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Custom kiln design photos

Posted: Tue Mar 05, 2013 8:05 pm
by Al Bray
I thought I would share some photos of a custom kiln design I worked with Denver Glass to make a reality.

I am quite happy with the older KL-50D I have when working on larger flat fusing and shallower slumping projects. However for a while now, I have wanted to pursue taller slumping/drop out work, manipulating molds at slumping temperatures, as well as some casting/combing/high fire projects that my older KL-50D was never really designed to handle for various reasons (not deep enough, not insulated enough, top only elements) and many times it is actually larger than I needed for the one-off projects I typically work on.

My first thoughts was a GL-24 ATSD. But the weight, dimensions, and inability to break the kiln down into sections so that I could move it through a narrow door at the top of the stairs going down into my basement studio ruled it out as a possibility.

I very much desired a front loading door so I could approach the manipulation of molds at 1200 degrees more easily/safely than reaching down into deep top loader or into a clamshell and worrying about the possibility of the them accidentally coming down on me (I work alone and don't get many volunteers for spotting me while working in a hot kiln ;-(

I also liked the a top loading door because I found the typical front loading door configuration to be limiting when one needs a clear "god's eye"/top down view of how things are laid out on the shelf or how projects centered on molds (kind of like working in a tunnel). From my experience and observations top opening doors are also more accommodating when peeking down into deep slumping molds to see how things are progressing or in the case of tall castings, monitoring/charging the reservoir.

Not to many offerings out there for both top and front opening doors and constructed in a way I could get it moved into place and positioned in the space I had to work with.

Since I was at it, I desired a custom height to so that it put the floor of the kiln chamber up at comfortable standing working height with little bending over and the controller/infinity dials up at my normal standing viewing level.

Other features include:

- Chamber Size is 24" x 24" x 21.5" tall (Leaving a true 18" of height with 2 inches of clearance from the lowest part of the top element rack).
- 3" Fiber lining (1" Fiber blanket cold face, 2" HD fiber board hot face on walls, 3" HD fiberboard on roof), Firebrick Floor
- Elements in top, sides, and door. Each with their own infinite dial/switch to be able to set and change the percentage of power/heat coming from them ... on the fly if need be as the kiln is firing a schedule.
- Auto power cut-off switches when kiln doors are opened.
- Double pole mercury relays for durability as well as an additional safety measure against a run-away kiln situation (both would have to fail at the same time in the closed/on position).
- Kiln venting system that automatically turns on/off during a segment in the firing schedule to removed moisture from molds/wet powders, fiber product burnout, or any other fumes.
- Power: 42 amps, 9250 Watts

All in all, I am impressed with how solidly the construction of this new kiln feels and I think Denver's casting line of kilns are beefed up construction wise because of the higher temps and long holds at those temps they have to accommodate.

The experience of working with Holley and Curtis at Denver Glass was a very smooth one with them listening to the things I need/desired and translating them into something I am confident will work for my intended use.

Not the cheapest avenue to pursue, but a heck of a lot cheaper than having to build a ground level studio onto the house and I was able to end up with something where I didn't feel I was having to make any significant sacrifices on from my want list.

When I think about it, all things considered (fiber roof, kiln stand, vent system/AOP control, etc.) it really only amounted to about a 25% up charge over a similarly equipped GL-24-ATSD and I ended up with some extra height to the chamber as well as the dual door design.

So if you find yourself in a situation where you need something a little different from the standard kiln designs, I would put Denver on the list of people to check with.

- Al

Side Note: The customizations I had done were around their base KL-TFC kiln they had built previously for Milon Towsend. I wanted a single front opening door with elements along with the other things outlined above.
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Custom kiln design photos

Posted: Tue Mar 05, 2013 8:10 pm
by Al Bray
Additional Photos

Re: Custom kiln design photos

Posted: Tue Mar 05, 2013 8:32 pm
by Valerie Adams
Ooooh! Aaaaaah!
It's beautiful!

Re: Custom kiln design photos

Posted: Tue Mar 05, 2013 9:37 pm
by twin vision glass
NOw that is super duper!!!!!!!!!!!!!! Les

Re: Custom kiln design photos

Posted: Tue Mar 05, 2013 10:19 pm
by Morganica
That is a beautaceamous kiln, alright. Congratulations! I like the front/top doors. I solved that dilemma by opting for a bell instead of a stationery box, but I like this way, too.

Make it about 6 inches deeper, lower the stand and put it on wheels, run elements across the bottom and all the way up the sides, give me a charging hatch on top, swap that controller for a Digitry, and I'd be in love..... ;-)

Re: Custom kiln design photos

Posted: Wed Mar 06, 2013 5:35 am
by bob proulx
Nice, you got to love a new toy.
Bob

Re: Custom kiln design photos

Posted: Wed Mar 06, 2013 8:27 am
by Don Burt
very very cool. Glass porn, were it not for my high moral virtue and ability to not succumb to primal lust. I appreciate it from an intellectual standpoint. Thank you for sharing, Al.

Re: Custom kiln design photos

Posted: Wed Mar 06, 2013 10:49 am
by Laurie Spray
Love love love

Re: Custom kiln design photos

Posted: Wed Mar 06, 2013 12:44 pm
by Barb R
I'm green with envy!

Barb

Re: Custom kiln design photos

Posted: Wed Mar 06, 2013 1:10 pm
by Bert Weiss
I seldom think kiln designs make much sense, this one included. What we need most is evenivity. If I want to create evenivity, in a deep kiln, I would put elements, only on the roof and the floor. If I were making a kiln for investment casting, I would put elements on all 6 sides.

Re: Custom kiln design photos

Posted: Thu Mar 07, 2013 1:13 pm
by Brock
Looks pretty sweet Al, how is it working out?

Re: Custom kiln design photos

Posted: Fri Mar 08, 2013 12:38 pm
by Al Bray
Brock wrote:Looks pretty sweet Al, how is it working out?
Hi Brock,
So far it's working out really well.

I am pleased with it both in terms of the ergonomics of using it, as well as the uniformity of the heating. At least at the level in the chamber I am working with things now.

The first blank I slumped into the deeper molds dropped so evenly I didn't even have to go in to make an adjustment. I was please about that but also had a tad sense of disappointment like I got all dressed up for a date and had no where to go. I am going to post a couple of photos in the photos section of that project so one can see the results if they are interested.

I plan on running through Bullseye Technote 1 "Knowing you Kiln" with the shelf elevated at different levels in the chamber to get a sense of the heating characteristics in those different areas and then if it is to far off think about using the infinity dials to possibly adjust things to compensate.

- Al

Re: Custom kiln design photos

Posted: Fri Mar 08, 2013 3:09 pm
by Bert Weiss
Al

I think you can utilize your configuration well. For instance, if you are mold slumping, placing the mold relatively low in the kiln (still above the floor), should promote heating the bottom of the mold, which would help draw the glass down in to the mold. In this case, you can use unevenivity to help. Just don't get the glass too hot.

And I do like the combo of front and top hinges. You can manage to get your nose over the glass while setting up glass in the kiln. I hate my front loader because I can't get my nose there. I worry a bit about the wire connections as they flex with the door or lid opening. Like Cynthia, I think the bell style can solve the most design challenges.

Each configuration works better for some projects than others. I'm not a fan of 3" thick kiln walls. I think these kilns get too hot on their exterior. Yes they cool faster. I still wouldn't choose this design factor.