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I put your numbers into feldon, and your a little small on everything. FB at the size you specified is only at 97%. Opening from FB to CC should be 110.59 square inches. And a 5" diameter stack comes up needing to be 34" tall. If I were you I'd do a 24" square FB would be 134% which is fine...
What he's saying is being that the weld seam is right there and it's not round for a couple inches. If you cut in that area it's much more likely to spring when you cut your door. Cutting the other side of the tank your less likely to have problems with the door springing. And cutting those...
Finished up the FB today. Vent is finished, latch is finished, and I fabbed the charcoal basket today. Still needs some grinding and cleanup but it's basically done. Sometime this week I'll get the tank leveled and start laying out the cuts on it. Once the CC and FB are welded together I'll...
I think an inch is more than you need on a tank that size. I'd overlap the plate onto the firebox. Assuming you lever the smoker when in use that 1/4 inch drop should be sufficient to run to the drain. In my 60 gallon RF I made the plate level and use drip pans for easy cleanup. Anything...
Using daves calculator the tank volume in gallons comes out to 137 gallons. I'm building a RF right now with a 24x60 tank which is 117 I believe I'm going with a 24" square box which is 150 percent of what's needed so same size FB should work well on your tank also.
Got quite a bit done to the firebox. Finished up the door minus latch and fabbed the air intake. I borrowed the saw tooth design from a build I seen on another BBQ forum. Still a bunch of grinding and cleanup left to do. But I should be cutting the tank soon.
Kyle
Got the door all welded and fitted. Next I'll do hinges and the latch. Door and box together I'm at about 44 feet of weld. Once the door is mounted I'll put in the angle for the basket, and do my intake. Then move onto cutting the tank.
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