Kiln Building Courses

Build your own warm glass kiln – from scratch or from a

partially prepared kit - from as low as $518 plus course fee.

Background

We work full time with glass art and have a well equipped studio which permits us to engage in our art without too many limitations.  We also teach others about the warm glass crafts and offer use of our studio facilities to those we have taught.  Many would like to have their own studio set up at home but until now could not afford the often high cost of the most basic piece of equipment required for glass fusing and slumping – the kiln.

We presently have 9 kilns in operation and 2 under construction – with firing chambers ranging in size from 1.5 m x 1 m down to 10 cm square.  In 2005, after having spent a large sum of money on a new kiln with a “top of the line” name brand digital controller which simply didn’t perform to our requirements, we decided that we needed to know more about kilns and, in particular, their control systems.

We learnt initially by working with an electrician (who specialises in kilns) repairing and eventually building several.  Concurrently, we spent a lot of time, effort (and money) in evaluating and testing a variety of process control systems which could be used with a kiln.

What we discovered through this was that kilns and their control systems were not necessarily overly complex and didn’t need to cost the earth to be effective. We even got our very expensive new kiln to work properly by replacing the $1200 controller with a $300 one – but that’s another story.

Over time, many of our students have sought our advice as to buying a used kiln and, seeing as though good used glass kilns are few and far between, we conceived the idea of designing a specialised warm glass kiln for the home studio user.  For more information about purchasing second hand kilns, see further Why that used kiln may not be such a bargain

We set to work with what we considered to be essential specifications-

• Effectiveness in warm glass techniques with either Bullseye or System 96 glasses
• Ease of operation
• Electrical efficiency
• Capable of operating from a standard household power point – just like a toaster or kettle.
• Safety in use in a non-industrial/commercial environment
• Durability and a long life
• Capable of working with projects up to 400 mm square

• During 2006 we developed, prototyped and refined a design which met these specifications.  We built 2 of these kilns for our own use and thoroughly tested them.  They continue to be in daily use. They have proved themselves to be real workhorses and given us great flexibility.

Our first kiln building courses (for others) further refined the presentation of the course – so that we now offer two levels of course depending on the student’s level of interest and basic skill with hand and power tools – saws, drills, etc.  Both courses contain the same theoretical content and participants produce an equivalent kiln. 

Participants in the one day “Build a Kiln Workshop” assemble their kiln from a kit of largely pre-prepared materials which require only minor fitting and adjustment.

Participants in the 2 day “Kiln Building Course” work from raw materials – cutting and shaping each component – except for the stainless steel enclosure.  We recommend the Kiln Building Course for those who have existing “handyman” type skills and are comfortable with saws, drills and other hand tools.  Any “wasted” materials in this course will be at the participant’s expense.

Irrespective of which path you take, we teach you a little about the relevant concepts so you can later do your own experiments if you wish and build proportionally bigger or smaller kilns.  We will introduce you to some of the “science” of power, heat and insulation and the most useful concepts and materials.  But best of all, you will build your own kiln as part of the course.

Why are we offering these courses rather than selling kilns ourselves?

There are several simple reasons why we want to make the kilns – and this information – more widely available by way of these courses.

• Firstly, we want to see more people able to explore their art in this area and that is more likely to occur if there is better and cheaper access to kiln capacity.
• Secondly, the greater understanding an artist can have about their essential tool, the better the work they produce – we have got to the point where we are quite comfortable designing and building a specific kiln for a specific job – rather than making the inevitable compromises.
• Thirdly, the firing service we provide may sometimes be restricted – as a rule it is somewhat difficult to either fire lots of experimental kilns or to make multiple commercial pieces at a time.  It is better for both of us therefore if you can have your own kiln.
• But most importantly, we don’t want to be kiln manufacturers – we want to spend our time making art.

What are the disadvantages of this design?

The kiln will only work for glass – it is incapable of reaching ceramic firing temperatures.  The maximum size of a piece of work is 400 mm square which ought be sufficient for most purposes.  But it is a bit large and perhaps a bit slow if all you want to do is make jewellery.

Of course, you will also need to buy your own shelves, molds, washes and accessories that are currently provided free by us as part of studio or firing fees.  For example, shelves of this size cost in the order of $60; molds range from $10 to $40; kiln wash is $40 per bucket; fibreboard is $88 per sheet.  Coupled with running costs, you may not think it a worthwhile investment.

And working at home alone isn’t necessarily as much fun as being in the studio with others for ideas, inspiration, advice and the occasional glass of wine ….

How much does it cost?

If you are able and willing to construct your own metal body kit – base, body shell and lid – then the materials for the kiln could cost you from $518 but for most we expect it to be $998.  A commercially built kiln of this size would normally cost you in the vicinity of $2,600. 

The course fee is $60 for the Build a Kiln Workshop or $100 per person or couple for the Kiln Building Course.  There are a maximum of 3 people/couples per course – whilst one person can assemble or build the kiln, you will benefit from an extra pair of hands and it should be a fun time. 

These prices do not include the necessary kiln controller of your choice – see further Build your own Kiln Controller

What about standards and safety?

A very important issue.  We believe that the kilns do comply with relevant Australian and international standards – but we are not willing to pay the cost of a formal independent laboratory evaluation.  We can provide you copies of the relevant standards for inspection if required.

We believe that the kilns are safe to use – with common sense– after all they generate heat and use electricity – both of which are inherently dangerous.

You can be assured of electrical safety because a licensed electrician will complete the relevant connections and checking as part of the course.  The cost of this safety check is included in the course fee.

What materials are involved (supplied by us)

All necessary tools are provided for use during the course.

The (not so fine) print

Kilns are dangerous.

We aim to teach you the mechanics of kiln construction and have gone through a process of trial and error to come to this design which we use ourselves.

We guarantee any materials and equipment which we sell to you but we can’t accept responsibility for any faults arising from your construction of the kiln or what you do with it once you have built it.

Most importantly you will need to install it and use it in a safe environment.  The kiln gets hot and is hot enough to cause a fire or contact burns.  You must therefore install it in a non flammable environment, away from children and others who might not realize it is hot.  And you must never, ever fire it unattended.

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