I was frustrated with the price of electric burnout kilns for ceramics, metal annealing, glass enameling, and melting precious metals etc,. so I decided to build my own. Most kilns that run at these temperatures cost between $600 and $1200. With a little help from a guy at a ceramics store, I built one for about $120 (not including the power controller and pyrometer). This little electric kiln can get up to 2000 degrees F and is easy to make without any special tools besides a handheld router. I also wanted one that I could take apart and replace the element, since these are inexpensive.
1. 8 x 10" bolts with nuts- 1/4" diameter
2. 7 x soft insulating fire bricks (4 1/2" x 9" x 2 1/2"- make sure they are soft)
3. About 7 feet of angle iron from Home Depot (this is the frame) (4 x 14" legs/corners, 2 x 9" floor supports)
4. One sheet of thin aluminum (for the door). At least a 9" by 9" square
5. One 3/8 inch x 19" coiled heating element (stretched to about 28") out of 16 gauge Kanthal wire. I had this wound for me at the local ceramics store. I recommend you wind your own or as a ceramic supplier in your area to wind one for you. In my other instructable, Electric Kiln -Top Loader, I give directions on how to wind your own.
6. One small hinge with screws
7. Fire proof pins (should come with element) or you can make these out of the Kanthal wire.
8. Short outdoor extension cord rated to at least 10 amps (cut down to about 6 feet)
9. Stand alone ICS kiln controller. Sundanceglass.com has one for $84.
10. 1" thick Kaowool- about 1 foot square
1. Hand held router with 3/8 inch bit
3. Needlenose pliers
5. Wire cutters/stripper
7. Tin snips
1. Pencil the channels in as a u-shape 3/8 inch wide. I left about an inch, to an inch and a half from the edge and the top of the "U" so the elements are not too close to the opening of the kiln.
2. Route out the channels with your router using a 3/8 inch bit.
3. You will need to cut one of your fire bricks down to a square 4 1/2" by 4 1/2" for the back and route out two straight channels. This will be the back wall.