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quentinflack

quentinflack

Newbie
Original poster
Mar 26, 2016
12
10
Hey guys, so last week I picked up a drum from one of my customers for free! (I deliver 5 Gal jugs of water)

So it's a 55 Gal Drum. It had varasol in it which is a solvent. And it's a sealed top :/

Firstly, how should I go about cutting this thing open? What size dome lid am I looking for? What size racks will fit in here? 22.5 or 18. How should I build my basket with ash catch?

Hopefully this weekend I'll drill my holes, cut it open, and burn 'er out!

Here's the drum!

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Before you get to cutting make sure the solvent is completely gone. I'd fill with water and a good bit of Dawn dish soap. Let it sit a few days then repeat.

Use a step bit to drill your holes for your intakes. For cutting the top off you can use a grinder or a jigsaw with a metal blade.

I used the racks from the 18" Weber. But I have adjustable racks so the supports eat up some room.

For the charcoal basket I used a grill grate for the bottom and expended metal from Home Depot for the sides. Added 4" bolts for feet and welded a pizza pan to those as an integrated ash catcher.
 
I like the extended lid idea! Does it matter what kind of metal I use? Just generic sheet metal?

Yea I'll do the dish soap thing a couple times.
Thanks for the tips guys!
 
I would use mild steel from a sheet metal shop...  no galvanizing...   or you can use roofing trim metal...  comes in rolls like at Home D...   It's a baked on paint that shouldn't cause any problems after you "condition" the barrel with a good burn out...

Below are pics of what it looks like...

https://www.google.com/?gws_rd=ssl#q=roofing+rolled++trim++metal&tbm=shop
 
Thanks guys! My wife really likes the blue so I guess that's what colour it's gonna end up. Maybe midnight blue or blue and black. [emoji]128077[/emoji][emoji]127996[/emoji]
Next step sanding! :/ lol
 
Finally was able to get some work done yesterday! Got the exterior sanded and the charcoal basket built and welded up! First time ever using an arc welder, but I got it done :)
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Next up is find my step drill bit and buy some hardware! Screws, pipe elbows, pipe, ball valves, grill racks.
I'd like to build a door on the front of it. That way I can add charcoal without loosing all my heat. Thoughts?
 
Hey guys! Finally looking into buying some parts. What size pipe and ball valves should I use? I'm assuming I should use black iron pipe for the intake stacks?
 
3 each 3/4" pipe nipples with electrical lock nuts inside and outside...  2 pipe caps and 1 each 3/4" ball valve.....    If the ball valve doesn't give enough air, remove 1 pipe cap and adjust the air flow with the ball valve...   

Your charcoal basket....  It's a good idea to have it 4-5" above the floor of the UDS for ash to fall out...   You should be able to run it 20+ hours with one load of charcoal...  no additions should be needed....  therefore no door required...   a door only causes air leaks which will really screw up the temp control...  an airtight unit is imperative for good temp control.....
 
So 3/4 will be big enough? I'm going to go 1 cap at the back and two pipe/ball valves on either side. For the door I was planning to use that silver heat seal stuff that you are on the glass of a gas fireplace.
 
If you decide to put a door in the UDS, get a second drum and cut the door from it...   overlap the cutout in the cooking drum by 2" on each side...   That way you will be assured to have a very good contour that can have a gasket added to it for a perfect air seal...
 
That's a great idea! If I decide to do that that's what I'll do [emoji]128077[/emoji][emoji]127996[/emoji]
 
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