100 gallon Silent Hunter build (lots of pics)

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I have some 4" square tube thats 1/4" thick (3.5" ID). Will this work for my smoke stack? the calc only has for round pipe.
 
Yes...    3.5 x 3.5 = 12.25 sq in... x12 = 147 cu inches per foot....  that is the same area as a 4" pipe.... or close "enough for gummint work"...  Dave
 
So, I have got some work on my fire box done. I will post pics later.

Is the 1/8" flat ok to use around the fire box door?
 
Is the 1/8" flat ok to use around the fire box door?

Yep....  If it's wide enough, drill holes and blind weld it.... Weld the end holes first.... then as you weld, the strap will shrink and be "tight"..  Clamp as you go to hold secure to the door....      Dave
 
Congrats on the beautiful build!  DaveOmak will never steer you wrong.  It looks like it will be a world class smoker in no time at all with you handling it.

Good luck!!!
 
Here's some pics to get up to date.

First I cut the spring mounts off the HF trailer and welded them to the new trailer. I also used the trailer as my saw horses to cut my 1/4 plate for the fire box.


Tacked the corners and made sure it was all square.


Then the non-stop welding.


Then the non-stop grinding of all the edges. I also made to intake vents that screw in and out. I am going to weld a handle or 1/4" x 1" flat on to them. Should be easy to adjust, just like an old wood stove.


Making the hinges are a pain in the butt. Here I cut them and drilled them. Next I bolted them together and used the grinder to even everything up.


hinges.


fire box is ready to mount. the door is a very tight fit and swings open very easy. The double shear is probably overkill, for the hinges. You can also see the fire box intake, in the open position.


If I was build another one, I would probably buy the hinges. These work great, but they are very time consuming.


I also cut some 1/4 x 1 to brace the inside of the door.

 
Looking GOOD
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Sorry for no updates, I have been working on a forest fire since this last weekend, I will post some more pics in a little while. 
 
Really nice Build!!!!  You are a very good fabricator!  I am having mine built out of a old 250 oil tank and will have a 2 x 2 side fire box.  It has 2 shelves the bottom one is 3 X 5 and the top shelve is 2 x 5.  Again nice build!
 
Thanks for the compliment. The fire is out and my daughter is turning 21 tomorrow. We are going to Vegas for the weekend. Once we get back from Vegas, I should be able to get the smoker all finished.
 
I am finally able to start working on this again.

Question: The calc says my flue should be 35.03 in length. Is this total or outside above the cook chamber?
 
The dimensions for the flue are inside diameter of the pipe and extended above the smoke chamber.... I do believe..   Dave
 
great build and great write up!!!  I am planning on building one of these, hopefully next summer and this is great! 
 
I believe my smoker is ready for paint! I am just waiting for my toogle clamps to arrive, and then I can start cookin'. I will try and get some pictures posted. This site was alot of help during my build.
 







I burned it out by building a fire in the box and on the baffle plate. I then used a 4.5" paint removing disk to get the paint off. I also welded some channel on top of the fire box, for a pot of beans.

 
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I did not want the counter weight, but the door was heavy and dangerous. The counter weight works great!
 
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