If you have been working with pottery for a while, you may find that your small electric kiln is not enough for the volume of pottery you are making. You can build your own kiln to meet the size that you need at a fraction of the cost of a commercial kiln. Although you have several options for a heat source, many professional potters prefer wood for its versatility and traditional design.
Instructions
Preparing the Location
1. Choose the location depending on the size of the kiln. Choose a reasonably flat stable area away from trees or flammable objects.
2. Check on local building codes and permits before you start building.
3. Grade the area so that it is flat and level.
Building the Kiln
4. If you can weld, assemble an angle iron frame for the size kiln and door that you want. You can also check with your local vocational or trade school for a list of welders willing to do small projects. Position the frame in the prepared area, making sure that you have room for the firebox.
5. Lay a layer of concrete block for the base of the kiln and layer the patio blocks on top.
6. Soak the bricks with water as you work so they don't dry the mortar too quickly.
7. Lay the bricks on the base on top of the patio blocks, applying a thin coat of mortar as you work. Cut the bricks to fit with the brick saw.
8. Build up the walls with the firebricks and mortar with the corners fitting against the frame.
9. Stagger the layers of bricks as you are building the sides. and leave several out in the area that you will be building the firebox. This will allow the heat from the wood fire to be transferred to the kiln.
10. Place the sheet metal arch on top of the walls with the edge extending slightly so that you can take it out after the bricks are laid. You'll remove the sheet metal once the mortar is dry.
11. Start laying the firebricks at the edges and work toward the middle. When the mortar has set, carefully work the sheet metal arch out from under the bricks. The weight of the bricks will hold the roof steady.
12. Leave several small gaps in the roof to vent out smoke and steam. The gaps shouldn't be large enough for significant heat to escape.
13. Attach the hinges for the door to the kiln. Drill into the firebricks with an even pressure. Assemble the door with firebricks and attach to the kiln with the hinges.
Building the Firebox
14. The firebox is used for building the wood fire that will heat the kiln. Generally, it is placed against one side of the kiln to provide the heat through openings in the side.
15. Create an area for airflow by leaving gaps in the concrete block, tile and brick base.
16. Using the same technique as for the kiln, begin stacking the firebricks so that they fit up against the side of the kiln where the openings were placed. Leave out one brick in the roof to vent the smoke.
17.Leave an opening on the side to add the wood and stoke the fire.
