I picked up the foam on Friday. It was a block 1000×800x600 and I spent Saturday morning shaping it. I am using 600 x 600 x 50  heeble blocks on a pallet as the base because I want to  make it transportable.

I covered the base with plastic (blue sheet) and then the mould with plastic. Don’t forget the chimney!

Plastic underneath, and room for the chimney

I decided to make it in to halves because I wasn’t sure of how strong it was going to be. Needn’t have worried as it sets very hard.

We had a few problems with plastering it !! The pyrocrete wanted to slide off!! Ended up with a process that worked but need to consider a better solution than swearing at it!!! The plastic could be the main part of the problem.

I did one half and then used another piece of plastic to cover the join and then the second half.

It was easy to get the shell of the mould though.

I had a few holes here and there so I have patched them up with a bit of left over material. The two halves would be grouted together when installing.

Sliding the set oven off the foam

Things to do.

• The foam needs to be shaped a bit more to get more sloppy sides, shorten it  a little and lower it a little.
• I think the chicken wire is a good thing particularly around the chimney area as that is weak point. Also using across the middle will add extra strength.
• I have seen a recent pizza building video and they use thermal insulation next covered by Alfoil and then vermiculite and render. I am not sure all of that is necessary.
• I am keen to put a fire in it and make sure it doesn’t shatter, maybe next weekend.
• The product I used is Pyrocrete it would be good to find a wholesale supplier rather than buy it from the retail shops. I used two 20 kg bags .

Seperating the two halves of the oven...