Thinking about a Plywood MES40 clone

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jsimpson

Fire Starter
Original poster
May 12, 2011
37
10
Houston, TX
Hello All,

Just signed up on your fine forum, but have been reading lots here to learn for a month or so. Seems like there is a lot more to learn than I thought!

I have an Oklahoma Joe BBQ pit w/ side firebox, but I'm thinking about something a little easier to use for cold smoking sausages. The pit works great for briskets, pork, etc., but it's pretty time- consuming to try to keep temps stable at low temps for smoking sausages. My first thought, after reading here, was to get an MES40 as it seems more of a set-and-forget type deal. After looking at the cost - and knowing I'm mostly looking for a sausage smoker - I started thinking about making my own.

I have a good bit of woodworking experience, and have built several sets of cabinets in the past, so I think I have average or above-average skills in that department. My thought was to build a cabinet out of 3/4" plywood approx 28" x 28" x 4 foot tall with a 1000w electric hotplate as a heat source. I would probably put some bricks/tile/metal on the bottom to protect the plywood, plus maybe sheet metal on the bottom half or so to help eliminate the chance of the whole thing catching fire. I also have an extra cast iron skillet (12" diameter, 2" tall) that I was thinking could be placed on top of the hotplate w/ woodchips inside for some smoke, then a driptray/waterpan above, then racks/dowels so that I can smoke up to 20 to 30lbs of sausage at a time. Seems lIke I'll need a small air intake near the bottom, some sort of venting near the top plus a thermometer to monitor inside temps (already have a meat probe thermo).

Suggestions on this? Am I missing anything building this at $150-200 versus buying a $400 unit?

Any input is appreciated.
 
Having built one, they are fairly simple. There are plenty of build threads to look at using the search. Here is mine: http://www.smokingmeatforums.com/forum/thread/85200/built-my-own-w-qview

A 1000W hot plate will work great for cold smoking and I use that same setup often. The water pan isn't necessary and won't get you anything unless your definition of cold smoking is different than mine. You can expect to reach about 120* at the most with a single hot plate cranked all the way up unless you bypass the thermostat. If you are looking to smoke the sausage beyond 120* you are going to need a different heat source.

Good luck with your build!
 
Here is a bug for your brain go to auberins.com and look at pids to control unit and make it a true set a forget.They have some that you just plug and play and some you have to wire up.They also have elements for your build.
goodluck.gif
 
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First off what you are talking about building is NOT an MES CLONE.What you are building is a smoker box with a 1000 watt hot plate.The MES 40' has digital controls for programing and 1200 watt element and a built in chip burner, & stainless steel interior.
 
Solaryellow,

Thanks for the link to your build. Now you have me thinking about building something larger (taller). Good info about the temps with the hotplates. Being in Houston (temps around 80-100deg. most of the year), I assumed 1 1000w unit would be enough since the MES seems to come with either 800w or 1200w units and I'm only looking to cold smoke sausage. Good thing is that it would be easy enough to add a hotplate if needed.

On your build - can you tell me about the venting you used. I see a vent a the bottom/front but I'm not sure what you used at the top. I was thinking that an electric smoker might not need as much vent area as others?

Thanks again for the help,

Joe
 
First off what you are talking about building is NOT an MES CLONE. What you are building is a smoker box with a 1000 watt hot plate. The MES 40' has digital controls for programing and 1200 watt element and a built in chip burner, & stainless steel interior.
Didn't mean to ruffle anyone's feathers here. By calling at an MES clone, I was referring to a smoker with about the same dimensions as an MES40, maybe slightly larger, and an electic heating element. Maybe  I should have called it a "Plywood MES Clone, at about the same overall dimensions, maybe larger, using about the same wattage but without the digital temperature controls, using a simple cast iron skillet with wood chips rather than a built in chip burner, and using plywood instead of stainless steel, but at a significantly lower cost ", but I was worried that the forum might not let me use such along title.

Everyone has their own preferences, and I'm just throwing this idea out to see if some folks think it is a feasible alternative. I have thought about buying ad MES40 and may still do so.

Joe
 
Solaryellow,

Thanks for the link to your build. Now you have me thinking about building something larger (taller). Good info about the temps with the hotplates. Being in Houston (temps around 80-100deg. most of the year), I assumed 1 1000w unit would be enough since the MES seems to come with either 800w or 1200w units and I'm only looking to cold smoke sausage. Good thing is that it would be easy enough to add a hotplate if needed.

On your build - can you tell me about the venting you used. I see a vent a the bottom/front but I'm not sure what you used at the top. I was thinking that an electric smoker might not need as much vent area as others?

Thanks again for the help,

Joe


The problem with the hotplate is the thermostat. You will have to bypass it but since you are cold smoking it shouldn't be an issue. Although again, I am not sure you and I are on the same page as to what the definition of cold smoking is. If you are looking to cook the sausage while smoking to 160*+ you will definitely need to do something different like a 220V oven element. My plywood smoker is pretty close to the dimensions you are planning on building but is 2' taller.

Those are just your everyday HVAC vents that I picked up at Lowes. I used the same kind on the top that I did on the bottom.

Good luck Joe!
 
I would make it taller if possible.  Then you have plenty of room for hanging sausages and snack sticks.

Call around and see if you can find an appliance recycler.  Many times they have piles of racks from old fridges or stoves, and you can get them cheap!

I like my MES, but need a larger box for cold smoking sausages. 

Keep us posted on your progress!!!

Todd
 
Several folks here have built very nice plywood smokers.

Pops6927,cowgirl and nepas to name a few..

Check them out..

  Craig
 
Thanks all for the suggestions and ideas. Gives me a lot of info to think about as I'm planning this.
 
building one is the way to go!!  Smokers are a rip off to buy, plus you can customize it the way you like!!!  I wouldn't go with the hot plate idea because of the thermostat like everyone is saying.  When it gets too hot it shuts off, and with a cast iron skillet on top it will shut off alot.  I would go with a heating element and wire it to a thermostat.  Good luck!!  post some pics!!!
 
Didn't mean to ruffle anyone's feathers here. By calling at an MES clone, I was referring to a smoker with about the same dimensions as an MES40, maybe slightly larger, and an electic heating element. Maybe  I should have called it a "Plywood MES Clone, at about the same overall dimensions, maybe larger, using about the same wattage but without the digital temperature controls, using a simple cast iron skillet with wood chips rather than a built in chip burner, and using plywood instead of stainless steel, but at a significantly lower cost ", but I was worried that the forum might not let me use such along title.

Everyone has their own preferences, and I'm just throwing this idea out to see if some folks think it is a feasible alternative. I have thought about buying ad MES40 and may still do so.

Joe
Joe, Sorry if I sounded like you ruffled my feathers, you didn't.  I was just pointing out what you would need to Clone the MES.

If it were me I would make the Box at least 6'x2'x'2.  That would give you more room to hang sausage. 

Pops used a propane burner he got from Northern Tool for his smoke house and it works great. 

Pop's Burner Here; http://www.smokingmeatforums.com/forum/thread/88853/found-a-burner-for-smokehouse

Electric Elements Can be found here: http://www.drillspot.com/products/518310/tempco_csf00014_finned_strip_ss_heater
 
I had a Cabela's electric vertical smoker first, but it wasn't big enough and wanted to hang sausages, slabs of bellies, hams, etc. so I modeled my smokehouse after the KOCH smokehouses my dad had in his store, just a smaller version.  6' tall, 3' wide and 3' deep (his were 9' tall, 5' wide and 5' deep).  Knew electric wouldn't be feasible,  so went with propane.  His were propane too; he had two huge tanks out back, just like a propane tank for a BBQ except about 5' tall and as appropriately as wide.  The burner I got was inexpensive and is actually three burners in one, so I have options.  Plus I added a needle valve and have great control, being able to adjust the flame height without fear of it blowing out.  I have operated the smokehouse in 35mph winds with no problems, being able to control the draft and not having any excessive wind inside; the flame burns steady with no wriggling from wind at all.  For an 8-10 hour smoke takes about 1/3 of a tank of propane; I can get about 3 smokes before I have to get a new tank.  That puts it at about $6.00 a smoke; more than reasonable enough for my usage.   And, I've got all the room I want; and I know when I'm able to retire and have more time it will be used a lot more, lol!  Both boys are addicted to my smoking, lol!

Check out my thread at the bottom of my post!
 
Pops,

Thanks for the suggestions. I've read your build thread several times, as well as quite a few others to start getting some information. As usual, I've changed my mind on some things.

For now, I think I'm going to stick with the size - 2' x 2' x 48" high internally, for a couple of reasons. It will allow me to build the smoker from 2 sheets of plywood, whereas if I increase the height at all it would double that to 4 sheets of plywood unless I decrease the width at the same time. Plus, the smoker will be stored under my covered patio, and I'm looking to keep it somewhat compact for now. I don't do large batches of sausage, and if I decide later down the road that the size is too much of a limitation, I could easily build another box and transfer everything over to it.

After hearing about other folks problems with the hotplate cycling on and off, I've decided to go with a small propane burner instead. I may still try the hotplate (already have 1 to test), but I ordered this from Amazon:


For $22 delivered, I figured it's worth a try even if it takes a little fabrication to get what I want.The burner is only 15,000 btu, so I'm hoping that the adjustable regulator I already have will let me regulate temps.

I may also copy the idea of using ceramic tiles to line the lower portion of the smoker that I saw in this thread:

http://www.smokingmeatforums.com/forum/thread/105067/first-smoker-build-from-the-ground-up/20

As my internal dimensions are going to be 2'x2', it would be very easy using 12" tiles with limited cutting involved. I posted on that thread to see if anyone thought the ceramic tiles would be a problem, but had no replies. I would be interested in hearing thoughts on this - keeping in mind that I intend in keeping max temps in the 170 degree range or less.

Anyway, I'll keep you guys updated as things progress.

Joe
 
Well, I've never been known as a real patient person, so I guess this is no longer a "thinking about ...." thread and is now a "started building a ..." thread.

Stopped by on the way home this evening and  bought two sheets of Oak plywood (hey, it's a smoker so might as well be a good smoking wood, right?), along with some stainless fasteners to go along with it. Cut the plywood down into sides, top, bottom, back, etc., and this is how it looks so far. Looks a lot smaller when cut down. Tomorrow will be time for dados and rabbets, then preliminary assembly of the carcass.

57a2709b_DSCN0118.jpg
 
Originally Posted by Beer-B-Q  
Joe, Sorry if I sounded like you ruffled my feathers, you didn't.  I was just pointing out what you would need to Clone the MES.
No problems at all. As you know, the internet can be hard to interpret sometimes.

Take care,

Joe
 
Made a little progress today.

Cut the dados and rabbets and dry-assembled to check how everything fits. Looks good, so broke it back down and made the brackets for holding racks/dowels. I used some soft maple that I had left over from another project, so cost was basically nothing for the brackets.

bd4af532_DSCN0120.jpg
 
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