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Oven Smoker Build

post #1 of 5
Thread Starter 

I'm new to smoking but learning alot.....I figured an old oven would work for smoking since it's insulated and made for cooking stuff.


Sooo, I called an appliance store and they sold me a non working oven for $10...it was in nice shape and had 2 racks....I took it...it was a tad smaller than I wanted but it should work fine.


Since it was small, I had to think of a way to move the burner out of the oven and give more room....I remembered I had an old charcoal grill (still sold at wal marts for about $25)....so I got it out of the junk pile....


I started out by gutting the oven inside.......then I cut a square hole in the top of the charcoal grill.  Next I inverted the oven, took the charcoal grill top and put it on the bottom of the oven to mark the hole......cut a hole out of the bottom of the oven....then I simply drilled holes and used sheet metal screws to attach the charcoal grill top to the underneat of the oven....so far so good.....now the more difficult part.  I bought a 2 burner hot plate from Wal Mart ($30).....took it home and unscrewed the bottom...had some weird screws in it....I was able to open it up, but then had to take some tin snips to cut out the plates.....I kept working and finally was able to unscrew part of the hot plates and take both burners out.....then I used the old burner housing to mark two holes in the bottom of the charcoal grill....I had to put them almost touching, otherwise they wouldn't fit the charcoal grill.  Cut holes out of char. grill and mounted hot plates.  Then I used self tapping sheet metal screws and fixed the bottom half of the charcoal grill to the top underneath the oven....so far so good! WHEW lol


Next I cut a hole in the top of the oven and outer metal housing, and attached a dryer vent (aluminum) to the oven...was just the right height for a smoke stack.....last thing I did was drill a small hole and put in a temp guage, (walmart again $5)....last thing was I made a small wood base for it....fired it up and worked great


BUT, I couldn't get to the controls and had to put the chips in through the oven...Well I knew that wouldn't work, so I took the bottom of the char grill off, and cut out an access panel for my chip pan, attached a piece of metal back with hinges, and made a little catch to hold it shut...then I reworked the wood frame to be higher and allow access to the controls....added casters and I'm done


The charcoal grill worked great since it has built in vents already...and a grill grate so I can put in a drip pan through the oven part to catch grease

OH the chip pan was a chicken cooker pan from walmart as well....was $2 or $4.....made of stainless.....perfect size and everything!


My temps get to about 255-260 max but when smoking drops to about 225-250.....I made it for making sausages but I'm happy with it so far...makes a good thin blue smoke now that I've figured out how to work with it some....and I can control the heat with the independent burners...I set my chip pan about 1/4 of the way on the small burner and use chunks of wood and get a thin blue smoke


Well here's the pics...hope this helps someone with a build....it's crude craftsmanship since I used a jigsaw and a drill only...and tin snips...but it works!







Front Controls...I just cut around the dials and attached to the char grill with sheet metal screws...there's vents like this on the front and back




Wood Chip trap door...I take pliers and take out my chip pan, then add more chips




Smoke vent and temp gauge...Im a newb, but I think this is thin blue smoke?





post #2 of 5

Wow, looks great!  Do you have Qview of any finished product you've smoked in it?  Love to see it in operation!

post #3 of 5

looks like TBS to me!  cant wait to see it in actionpopcorn.gif

post #4 of 5

I gave that idea some thought and wanted to redo the burner area for a grill and the smoker below. still seems doable, So how did it all turn out?

post #5 of 5

You are on the right track.  


We upgraded my mother's vertical double oven in the early 80's and my father just couldn't part with it.  Several years later, he converted it to a smoker.  


He cut a large square hole between the lower oven an the upper oven and flashed it with valley tin.  He made the hole about 2 or 3 inches smaller than the upper oven element.    


He left the upper oven heat element and controls in but rewired it to 110VAC.  


He added a small 110VAC element in the bottom oven and slid a doghouse type smoke box over it.  When you need to add wood, you just open the lower oven door and slide the doghouse out and refill it.  


He drilled about a 1.25" hole thought the top and used EMT conduit for a very small smokestack (just enough to draw the smoke around the meat.)  


He made a 1/2" galvanized pipe frame on wheels and connected the oven to it with conduit clamps.  You can roll the oven outside when you need to use it.  


I have inherited it and it has become my primary smoker.  


I didn't like it until I rewired it to 220VAC.  It really couldn't maintain temperature at 100VAC.  


I think you need to be able to do two things really well to get consistent results:  1) You need to be able to accurately control the cooking temperature.  2) You need to be able to accurately measure the meat temperature so you know when to take it out.  An oven is perfect for item #1.  


I plug it into my 30 amp air compressor outlet and run the cord under my garage door.  Since I only run one large element at a time and I never smoke above about 250 degrees, the 30 amp service is plenty to run both elements.  


I have done two whole beef briskets at the same time and I actually smoked a couple of cases of pork butts (in several batches) for a friend's daughter's wedding.  The results are excellent.  The oven is very well insulated and it is very easy to control the heat.  I just set it and forget it.  


I like this smoker so much, I am thinking about building a larger one (since the vertical ovens are a few inches narrower than a regular oven).  I have a brand new built-in oven that a friend took out of his house because his wife wanted a different color.  I may end up using a large dutch oven over a hotplate-like element as a smoke box. I should be able to pipe the smoke into the side of the single oven unit. 

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