Maple Syrup

This past weekend William and I boiled down 30+ gallons of maple sap over a wood fire. The day was cool and breezy, but the fire kept us warm. Early on we decided to put a lid over the large boiling pot of sap in order to prevent smoke and ashes from ruining the taste of our syrup. It took us about 7 hrs to reduce by boiling the sap down to about 4 gallons of sweet water.

We finished boiling the sap indoors over the stovetop. The final result was about 3 and 1/2 quarts of very tasty 100% homemade maple syrup. YUM!!!

Visit to a nearby treasure. Colonial Brick kilns at Cayuga.

Driving home to Indiana from Denver, Colorado over the weekend with my wife, my sister and her daughter, I made a short visit to a brickworks in Cayuga, Indiana. Id known about it being in my state for over a year. But never had found time to make the trip to see it.

The 10 or so beehive downdraught kilns are operated by Colonial Brick Co. and still are coal fired to this day. They specialize in recreating old and out of date brick for important historical restorations all over the country.

The sights and smells of the smoke here is a powerful step back in time. If I lived closer, id work for free on the side, just to learn better some of the old ways they made and fired the brick.

I really want to build my next brick kiln like one of these scaled down for my needs. Maybe next year.

Firing results from the brick clamp kiln.

As promised, some photos of fired brick and tile from my latest kiln. It worked very well for a first firing. I have some cold spots and hot spots to improve on next firing. I think nothing will change with the kiln design for now. I will modify how I push the hot coals around in the firebox and stoking in the later stages. Its a learning process, but Im excited about this. Looks like it should be alot of fun!

First firing of the brick kiln at Canal Park.

We had our first firing of the brick kiln at the Wabash and Erie Canal Park in Delphi, Indiana friday and saturday. Thankfully the rain didn't come as had been forcasted. All went well and the firing from start to finish took a little over 26 hours. The kilns hunger for wood wasn't as bad as I thought it was going to be either. We went through about half of the wood I had set aside for the firing. In total, about 120 bricks, 50 tiles, and 30 clay coasters were loaded inside.

My pyrometer temp sensors wern't in the best locations as they didn't seem to reflect temps I was observing in the kiln. So next time they will be relocated.

Today I will be going out to break it open and see the results of all the hard work. I will post pics and results soon.

Death and rebirth, A new kiln for Wabash and Erie Canal Park in Delphi.

With much excitement and some sadness I report to you the ongoing construction of a new brick and tile kiln in Delphi. I have been honored with the task of building a replica historical brickmaking kiln at the Wabash and Erie Canal Park. There you can find a village with several cabins and period homes and other structures from the 1830's to 1880's time frame. They also have an actual reconstructed canal boat that offers rides. For those of you with an interest in metalworking there is a blacksmith shop as well as two iron bridges nearby that have been restored.

The new kiln is a scaled down simple updraft clamp scove fired by wood. This is much like kilns of that time in this area. It is designed to fire a few hundred bricks or tiles each time. The inner body of the kiln is made out of recycled firebrick. This is surrounded by an outer shell of common red brick. In between is filled with dirt for insulation and to stop cold air leakage into the kiln.

The new kiln is the largest I have ever built so far. Because of that it has put a strain on my supply of brick, requiring me to tear down and recycle both of my other kilns for the needed brick.

The barn kiln wasn't a big loss to me as it never worked out as well as I would have liked. Failing to reach peak temps no matter what I tried.

But to loose my backyard bottlekiln is sad. It more than did as I hoped it would. Its sacrafice for the greater good will not be in vain. I hope to one day bring it back bigger and better.

Wildcat Creek now on Facebook

Hey, my new brickmaking business is on facebook too.
You would need to be logged in to facebook to see this page.

http://www.facebook.com/home.php?#!/pages/Wildcat-Creek-Brick-Company/110729915664390

Update photo progress.

Its been awhile since I posted any pics on the my woodfired water boiler project for home heating. Here is the boilerhouse showing the summers progress. Pretty much all the brickwork is now done. I still need to fit the windows in and build a door. Finish the roof and add the firewood chute from the adjacent wood shed are after that.

Video of my latest firing of my bottle kiln.

Here is my latest brick kiln firing video.

http://www.youtube.com/watch?v=MZ2vs7IdjAs

Bottle kiln, firing #2, better but not good

I kept the top temp of the firing down to around 1850'F at the pryometer. But the center of the chamber still got much hotter than that! Gonna have to rethink the kiln and firing cycle some.

Improved results over first firing of the new bottle kiln, but along way from good results.

Can you tell which brick is wood fired and which one is electric fired? Both were fired to 1850'F.

Monster results. Too hot!

The bricks literally MELTED! Wow thats gotta be the hottest kiln Ive made ever.

It took me a few hours with a hammer and chisel to force remove these clinkers.

Heres what it looked like when I first opened it up. You can see that more heat was at the center of the chamber. It was cooler th the edges. Well over 2000 in the middle. Maybe 1800 by the walls.

I do like the wood glazing that occurred on the bricks. The cracking and tearing is most likely from the rapid heating of the clay in the bricks. Need to slow it down to at least double the time on firing. At least 8 to 10 hours. And max temp no more than 1850'F.

Here are a few more pics.

The firebox door.

A look down thru the chimney.

A cutaway diagram.

New brick bottle kiln. The 'Monster'

My latest clay furnace is a small bottle updraft named 'Monster' by my daughter after an energy drink she says it looks like.

Ive wanted to experiment with a different design, hoping to gain easier firings and higher temps.

Just a bunch of firebricks surrounding an old cut up 55 gallon barrell. That surrounded by red brick.

It took me only 4.5 hours to reach 2000'F, and it could have went further if I pushed it. May have went too hot for the clay I was using for the test bricks inside.

Looks to be a real improvement so far though. I will post the results soon.

I pressed out 12 clay bricks last week just for this test firing today. Finished drying them in my electric kiln last night.

Heres a peek inside at the end. See the brick slumped over. Got too hot I think. Gonna have to slow down this beast and run it to 1850 - 1900'F max.

Tennessee red clay test firing.

My wife and I went on vacation last week to the mountains of Gatlinburg, Tennessee. I gathered a sample of the well known local red clay to test once I got back home. I wanted to try it out to see how it compared to the clay from my back yard here in Indiana.


The differences in clay is most noticed by color from the iron oxides. Both types have it, but it is more obvious in states of the south. It may have to do with glaciers that overran the northern states like Indiana thousands of years ago.

I brought back several pounds of red clay from my vacation in a plastic tub for test firing.

The outer two are Tennessee red clay and the inner two are Indiana clay. Green unfired from the brick press. The sample clay is very sticky and plastic. It makes a nice unfired brick.

The brick on top is Pigeon Forge, Tennessee red clay. The other three are Flora, Indiana brown clay. Fired in the same kiln for 9 hrs to 1875deg F. Notice the difference in shrinkage.

Heres the address if you are interested in why some clays are so much more red than brown, yellow, or grey.

http://www.ga.nrcs.usda.gov/technical/soils/red.html

Progress at the boilerhouse.

Heres a new photo for all of you. As you can see Its comming along now. I still have alot of work to do on the north and east walls. Then its a door and a window along with finishing the roof.