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TR A D ITI O NAL C L AY
OV E N
A STEP-BY-STEP GUIDE
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B U I L D I N G A C L AY OV E N - T H E
BA S I C S
I assume that most people will already know
what a clay oven is, however it is probably
useful if I define what I mean by a clay oven
for the purpose of this guide. Before I do
that though a quick word about
nomenclature. I will use various names for
the clay oven interchangeably; these include
"clay oven", "traditional clay oven", "wood
fired oven", "pizza oven" and "traditional
bread oven". If you browse around the web
you will also see the name "cob oven" being
used - cob being a mixture of clay and straw
The Clay Oven in my Garden
(+ or - sand). As I am not using straw in my
build I will not use the term cob but will include it in my definition, as this type of construction is
probably the most ancient of all clay ovens. Another name commonly used is earth oven.
Clay ovens are amazing things. They look incredible and create a feature in any garden, large or
small. The main reason most people want a clay oven of course is for cooking. If you have never
eaten a pizza cooked at 350°C for 1 minute in a clay oven - you have never eaten a pizza! Just
imagine a thin, crispy, slightly charred base covered in hot melted cheese, olive oil, garlic, sun-dried
tomatoes, dried cured sausage, smoked ham, anchovies...do I need to continue? How about loaves
of hot bread cooked to perfection, cracked open and smothered in real butter or a large joint of lamb
or pork belly cooked slowly with herbs over night in the oven's residual heat, falling off the bone
when you come to carve it the next day. OK enough of the M&S style adverts already! I think you
get the picture. Cooking in a traditional clay oven is wonderful; it feels different and definitely tastes
different.
Building your own clay oven is not difficult. I am by no means an expert when it comes to DIY but
am normally happy to give things a go. I have never built anything like this before but managed to
complete my oven without any major disasters. The beauty of building a clay oven is that you use
mostly natural and, if you are lucky, recycled or free materials. There is something very primeval
about building one of these ovens. The process is a direct link back to our ancestors who would
have used similar techniques for cooking many millennia ago. I thoroughly enjoyed building it! It is a
very physical and tactile experience - you will handle and form every single piece of clay, sand and
wood that goes into it and the finished product is something that you will be extremely proud of.
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W H A T YO U W I L L N E E D - M A T E R I A L S A N D E Q U I P M E N T
OK lets crack on with getting this baby built! Here I will list most of the equipment and materials
you are going to need to build your own clay oven. I will provide details such as quantities later on as
I step through the build process.
MATERIALS
Builders sand
Clay
Water
Rubble / hardcore
Wood shavings
Normal building bricks (e.g. London Bricks) for oven base
Large wooden "beams" or bricks or stone for plinth (I used beams as you will see later)
Cement if you are building plinth out of brick
Right-angled brackets and screws if constructing plinth from wood
Glass bottles (optional)
Old Newspapers
Plastic rubble sacks
Wood for burning in the oven
EQUIPMENT
Saw (chainsaw?)
Wheelbarrow
Bucket
Tarpaulin or thick plastic sheeting
Shovel
Spirit level
Large knife
Hands and feet!
Wellington boots or other sturdy boots
T H E BU I L D O R D E R
So you have your equipment and materials list. Next I thought it would be useful to outline the
order of construction. This will also form the basis for the rest of the sections in this guide, each
section providing details for each stage in the build process. Simple - I hope! As you might have
guessed already, I love a good list so here goes another:
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3. The dome sand-former and first layer or the oven layer
4. The oven entrance and chimney
5. The wood shavings and clay slip layer or the insulation layer
6. The final clay-sand layer
7. Firing the clay oven
8. Cooking in the clay oven
9. How Long Does it Take to Build a Clay Oven?
Construction involves quite a few steps and each step takes variable amounts of time to complete.
Probably one of the most time consuming processes is puddling the clay-sand mixture (mixing with
your feet!). One batch (two buckets of sand to one bucket of clay) will take about an hour to an hour
and a half depending on the consistency of the component parts. If you get a group of people to
help then obviously you can speed the process up. Many feet make light work of puddling! Building
the oven layers is also very time consuming and you need to leave drying time between each layer if
possible. The other major factor which affects the length of time it takes to build your oven is the
weather. You can't construct anything other than the plinth if it is raining and it does tend to rain
quite regularly in the UK!
What with interruptions (both weather and non-weather related) from start to finish my oven took 6
weeks to build on my own. However if you have a spell of good weather and a few helping hands
(and feet) I think you could build one in a week.
H OW L O N G W I L L A C L AY OV E N L A S T ?
To be totally honest I have no idea how long it will last. My original garden oven is now two years
old and still going strong (with some care and maintenance!). The good people at River Cottage HQ
suggest a couple of years but obviously this will vary dependent on your location, local temperatures,
weather conditions, air moisture content, the type of cover or shelter your oven is housed in, the
amount of use your oven gets, the type of clay you use for construction and many other factors.
They are pretty robust but they are organic structures and they do crack after repeated heating and
cooling. This is not a problem if cracking only affects the outer layer - you can fill the cracks with
spare clay-sand mixture. However, once you get cracks in the internal oven layer then the oven's
days are numbered. I say, don't worry too much, enjoy it and use it and if it falls apart you can build
another one!
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T H E P L I N T H A N D B R I C K OV E N
FLOOR
Your plinth has two main functions. Firstly, it raises your oven to a height that makes it practical to
use. Imagine trying to slide pizzas in and out of the oven on a baker's peel if the entrance is at ankle
level. You would end up with a bad back and a charred mess in the oven! Secondly the top of the
plinth forms the all important brick base to your oven.
M A T E R I A L S F O R P L I N T H C O N S T R U C T I ON
Your choice of materials is dependent on personal taste, availability and budget. If you scour around
the Internet you will find plinths made from natural stone, bricks, cob, wood and earth and wood
alone (like mine). No one solution is better than the other so take your pick. I am going to show
you how to build a simple but beautiful plinth made from wood. I was lucky enough to get hold of
some oak beam off-cuts from a local timber merchant. They are very attractive and very heavy!
P L I N T H F O U N DA T I ON C O N S T R U C T I O N
If you are going to use a construction material with substantial weight from which to build your
plinth and are building on soft ground you will need to establish a foundation first. This is pretty
easy. In my case I dug a 40-50 cm deep hole slightly wider and longer than my intended plinth
dimensions (120 cm x 120 cm) and filled it with hardcore (rubble) to a level just below the top of the
hole. I then topped this off with a layer of builders sand and finally laid a paving top onto the sand.
In pursuing the spirit of sustainability, I managed to get hold of some broken slabs which I laid as
crazy paving to form the flat level of my plinth foundation. You can of course use other foundation
methods such as concrete. If you are lucky enough to have a chosen a location with a solid floor on
which to build your oven then you can skip this step.
P L I N T H C O N S T R U C T I ON
So you have a nice flat and solid base it is time to start building the plinth. This is where building
with timber comes into its own because it is just so simple! Before you start building though you
need to think about dimensions and this will involve a little forward planning.
PLINTH DIMENSIONS
The plinth needs to be wide enough (and as your oven is going to be circular I suggest you make the
plinth square) to accommodate all three layers of your oven. The most important measurement is
the diameter of the first layer - the inside of your oven. You need to decide what is practical for your
needs. If you only ever intend to bake pizzas in it then it could be quite small but if you want to use
it to roast legs of lamb or pork joints you need to make the oven layer wide enough in diameter to
accommodate a roasting tin. The internal diameter of my oven layer is 80cm which therefore means
the brick floor on the top of my plinth is also 80cm x 80cm (you wouldn't want any part of the
wooden walls to be inside the oven when you fire it!). Working out from here, each of the 3 layers
should be approximately 7cm thick, so the total thickness of the oven walls will be around 21cm.
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Add this dimension to each side of your brick
floor width and you will end up with the
correct dimensions for your plinth. Phew! So
my plinth top dimensions are 120cm x 120cm.
Your next task is to fill the plinth "box" with rubble (hardcore) to a level of about 30-40 cm below
the top.
B R I C K OV E N F L O O R C ON S T RU C T I O N
This is the last stage in construction of your plinth. The brick floor is obviously a critical component
of your oven so I suggest you take your time with this and do it right.
You'll need some bricks, something to cut them with and some more builders sand. I used bog-
standard London bricks and a hammer and bolster to cut the bricks (although I'm not very good at
this and broke quite a few!). Use any bricks you can get your hands on but try and look for ones with
a nice flat surface, without cracks and avoid any that look too porous. Bricks with hairline cracks will
break when you come to cut them, or worse still, when they are fired in the oven later.
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LAYING THE BRICK OVEN FLOOR.
All you need to do then is fill the top layer of your plinth with bricks. I chose to use a herringbone
pattern which holds together nicely without cement. Remember to try and keep the oven floor as
level as possible.
Once you have laid all of the bricks in place brush handfuls of building sand into any gaps to prevent
any further movement of the bricks.
That's it! Your plinth is complete and ready for the next stage - building the oven!
Constructing the herring bone pattern floor The finished plinth and oven floor
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T H E C L AY- S A N D M I X T U R E A N D
PUDDLING TECHNIQUE
So now the fun begins! Before I get on to detailed instructions of how to build the oven I want to
provide some details on preparing the all important building material - the sand-clay mixture.
INGREDIENTS
Builders sand
Clay
Water (optional)
EQUIPMENT
Shovel
Bucket
Tarpaulin
Thick plastic bags
Wheelbarrow
Wellington or other sturdy boots
Legs!
You can buy builders sand from any building suppliers, some garden centres and DIY stores (e.g.
B&Q). Either buy it in individual plastic bags or get a job-lot delivered - you will use quite a lot.
W H A T T Y P E O F C L AY S H OU L D I U S E ?
I have had quite a few questions about the type of clay to use. As far as I know you can use any type
of clay you can get your hands on. I dug my clay from a local farmer's field here in Hampshire (clay
overlying Upper Cretaceous chalk if you are geologically minded - maybe Paleogene?). The team at
River Cottage get theirs from a pond on site, in Dorset (I think it is Blue Lias). If you can't find any
clay locally you could always buy potters clay which would be wonderfully homogeneous i.e. free
from large particulate matter (stones!). Which reminds me, try to get clay that does not contain too
many stones - they are liable to form the focus of cracks in your oven if left in the mixture.
QUA N T I T I E S
The ratio of clay to sand is 1:2 (one part clay to two parts sand). I used a bucket as a convenient
measure and found that one bag of builders sand almost filled two buckets which was nice!
I think it is wise to make-up just enough mixture (with a little bit extra) to complete one layer of your
oven at a time. Why? Well if you make up a huge batch (enough to complete your oven) it could dry
out before you get a chance to use it if you get delays between layers (if it rains for example). So how
much do you need for one layer? This will vary depending on the size of your oven. For mine, if we
define one "batch" as two buckets of sand mixed with one bucket of clay, the first (oven) layer took
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three batches (6 sand to 3 clay). This left enough over to fill small cracks after drying and to begin
building the chimney. The outer layer required more mixture because it is covered a larger surface
area. I used four and a half batches for this layer.
Comment from the blog
I might be wrong, but, if the oven is roughly a spherical shape, then you could calculate the volume of the half sphere formed by the internal
part of the oven (80cm), then calculate the volume of the half sphere formed when the first layer is laid (94cm), and subtract one from the
other. Converting it to liters, you would have an approximate quantity.
I did the math (correctly, I hope – I suck at math), and got the following results (please correct me if I’m wrong):
MIXING OR PUDDLING
I found it takes somewhere between 45 minutes to 1 hour to mix one batch. One tip I discovered
which speeds things up is make sure the sand is damp before you start mixing. It definitely helps the
clay mix in better (essentially you are coating sand grains with clay and water helps break down the
clay mineral bonds I assume?). Add some water before hand if you need to but dont go mad with it!
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The last thing you need to do is check that the
mixture is of the correct consistency i.e. not
too wet and not too dry. You might be
surprised at how sandy the mixture seems but
this is how it is meant to be. The team at
River Cottage HQ had a great method for
testing the consistency though which I will
share with you.
Once you are happy that your mixture is just right shovel it into a thick plastic bag to keep it moist
while you mix the next batch.
If you are ready to start building your first layer I recommend shoveling the final batch into a
wheelbarrow for ease of use. Wheel it over to your plinth - it's time to start building your oven!
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THE DOME SAND-FORMER AND
FIRST (OVEN) LAYER
Builders sand
Old newspapers
Water
Tape measure or long steel ruler
Clay-sand mixture
Tip lots of sand onto the brick floor of your oven. I'm not sure how many bags I used but I
remember being amazed at how much was needed to build up the dome to the required dimensions.
Remember the outside of this dome will form the inside dimensions of your finished oven. The base
(widest part) of my oven is the same dimensions as the length and width of the brick floor (80x80
cm). I decided to make the height of my oven approximately half that of the diameter (40-45cm).
Build up the dome, molding and sculpting with your hands until it is the desired height and a nice
shape. A top tip from Steve at River Cottage HQ is to keep checking the shape of the dome from
above, so periodically stand on your plinth to get that birds-eye view! Once you are happy with the
shape, firm-down the sand with your hands.
S A N D F O R M E R C OV E R E D W I T H N E W S PA P E R
Next you need to add a layer of wet newspaper. This makes removal of the sand from inside the
cavity much easier later on. It is a little tricky to get the paper to stick but persevere and you'll crack
it. That’s the dome complete. Now you are ready for your first oven layer.
T H E F I R S T ( OV E N ) L A Y E R
If you are doing this alone make sure you leave three or four hours to build your first oven layer. I
made the mistake of starting in the early evening and ended up finishing it at midnight wearing a
head-torch!
Take some of the clay-sand mixture from your wheelbarrow in cupped hands and form it into an
elongated/rounded brick shape. Press this first "brick" against the base of the dome and compress
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it into place, with one hand holding it against
the sand former while the other makes a
"karate-chop" type movement (using a
straight hand) against the "domeward" side of
the brick. This creates a wedge-shaped "brick"
(sloping towards the dome) which helps when
adding layers above and also removes any air
bubbles from the mixture which may
subsequently expand and crack the oven. You
are aiming for an oven layer that is
approximately 7cm thick and the simplest way
to keep check of this is to measure the bricks
periodically against a marked stick or even a
First few "brick" layers.
piece of straw. Add another "brick" next to
the previous one and, using the same technique, mold it into the first. Repeat the process until you
have laid "bricks" around the whole circumference of the dome.
Begin laying "bricks" on top of this first layer and continue, round and round, up and up, until you
have completely covered the sand dome former. Remember to keep checking the oven layer
thickness as you go. Don't worry if you end up with some variation in thickness - as you build the
oven layer up you might find that the base widens out a little from the weight of "bricks" above.
Smooth and shape the oven layer into a neat, coherent shape and don't forget to check from above.
That's it! Your first layer is complete. You need to leave it to dry for a few hours before you cut the
hole for the oven entrance - which I'll discuss next.
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T H E OV E N E N T R A N C E A N D
CHIMNEY
You have completed your first layer and now you need to build a nice entrance at the front of it in
order to get food in an out (unless you leave it as a dome shaped sculpture!). At this stage we will also
be removing the sand former and build a chimney. You should have left the oven layer to dry for at
least 4 hours before you attempt to cut the oven door but don't leave it so long that the clay-sand
mixture dries too hard or you will find it tricky to cut.
This is the moment of truth! Get yourself a bucket and start to excavate the sand from within the
oven layer. Don't forget to keep the sand for later clay-sand layers. Hopefully you will be able to
excavate the sand until you reach the newspaper layer on the inside of your oven without the dome
collapsing. Take it nice n slow but I'm sure you'll be absolutely fine. Remove as much newspaper as
you can but don't worry too much because it'll burn off anyway the first time you fire the oven.
D RY I N G T H E F I R S T L A Y E R – F I R I N G T H E OV E N
Next you need to dry your oven layer. If you are lucky enough it will dry nicely over a few days in
direct sunlight. However you should also fire the oven at least once to help the drying process but
also to check the entrance is high enough to allow smoke to escape (see below).
The method for firing the oven is quite simple but do bear in mind that at this stage the oven will be
rather damp and does not have a chimney so you might find it takes a little bit of perseverance to get
the fire going. This is how I do it:
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1. Prepare some nice "pencils" of
kindling.
2. Scrunch up five or six pages of
newspaper into balls and form into a
rough pyramid inside but near the
entrance to your oven.
3. Build up kindling around the
newspaper as if building a wigwam.
4. Light the paper and hopefully the
kindling will soon ignite.
5. Watch the fire closely and keep
slowly adding more and more
kindling until it starts to burn well.
6. At this point, using a spade, metal
rake or even a bakers peel, slowly Kindling burning in the entrance to the oven.
push the fire back a little into the
oven. Don't push it too far because it is likely to go out.
7. Add more wood and when it is burning fiercely move it back some more. Eventually you
want the fire to be burning in the centre-back part of the oven.
A couple of tips here. Firstly, take it slowly. If you try to move things along too quickly you are likely
to extinguish the fire. If it looks like it is going out, screw-up a few balls of newspaper and throw
them in. This is usually enough to re-kindle the blaze. Secondly don't use large chunks of wood -
smaller pieces burn better.
At this point you can modify the height of the oven entrance if you need to. Look carefully at how
the smoke is moving. If it is "pooling" inside the top of the oven you need to cut your entrance
higher to allow the smoke to escape.
As the oven dries it will steam and might produce a few cracks. Don't panic! Fill in any cracks with
spare sand-clay mixture before you move on.
BU I L D I N G T H E B R I C K A RC H
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can see in my photographs below). The last brick should form the keystone of the arch. Leave the
"mortar" to dry a little then remove the sand former. Hey presto - a perfect arch!
THE CHIMNEY
Entrance and Chimney done! Leave it to dry The brick arch and chimney from the front.
before we move onto the next stage - the
insulation layer.
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T H E I N S U L A T I O N L AY E R
Entrance dry? Chimney dry? Great! Let's start building the next layer - the insulation layer.
Some clay
Some wood shavings
Some water
A bucket
A wheelbarrow
A spade
A power drill and plaster mixer (optional)
Next throw some wood shavings into a wheelbarrow. I bought a huge bag of wood shavings from a
local pet shop and I still have three-quarters left (any takers?). Add some of the clay slip and mix well
with a spade or get your hands dirty. The mixture should be wet enough to form "bricks" similar to
those you made for the clay-sand layer.
Build up the insulation layer using exactly the same technique as before. Simple! Leave it to dry and
then you can move on to the last step in the build - woo hoo!
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T H E F I N A L L AY E R
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F I R I N G T H E OV E N
I discussed the process of firing the oven earlier but I thought it warranted its own section because if
you don’t get this right – you won’t be cooking anything!
Finally a word of warning. If you have any sort of hair on the front of your head and want to keep it
that way WEAR A HAT OR CAP when you fire your oven. You will need to keep looking into the
oven and when it is throwing out 450-500 degrees Centigrade of heat you will singe your hair. You
may not find this as hilarious as my wife did!
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THE BEST PIZZA EVER!
Firstly, if you want the best pizza ever you really need to buy the best ingredients you can get your
hands on. Make sure you buy good quality flour, organic if possible. Dried yeast is perfectly adequate
so don’t worry about trying to get hold of the fresh stuff. The toppings are crucial too so don’t
scrimp and buy cheap ingredients – you don’t need masses, so splash out and treat yourself to
quality. The following recipe is borrowed/copied from Dan Stevens, a chef from River Cottage HQ
(Dan has recently written the River Cottage Bread Handbook which available in all good bookshops).
THE DOUGH
Add all of the dry ingredients to a large mixing bowl and give it a quick mix. Next add the water and
mix into a rough dough. Finally add the oil and squidge it well into the dough. Flour a surface and
tip your dough out onto it – it’s time for kneading! You can use a electric mixer with a dough hook
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to do this if you prefer but I like to get working on the dough with my hands – it just seems right
somehow! You will find that this dough is quite wet (sticky) compared to traditional bread dough.
There are lots of methods you can use for kneading dough but I like to use this one (again thanks
Dan at River Cottage). Hold the dough ball to the surface of your table with the tips of your left
hand. Then with the heel of your right hand placed in front of the fingers of your left, push the
dough forward, stretching it along the surface top then, in a fluid motion, pull the dough back
towards your stationary left hand. Rotate the ball and repeat. I normally knead for about 10 minutes
or so. Lightly oil a large bowl, put the dough into it, cover with cling film and leave to rise until it is
double the original size. That’s it – dough done!
TOP P I N G S
The choice of toppings is totally up to you but here are a few essentials as far as I am concerned:
A mixture of olive oil, crushed garlic and herbs is, for my money, a much better pizza base
topping than the traditional tomato sauce. Just drizzle or paint it over the surface of the
dough before you add the rest of your toppings – it’s delicious!
Grated cheese (mozzarella, Gruyere, Cheddar)
Chunks of other cheeses (buffalo mozzarella, blue cheese)
Mixed cured meats (spicy sausages like salami and chorizo chopped or sliced, chunks of
good organic ham)
Roasted artichoke hearts
Fresh basil
I would have suggested anchovies to give that powerful salty, fishy blast but unfortunately
anchovies stocks are in crisis due to over fishing so I no longer buy them – I suggest you do
the same for the time being.
OT H E R T H I N G S YO U ’ L L N E E D ( I D E A L LY )
A rolling pin
A wooden chopping board
A bakers peel (pretty much essential)
A sharp knife
One of the best things about making pizzas outside using your own clay oven is building your own
pizza – rolling out the dough, selecting various topping mixes from pots of delicious, fresh
ingredients, sliding it onto a peel and finally into the hot oven. It is enormously rewarding and great
fun so I always get everything ready outside then let friends and family make-up their own pizzas as
they go – trust me everyone loves it! The process is simple:
1. Make sure your oven is really hot. I normally fire mine for about 2 hours before cooking.
Leave a fire burning at the rear of the oven and keep feeding this throughout the cooking
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period with extra wood. Scrape clear the floor of your oven. I normally push any embers to
the back of my oven using the upside down blade of my bakers peel.
2. Grab a small piece of dough and roll into a rough ball – about golf ball sized should do. I
prefer to make smallish (maybe 7-8″ diameter) pizzas because they are much easier to handle
in and out of the oven.
3. Flour your rolling surface and rolling pin well but don’t overdo it with flour. You need
enough to stop it from sticking to the surface but too much and it burns on the base of the
pizza once in the oven.
4. Roll the dough out into a very thin disc (mine often come out looking like strange “country”
shapes but it doesn’t matter). Add more flour if it sticks. Critically you want to ensure the
base is NOT sticking to the surface because you will have all sorts of problems getting it
onto your peel once the toppings are on otherwise.
5. Paint or drizzle the base with the olive oil or traditional tomato topping.
6. Throw on your toppings. Hint: don’t pile too much on your pizzas because toppings have a
tendency to fly off when you slide the pizza from the peel into the oven!
7. Slide the pizza onto your bakers peel – I find if you lightly dust it with flour first, then lift
one edge of the pizza and with a quick, fluid movement pull it onto the peel. Practice makes
perfect!
8. Next you need to slide the pizza from the peel onto the hot floor of your oven. Again you
might not get this right the first few times but persist and you’ll have it cracked!. The
technique you need to master is “yanking” the peel from underneath the pizza - very much
like pulling a tablecloth from underneath a fully laid table without breaking the plates or
spilling the drinks!
9. Let the pizza cook for about a minute – keeping a close eye on it. I normally then slide the
peel underneath it, take it out of the oven and rotate it through 180° so that the side that was
facing the open oven entrance is now facing the fire burning at the back of the oven and
vice-versa. You might end up with a pizza burnt on one side if you fail to do this. Pop it
back in for a little while longer until you are happy that it looks cooked.
10. Slide the pizza out of the oven onto the peel then transfer onto a wooden chopping board.
Slice and serve.
11. Savor the best pizza ever and feel smug that you have created such a spectacular thing!
12. Repeat until you and your guests can’t move for eating pizza.
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