TechnicalNotesonbuildingtrailersformobilemasonryovens,byDanWing

TECHNICALNOTESONOVENTRAILERS, BYDANWING Kikoaskedmetowriteasectionabouttrailersfor mobileovensbecauseIhavebuiltseveralofdifferent kinds,andbecauseIhaveatrailermountedoventhatis stillgoingstrongtenyearsafterIbuiltit. First,though:IagreewithKiko(andwiththestaffof AmericanFlatbread)thatformanypurposes,buildinga temporaryovenofrocksandmud,orofearthalone, overaplatformofbricksthatcanbeassembledand brokendownonsite,isabetterchoicethanamobile oven.Thereasons? Itisexpensivetobuildatrailerstrongandsafeenough tohaulanoven.Suchatrailerisgoingtoneedacaror truckthatisheavierthanitis(preferablywithfour wheeldrive)topullit.Soifyoualreadyhavearigthat canhaulrocks,bricks,anddirt,youmightwanttospare yourselftheextracostofthetrailer.Itiseasiertostorea pileofrocksthanatrailerandthereissomethingabout trailertonguesandtrailerlightsthatseemtoinvite accidentsbarkedshinsinthedark,lightssmashedon unseenrocks,runawaytrailereventsthatwrecktheside oftheneighborsHonda.Thisaccidentpronebehavioris seenevenintrailersthatareparkedandinuse,because theytakeupmorespacethantheovenalonewould,and theyareungainly.Anotherpracticaldifficultyisabasic, physicalmismatchbetweenmasonryconstructionand movingdownthehighway:youwillalwaysbedealing withthevibrationofthetrailerversusthebrittle,crack pronenatureofmasonry. Manytimes,theovenisgoingtobeusedinacontext (school,camp,workshop,CreativeAnachronismor RenaissanceFairegathering)wherelaborisplentiful, peoplearepotentiallybored,andtheprojectofbuilding, using,andbreakingdowntheovencanbeanimportant partofthegroupprocess.Trailersthatarestrong enoughforanovendonthavemuchaestheticappeal,

andthatmaynothelpsetthemoodforyourgathering. Ontheotherhand,thereareneedsandsituationsthatcanbe bestmetbyamobileoven.Forexample:acateringbusiness orafocacciabusiness,whereyoubakeeveryweekata farmersmarket.Atrailerovenallowsyoutoavoidoverhead expenses(andsomeofthefireandhealthlaws)becauseyou areafoodpeddler,notastore. So,letsassumeyouaregoingtohaveamobileoven.It doesnothavetobeonatrailer.Youcouldbuilditontoa flatbedtruckanddriveitaroundthatway(thereisa greatmasonryovencateringsetupbuiltontoanantique trucknearNewHaven,CT,andoventrucksare relativelycommoninEurope).Truckbedsarerelatively high,andthatgivesyouaconvenientheightforthe hearth.Ifyouhavetousethetruckforotheruses,build theovenintoametalcradlewitharingontop,andliftit outwithasuitablehoistasnecessaryIhaveseenan outfitlikethatinPointReyes,CA.Justusecommon senseaboutthecombinationofmotorfuelandfire,by openingtheoventowardthebackofthetruck,oronthe sideawayfromthefueltankandfiller. BASICCONSIDERATIONS

1. Makesureyourtowvehicleisadequatetothetask. 2. Buildatrailerfromscratch,usingrubbersprung

3. Usetwoaxles.Thiswillallowtheheavymassofthe 4. Specifyfreebackinghydraulicbrakesforthe
axles,andinstallahydraulicsurgecouplerasthe trailerhitch.Thisensuresthatthetrailerbrakeswill alwayscomeonwhenyousteponthebrakes,and eliminatestheneedforabrakecontrollerinyour towvehicle. oventostaybalancedoverthewheels.

torsionaxles.Thesecombineaspringeffect,ashock absorbereffect,andcrossbracingforthetrailer frame.Thiswillbestrongerandsaferthananything youcanmakefromthewreckingyard.

5. Themetaldeckforyourovenshouldbepartofthe

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TechnicalNotesonbuildingtrailersformobilemasonryovens,byDanWing

trailer'soverallstructure.Theroofframingcanbe weldedontothedeck,andwillfurtherstiffenit.

6. Sinceeventhebesttrailerprobablywon'tbeableto
keepatruemudovenintact,you'llneedtobuilda domefromstrongermaterial,eitherbrick,or refractorycement,orboth.Attheveryleast,itwill bemoreexpensivethanplainmud.

7. Weightconsiderationswilllimithowmuchmass

youcaneasilybuildintoamobileoven.Thismay limityoutopizzaandotherflashroastedfoods,and perhapsasinglebatchofbread. THEDETAILS Thereislittlegoodpublishedinformationonbuilding trailers.Theonecommonseriesonthesubject,Trailers, HowtoDesignandBuild,byM.M.Smith(Techni Visions,Downey,CA),isnotwellwritten.Ihavefound itbettertorelyonpdf.downloadsfromthecorporate websitesofpartsmanufacturers(suchasDexterAxle) andthelarge,free,illustratedcatalogsoftrailerparts wholesalers(suchasLuckyBTrailerParts)toseewhatis availableandhowtouseit. Someopinionsbasedonexperience(Pleaseforgivethe useoftechnicaltermsthatwillbeexplainedlater): Forthebestcombinationoflowweight,structural integrity,andtowability,itisbettertobuildatrailer dedicatedtoanddesignedwiththeintetnetofhaving ovenmountedonitthantoadaptanexistingtrailer.The exceptionisamultipleusetraileronwhichyouplace theovenforspecialoccasions,usingthetrailerforother purposesatothertimes. Itisbettertospendthemoneytobuynewparts designedfortraileruseandsizedtoyourneedsthanto adaptoldcar,truck,ortrailerparts.Thisisespecially trueforaxles,wheels,andbrakingsystems.Anunsafe trailerisaweaponofmassdestruction. Hydraulicorsocalledsurgebrakingsystemsarethe easiesttosetupandmostreliableinoperation,and becomeincreasinglyfavoredastheweightofthetrailer andloadincrease.Itisneversafetooperateabrakeless

heavytrailerontheroad. Thecenterofgravityofatraileranditsloadshouldbe keptaslowaspossibletoreduceitstendencytorolland sway.Ifyouneedthehearthoftheoventobehighfor bakingconvenience,figureouthowtoraisethetrailer and/ortheovenupwhenyouareparked,andkeepthe COGlowwhenontheroad.(Iparkmyovenonabroad moundinmyyard.Thehearthheightisthusimproved whenIamstandingonthelowergradeoftheyard. Alternatively,takespecialrampswithyoutopullthe traileruponwhenyougetwhereyouaregoing,or engineerajacksystemtoliftitsafelyup. Rubberdampedtorsionsprungtraileraxlesarethe easiesttoinstallandsetup.Theyalsoprovidethe smoothestridefortheovenandreducetheshock transmittedtothetowingrig,Becausethetorsiontube becomesarigidsidetosidepartoftheframeofthe trailer,andbecauseyoueliminateheavymetalsprings, torsionaxlesreduceoverallandunsprungtrailerweight, makingforeasiertowing. Ifyouuseaconventionalstraighttraileraxlewith metalsprings(whichIdonotadvise)youmaywantto use(longer,morecompliant)truckspringswithshock absorbersand(preferably)anantiswaybar.Trailer springsareshortandstiff,andwillprovidearoughride fortheoven.Dontusetruckspringswithoutshock absorbers,though,astruckspringscouldallowupand downandsidetosideflexibilityandmayallowthe trailertosetupadangeroushighspeedsway,tossing fromsidetoside. Twoaxledesigns(socalledtandemtrailers)withthe trailerscenterofgravitylocatednearthecenterofthe suspension(butfarenoughbacktoprovideconsistent tongueweight)willsitsomewhatlevelevenwhenthe tongueisnotjackedup.Dontconsiderasingleaxle design.Balancingtheweightoveroneaxleisan invitationtodisasterevenifthataxlehastherated capacitytoholditup.Thetrailerstongueweight (downwardloadonthehitch)willvarytoomuchasyou goupanddownhills,throwingthetowrigaround. Thedistancefromthetrailerhitchtotheaxle(s)should

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TechnicalNotesonbuildingtrailersformobilemasonryovens,byDanWing

belongerthanyouthink.Themaincauseofpoortrailer stabilityatlowspeedisatonguethatistooshort,anda trailerwithashorttongueismoredifficulttobackup. Thetongueweightofthetrailershouldbeatleast8% ofitsloadedweight,toreducetrailerpitchingandsway. Themaximumtongueweightisdeterminedbythe weightofthetrailerandtheratedcapacityofthetow vehicle;toomuchtongueweightwillmakesteeringand brakingunsafe.Agoalis10%ofthetrailersloaded weight,anditshouldnotbemorethan15%.Designthe towhitchandtrailerhitch/tonguesothetraileris approximatelylevelwhenhitched. Thetonguesystemofthetrailershouldbepartofthe frameofthetrailer,eitherbyhavingtheframerails extendtoformthetongueorextendingseparatetongue memberswellbackundertheframeofthetrailerto provideadequatestructuralattachment..Itisbetterto haveatriangulartongueconfigurationthanasingle tube(Tbar),butaTbarisacceptableifitisstiffenough (thickwalled)andextendswellunderthetrailer. Fortheuniqueconstructionofanoventrailer: 1.Forma14or16gaugesheetmetalpan(45inches deep)thatwillserveasthetrailerbed.Itwillalso serveastheformfora)athininsulating vermiculite/concreteorpumice/concretelayerandb)a thin,reinforcedfullstrengthslabthatservesasyour hearthbase. 2.Beforeyoupourconcreteintothepan,youcanweld foreandaftframerails(boxbeams)totheundersideof thepan,withthecorrectspacingtoaccommodatethe axlemounts. 3.Ifyoudontattachtheaxlespermanentlyatthistime youcaninstalltheaxlesintheirfinalpositionsafteryou havebuilttheoven,whichmakesiteasytogettheir locationscorrectwithrespecttothecenterofgravity. 4.Youwillneedatransversecrossmemberofsimilar dimensionsecurelyweldedbetweenthestringersunder thefront(andback)ofthepan,topreventtwistingofthe bedandtosupportofthelegsofthetongue,asthey coursebacktoendunderthesidestingers.

5.Youdonotneedlargecrossmembersinthemiddleof theframeundertheoven,butbetweenandoutsideof theforeandaftstringersstringersyoushouldwelda gridofstiffeningwebs(tackingthemuptothepanas well)toreinforceitwithoutaddingmuchweight.They performthefunctionofthecrosssillsinaconventional trailer,allowingframe/panstructuretocreate lightweight,stiff,unitizedsubstructureforthemasonry elements,whilekeepingtheovenscenterofgravitylow. 6.Youcanweldstubpocketsintothecornerofthepan tocatchtheroofsupports,and(iftheovendoorisatthe rearoftheoven)youcanformahearthlevelshelf. Differencesbetweenconventionalandoventrailers: RunninggearforCONVENTIONALtrailersconsistsof: 1.springperchesandshacklesbetweentheframeand thesprings, 2.longitudinalmetalsprings, 3.straightaxleshungfromthesprings, 4.wheelspindlesweldedtotheendsoftheaxles, 5.Brakebakingplatesboltedtotheendsoftheaxlesto holdthebrakeparts, 6.brakeparts(operatingmechanism,withshoesand links)attachedtothebackingplate, 7.wheelhubs,whichcontainthelubricatedbearings thatrideonthespindles, 8.brakedrumsfortheshoestoworkagainst, 9.wheels,and 10.tires. Ihavementionedthatthelackofcomplianceofmetal springsmakesforabumpyrideforthemasonry.Italso meansthetowvehicleisjarredbyastronglongitudinal tongueforce(trailertuggingbackward)whenthewheels ofthetrailerencounterabump.Theentireaxleassembly representsanundesirablemass,calledunsprung weight(becauseitissupportedbytheroadbutnotby thesprings)andtheverticalforcethatacceleratesthis massupwardoverabumphasahorizontalcomponent thatistransferredtothetowvehicleasalongitudinal shock.Becausethespringsandshacklesintroducea

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TechnicalNotesonbuildingtrailersformobilemasonryovens,byDanWing

planeofflexibilitybetweentheaxleandthebodyofthe trailer,thestrengthofthestraightaxle(s)cannotbe consideredasasidetosidestiffener(crossmember)of thetrailerframe,soinconventionaltrailersadditional weightisdevotedtostrongtransversesteelelementsto holdthelongitudinalstringersinplace. Youcanavoidtheseproblemsbyusingrubbersprung torsionaxles.Thestyleappropriateforanovenconsists ofarigidtube(usuallysquareinsectionalview)welded toflangesneareachend.Theflangescanbeboltedor (carefully)weldedtothelongitudinalstringersofa trailerframe.Withinthesquaretubearetwohigh strengthsteelstubaxles,oneateachend,withrubber cordstrappedinsidebetweentubeandaxlestub.A short(roughlyhorizontal)crankarmisweldedtothe outboardendofthestub,andabrakebackingplateand wheelspindleareweldedtotheotherendofthecrank. Thecrankisalwayssetuptotrailtheaxle.Whenthe trailerisloaded,thestubaxleturnsslightlyinsidethe tube,loadingtherubbercords,whichactasthesprings. Whenthewheelhitsabumpthecrankistwistedupand awayfromthebump,furthercompressingthecords insidethetube.Becausethewheelmovessmoothly awayfromthebump,andbecausetheunsprungweight islow(basicallyjusttheweightofthewheelandthe brake)thereisalmostnobumpeffectonthetowvehicle andlittlejarringoftheload.Also,therigidtubecanbe countedonaspartoftheframeofthetrailer,eliminating heavysidetosideframingundertheoven.Thestarting angleofthecrankcanbeorderedinseveralpositions,so itiseasytogetthetrailerandovencenterofgravitylow, whilepreservinggroundclearance.Also,uptothree axlescanbeusedwithoutrequiringmechanicallinks (equalizers)betweenthem(suchasarenecessarywith conventionalaxles).Whenyouordertheaxles,specify: a)theloadcapacityoftheaxle, b)theoverallwidth(brakedrumoutersurfacetobrake drumoutersurface)youneed, c)thecrankangle,and

d)thelocationoftheflangesthatattachthetubetothe trailer(accordingtothespacingofyourstringers). Thecostofeachaxle,includinghydraulicfreebacking brakes,wheels,andtires,isabout$450for3,500lbaxles. Brakes,lights,fenders Conventionalelectrictrailerbrakescanbeenergizedby theelectricsignalfromyourbrakelightswitch,and therearemanyproblemswiththisarrangement,anditis notrecommended.Someofthemcanbeovercomeby usingaseparatetrailerbrakecontrollermountedbelow yourdashboard,butthatisanextraexpenseand complication.Hydraulicbrakesareamuchbetter option,especiallyforsomethingasheavyasanoven.In thissystem,thehitchonthetrailerisjoinedtoabrake mastercylinderthatisprogressivelypressurizedas moreandmorelongitudinalbrakingloadisexperienced bythehitch:theharderyoubrake,theharderthetrailer brakescomeon,automatically.Thereisnodirect hydraulicconnectiontoyourtowvehicle,soiteven worksifyoushiftgearsdownonahill,andthetrailer brakesaresetuptoautomaticallycomeonfullifthe trailercomesunhitchedorbreaksfree.Freebacking brakesatthewheelsmeanyoudonotneedtoplacea boltinthehitchtolockoutbrakingwhenyoubackup agreatconvenience.Thehydraulichitchescostabout $130,plus$10foraconnectionkit. Iliketotemporarilybolttheflangesonthetorsionaxle tothestringerswhileIbuildtheoven(orwhateverIam attachingtothetrailerstructure),thensetupthehitch, THENadjustthepositionoftheaxlesonthestringersto getthetongueweightIwantbeforepermanentlybolting orweldingtheminplace.ThenIplumbthebrakelines andwirethelights.Allstatesrequiretrailerstohave somekindoffenders,andtheycanbebuiltontoor attachedtothemetalpanthatsupportsyouroven. Lightsarealsoalwaysnecessary,andmayrequirean electronicadapterfromanautopartsstore,ifthetow vehiclehasseparatebrakeandturnsignalbulbs.Tow axles,hitch,lights,andsteelforanoven/trailermight

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TechnicalNotesonbuildingtrailersformobilemasonryovens,byDanWing

runto$1500ifyoucanweldityourself. Notesonovens: Clay,mud,earth,andcobarenotgoingtobegood choicesforatraileroven,asroadvibrationwillcause crackingand/orbreakage.Theotherpossibilitiesare: a)solidrefractory, b)segmentedrefractory(modular)witharetentionband ofsometypeand, c)brickdomewith(concrete)cladding. Allofthemaregoingtostartwithaninsulatedslab base,coveredwithfirebrick. Solidrefractory:Refractorycementsutilizeadifferent chemistrythanconventionalPortlandcement,whichloses halfofitsstrengthattemperaturesof750degreesF.They cannotbemixedwithPortland,butaremixedwith aggregatestomakerefractoryconcretes(orcanbebought premixedwetordryasconcretesandmortars). Rigidmetalreinforcementisinadvisableinarefractory massexposedtogreattemperatureswings,becausethe massandthemetalexpandatdifferentrates.However, thin,crimpedmetalrodsmaybeusedtojoinarefractory masstoasurroundingstructure,likeatrailer.The crimpingincreasestheholdingpowerofthe reinforcementandshortensthelengthofeachsectionof therod,reducingexpansionstresses. Arefractorydomeisformedlikeanearthdome,overa sandform.Theinnermostlayerofrefractoryisfull strengthandweightandabout2thick,andfollowed immediatelywithalayerinwhichhalfofthedense aggregateisreplacedwithpumice,vermiculite,ornon siliconizedperlite,followedbyalayermixedwith lightweightaggregateonly,whichcanbecoveredwitha layeroftintedstucco.Youmaywantathermocouple probeattheboundaryoftheinnerandmiddlelayer, halfwayupthedome,ifyouaregoingtouseabattery poweredthermocoupletemperaturegauge.

Segmentedrefractory:Imaginethatyoupeeledan orange,cutitinhalfattheequator,separatedthehalf segments,andthensetthemupontheircutendsintheir originalorientation.Thatishowsomemodularoven builders(suchasLePanyol)maketheirformed refractorymodularovenkits.Youcanputspacer sectionsbetweenthetaperedsectionstomaketheoven longerorwider,ifyouliketomakeitalittlesquared offoroblongtousethespaceonatrailermore efficiently.Becausethesegmentsarenotgoingtomeet perfectlywellatthetop,youcanmakearound,slightly taperedkeystoneofrefractoryforthetopoftheoven, andformflatsonthetopendsofthewedgedsectionsto match.Youmakeaspecialsegmenttoformthe

doorway,withshortenedwedgesaboveit.Alltheother sectionscanbemadeinonemold,oneatatime.After everythingisinplace,youhavetoeitherbindthe segmentstogetherwithasteelbandaroundtheoutside (asLePanyoldoes)oryoupourareinforcingbuttress aroundthebaseofthearchwedgestokeepthemin place.Youmixupamortarslurry(quitethin),coverthe hearthwithplasticorpaper,andworktheslurryintoall thegapswithglovedhandstosealthedome.Thenyou caninsulateitandprotectitasyouwish. Brick:SeveralovensliketheoneAlanScottandIdescribein ourbookhavebeensuccessfullybuiltontrailers.The

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TechnicalNotesonbuildingtrailersformobilemasonryovens,byDanWing

reinforcedcladdingholdsthebrickinplaceasyoubarrel downtheroad.Asdesigned,though,theovenisgoingtobe ratherheavyforthisapplication.Thatisbecausethe emphasisinthatdesignisonhavingenoughmassforseveral bakesofloafbread.Ifyouaregoingtobeprimarilydoing pizzaorroasting,orifonebakeperfiringissufficient,you canmodifythedesignbyturningthearchbrickssideways, tomakethearchesalittlemorethanhalfasthickasthebasic design,onahearththatisagainlaidflatinsteadofonedge. Youmaywanttoomitthechimney,oryoucanmakethe chimneyrecessandstackoutofmetal,soyoucanclipitinto placewhenyouarefiringandbaking,andcarryitinthe backofthetruckwhenyouareonthemove.Therealsoisa freedesignforaroundoven(thePompeii)onJamesBaireys website(FornoBravo)whichcouldbebuiltina22 thickness(plusreinforcedcladding)formountingonatrailer. Roof:Myovensroofconsistsoffourboxtubepostsup togables(rafters)ofboxtube,withlightweightboxtube stringers(purlins)tosupportformedmetalroofing,held onbyneoprenegasketedscrews.Imadethehandlesof myoventoolsthesamethicknessasthepurlins,soIcan shovethemlengthwiseundertheroof(overthegable structures)whenIdontneedthem.

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