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Rebuilding a Screwed up 200 Gallon Crossflow Smoker

post #1 of 10
Thread Starter 

A guy who lives about 25 miles from me brought me his smoker to rebuild. It was made 2 years ago by another builder 4 miles from my shop. the firebox was 54% of needed, and mounted in the middle of the tank, stack was too small, Door hinges in the wrong place so no door seal across the top. He has had it for 2 years,and could only cook on the first 18 inches of the tank from the firebox, there was so much creosote inside the cook chamber and on the grates we could not scrape it off with putty knives, I was scared of having a house type chimney fire while working on it so I started by having the cook chamber and grates sandblasted.

We had to remove the tank side tire and fender to cut the tank loose to raise it so the proper size firebox would fit.,Intel(R) JPEG Library, version 1,5,4,36Junk Firebox on cherry picker

 

Intel(R) JPEG Library, version 1,5,4,36Fbox air inlet

 

Intel(R) JPEG Library, version 1,5,4,36Stack

 

Intel(R) JPEG Library, version 1,5,4,36

 

Intel(R) JPEG Library, version 1,5,4,36Fbox in center of tankIntel(R) JPEG Library, version 1,5,4,36Tank cut loose

 

Intel(R) JPEG Library, version 1,5,4,36Lifting tank to new height with cherry picker

 

Intel(R) JPEG Library, version 1,5,4,36Tank up on blocks to make new mounts

 

Intel(R) JPEG Library, version 1,5,4,36Fender and tire off to cut brackets

 

Intel(R) JPEG Library, version 1,5,4,36Nice work on old firebox to cook chamber opening !! LOL

 

 

Intel(R) JPEG Library, version 1,5,4,36

post #2 of 10
Thread Starter 

We are going to make new door hinges and add upper seal, new proper size firebox, proper size stack, crossflow baffle/drip tray, and rebuild wood storage areas.Intel(R) JPEG Library, version 1,5,4,36Insise cc sandblasted

 

Intel(R) JPEG Library, version 1,5,4,36CC sandblasted

 

Intel(R) JPEG Library, version 1,5,4,36Grates sandblasted

 

Intel(R) JPEG Library, version 1,5,4,361/4 inch of creosote in cook chamber

 

Intel(R) JPEG Library, version 1,5,4,36Creosote covered grates

 

Intel(R) JPEG Library, version 1,5,4,36Grates sandblasted

post #3 of 10
Looks like it's in better hands now. Are you welding upper seal to the door or on the inside of cooking chamber? I have seen it done both ways and wondered what works the best. I was even thinking about welding seal on both. I cant weld seal inside cc on sides or bottom due blocking the racks, but was thinking about it on top. I am about to build my first smoker.
Cheers, Steve
post #4 of 10
Looks like it's in better hands now. Are you welding uppet seal to then door or on the inside of cooking chamber? I have seen it done both ways and wondered what works the best. I was even thinking about welding seal on both. I am currently building a smoker.
Cheers, Steve
post #5 of 10
Thread Starter 
Quote:
Originally Posted by smaloof View Post

Looks like it's in better hands now. Are you welding uppet seal to then door or on the inside of cooking chamber? I have seen it done both ways and wondered what works the best. I was even thinking about welding seal on both. I am currently building a smoker.
Cheers, Steve


After I do the new hinges, I'll put the seal on the top, the door is already sealed on the other 3 sides on top,so it will match, plus the cut across the top is very uneven,so I'm tack welding the sides of the door before cutting the old hinges off, and running a skillsaw with a 1/8 cutoff wheel down the cut line to even it out before adding the new seal,and hinges, it looks like an uneven sawsall cut so a 1/8 cutoff wheel will even it out as well as give a little more clearance for the door opening. The door has a welded chain handle that isn't straight,so I'm cutting it off and adding 2 7 inch spring handles to match the one for the new firebox I made before he delivered the pit to me.

post #6 of 10
Thread Starter 

Had help for a few hours on the 4th, so I got the tank lined up for new mounts, old small stack cut off, and back of trailer cut to fit new firebox.

MikeIntel(R) JPEG Library, version 1,5,4,36Small stack cut off

 

Intel(R) JPEG Library, version 1,5,4,36Lined up for new mounts,and trailer cut for fbox

 

Intel(R) JPEG Library, version 1,5,4,36Crooked chan handle blocks shelf, getting spring handles to match firebox handle

Intel(R) JPEG Library, version 1,5,4,36

post #7 of 10

:popcorn

post #8 of 10
Thread Starter 

Finally back on rebuilding the Smoker ! Finally in just a small aircast for the broken ankle, so my boss asked me if I could work a few weeks at my own pace to cover a few guys vacations as the shop was swamped with work, I figured I owed him as he has been holding my job for m,e since last sept when I broke the leg and ankle, now I only have to go in part time to do the frame work in the bodyshop,and can get caught up on the jobs I had in progress. Mounted the Tank at the new height,and started putting the new firebox on this last weekend, After its finished I'll clean up the mess from the old firebox,and add the new handles,stack,and hinges.

MikeIntel(R) JPEG Library, version 1,5,4,36Fitting up firebox

 

Intel(R) JPEG Library, version 1,5,4,36New tank Mounts

 

Intel(R) JPEG Library, version 1,5,4,36New opening for firebox

 

Intel(R) JPEG Library, version 1,5,4,36Fitting up firebox

post #9 of 10
What kind of spring did you use on the door?
post #10 of 10
Thread Starter 

The spring with a safety cable was already on the smoker when it was brought to me to rebuild, it works good to hold the door open,but actually doesn't help that much with the lifting, It does chew the crap out of the paint where it rubs the tank and door.

Mike

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