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I had a pretty good idea of how to build one but with the amount of time and material that goes into building one of these I chickened out and bought the plans, as far as the grate size I'd have to measure it I don't remember the dimensions. I can tell you these things are amazing, I've had...

Been away for awhile but wanted to update this thread, I completed this build back in June. I cooked 120# of butts for my son's graduation party, another 120# for a friends party and more for my neighbors. I couldn't be happier with this thing it works flawlessly.

1/2" plate for the fire box is best for longevity but 1/4" will work, not sure which pipe you are referring to but if it's the pipe on my old smoker that was a supplemental smoke chamber. Good luck with your build and most of all have fun.

Made a little more progress

Made a little progress yesterday, this smoker will be replacing my old faithful I built a few years ago

Been collecting parts and pieces and finally started building last weekend.