For several months I have been contemplating pizza.
As we get pretty excited about outdoor life and food it seemed obvious to us that we needed a garden campfire, TICK. First thing we did.
I then started reading up about these outdoor pizza ovens and it led me into one of my biggest projects to date.
Having found a suitable space in the garden I started to research in earnest and here was the first big problem. There sees to be masses of info about these sort of cooking projects but they fall loosely into two categories; first, very quick (and efficient) clay cob ovens that are often thrown up in a weekend from nothing but clay, sawdust, sand and some community spirit or, second, a professionally styled bricks and mortar oven that are generally designed by practical people who know a lot about thermo regulation and proper construction.
Here was the issue, I am awful at brickwork. The very limited amount I have been involved with has demonstrated again and again that me, concrete and bricks are not a happy coupling, however, I also wanted to build something sturdier than a clay cob oven which generally are affected by the weather.
By chance I stumbled upon a man and a blog, he had pondered similar points and designed his own that used limited brick skill and made a permanent oven at little cost and hardship. BINGO.
I paid the two quid for his plans and got started, having mostly followed his original design I don't think it would be right to put a step by step guide up here, he's earned his two quid fairly.
So here's a summary,
I chose to build a concrete slab on which I placed railway sleepers as a platform and base for the oven just as he did, he correctly pointed out that the same platform could be built from blocks at far less cost but there was no way I was going to attempt it. The finished project probably weighs an easy ton and frankly I was stressed enough about getting the slab right.
Then, he used bottle and clay to fill a square 'doughnut' in the platform for insulation and upon which his floor bricks then oven would stand. I didn't fancy collecting bottles for weeks so I took an alternate suggestion from him and used Celotex (like Kingspan) that I had a supply of from other builds. This was a huge mistake, more about this later.
On went paver bricks which are cheap and have a nice flat side all packed in with sand.
The next big bit was the brick arch and dome (think igloo). I was unable to tell what kind of bricks he'd used - he did say they were normal house bricks, not expensive firebricks - but I couldn't see from his pictures whether he'd used solid ones or those that have a frog. I was concerned that a frog might enable an air pocket to build up in the structure so I decided to get solid bricks. Not a massive problem but the only ones I could find locally were engineering blocks, great little bricks but they cost about £60 as apposed to the planned £15!!!
Also the fire screed he recommended (which is great) cost about £50 in P&P because I couldn't get it locally and these issues really jumped my budget. Came out better than expected though.
Perhaps the biggest drama occurred with the insulation layer. Most people who are making a modern brick oven simply mix loads of vermiculite or perlite with a bit of cement and slap on a good thick layer. I'd decided however that as I was following an instructional I should really follow it properly. I therefore used clay slip (liquid clay mixed with sawdust). At first I got hold of lumps of clay (which actually cost more than I expected) and then mixed it by hand with water to make a yoghurt slush. This took about five soul-destroying hours and my fingernails are still split. Half way through I switched to powdered fire clay which was far cheaper and almost instant in its preparation.

This method of insulation did work very well and would be great if you could dig the clay out of your garden for free but it took about three weeks to get it on and properly dried out (vermiculite/cement mix would have taken a couple of days). Fortunately I was forced to do this part of the build at a time when I was away for days at a time with work and so would stick on some slip then have to leave it to dry while I was away - had I been sitting here waiting for it to cure before moving in I'd have gone crazy waiting and waiting.
The final cement/sand/lime layer was a doddle and makes it look pretty rustic and funky.
The first firing went really well, pictures of the pizza can be seen below but after the second go it became apparent that the floor was dropping. MASSIVE PANIC because the brickwork layer of the oven sits entirely on this. The reason was the Celotex insulation was getting so hot that it was giving way. I had visions of the whole oven collapsing and having to start from scratch.
I had taken a match to a scrap of Celotex before putting it into the build to make sure nothing sinister happened and it was fine but the awesome insulated oven heat simply melted it. Here I had some seriously good luck. I was able to take out the sand/paver brick floor and rip out what remained of the Celotex, I then hastily poured in a vermiculite/cement mix and repacked the bricks back on top. Scary work because had the oven collapsed while I was scraping it all out I'd have probably lost a hand!
All done now and it works fine (so far). This fortnight project ended up taking six stressful weeks and I probably spent close to £200 more than I budgeted thanks to unexpected P&P, more expensive bricks and dealing with the floor problem. Had I had the benefit of hindsight I'd have used vermiculite in the production of the base and insulation layer instead of clay and sawdust, it would have cost no more (probably a little less) and meant I could do it from start to finish in a weather dependant 8 or 9 days with the drying times.
Still, it all seemed worth it when I plonked in a pizza and 90 seconds later this came out...
Best pizza I've ever tasted!