fpmich , I'll try to help , I bought one and it's sitting out rusting , gave-up on the Mods, I didn't have the stock or tools to do the Mods... here were my ideas...
1. Could I do it with just one upside down L angle stock (just the bottom angle stock in his pics).
Then lay an adhesive bead & stove rope (round or flat). The lid should sit & seal itself on the rope wouldn't it?.
Yes.a good silicone adhesive will work (get high temp.)
2. Any reason not to use aluminum with rivets or screws, as opposed to steel & bolts for this? Conflict with metals? Steel rusts.
, add a drop of Lock
Actually , I believe the Steel ones will do , 'hint , drop a spot of Lock Tight ' to each nut to keep them from loosening from the Contraction , and Expnsion of the metal during cooking nd in
Winter.
I will be using my Char Griller Smokin Pro, for
both smoking & direct grilling.
You will have no trouble , here is a good bit of reading that may help you . . .
http://www.smokingmeatforums.com/a/stickburning101
3. Temperature question: Will direct grilling exceed the temperature limits on the Permetex high heat sealants like the Red (500*F) or Copper (700*F) and cause either of them to fail?
No.
4. I know that most of you use the Permetex Red. Any reason not to use the higher heat rated Copper? Is there a problem I don't recognize?
Get the highest heat you want , that's your choice and pocketbook.
5. Any reason not to have smoke stack extended down to great for direct grilling? Probably a silly question. I can see no reason for it to interfere.
Yes, you get a better smoke flow over your Meat . The heat (and Smoke( rise and cross above the Meat .
That should be easy to understand ...
Thanks in advance for your help. Don't get too technical on me tho'. I'm a simple guy.
KISS principle apply's to me. Keep It Stupid Simple!
Have fun and don't give up on the Smoker , I hear lots of good input on these units , once Modded .
Have fun and . . .