ended up with something that resembles a massive kitchen dresser. One on each side of the room, with another huge slab table in the centre. This gives us plenty of storage space in the cupboards and a lot of flat display space. We spent today sweeping, vacuuming and generally cleaning up all the saw dust that ended up coating everything in the place. That is all now done. This was the last really messy job. We can now relax a bit and look forward to making some creative work.


Tomorrow I will start by making some throwing and turning tools. My first job on the wheel will be to make some clay ‘chucks’ to get them stiffened up so that I can turn my pots once I start to make them.

‘The Elements’, Bush fire pod cast

This podcast is about the 2019 bushfires that raged down the East Coast of Australia in 2019. Stewart Diver, the man who survived the Kosciusko landslide and spent a week under a collapsed chalet, until he was rescued, has made a series of podcasts called ‘The Elements’.

The first one was titled ‘Water’ and is about the Sydney Hobart yacht race disaster.  This second episode concerns ‘Fire’ and covers some of the events that happened here in Balmoral Village in December 2019.

https://podcasts.apple.com/au/podcast/fire-black-summer/id1577294004?i=1000530782341

You might find it worth a listen?

They got the award winning novelist, Trent Walton, author of ‘Boy Swallows Universe’, to read out certain passages from my blog to fill in the gaps. So that is good.

Finishing Touches – This week it’s plumbing

There are still a lot of small jobs remaining that we have to complete before we can call the Council Building Inspectors and apply for a final inspection. We need the final inspection to get our Occupancy Certificate, then we can be potters again instead of being stuck in this perpetual builders labourer mode. One of the main jobs on the list was to bring water down form the big new water tanks up near the street in front of the barn down to the pottery.
This sounds simple if you say it quickly, but like all jobs it develops a life of its own. Firstly I needed to dig just over 100 metres of trench to bury the plastic water pipe. The trench has to go down the side of the new shed and around the back, across the back retaining wall, across the courtyard and finally up to the North wall of the pottery studio and into the sink inside. 
I wasn’t going to have a sink in this new pottery. We had lived without one in the old pottery for the past 36 years, just using buckets to bring in water from the water tank outside. This avoided any problems with silting up, or clogging up of the drains. However, it was the building inspector who came to do the site visit who talked me into it. He told me that it was a simple matter of getting an S64 certificate, nothing!
Well it’s something! But once committed, I’m following through. First we needed a seepage trench 600mm x 600mm by 10 metres long, then a grease trap, ’S’ bends etc. It all takes time and money and a lot of effort, but we are almost there with the pottery sink and all that it entails.


We are lucky that have very good friends who have a half share in a trench digging machine, so I asked to borrow it for a day last Saturday. It’s a fantastic gadget. I was able to dig the 100 metres of trench in a little over 2 hours. I hit a lot of flat iron stones that are very common in this soil. They sit horizontally in layers not unlike shingles, so digging through them is quite an effort with a mattock and crow bar. The last time I did it manually to do a short 11 metre trench for some storm water pipe on the barn, it took me most of the day, and I ended up digging a trench 300 mm deep x 300 mm. wide flaring open towards the top as I prised out the multiple pieces of flat stone. I only need to bury 9cm. pipe, but the hole was more like the Suez canal!
So on this occasion the powerful machine makes short work of such matters as flat iron stone. But there is always a down side, and that is such that as the machine loosens and evicts each large flat stone, it jambs the drive mechanism. So I had to put it in reverse to spit the stone out. It does this easily, but in so doing, it spits the stone and all the dirt along with it back into the trench just dug. I proceed onwards and will deal with that later.
I was finished with the machine by lunch time. I spent the rest of the afternoon digging the flat stones and soil out of the trench and cleaning it of rubble and roots.
Sunday was spent laying the pipe work. I decided that if I was going to dig such a big trench, to save time and effort later, I would put 4 different pipes into the trench at this time, so that I can use those other pipes to supply high pressure water from the fire pump to the fire fighting sprinklers on the walls and roof of the new shed. Fitting the sprinklers doesn’t need to be done now in the midst of winter, but laying the pipes now is a good idea.


I put in a 2nd trench to the front of the pottery shed to take the fire fighting sprinkler line to the front of the shed while I was at it. This is all taking more time now and is a bit off putting and seems a bit like a waste of time seeing that I’m in such a rush to get this shed finished and passed, but it will be so much easier later when I get up to that job.
With the trenches filled with the 4 different pipes, it was time to refill the trench and cover the pipes. The chickens love to be busy where ever there is fresh dirt exposed.


While I was involved in the plumbing side of things, taking the sprinkler lines up the walls, attaching them and caping them off. Janine and the chickens back filled the trenches.


The last part of this job is to run the pipe into the studio and install the goose neck mixer and taps. We found this set of old hospital taps in a junk shop 40 years ago and bought them for $40 to use in our house when we were building the kitchen way back then. It turned out that they didn’t fit in the place that we envisioned them to go when the time came, so I put them in storage in the barn wrapped in an old tea towel, and there they sat until now when we remembered them. Luckily for us, they were stored in the part of the barn that didn’t burn down. The barn caught fire, but I was there on hand and was able to fight the fire and stop it from spreading too much, so I managed to save most of the barn. These taps included. 


I gave them an overhaul, I pulled them to bits and replaced all the seals and washers, then lubricated all the working parts, reassembled them and gave them a good clean and polish. They never looked so good. I had an old piece of 6mm thick solid brass plate given to me many years ago. It was an off cut from a big job at an engineering place that closed down. I couldn’t ever really find a use for it that justified cutting it. So it just remained stored in my kiln factory. After the fire, I saw it sticking out from the ashes, all bent and twisted and a little bit melted in one corner. Luckily it was on the floor in a part of the shed that didn’t get too hot, in amongst metal machinery and up against the mud brick wall. 


I spent the best part of a day straightening it out and hammering it flat. Well, as flat as I could get it. I gave the centre part a bit of a polish to show that it really is brass, and left the rest with its fire-scarred patina. It makes a suitably steam punk splash-back for the ancient taps.


Winter Solstice

We have survived the longest night of the winter. The frosts have cut the last of the soft plants from the garden. We have harvested the last tomatoes from the dried brown burnt stems of the last surviving tomato plants. We come inside earlier these days at 4:30 and light the fires in the kitchen stove and the lounge room heater. We have just picked the first of the red cabbages for our dinner.


Fortunately for us, we have almost finished all the immediate outside work on the new pottery shed, at least until spring, and we are now concentrating on working inside each day in the relative warmth and comfort of the passively heated and draft free environment of the new pottery. It’s quite amazing how warm it gets in there with no heater on, with just the sunshine in through the north facing windows. 
It is particularly noticeable that there is no draught inside from the gusty cold chilling wind outside. This is the first pottery that we have had out of the 4 of them that has had no draughty gaps somewhere in the walls, roof or around the doors. 
Our first 3 buildings burnt down over the 47 years of our life together as potters, All the previous potteries were all home made buildings, as we have never had sufficient money to employ builders. These earlier buildings were created from recycled and scrounged materials, plus home made mud bricks, all with ill fitting and odd shaped windows and doors and no insulation. The last pottery did at least have silver paper in the roof, but no insulation, as it was just too expensive for us at the time.
This new pottery is just a tin shed, but the wall cavity is stuffed full of insulwool and all the doors and windows are mostly BAL rated commercial units. We have done all this to get a high BAL fire rating and to prevent this one from burning down in any coming catastrophic bush fire, of which there is bound to be one sometime in the future. 
This past week I have been lining the pottery studio room with the timber planks that we milled from our own home grown pine trees. Janine and I planed them and sanded them over the past few weeks and now we have had the satisfaction of actually installing them in the metal frame shed. This is just about the only timber in the whole complex of 5 the rooms of the new pottery. It looks great, It is just so nice to have some timber in the place to give that warm natural look and feel. It’s even better to have some of our own home grown timber in the throwing room. The place where we will spend most of our time.


As the big maintenance shed is now almost finished, and I had access to my friend Dave’s big crane truck, as he was working just down the street from me. i got him to move my pan break and guillotine into the new shed while the opportunity presented itself.

Dave picked them up from their temporary home in the new car port building that we hastily built as soon as possible after the fire to house all the equipment that I was busy trying to restore and protect from the elements.We installed them in their new, and hopefully permanent, home in the big new shed. We only just finished the ceiling of this shed a month ago, so this is very timely. It’s also important, because my friend Dave is selling his truck at the end of this month EOFY. After that time it would be a whole lot more difficult to get jobs like these done.


Such an incredible machine, so powerful! This big crane can lift a tonne up to 16 metres from the truck and lifted my big 3 tonne pan break 9 metres into the shed

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Everything seems to be moving along at speed now. I’m beginning to feel positive and optimistic again

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Janine made a beautiful morning soyachino coffee with a gingko leaf



I had it with my piece of toast and some delicious goats milk curd, creamy smooth and with a delicate acidity. Lovely.

Lining the Studio

We have been spending some time, on and off, over the past 3 weeks in planing the stack of pine lining boards that we milled out of the dead pine trees that used to grow over our house. Killed by the fire. I couldn’t just let them go. I needed to use the wood for something positive. I also wanted to incorporate something of the old into the new studio. An act of reconciliation. Creating something positive out of this disaster. A creative, positive gesture.

Having sawn the planks to 250mm x 30mm. out of the logs last February, they are now dry enough to use, and we are now ready for them. We spent a week pushing them through the planer machine, thinning them down 1/4 of a millimetre at a time, because the machine is only a toy, and the blades are blunt. We only need to remote most of the circular saw teeth marks. I don’t want them perfect – they’re not, they are full of natural imperfections like knots, resin filled hollows, splits and what might be felling shakes? Half a day at this was enough each day, as there was always so much else to get done. Plus we both have sore arms from a bit of over use.

Last week we spent half of each day sanding the boards. First with a belt sander using a 40# grit belt, then again with a 60# belt. We could only work at this work for a few hours a day as the vibration from the sanding machine affected our hands. Too much of this kind of work can cause pins and needles in our fingers. This is natures way of telling you to stop doing whatever you’re doing. So we did.

We used an orbital sander the next day to get a finer finish, we used a 80# paper for this session. After this finer sanding, we wet the boards to raise the grain and stood them up in the pottery to let them dry over night. After drying out, the next day we sanded them all again using a 100# paper. This final sanding left them pretty silky smooth, but still with a lot of their ‘natural’ character. There are 120 boards to be done 4 times over. That’s why it has taken a week.



My friend Len Smith gave me all his power tools when we started to rebuild after the fire. Len built his own house, so had collected all the tools that you need to do this sort of work. I used to have a similar set. Having Lens tools allowed me to get a lot done, and saved me a lot of money. Thanks Len!
This week I started to put the first few planks up on the wall. It’s very slow work, as each plank has warped around the knots, so has wobbly edges. Fortunately, Len gave me his circular saw and his electric planer. Even so, it still takes time to get the individual warps in each plank to match fairly evenly. Added to that the planks also have some degree of wind and camber. In other words, they have warped in 3 dimensions, like a snow ski and a banana on its side simultaneously. I don’t aspire to perfection. I want a more natural feel. I’m not perfect. We all have our quirks. I don’t expect my pottery studio to be perfect. I want it to express something about me, just like the work that will be made in it.



12 boards up in three days, tediously slow, but kind of rewarding. I’m happy doing this work slowly by myself. Although I’m in a rush to get this epic job finished. I don’t want to miss out on any of the joy of actually doing it, enjoying the feeling of achieving something at each completed stage. This is a hand made shed for potters making hand made pots. It has to have the apropriate character. Although we purchased 5 commercial kit form steel sheds, for speed and convenience, we have given them a character or quality that reflects us. Hopefully it reflects all the thought and effort that we have put into it.There is an aphorism about the journey being more important than arriving. I really feel that to be true just now.

Our Old Twice Burnt Dough Mixer Proves to be a ‘Pheonix’ mixer

Janine and I bought a very old and well used bakery dough mixer back in 1978. This was a time when a lot of old, small, family run bakeries were being forced out of business by the big multinational food corporations, and a trend towards people buying mass produced bread in super markets, rather than going to the small family bakery.We didn’t have 3 phase power back in those days, so I adapted the dough mixer to run on the power from a 5HP petrol engine interfaced through a rather snazzy torque converter. The sort of thing that adapts automatic gear boxes to engines in cars. I was given it, so didn’t realise how expensive they were.
We used that dough mixer in conjunction with a 200 mm. Venco de-airing pug mill for 5 years to mix all our clay bodies. Tragically, That pottery burnt down in 1983. That was a timber building and was totally destroyed by the fire. What was really amazing, was that I was able to rebuild both the pug mill and the dough mixer from the melted and charred remains. I spent a lot of time working on that equipment to get it going again. Luckily this machine was housed in a corner of the building with 2 sets of glass double doors on the corner, so as to allow for good ventilation. As this part of the building had very little wood in it,  the machine didn’t get too hot during the fire and none of the cast iron parts cracked.
The shaft of the dough mixer got rather bent during the fire, so had a very noticeable wobble in it when I got it going again, but at least I got it going. It was a bit of a mess, but I managed to keep it going for the next 36 years. After that fire, I converted it to a 3 hp single phase electric motor. The biggest motor that you can plug into a 15 amp power point, as that was all the power that we had at the time. It only just managed to do the job, as it wasn’t really powerfull enough, but I was carefull with it and nursed it along. I set it up with a home made, somewhat loose, slip-belt clutch as torque converters are so expensive.

After this last fire in 2019, The machine really got cooked, That’s it in the centre of the picture above, in the burnt out shed. Fortunately, the fire didn’t crack the castings. However, this time the main shaft was so badly bent, that it wouldn’t even rotate. I gave up on it, as I had so much to do to rebuild the new pottery shed that I couldn’t see myself ever really finding the time to fix it. Then, when my friend John Edye retired. I was able to buy his dough mixer. Very lucky timing. I didn’t have a pottery to put it in at the time, but bought it anyway, to make sure that I had it ready for when I could install it. As it happened, John also had loads of other jobs to do, so it sat there for several months, before we could find a mutual time that suited us both, for me to go and collect it.
In the interval, my friend Ross turned up one day, He is a really amazing person, who has so much knowledge and life experience with machinery. He saw me working on some of my ruined gear and asked what I planned for the dough mixer. I told him that I had given up on it for the time being, but couldn’t bring myself to abandon it. Ross had a good look at it and said that he thought that he could extract the main shaft from the gearbox and straighten it in his hydraulic press. He had done other jobs like that in the past. So I said “yes please, have a go at it”. I know that I won’t get around to it for a long time – if ever.
Luckily, I had poured spent engine oil all over most of the machines to stop them from rusting too much and greased all the bearings to prevent them from siezing up, so as to preserve them until I could find the time to get to them and try to fix them. I also bought a massive tarpolin to cover them. This turned out to be a smart move, as they remained there, under cover, for over a year. I found out through this experience that there is a massive amount of condensation under a plastic tarp, so all the machines that wern’t oiled were very badly rusted.
We worked on the dough mixer. Ross and I were able to dismantle all of the moving parts that still moved, and Ross took the main shaft home with him. He called a few weeks ago to say that it was now back in a good shape. Not perfect, but very good. We water-blasted the carcas to remove all the old oil, carbon, ash and burnt paint from it and I moved all the other bits inside, to keep them dry while I set about re-assembling the gearbox and all other moving parts. Ross organised a new oil seal and I had removed the main bearings and soaked it in oil to rinse clean and preserve them.

At this point, it’s looking a bit like a burnt out darlek!

A new 3 phase electric motor, a good clean, some rust converter and a coat of zinc primer and it starts to look as though it will go again.
The mixing bowl on the other hand had copped a bit of a hiding. It was split in 4 places around the rim and was no longer completely round, in fact it was a little bit heart shaped. I spent some time on it, a bit at a time, clamping it back in shape and tack welding it together,  getting it as round as possible, then welding all the splits back solid again.

After a week of nights, doing all the usual things, rust converter, penetrol sealer, zinc primer, several top coats of hard gloss oil paint and its looking great.

Everything is coming together now. The housing, gearbox and mixing arm have been given their severel top coats and are looking good. I bought a new 3 phase motor, new drive belts and electricals, so when I plugged it in the first time, and it actually went – I was really moved that it was back from the dead. Again! Thanks to Ross! 

Now I need a pug mill and we are back in business, ready to make clay again. This restored ‘phoenix like’ twice burnt, and twice restored dough mixer sits in the same room as John Edye’s mixer that I bought when I had absolutely no idea that mine might be recoverable. Hints of ‘two-sheds Jackson’ here. Steve ‘two-mixers’ Harrison.
Weirdly, my old ruined one is now ready to work before I have finally gotten around to finishing cleaning out and painting the bowl of John’s machine.

Rust converter being applied inside the bowl and the mixing arm to neutralise the rust, by converting the iron oxide that is very susceptible to oxidation with air when it gets wet, and converting the iron oxide to iron phosphate, which is quite stable and inhibits further rusting. However. The iron phosphate really needs to be sealed with a water impermeable membrane. In this case it also needs to be fairly impact and wear resistant. I have found that an oil based, high zinc, machinery paint works quite well. Well, similar stuff that I used in 1983, the first time that I restored this mixing bowl worked really well and lasted for 36 years! Of course, there is no guarantee that anything on sale today will last as long.

The bowl after rust conversion. I sent this image to John and we both agreed that the inside looked al to like an ancient ‘hare’s fur’ tenmoku glazed tea bowl.

Ready for the primer and top coat.

The first coat going on.

ready for work.