4 x 4 x 6 Oven Pics

[krusty2111us]

Here's the new (for now) frame work. Monday morning I start to put the sheet metal on! I'm gonna' wait on the door until I find the right hinges and latches.

[ublinkd]

Originally Posted by krusty2111us

Oh yeah I don't know about your area, but one of my metal distributors quoted me:
18g galvanized 4x8 $56.10 per sheet
20g galvanized 4x8 $43.10 per sheet
Not too bad, but still puts a dent in the pocket book. Laters

Have you looked at the wall material in this post. I know I will be using it for my oven!

[krusty2111us]

OK, I ordered my temp controller:

http://cgi.ebay.com/ws/eBayISAPI.dll...m=250037037517

Got it for $50 including shipping.
Picked up my interior sheet metal today. It took 3 1/2 sheets of 4 X 10 18g galv @ $65 per sheet and $47.50 labor to have all the pieces cut for me. $297. I thought about trying to make some kind of a line follower for my plasma cutter, then said the hell with it, let them cut it. I'm not going to get the exterior sheet until I have the interior sheeted and the frame assembled. That way my measurements won't be too off.

Hopefully my furnace cement will be here tomorrow and I can get to work. I looked all over town, Lowe's, Home Depot, a few small hardware shops nobody had the cement. So I ordered it from McMaster-Carr. I went to a rinky-dink hardware store today, and lo and behold the only people in town to have it, and I already ordered it on-line. Damn!

[krusty2111us]

I got the top and one side drilled, cemented, and riveted in place today. I started outside in the driveway, garage is kinda full, but with the sheet metal acting like a mirror, I was getting cooked by the sun. Spent a while rearranging the garage, so I could work inside. The first pic is the center of the top frame assembly showing how I cut it to allow another stud to cross-brace underneath. On the top and bottom pieces I'm gonna' do this in 3 places for stiffness. The sides and back only get one. I situated the sheet metal in place, clamped and measured and drilled the holes for the rivets. Then I applied the cement and re situated the sheets, using a pin punch to align and clean the holes. The furnace cement is pretty easy to apply. Keep a bucket of water and a rag as you go. When you have one side/rail done, squeeze some water on it to keep it wet until you place the sheet metal on. Once all the rivets are in-place...I'm beginning to hate rivets...lol...wipe the seams (in/out down) to remove the excess. I tried to get a close-up shot of the corner seams/edge. I'm supposed to get my elements from UPS this evening.

[krusty2111us]

Overall shot...and I tried to photo-shop a picture of how I added a center stud and applied my cement. The left side has a darker line, that's where I applied the cement, of course to the whole thing, but for photo-shop purposes I only did half. My goal is to have no metal to metal contact between the inner and outer skins. Tight, tight, tight, means faster heat-up, stable temps, and good quality. Just got my elements in! Laters

[krusty2111us]

Well, I got all of the interior sheet metal done!!!!!!! Tomorrow I'm installing the cross braces in the top and bottom pieces, and assembling the structure. Once it's all attached, I can measure for the exterior sheet metal. The pieces are from front to back are;
back, side wall, side wall, top, bottom

Laters

[krusty2111us]

Finally starting to make some progress. I have the structure assembled! You might be looking at the way I built it as weird. I assembled the walls/floor/ceiling in that fashion to ensure I had the 4" of insulation on every outside surface. The back wall slides in between the side walls, sits on top of the floor, and is flush with the edges. The interior dimensions are still 4 X 4 X 4. This weekend I have to cut the burner pans for the side walls and back wall and hopefully get those done so I can wire it and stuff it with insulation. Laters

[krusty2111us]

Well a little update, but not much, and no pics until tomorrow. Spent most of the weekend tearing down a 68 Cougar to part out on Ebay and other places. Gotta get the money for this thing somewhere...lol. The last pic was the final mock-up without the cement applied between each piece. It's finally all cemented and bolted together. I chose to use 5 per side 1/4 x 3/4 bolts/nuts/lock washers to assemble the unit, instead of more rivets. It's a sturdy thing though. I started work on the door. Instead of having 1 big 55" X 55" door, I decided to split the doors into two side by side style. It would take forever to explain the latch mechanism, but once it's done you'll see how simple and efficient it is. While working on it today, the sun was blazing down on the inside of the oven, burning to the touch. I grabbed the IR thermometer, and the inner skin was 207 degrees. The stud attached to the skin(with furnace cement between) was at 71 degrees. So I think as far as insulation I'll be more than OK. Getting the exterior sheet metal tomorrow afternoon or the next morning. Well laters, Pics tomorrow

[krusty2111us]

More progress...The doors are built, the hole for the fan and duct are done, and the fan is installed. I still have to cut the final hole for the inlet side of the duct. The burner pans, I recessed the burners to be flush with the side walls, are designed and layed out on poster board. The outside sheet metal design is all layed out also. That took some serious designing to ensure it made it more structurally sound, and looked good. I still have to get the viewing window and a switch in the door for the lights, and my latches. I thought I had sticker shock with the sheet metal, but the wire is killing my budget too. It's mostly my fault, I want the wires to be inside the walls, not ran on the outside. I figure 40' of 12awg high temp for the elements, and 20' of 18awg high temp for the lights and fan. My relay(contactor) is on the way.
http://cgi.ebay.com/ws/eBayISAPI.dll...0026&rd=1&rd=1
The following pics are the making of the fan stencil, and cutting and installing it. Basically I just used the old rubbing the pencil across the paper against the fan to get a good stencil. The hole doesn't look too bad for free hand with my plasma cutter....huh.

[krusty2111us]

the fan installed and the duct stencil/ poster board