Home kilns are a great way to fire your own ceramic projects and create designs that are unique. While it is possible to purchase kilns and install them in a work area at home, the process for building your own kiln is not difficult. Here are the basics of building a home kiln as a weekend project.
Instructions
1. Obtain your blueprints. This can usually be accomplished by purchasing plans at a local home store, or by going online and finding free blueprints for a home kiln that is roughly the size and shape you have in mind (see Resources below). Keep in mind the prints will help determine the amount of bricks and other materials you will need for the project.
2. Collect all necessary materials. Lay everything out so that you can easily grab what you need when you need it. This will save a lot of time during the assembly process, since you will not be scrambling to locate a saw or a trowel when the time comes.
3. Prepare yourself for working on the project. This will involve donning the safety glasses and the face mask. Both these devices will help to protect you from the brick dust that will be generated as you mix the mortar and cut the firebricks to meet the design specifications.
4. Create a template for the base and the top of the kiln using the poster board, a pencil, and enough of the bricks to make an outline of the outer width and length for the device. Before using the pencil to mark the outline, use the miter saw to cut the angles into the corner bricks, making for a tighter fit at the corners. Along with creating the general template for the base of the kiln, also use a portion of the poster paper to create a template for the angled corner bricks.
5. Begin construction of the body. Spread the sheet of plastic on a smooth surface and assemble the bottom layer of bricks, joining them with the high heat mortar. Once in place, use the template to make sure the bricks are spaced evenly and are lined up properly. Secure a second row of bricks using the mortar between the first and second rows, and between the bricks of the second row. Repeat the process until the body of the kiln is complete. Make sure to leave one opening for the door of the kiln on one side of the device.
6. Allow the whole structure to dry for at least 24 hours, or according to the instructions provided on the mix for the high heat mortar.
7. Drill the holes that will allow for the placement of the coils and the conduit and wiring for connection to the control box. Also, drill holes that make it possible to attach the control box to the side of the kiln.
8. Place the dried kiln on one piece of the metal sheeting. Firebricks are somewhat less stable and contact with the ground or similar materials will speed up the erosion of the bricks. The metal sheet will inhibit the breakdown a great deal. Place a second section of sheet metal over the open top of the kiln as well, if the design did not call for a graduated brick enclosure as a ceiling for the kiln.
9. Install the coils and connect the control box to the coils. Using screws, attach the control box to the side of the kiln. Connect to a power source and make sure the coils are heating properly and there appear to be no leaks along the mortar lines.
