New build, need guidance

cy-gor · Nov 15, 2011

So i have a Webber kettle that i will use for small stuff but i want to build a dedicated smoker eventually.

here is what i have to start with:

currently it is covered in junk so it will be hard to get a pic of the real item but thats basically what i have to work with.

I have some scrap steel and i want to avoid buying too much.

I am debating on a regular vertical smoker that will be insulated, or an insulated reverse flow.

Would it be better to make a firebox below it or integrate the firebox into the current skeleton?

Also i have a piece of what i think is 3/8" plate, though it may be 1/2. would using that as the barrier between the firebox and the cooking area be a good idea? The mass i would think would have an advantage from a heat retention standpoint but it might not help and just make the thing heavy.

Last thing, i have some 2 inch square steel that i plan to use as the chimney but i am not sure if that is enough for the size of the smoker, should i use 2x pipes?

Thoughts?

sunman76 · Nov 16, 2011

That will be a good start you can hit the junk yards and find some good matl's or if you have any friends that are welders they might have some stuff laying around.

To me it looks like you could build a nice insulated vertical smoker here is a very rough idea of what I was thinking.

there should be some real builders along to help you out.

here is a idea of size

NOTE:

Rule of thumb, firebox volume should be 1/3 the size of the cooking section

Cooker chamber size

Enter your tank size below. The green cell will show the volume you will need your firebox to be.

Diameter

Length

Tank volume in gallons

Height

Width

Length

0.00

or

0.00

or

33.50

20.00

19.00

4243.33

cubic in.

Fire box size (square or rectangular)

Enter the dimensions that you would like for your firebox.

If the green cells match your firebox is 1/3 the size of your cooking chamber.

Disregard if you want a firebox laeger or smaller than 1/3.

Height

Width

Length

The rest of the calculator will work for whatever size you choose.

19.00

20.00

12.00

4560.00

cubic in.

Exhaust chimney volume needed

Size of pipe for chimney

Length of chimney needed in inches

228.00

Dia

4.00

18.15

12.56

cubic in.

Enter the size pipe you want to use to see how long it will need to be.

Firebox air inlet opening

Air inlet opening area needed

Enter the opening size you want to use to see how many you will need.

13.68

Sq. in.

Square or rectangular

Area

Number of openings needed to match area listed above.

2.00

by

2.00

=

4.00

3.42

Sq.in.

Note: number above should be 1 or more.

Circular

Number of openings needed to match area listed above.

2.00

=

3.14

4.36

Sq. in.

Note: number above should be 1 or more.

Fire box to cook chamber opening

Firebox to cook chamber opening area needed

Enter the opening size you want to use to see how many you will need.

36.48

Sq. in.

Square or rectangular

Area

Number of openings needed to match area listed above.

6.00

by

6.00

=

36.00

1.01

Sq. in.

Note: number above should be 1 or more.

Circular

Number of openings needed to match area listed above.

6.00

=

28.26

1.29

Sq. in.

Note: number above should be 1 or more.

SmokinAl · Nov 16, 2011

There you go!

cy-gor · Nov 16, 2011

Thanks, i had been messing with the calculator as well

Also, been playing around with a reverse flow design.

Between my dad and I, we have most of the tube steel needed. however neither of us have the sheet metal needed.

if i insulate the firebox is 1/4 inch really needed?

is 1/8th the recommended thickness for this type of application? or is thinner possible?

shoneyboy · Nov 16, 2011

Great looking start !

Were are you located at ?

sunman76 · Nov 16, 2011

I over do everything I build

cy-gor · Nov 16, 2011

Thanks! I am in Austin TX

sunman76 said:
I over do everything I build

Is this in reply to the 1/4 inch plate?

I dont have a problem over building, just wanted to know how much of an issue it was.

daveomak · Nov 16, 2011

Cy-Gor, morning.... Have you got the racks figured out yet.... Suggest you find the racks first and build to fit.... easier than finding racks to fit the build... just a thought... Dave

An example of what is out there

http://stores.ebay.com/RestaurantParts/_i.html?_nkw=rack&_sid=142095880

cy-gor · Nov 16, 2011

DaveOmak said:
Cy-Gor, morning.... Have you got the racks figured out yet.... Suggest you find the racks first and build to fit.... easier than finding racks to fit the build... just a thought... Dave

The very first pic on the thread is an existing part. i am building around that.

For the racks i plan on getting some expanded metal to use with half inch tube i have laying around.

alelover · Nov 16, 2011

I like the reverse flow plan.

sunman76 · Nov 16, 2011

cy-gor said:
Thanks! I am in Austin TX

Is this in reply to the 1/4 inch plate?

I dont have a problem over building, just wanted to know how much of an issue it was.

not sure other than lasting longer

raptor700 · Nov 16, 2011

if i insulate the firebox is 1/4 inch really needed?

It's not necessary, with it being double walled it's going to be heavy already.

With ¼" it will be very heavy.

I love the vertical RF idea.

I would like to build a vertical RF (Backwoods) combined with the gravity feed of a (Stumps)

Good Luck

solaryellow · Nov 16, 2011

raptor700 said:
It's not necessary, with it being double walled it's going to be heavy already.

With ¼" it will be very heavy.

I love the vertical RF idea.

I would like to build a vertical RF (Backwoods) combined with the gravity feed of a (Stumps)

Good Luck

x2 on the gravity feed.

cy-gor · Nov 18, 2011

Gravity feed seems cool, but a lot of work. Maybe on the next build when i do the whole thing from scratch.

Is 1 inch of insulation enough? or should i bump it up to 2 inches?

raptor700 · Nov 20, 2011

I would think 1" would be enough.

cy-gor · Nov 29, 2011

things got busy but i have started to price things out.

1/8" plate for $120 each and 3/4 #9 mesh for $52

Not sure how competitive that is but i called a different place in the area and they were a bit more expensive.

I have made a bit more progress on the drawings as well.

I figure 2.5 inches is sufficient between the racks.

SmokinAl · Nov 29, 2011

The drawings look really good. Will be along for the ride!

cy-gor · Jan 4, 2012

So i think i decided to start from scratch but stick with the same design.

i am thinking cooking racks of 20x20.

This leaves me enough mesh to make a 16x16 basket for fuel with an 8inch wall. which i figure is big enough for most situations.

My original design has racks at 2.5 inches. is it worth it to go to 3? or will i still need to remove the racks just as much even with the extra half inch?

I see myself cooking lots of ribs and chicken so i don't need the extra space for brisket or shoulders as often.

Once i figure the cook area i will build the firebox accordingly.

shoneyboy · Jan 4, 2012

cy-gor said:
Thanks, i had been messing with the calculator as well

Also, been playing around with a reverse flow design.

Between my dad and I, we have most of the tube steel needed. however neither of us have the sheet metal needed.

if i insulate the firebox is 1/4 inch really needed?

is 1/8th the recommended thickness for this type of application? or is thinner possible?

In the last picture....Why are you doubling the frame ??? or am I looking at wrong ???? Just use the one that you have as your frame and weld to it.....if you want to metal cut to fit to the inside and if you want to insulate add metal to the outside...does this make sense ????

cy-gor · Jan 4, 2012

The frame is doubled for insulation. between the furthest outside panel and the middle panel will be 1" of insulation. The reason is this is a reverse flow. if it was a normal vertical smoker i would not need to do the double up to add insulation.

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