Day 11

This weekend was all about cement - one ton of it!

Before we could start mixing cement. Tom needed to cut out all the center supports of each block on top of the oven foundation so that they could then be filled with cement and re bar.

Once the center of the block was cut on each side, it was easily knocked out with a hammer.

A complete open channel now existed around the
top of the oven foundation.

With the channel clear - the re bar is positioned around the top of the foundation. This will act as a support when the oven expands and contracts with each firing. The re bar will help stabilize the oven so the walls are not pushed out.

The re bar was then removed so that the channel could be partially filled with cement. Then the re bar was repositioned on top of the wet cement and then covered with cement. It would be totally embedded as shown in the photos to follow.

Small notches are now created with the saw on the inside two opposite edges of the oven foundation so that re bar can be laid across the opening. The notches will also allow for expansion and contraction of the oven.

Tom confirming that the notches would be wide enough to allow for the re bar to move back and forth.

After all this prep work, we were ready to start mixing cement. We were thrilled to find out that one of Tom's co-workers actually had a cement mixer that he graciously offered for our use for as long as we needed. What a blessing.

The mixing station all ready to go

The first section to be filled with cement is the center support column. I used re bar to work the wet cement down in to the openings and help to remove any air pockets. 

Hey - look what I was doing in 2006!

As I filled the channels with cement, Tom smoothed it out and positioned the re bar. He worked the cement in until we had it flush with the top edge of the oven foundation.

Smoothing out the cement in the channel. 

 Once finished, we had a nice smooth top.

We mixed and used a total of One Ton of cement!

After the cement had some time to set up, we took a piece of re bar and made an impression in the cement that will act as a channel for the re bar to be able to move as the oven contracts and expands when being used.

 

Time to say good night.

Tom and I are both very encouraged with what we got accomplished this weekend. Next weekend looks to be just as exciting and we look forward to sharing it with you. Thanks again for stopping. Thoughtfully, Kath & Tom

Day 10

This week I started gathering all the document information that needs to be filled out and sent to Santa Fe for the BakeHouse. A visit to the Tax office and also my accountant proved to be wise since I found out that the offices in Santa Fe are running at least 3 months behind in getting new businesses their Public Regulation Commission number, which is needed before I can get our EIN number! If it all works out the way they foresee, we'll have what we need at least a month before we start baking! 

Tom was also able get the load of Sand and Gravel mix that he'll need to finish off the oven foundation and to add to the Lumnite for the laying of the hearth bed. We found a company locally that sold the Sand and Gravel already mixed in the proportion we needed. It proved to be a lot more cost effective this way rather than buying the sand in bags and getting a load of gravel delivered like we had to do in New Jersey.

Copper doing his job of inspecting the load. He's such a Corgi.

The most exciting part of the day was they placement of the final block in the oven foundation!

The final block getting tapped in place

The finished oven foundation. It's still hard to believe that we're ready to move on to the next phase. The top row of block will now be filled with concrete and then Tom will start the foundation for the hearth bed. This week we'll be ordering the Foamglass Insulation and we're hoping that the Winter Storm that is rolling in tonight will work itself out and clear off for another beautiful weekend next weekend.

We've had to cover the sand and gravel pile since the rain,
wind and snow are suppose to start tonight. New Mexico
weather is a bit cranky lately!

We're looking forward to sharing the next phase of the oven construction with you.  So until next weekend, thanks for stopping by. Kath

Day 9

HAPPY NEW YEAR! After a wintry two weeks we celebrated New Year's Day with family and had clear blue skies and temperatures reaching 65°! What a treat. Even with the Christmas and New Year holiday, Tom was able to spend some time working on the oven.

Custom cut in block to fit over ash dump lintel

Center support column

The view of the BakeHouse from our bedroom window - it's so exciting!

Where the project stands at the end of New Year's Day 

Bradley and Petie worn out from all the celebrating.
Tom was a bit worn out too. The remote is in his hands, but his eyes were closed:)

This coming week the Foamglass will be ordered and the final course of block will be laid. Then the hearth bed will begin! Thanks again for stopping by. Kath

Day 8

This past week has been a blur. So much was going on all at once that I'm glad we were taking photos or I wouldn't have believed that it all happened! It started out with Tom going to Phoenix, AZ to pick up dumpsters and trash cans for the company he works for. It worked out really nicely since we needed to go to Phoenix to pick up the firebrick and the lumnite that we needed for the oven.

The pallet of fire bricks fit just perfect amongst the dumpsters.

Mason Mart in Phoenix, AZ was Tom's first stop.
Bruce was kind enough to hold our order for several weeks.

While Tom was in Phoenix I found myself at a friend's catering kitchen baking bread. The customer had specifically requested Sourdough bread for their catered affair. Fortunately I had taken my starters out of dormancy several weeks ago and they were active and ready to make bread! 

This old behemoth has a way of keeping you very, very humble.
I only used the paddle attachment for a short time.
In the end, with careful monitoring, the dough did just fine.

It felt good to be standing at a bench again - I can't wait to have
my prep kitchen ready to go!

Then it was Saturday. We did have a beautiful day. I was able to unload all the fire bricks while Tom continued to work on the base of the oven. Tom is looking forward to having a full day to work on the oven without having to take part of his day traveling to get the roll off truck to transport all the supplies. 

I had a constant companion in Copper while stacked the fire bricks.

Copper also kept an eye on Tom. 

The days end.

The supplies are stacking up.

As I update the blog today, it is overcast, windy, cold and spitting a mix of snow and rain here in Las Cruces. All of our dear friends on the East Coast would laugh at how soft we all are! We get one day without any sunshine and we're all whining. It's pitiful! So we're not expecting any sympathy :)

Bradley is growing up fast. He's one of the most curious dogs we've ever met.
And he continues to be too cute!

Tom and I want to wish all of you a very Merry Christmas.
Thoughtfully - Kath

Day 7

It started out to be an East Coast Winter sort of week. We thought that Sunday's snow event was it and then Monday arrived. The morning started out sunny and dry, but as the afternoon progressed, so did the snow fall. I guess this is to keep us humble. Las Cruces was basically shut down on Tuesday as many of you might have seen on The Weather Channel. We've become softies.

Our patio set. You can get a tiny glimpse of the cement block way in the  back.

 Fortunately, the sun came out for the rest of the week and dried things up so that Tom could start laying block on Saturday. When the temperature in our backyard reached 55°, the memory of Tuesday had already melted away.

The Man Eater. This saw has been with us for almost 30 years!
It's like a trustworthy friend.

The corners of the oven are established.

Setting block.

The day's end. Tom wanted to get more done,
but the sun was setting fast.

We had to cover the block to protect it from
FROST!

We added the tarp for extra protection.

Bradley thought the tarp was a game.
He's just too cute for his own good

Tomorrow will be a very exciting day. Tom will be making the long trip to Phoenix, AZ for the company he works for. His boss has kindly allowed Tom to also use the time to pick up the Calcium Lumnite and also our Firebrick. We found it amazing how difficult is was to get these two items here in New Mexico. Fortunately we didn't have to go all the way to California!

We'll continue to keep you posted of our progress and thanks for stopping by - Kath 

Day 6

The weather report stated that there would be snow in the area on Friday night. We woke up Saturday and we couldn't even see the Organ Mountains because of the cloud cover. It ended up being overcast and drizzly most of the day, but then it happened . . . the clouds gently blew over and we were greeted with the view of the magnificent Organ Mountains dusted with snow!

The Organ Mountains 

The snow line is obvious

Tom decided to make the best of the day, and with his employer's blessing, he was able to take a company Roll Off truck over to the local construction supply house and pick up all the Cement Block, Mortar and Re bar for the base of the oven. 

All the supplies needed to start the base of the oven

Tom unloading while being overseen by Copper the Corgi

Copper making sure Tom is doing it right.
Our old wood cart is getting put to good use. 

All stacked up and ready for next Saturday!

The days end. One experience that is amazing about storm fronts that come
through Las Cruces is that we're left with an amazing visual experience once they blow over.
It's as if God has revealed one of His many masterpieces for us to enjoy.

Thanks for checking in and sharing the journey - Kath

Day 5 and waiting . . . .

Although we feel as though nothing is happening with the BakeHouse project, we've finalized several very important steps. The biggest one was finding a supplier for Foamglass insulation that Tom wants to use for the Hearth bed and also around the cladding of the chamber. We found a supplier in Tucson, AZ , which is quite fun since I lived there back in the 70's! Who would have thought that I'd revisit this place because of our business all these years later!

Marking out the corners of the Oven

 The next search was for Thermocouplers and a better way to embed them in the cladding and firebricks. Tom wasn't thrilled with how they took a beating and we did have several of them fail after two years. Fortunately an Engineer friend finds this problem easy to solve - so we look forward to working with him on a good solution.

We saved the Temp Gauge from the original oven and will reuse it in our new oven

And we pulled out the original wood cart and did some maintenance on it.

Tom made the cart from the base of an old Wheel Barrow!

It looks like we'll not be able to make any outside progress this weekend since we're suppose to get some nasty weather over the next few days. Right now it's very, very windy and the Organ Mts are disappearing from the rising dust. So we'll patiently wait to start the next phase which is constructing the cement brick base. I can't wait to share it with you. Thanks for stopping by - Kath