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I would increase the opening to 14" wide x 7" tall and put a 1.5" grease bridge in.
On your intakes if you use horizontal slides three 5" tall x 2" wide will be plenty.
I would also look into a 5" exhaust 24" tall. The 4" at 31" will work but I just prefer more breathing room in diameter and...
For me the question I would ask myself if I were buying or building one is do I want the heat/smoke coming up on my meat or going down on my meat? Both designs work well if built properly the reverse flow is more demanding on having a completely sealed chamber because of the way the smoke has to...
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Best choice in my opinion.
If sweep blasting is not an option finish your cooker then clean out as much of the heavy rust and by heavy I mean if it is raised and can feel it. Most surface rust can be smoothed down with just sand paper. Once this is done rinse out the cooker...
The warmer on my big cooker is set up to accept smoke through a slide damper connected to the cooking chamber. During normal running the the damper is closed and the warmer runs around 155° / 175°. If I slide my tuning plates and open the damper and warmers exhaust she will climb to above 250°...
Has the teacher tried using a couple of bottle jacks and some chains on the door? Wrap the door with a chain and put the jack in the arc with the chain on the jack and pump it up pulling the door in. Measure top to bottom flange and make note of it then pump the door and pull it in release it...
Your door looks great buddy. :) On the welds get your grinder on edge bring the edges down as well as the center and make a clean single pass cap if you want. :)
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