I plan to use 2.5 x 2.5 bricks, so I cast a slab measuring 65cm x 65cm as a foundation. This is because 2.5 bricks + 2 joints measure just over 67 cm. I want the bricks to extend about 1 cm outside the slab to prevent frost damage. It will be about 8 (+/- 1) rows of bricks.
I have acquired an old stove door and I'm now wondering how on earth to secure it. I've identified three problems that I'm not quite sure how to solve in the best way.
1. The door is completely smooth around the edges. Is it enough to attach it with mortar or is there a risk it will fall out of the "hole" over time; does the mortar stick well enough to the cast iron? Could one, for example, drill four holes (two upper and two lower) at suitable joint heights and insert ~10 cm long reinforcement bars a few mm that you then secure with mortar in the joint, or is that unnecessary?
2. Inside the stove doors, there is a spark guard that is attached and guided around an "iron bar" that comes out and is slightly curved under the edge. This "curve" moves when opening/closing. I'm considering that the door must be raised and ensure no mortar gets under this small area with a thin bent sheet metal. If you look closely at the first picture, I have placed a 10mm reinforcement bar under the door on the outer edge, and it comes up just right so that the spark guard is free to move.
3. I have acquired some thinner firebricks that I plan to use at the bottom of the firebox. How would you approach this? I first thought to mortar them in place, but since they will be closely packed, it's probably unnecessary. But how do I handle the height difference? First, there's a height difference from point 2, and then another since they are significantly thinner than the bricks. Should I mortar regular bricks for the entire first row inside the firebox and then add the firebricks on top? This would make the inside a little higher than the bottom edge of the door, but if you cut down that edge, there should be a slight slope when removing ash, right?
If you raise the hatch a bit according to point 2, there will actually be a minimal edge if you fill the entire first row with bricks and then add the refractory ones. I think I'll go with this. A small edge is fine, it doesn't disturb:
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