Well it’s done. It started with finding an 80 gallon propane refill tank in an old Chevrolet dealership’s basement and obviously snowballed from there. In the discovery phase, it became obvious to me that moving heat and smoke was a science and not just as simple as cutting a door and welding on a smoke stack. From there I focused on meeting the technical requirements for the cook volume I had and tried to solve design problems with flair and an eye towards functionality and durability. The end result was way more than I set out to accomplish. The cost was too, but I’m in at less than a third of what it would have cost me to farm it out in a much simpler form. It was a great project that was tons of fun and a great chance to get to know Ben better. So many of the details we quibbled over during the build, and resulted in a very long list of great features on this smoker. Steel is expensive, perfection takes time and two heads are way better than one are some key takeaways from this project. In the end I’ve got a one-of-a-kind smoker built to last generations that works perfectly. I’d say it was a success. Now to get some meat and get on with the cooking!
- An initial iphone sketch before this project kicked off.
- Two tanks. One mission.
- Removing the hardware from the tanks.
- Welding up bungs.
- Removal of all the tank hardware.
- Removal of all the tank hardware.
- We removed a specified amount from the smaller tank to withing spec for the required specified firebox dimensions.
- The firebox before being welded up.
- a more substantial trailer will utilize the hardware from the red one in the background.
- Tacking the basic trailer frame together.
- First mock up of our layout.
- Mocking up the layout in three axis.
- Bent tubing for structural bits.
- welding the supports in.
- bending tubing for the arched supports.
- welding the supports braces.
- proof that the support braces are strong enough.
- moving this party to the floor to finish the welds.
- finishing the welds on the supports/
- The basic concept moving to the foor.
- sitting on wheels.
- Fences in place to guide the plasma cutter.
- Very nice results for the fenced plasma cut.
- Plasma cutting the cook chamber door.
- Plasma cutting the cook chamber door.
- Tacked fences for the plasma cutter to follow.
- The finished plasma cut cook chamber door.
- Headed home after the first weekend on this project.
- Plasma cutting the firebox door.
- Laying out the basic framework of the firebox to cook chamber plenum.
- Hand fitting the first plenum side. dual curves.
- Cardboard templace for plenum pieces.
- Mocked up plenum pieces in cardboard.
- Plasma cutting the exit from the firebox.
- Plasma cutting the exit from the firebox.
- Plasma cutting the entrance into the cook chamber.
- Plasma cutting the entrance into the cook chamber.
- The raw pieces cut and fitted for the firebox to cook chamber plenum.
- Welding the firebox plenum.
- Welding the firebox plenum.
- The Firebox to Cook chamber plenum. This is a precise throat size.
- Welding in the baffle plate in two pieces.
- Good look at the fully welded baffle plate andcook chamber door hinges.
- Baffle plate fully welded in. The exits of the baffle plate are a precise measurement.
- Human load testing the cook chamber.
- The hinge concept.
- Precision alignment using a forklift.
- Plasma cuts are very nice on this door seam.
- Welding the cook chamber door hinges. note the forklift precision alignment tool.
- firebox hinge welded on.
- Welding the hinges on the firebox door.
- building the firebox grate from strips of 10 gauge.
- The firebox grate all welded up.
- heavy duty firebox grate. with handles.
- Welding the brackets that support the firebox grate.
- The working side of the smoker rig.
- The back side of the rig, you can see the Firebox dampener and the plenum.
- welding the hinges onto the firebox door.
- The fresh air dampener for the firebox. simple and effective.
- Cook chamber door fully hinged.
- closeup shot of the cooking grate.
- the cooking grate. removeable.
- bending tubing for shelf
- fitting the bent tubing shelf frame.
- Proof that this design is a good one.
- welded in cup holders.
- cup holders on work shelf.
- 10 gauge flange material for door seals.
- The top flange needed to be on the inside to clear the hinges.
- Welding flanges onto the cook chamber door.
- Flanges welded in on the cook chamber door.
- 500# viertical toggle clamps to seal the doors.
- Flanges welded in on the cook chamber door.
- Cutting the stack.
- Flanges and clamp welded in on the Firebox door.
- framing the wood basket.
- The wood basket front view
- framing the wood basket.
- Welding the wood basket frame.
- welding the elbow onto the 37 inch stack.
- Unanimous votes for slash cut tip.
- Welding the 37 inch stack.
- welding the 37 inch stack.
- Firebox dampener handle
- Welding expanded metal onto trailer deck.
- test fit expanded metal onto trailer deck.
- expanded metal in place with wood basket.
- Fitting expanded metal onto the trailer deck.
- The nearly finished product.
- Going home for some test burns before paint.
- This is the answer to the question of protecting the tail lights.
- Possibly one of my favorite engineering problems solves. Folding stability leg.
- Toggle clamp and heat handle in place.
- Finished Fire Box
- Close Up shot of the stability leg folded in.
- Yeti Cooler rack from bent tubing.
- Reverse view of the cooler rack.
- Fresh out of power coating. 1200 degree silicone based powder.
- All of the bits bolted back on for the final time.
- Hitche dup and going home for good!
- This thing even trailers well, somehow we got that right.
- Parking it in the back yard and glad to have it home.
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