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Well it has been a long time in the making and an even longer time in the dreaming about, but it is finally done.... Just in time for winter. Doh. Oh well better late than never.

I have been dreaming about building my own oven for ages now. I started talking about how much I would love to build one when I was renting a two bedroom flat. So I couldn’t really make one then. A couple of years after that we moved to a house, but were still renting and I wasn't going to spend all that effort improving someone else's garden. My girlfriend (Now wife) one Christmas got me all the pizza tools and booked me on the "Build and Bake" course at river cottage. She also got me a copy of "Kiko Denzer - Build Your Own Earth Oven" Which I read cover to cover on the train many times and can’t recommend highly enough. There was no turning back from that point. Finally last year we bought our own house and I could finally build my oven I had been dreaming of all this time!

Step 1: Base

First the base..... I poured a concrete slab and set to building the walls, both of which were a first for me. I was going poor a slab of concrete but saw these small lintels at the builders merchant and laid 4 square flag stones on top that had been left in the garden when we bought the house. I wanted to store wood under the oven as we don’t have a lot of space for a separate wood pile. Thinking about it later I wish I had left the back open so there would have been better air flow around the wood keeping it dryer. Instead in the finished oven you can see I have chopped down a wooden pallet to fit in the bottom, so the air can circulate.

Step 2: Fire Bricks

I picked up some fire bricks from http://www.kilnlinings.co.uk (found through the fantastic http://ukwoodfiredovenforum.proboards.com/index.cgi, thanks guys, lovely bloke really helpful) and laid them out to give me an idea of the size of the floor area. It helped me work out if I would have enough room for all the layers.


Step 3: Bottom Insulation

After a bit more bricklaying. I decided to use the wine bottle insulation method. I had been diligently drinking lots of beer and wine for months. I think I had about 3 times as many bottles as I needed when I actually built it. The gaps in the bottles (leaving room for them to expand under heat) are filled with a clay slip and saw dust used for pet bedding which I picked up from a pet warehouse place. The clay slip is clay that I had kept from digging the foundations, not much but enough for the base. I soaked the clay in water over night and mixed to a double cream type consistency with a plaster mixing attachment I had for my drill.

Step 4: Oven Floor

You are meant to (so I read) put a layer of build soil mix under the fire bricks to give yourself a firm level base to put your fire bricks on. No cement or clay needed. Just work out the best fitting bricks on the floor first. Choosing the best fitting ones for the middle where your bread or pizza will go.

Step 5: Clay

Now to get a lot more clay. I found this a bit of a problem as we only have a small garden and live up in the hills on gritstone. So not a lot of clay beneath our feet, or not very pure stuff at least. After scratching of my head the only place I could think of was my mum and dads house down in the Cheshire planes. Not very local but I knew it would be good as there house is made out of Cheshire brick. Which was probably made with clay dug out of the back field which is very common round there. Surprisingly they agreed to me digging a massive whole in there garden. Mum is a keen gardener and says she suffers from clay bound soil. So digging a massive hole would loosen up the soil and be really good for her plants. Result...

I think we measured took about 13 3 gallon buckets of clay when we finally hit pure stuff. which turned out just enough.

Makeing test bricks is a really good idea. All clay is different (unless you buy it pure I imagine). If you mix up enough clay and sand to make a 1" thick brick shaped lump of clay out of pure clay, 1:1, 1:2, 1:3, 1:4 using more clay. The clay is made up of very fine particals and fills in the gaps between the sand. It stops it shrinking and cracking. Use a ruler and score two lines on the bricks 10" ish apart. When they have dried out naturally (dont rush it) You can see how much the bricks have shrunk and cracked. The mix you choose should be hard and not crumble but not have not shrunk by more than 2% in length.

After making some test bricks I came up with a ratio of about 1-1 sand and clay. I think there was a lot of sand in the clay when it came out of the ground.

p.s. I just went down to the builders yard again for the sand. you need a lot. enough to mix with the clay to make a building mix and make the sand form for the dome. Because clay is made of very fine particales that when mixed with sand, fill in the gaps between the grains of sand. So 1 bucket of clay + 1 bucket of sand does not equal 2 buckets of building mix. Again you will have to trail and error the amounts.

Step 6: Build Day

Build day! As my parents were so happy to help me dig up some clay I thought I would push my luck and rope them into treading some mud. It is a long day and I was glad of the help. I would never have done it on my own. Thanks Mum, Dad, Claire and baby rosemary for all your help.

So after marking out the shape of the oven on the bricks wit marker pen (so you can still see it when wet) I piled up sand in to a form. using a stick 16" in height stuck in the middle of the form. So when you start to bury the stick you know the exact height. Kiko Denzer in his book says it is really important to get the ratio of height to door height right apparently. 16" seams the ideal height which at a ratio of 63% gives a door height of 10". It is all in the Kiko book. Shape the sand into a perfect dome nicely compacted down. Then layer the finished sand form with damp newspaper. This is so when emptying it you can feel where to stop digging the sand out.

Now comes the clay sand mix. No straw like in a traditional cob mix which gives it strength. In an oven straw just leaves gaps and air which you don't want. You want supper compacted clay and sand for thermal mass. To make the mix you spread out a big tarp and cover it with a couple of buckets of sand and in my case a couple of bucket of clay (broken up in to little wallnut sized bits). Then tread it into to each other with your feet. If you have made pastry it is very much like rubbing the fat into the flour. You need to really thoroughly mix them together. A tarp come in really useful to do this as you can turn it all over really easily by pulling one side of the tarp to the other (the bigger the tarp the better). When you think it is all mixed in really well do it a bit more. add a bit of water till it holds together but doesn't splat when dropped from a waist height and you are ready to start building. You are going to do this a lot of times before the day is out. You want to build the first layer all in one go so you dont get and dry joints which will crack under high heat.

Grab a hand full of mix and compact it down into a solid ball in your hand. build it up this way hand full by hand full (4" thick) until you reach the top. My mix was a bit wet and it started to sag slightly. So the higher we got the thicker the bottom got. So by the time I got to the top the bottom was about 7" thick.

Step 7: Dome

It looked a bit of a mess at first and I was a bit worried. Until when we had finished I got my plastering trowel out and with some elbow grease and it came up lovely. it looked like a massive one of those marshmallow chocolate teacake things.

Step 8: Drying

It was a really wet summer, I don’t know if you noticed. When I was trying to dry it out was one of the wettest parts. So it took forever to get to a point where I was confident it wouldn't collapse. It was about 3 weeks in the end because it was under a tarpaulin most of the time. When I did open it up and pull all the sand out I also cut back the wall a bit and put in a brick arch (only house bricks though forgot to buy fire bricks for this bit). Also I had a good look at the inner surface of the oven and smoothed out and deformities or cracks with a bit of water and the back of a spoon. The smoother and uniform the inner surface of the oven the better.

Then more drying and waiting... It is SO tempting to light a fire in there and just heat it up and be done with it. Slowly slowly catchy monkey. Just air drying then a few days later couple of tea lights. Then some of those big chunky candles going for hours on end. Then a small fire with kindling. Then next night I tried to do another small fire but it got a bit large and dried it out but some hairline cracks appeared. Next time small fire and decided it looked pretty dry, so cranked it up. I got some cracks about 5 MM on the outside appear but nothing on the inside. Pizzas were good but I don’t think I got it hot enough. and maybe some moister was still in the walls. It took about 5-6 mins to cook a pizza. I am sure I can get that down with more drying and with the insulation layers added.

The final two layers were one of clay slip with sawdust (Nice and loosely packed with loads of air pockets for insulation about 4" thick). When that layer had dried I applied a thin layer of clay, sand and straw mix for plaster (About 1" thick with a very thin coat without the straw to give it a smooth finish).

Step 9: Roof

Finally I built a little roof for it with a removable front so it wont go up in flames. I was really fed up of having a tarp in the garden right outside of my kitchen window. You really need to keep it covered or it will turn back into a pile of clay and sand in the rain. The dome is a lot dryer now with the ventilated roof, I think the tarp was keeping in the moister, much like cling film would. My wife is now calling it the pizza hut, not sure if I like being linked to that establishment but it is better than my mates at work who call it a dog kennel. I really enjoyed making the roof. It was the first time since A-Level Design Tech that I had done any project like this. The amount of cuts on my hands are testament to that.

So I finished this afternoon just in time for winter to hit... oh well couple of weeks the wife and I are hosting a pizza party. So I have got to get the hang of using it before then.

I am no in no way calling myself an expert. I just read a lot about it for a long time before I had a go at it. I hope this helps any of you if you are thinking of doing your own.

If you need any help get yourself over to http://ukwoodfiredovenforum.proboards.com/index.cgi There really is a forum for everything on the internet. There is a wealth of information out there.

p.s. I have full CAD designs for the base and roof if anyone wants them. (I did say I had a lot of time to plan this)
ATTACHED BELOW

Step 10: Update: Door

Update:

I finally decided to bite the bullet and make a proper door for my oven. I have been using the form (see below) that i used to make my arch. but as well as it not looking very pretty there were a lot of gaps for air to pass through. you could feel it pouring out with your hand. after all this effort insulating my oven letting all the heat out makes no sense. I picked up a flue thermometer from Clus Olssen which is an amazing £8.49. 

It is all wood and has no real protection. It is only meant as a bake door as I have not chimney so cant fire it with a door on so there will be no flame in the oven when it is being used. So I am not worried about it burning too much.

I glued and doweled together three pieces of 4" x 4" fence post I had left over from building the roof for my oven (best £20 I ever spent on ebay still got enough for a prep table). I cut it large then using a electric planer skimmed off the edges at a slight taper till I got a perfect fit. The handle is also carved out of off-cuts of the fence post.

I added some stove rope in a routed gully just to give it an extra seal.

I kind of like the massive probe. My only worry with this project is that because the first 4" are encased in solid wood so the whole of the probe is not exposed to the full heat. It works really well. I let it get down to normal oven temps and put a kitchen oven thermometer in it and it was bang on the money.

Step 11: Cooking

Now what I actually made it for cooking. It takes a while to get the hang of building the fire controlling the heat, having the food ready at the same time the oven is ready. but the results WOW!



Step 12: Recipe

The Pizza Recipe is a whole instructable on its own but this is an outline of what I like to do....

Napoletana Pizza Recipe makes 4 10" Pizzas

637g Flour
10g Salt (1 3/4 Tsp) Table salt
3.15g (1 Tsp) instant yeast
450ml cool water

Mix the flour, salt & Yeast together well (making sure that the salt and yeast do not come into contact) add the water all at once and mix to a shaggy ball.
Leave it for 5 minutes for the flour to become fully hydrated and gluten to start to form.
Now knead for 10 minutes or until the dough will pass the windowpane test. (stretch out the dough thinly, it should form a thin skin that will support your finger without ripping)
divide the dough into 4 balls (about 275g each) and place into individual oiled tupperware containers.
leave out for half an hour then put in the fridge overnight.
an hour before baking take them out of the fridge and let come back to room temp. They will have already risen.

Sauce

1 1/2 tins (400g) crushed Tomatoes / Plum tomatoes drained of most liquid
clove of garlic
1/2 Tsp of red wine vinegar
salt & Pepper
1/2 Tsp Oregano & Basil (fresh if you can get it)

Either lightly blend the sauce with a stick blender or just crush with your hands. there is no need to cook the sauce as the tomato is cooked in the can. the beautiful fresh tomato flavors will be lost if you overcook it.

Topping combinations I really like

Saute some mushrooms with garlic in a frying pan
Fresh Cherry Tomatoes with Artichoke hearts and feta cheese
Olives, Capers & Chilli Flakes
<p>Great instructable. I LOVE the removable front on your cover. Great idea. One great source for clay is the local cemetery. I built one of these from Kiko's book a few years back. Ours had a large pile where they put all the dirt that had been dug for the graves. Of course I got permission. I did get a few odd looks driving into a cemetery and breaking out a shovel but the digging was easy and within a few trips I had the clay I needed.</p><p>These are a lot of work up front but can last a long time if properly cared for and well worth the effort. I've moved since then and doubt I will do it again but I would highly recommend this if you are a pizza/bread lover or just fancy cooking by wood.</p>
<p>Could you tell me the title of the book, please?</p>
My husband and I are thinking about offering to build wood fire pizza ovens as a custom service for our stucco/masonry business... the demand seems to be very high right now!! Looks like so much fun!
<p>Thanks for the instructable! very useful guide. </p><p>What did you use between the arch bricks? just regular mortar,clay or fire resistant mortar?</p>
<p>Bloody fantastic, well done on a top notch job!</p>
<p>beautiful work</p><p>see this my instructables neapolitan recipe STG from Massimo Curr&ograve; italian pizza maker, highly appreciated </p><p><a href="https://www.instructables.com/id/How-to-Make-Neapolitan-Pizza-orginal-recipe/" rel="nofollow">https://www.instructables.com/id/How-to-Make-Neapol...</a></p>
<p>AWESOME instructable!</p><p>This was exactly what I had in mind.</p><p>How warm does it get right outside and above the &quot;house&quot;?<br>I am wondering if I can fit the oven right in between my girlfriends to small trees without burning the trees.</p>
<p>Thanks for the detailed instructions! Looks great, and sounds like you properly did your research. Hope the party went great. As soon as I've got a flat area I'm building myself one of those bad boys.</p>
Will it stand against winter freezing temperatures?? As I live in central Europe and the winters here can get really freezing. Below minus ten Celsius is quite normal...
With the hut and roof mine was u effected by 2 winters. I lived in Peak District and we have a lot of rain and winters with odd weeks of snow.
<p>Man, that's a good instructable !</p>
<p>Very Nice Instructable! You are my pizza hero! Love the video! What makes this a great guide is your comments and thoughts about the build. Thanks again!</p>
<br> Very nicely done. I can almost taste that wonderfully crunchy crust!<br> <br> Ovens like this are <a href="http://www.inspirationgreen.com/outdoor-earth-ovens.html" rel="nofollow">common in the US Southwest</a>...many are finished with a plaster similar to that used on adobe structures to protect them from the elements, although others have come to the same conclusion you have regarding a <a href="http://www.appropedia.org/Blue_ox_earthen_oven" rel="nofollow">structure.</a>
Unfortunately here in the Peak District England we get a LOT of rain. I would have to do a lot more up keep with out a roof. But I do agree they look nicer without a roof
<p>after you use it a good number of times assuming you have added a good insulation layer, use a batch of water proof stucco for the outer layer. WALLA, no break down</p>
Can you not cover it with plaster. (Sand and cement). This way you keep shape, you don't need the roof and it is more weather proof.
You can't render it with cement because it needs to be breathable. If you had a waterproof top to it the moister would build up and the roof would collapse inside. You can use a lime render apparently which is breathable. But I went for the roof option
<p>Hi just about to start this build just one question why the layer of bottles, why insulate the base, is it for the chance of cracking ? please advise jw from newcastle</p>
The idea is to retain as much heat as possible. The oven is surrounded by a layer of insulation. The clay and sawdust layer acts as a honeycomb. With the air gaps retaining heat. If you didn't insulate the base and set it on the ground you would ex spend a lot of energy heating up the soil underneath the oven. If you don't use fire bricks and just put the fire on flagstones they will crack and crumble with the heat.
<p>From reading on this subject for years, </p><p>1) they sell firebricks that are insulator bricks and they are light for the size as opposed to the hearth bricks. You couls insulate with them and they are more effective then glass bottles. They also have other flame/heat items that will insulate better, but as long as you do something it will work better.</p><p>2) One could use common clay bricks but they will over time spall, as will the dome surface of this oven, so keep an eye out for falling bits on the pie. The good news is, unless you fire this up daily and really get it &quot;soaked&quot; in eat, that will probably be an issue for whom ever it is that buys your house when you retire. But you never know. That is why the longer you let it dry the better. </p><p>3) if you have access to a wet saw with the right blade, you could cut bricks to make the true arch/dome and use the mix to fill in the gaps on the outside of the dome. Then give it a solid 2 inch layer of the stuff, then do the insulation layers. My neighbor built one but instead of sand he built the arc and arm and his dome is darn near perfect inside. He waited a few weeks b4 firing it up. But he used all firebrick and motor and his joint are very very close. </p><p>Try the Forno Bravo site for more info.</p><p>last I live in NYC area, Forno Bravo is in California... they sell a kit made in Italy the entire oven is in 7 pieces and they go together nicely. If you are in the UK you can get it way way cheaper then me ordering it from Italy through California</p><p>This is a great instructable. Due to building codes and taxes, I opted for lining my gas grill with fire bricks cranking the things to 900 degrees and making pie on that, as well, I can drop the temperature on preheat and bake 2 crust fruit pies in it during the summer.</p><p>thanks fer the nice instructable</p>
<p>Fantastic project ,well done .</p><p>I have to dig a large hole for a soakway will not be skipping the clay &gt;</p>
<p>What an ambitious project. It is magnificent! But it is also an impossible task for me to even contemplate beyond the admire stage. </p>
<p>Oh dear, I'll worship you from now on. My fiance and I are at your second step : we rent a house and can't wait to buy our own, but we dream of that oven and the big garden parties with friends and family since ages ! Thank you so much, I'll preciously keep your instructable.</p>
Nice work! I've read Kiko's book a few times now and hope to build one next summer. Just need a source for clay. Thanks for the fine post and photos.
<p>hi. Could you tell me where you brought your clay from. I'm having right trouble locating some. Thank you </p>
Dig a big hole. You will most likly hit clay eventually.
<p>have no where to dig in the garden as base built and garden decked. Didn't know if there was a supplier who sells pizza oven clay. Thanks tho </p>
<p>hi all. I'm in need of some help. We're building our pizza oven but I cannot find a supplier for the clay. Anybody have any suggestions please. Really appreciate the help </p>
<p>hi jw again kud i put my fire bricks straight ontop of my fags which are 2ft x 2ft and 60mmm thick. are your flags in the photos 2x2 ?</p>
Yes they are 2ft x 2ft. You could just put it straight on the flag stones but then you will only have insulation on the top and sides not the bottom. The bricks will acts as thermal mass. Which will be fine it you just want to cook pizzas. Which is fine But if you want to do any thing like a roast joint of meat with retained heat / bread (no fire in the oven) all the heat will escape out of the bottom. Having said that I have not tried it, I am just going off my research. You will find that if you make a clay done with no insulation it will work but not as well as an insulated one. I am moving house soon so going to have to build a new one and I am thinking of doubling the insulation. The base is not a lot more effort and to be on the safe side I would insulate it. Plus it means you have to drink lots of beer / wine to get bottle and that no bad thing.
<p>Hi just about to start this build just one question why the layer of bottles, why insulate the base, is it for the chance of cracking ? please advise jw from newcastle</p>
What an inspirational instructable. So good ! I copied your structure (bar the clay) i'll not even attempt your roof (i'm gonna buy a dog kennel and modify it). On a serious note - this is more informative than kilo denzer's book - which i bought. I found myself turning to your instructable for information and pictures. I'm about 2/3rds of the way through my project. Thank you for the inspiration - you gave me the confidence the build one myself.
Thank you for such a lovely comment. I am thrilled you found it so useful. <br><br>I have just sold my house and so there might be brick built oven instructable coming in a few years.<br><br>Any questions at all I would be happy to help.
The oven was probably the deal clincher for house sale!!! Good luck with the next build. I'm looking forward to the instructable already. Hope you are staying in the peak district. Lovely part of the world. I've done some mountain biking over there. Sure can get wet (like here in Co. Down). What is the internal diameter of your oven?
27&quot; which is plenty big enough for me.
I've gone 27&quot; too. How many bags of sand did it take for the dome?
<p>To be honest I cant remember the exact figure. but it was like 10 or something like that. I do remember thinking it would have been a cheaper to buy a half ton bag. but I can't remember if that included the sand needed for the cement base as well.</p>
Hi there, <br> <br>Is it 1 part fire-clay, 1 part sand and a little bit of water ? <br>Is it the same amount if you buy the clay <br>
It all depends how pure the clay is. I made some small test bricks with diffrent ratios. I suspect if you buy clay it will be a lot more pure than what you dig out of the ground.
In what part of the country do you live? I was wondering how it held up to winter weather. <br>How is it working out for you?
I live in the Peak District near Manchester. So it has seen a lot of rain and snow. Which is why it needed such a full on roof. It is absolutely fine, in fact it improves each time you use it as more and more moister steams off.
Congratulations on your project. I too want to build one of these when we finally get retired and move into our retirement home next year. <br> <br>You did a excellent job and thank you for your post. <br> <br>All The Best, <br>Sparkie Waller <br>Birmingham, Alabama
this makes a touch jealous, anybow, nice work both on the building and the pizza , did you build that huge chopping block too ?
Thanks, <br>i bought the butchers block in a supermarket years ago for next to nothing.
Pizza Hut....ha!
Great story, and I love how you got the clay for the oven.
Wow, amazing--I want one! :) Pizza looks super yummy too!
This is amazing - well done!
So you only need the fire bricks for the bottom? I thought it was for the whole dome thing too. Good to know! Thanks for this awesome instructable.
<strong>Very nice oven.</strong><br> <br> You have my vote and 5*.<br> <br> I'm also a lucky and proud owner of such a oven for six years.<br> <br> <a href="https://www.instructables.com/id/How-to-build-a-Pizza-Oven/" rel="nofollow">https://www.instructables.com/id/How-to-build-a-Pizza-Oven/</a><br> <br> It was already in action last weekend...<br> <br> Last year, i built this smaller oven for a friend.<br> <br> <br> <br> Some things were done differently, but many roads lead to happiness ;-)<br> <br> Having such a oven is just awesome.<br> <br> You also make the pizza dough quite similar with a long cold fermentation.<br> This really sets it apart from a store-bought, or a one hour quick rise dough with lots of yeast.<br> <br> I also don't cook the tomatoes. Only the liquid part from the can with onions and garlic.<br> I intend to make a pizza instructable this year, if i find the time.<br> <br> A little tip. Make a Margherita with some ripe Taleggio cheese and put a little Prosciutto di Parma and a little Rucola on it after baking. This rocks.<br> <br> For pizza parties, i also like to make some &quot;Flammkuchens&quot;.<br> For the inauguration of the small oven, i made some sweet&nbsp; &quot;Flammkuchen&quot; with apples/pears and cinnamon.<br> The kids love it...<br> <br> <a href="https://www.instructables.com/id/Flammkuchen-the-other-type-of-pizza/" rel="nofollow">https://www.instructables.com/id/Flammkuchen-the-other-type-of-pizza/</a><br> <br> Keep on baking<br> <br> Thomas<br> <br> <br>

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