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Heat-kit HK-22fo Assembly Manual

Modular contraflow masonry heater core
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Heat-Kit System
Modular Contraflow Masonry Heater Core
Assembly Manual
HK-22fo
22" Firebox with Front or Rear Bake Oven
AUTHOR NAME
Updated on November 21, 2017
Masonry Stove Builders
25 Brouse Rd., RR 5
Shawville, Quebec J0X 2Y0
HeatKit core assembly manual
(819)647-5092
norbert.senf@gmail.com

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Summary of Contents for Heat-kit HK-22fo

  • Page 1 Heat-Kit System Modular Contraflow Masonry Heater Core Assembly Manual HK-22fo 22” Firebox with Front or Rear Bake Oven AUTHOR NAME Updated on November 21, 2017 Masonry Stove Builders 25 Brouse Rd., RR 5 Shawville, Quebec J0X 2Y0 HeatKit core assembly manual (819)647-5092 norbert.senf@gmail.com...
  • Page 2 We’ve removed as much of this complication as possible with the Heat-Kit system. The insulated base slab allows you to do a dry layout first and make sure that everything is located properly in relation to the chimney and the slab.
  • Page 3 Position insulating base slab dry to determine layout for heater and chimney. Mark final position at corners with a pencil. Set insulating base slab in a 1/2" mortar bed, and level. Determine location of chimney connection and location of 2 cleanouts, one for each bottom channel.
  • Page 4 Brick Cuts: For firebricks standard sizes are: full ---- 9" 3/4 ---- 6-3/4" half ---- 4-1/2" 1/4 ---- 2-1/4" Build connecting channel, using refractory mortar. If there is a rear chimney, leave opening and span with flat bar supplied. Notch bricks to accept flat bars, thus allowing you to maintain thin joints.
  • Page 5 Second course. Refer to isometric views on next page. Cut 1/4" deep notches for flat bars as shown. November 21, 2017 HeatKit core assembly manual...
  • Page 6 Set flat bars as shown. You can use a refractory mortar bed if they need levelling. November 21, 2017 HeatKit core assembly manual...
  • Page 7 Set sub-floor slabs in refractory mortar. Use a thick bed to allow some room for levelling. Refer to install video https://vimeo.com/211 742460 at 2:15. Set the slabs flush with the front firebricks. Use the channel edges as a guide. Note (below) that at the rear there will be a jump and the slabs are not flush with the firebricks below.
  • Page 8 1" Do a dry layout of the firebricks for the firebox floor. You are using standard shapes - 1/2's and soaps. (Soap = firebrick ripped lengthways into two 9" x 2-1/4" pieces). Cut the notches to fit the two grates. Set the floor bricks.
  • Page 9 9” long by 2 ¼” thick. The thickness will vary between 2 ¼” and 2 ½” depending on the supplier. Since the Heat-Kit is designed around the standard firebrick module, it is important to check the width and length of your bricks beforehand, to avoid having to make modifications to the assembly procedure.
  • Page 10 Lay out the firebox as indicated, using air setting refractory 2" 4-1/4" mortar. Non-standard cuts are indicated by dimensions (2" and 4-1/4" here) instead of the standard firebrick shapes ie., 1/4, 1/2, 3/4, full Firebrick corners sit dry against the fiberglass rope gaskets.
  • Page 11 (Below): Completed outer shell of firebox. Top front firebricks are notched 1/4" x 4" for firebox lintel. Install next set of side channels onto a refractory mortar bed. (see next page showing plywood spacer). Clean up any mortar squeeze out inside the channels.
  • Page 12 Gas slot details: For easier heater startup during difficult conditions (cold heater, warm outside temperatures) we highly recommend installing a gas slot. This consists of a 2” X 2” direct connect. Cut a notch in the channel at the appropriate location to line up with the flue liner where the chimney will be.
  • Page 13 Install two 2-1/4" strips of ceramic paper (supplied) at the rear corners. A few light dabs of refractory mortar will hold them in place. November 21, 2017 HeatKit core assembly manual...
  • Page 14 Begin inner firebox. Note that the bricks are left about 1/4" - 1” short at the blind inside corners. The cut edges on these bricks are hidden. On each course, you begin with the half brick at the front. Depending on the thickness of your firebrick, it will project past the outer firebox.
  • Page 15 Your second course will be same as the fourth course, which is shown here. It is the same as the first course, except the half brick starts on the left. Notch top course of firebox liner as shown. Notch Notches are 1/4”...
  • Page 16 Immediately wash down the firebox with a sponge and a liberal amount of water. Rinse with clean water. If this is done right away, it is easy to get a clean looking firebox. November 21, 2017 HeatKit core assembly manual...
  • Page 17 Install firebox lintel. Use a refractory bed under the ends if they need levelling. Vertical face is slightly proud of channels, see bottom illustration. Raise strap as shown, so that you can remove the plywood spacer for easier access. The precast firebox floor slopes are shown for completeness.
  • Page 18 Building the Upper Firebox: Rear Bake Oven: The drawings show a front bake oven. For a rear oven, reverse the plan at this point. In other words, flip the remaining layout by 180 degrees. If you have access to strapping tools, this course can be strapped as shown on the next page. This is optional.
  • Page 19 Course strapped with 5/8" steel strapping (optional). Strapping runs inside the lintel, next to the brick. Next course layout. Three 3/4 bricks (6-3/4") One 1/4 brick (2-1/4") 2 soaps (bricks ripped lengthwise) 2 three-quarter soaps (6-3/4" long) soap soap soap soap November 21, 2017 HeatKit core assembly manual...
  • Page 20 This is the course that the oven floor will sit on (see next illustration). 4-1/4" For the portion that will support the floor, take extra care to level the bricks. This will make it easier to level the floor. Determine your high spot, and work from there.
  • Page 21 (Side channel not shown) Set oven floor onto a generous mortar bed. Note that it will overhang in the front about 1/4" Set it down carefully to 6 3/4" avoid mortar squeeze out, to allow you some room for levelling by tapping down the high spots.
  • Page 22 Set the rear wall dry. Build up the sidwalls from firebrick shiners. Use a mortar joint against the rear wall. Install gasket as shown. Use a thin coat of refractory mortar to glue the gasket, to avoid movement when you install the ceiling slab.
  • Page 23 Install oven ceiling dry onto ceramic paper gaskets. Install upper channels onto a refractory mortar bed. Clean up any mortar squeezeout inside the channel. The channels are marked with an arrow indicating the "up" direction. Add the second temporary strap to stabilize the channels.
  • Page 24 Build the transition piece at the rear wall. See detail, below. November 21, 2017 HeatKit core assembly manual...
  • Page 25 Measure the thickness of your firebricks (for example, 2-1/4", 2-5/16", etc.) Measure from the top arrow, down to 5" + the thickness of your firebrick. For example, if your firebrick is 1/4", then you would measure down 7-1/4". Put a mark on the channel at this height.
  • Page 26 Install the precast ceiling slabs. Use 2 people, and be careful with your staging, and plan your moves. The pieces are heavy and need to be lifted above shoulder height. Set the pieces dry onto the core. Leave 1/8" gap at the joints. Seal the pieces carefully with GE silicone (provided).
  • Page 27 Seal the core at the fiberglass rope side channel gaskets by applying a bead of silicone where the gasket touches the firebricks. This takes care of any small gaps, etc., that may be there. Silicone is good to 500F and remains flexible, and is suitable even for sealing fairly large gaps if you have them.
  • Page 28 The metal tape is shown in place. Repeat the process with the longer roll. November 21, 2017 HeatKit core assembly manual...
  • Page 29 Metal tape in place on the longer piece of wrap. Most expansion happens in the upper portion of the core, hence the doubling up of the wrap near the top. Vertical expansion is cumulative, and there is almost none at the bottom. Therefore, no wrap is required there, and you can touch the core directly with mortar slush.
  • Page 30 Using a utility knife with a fresh blade, trim around the openings as shown. Make sure to trim around the 2" x 2" bypass opening also, which is easy to miss. You will have a fuzzy edge with fibers sticking out. Around the oven open, trim these off using scissors.
  • Page 31 Heater core with fiberglass matt slip joint installed. Ready for facing. This one does not have an oven. November 21, 2017 HeatKit core assembly manual...