Firebox for Weber kettle

[speedmetal]

So I had the idea a while back to build an external firebox for my kettle. I had considered just doing a mailbox mod, but where is the fun in not going overboard? It is made of 3/16 hrs and the chamber is an 18" cube. It will come in just under the grate on the opposite side of the handle. I will be cutting the hole in the side of the Weber this week and I'll update with more pictures if anyone is interested. Thinking of leaving this as a modular firebox that I can move around and hook up to different cook chambers I am planning to build in the future. It is currently getting seasoned with some peanut oil as it is what I happened to have on hand.

 

[cpaysonc]

Awesome!! You could sell those!

 

[BigW.]

Nice work. How are you going to account for the added weight on the legs?

 

[chopsaw]

The way I see it , the box sits on the ground .
I've been tossing the idea around for a couple years , but using a side fire box from a Char griller .
I was going to connect with stove pipe , and add legs to the fire box . The price of the fire box was more than I wanted to spend on the project , so went the way of an electric element .

S speedmetal Nice work on that .

 

[speedmetal]

Chopsaw is indeed correct. This will just sit on the ground and I will be able to wheel the weber up to it, though I may make a cart for the weber at some point so I can more freely wheel it around. It can definitely get pricey depending on materials you use. Luckily I was able to do it all myself to keep cost down to material and my time.

 

[millerbuilds]

Pretty cool idea!

- Jason

 

[chopsaw]

I may make a cart for the weber at some point so I can more freely wheel it around

This was the start of mine . Only pic I had of it , the WSM was being fired up . That's actually a Happy Cooker kettle , 1974 .
The char griller fire box was going to go on the bottom shelf , and connect with a stove pipe .

You may or may not be interested , but something else in the plan was this .

It's a charcoal grate from an Old Smokey 22" smoker . It fits in place of the charcoal rack on a 22" kettle . I was going to use it as a diffuser / deflector with the side fire box .
You can get them on Amazon fairly cheap . There's a couple different sizes .

 

[speedmetal]

That is a nice cart. Definitely a sweet setup. I just finished cutting the hole for the firebox.

 

[chopsaw]

That compound radius cut can be a challenge to get tight . Maybe you wanted it big ?

 

[speedmetal]

That compound radius cut can be a challenge to get tight . Maybe you wanted it big ?

I wasn't very concerned about getting it perfect on this one. I wanted the slot big for ease of removal since I am thinking this will be a modular firebox. I plan to make a sleeve to fill in the air gap at some point. If I make more I will make a template in cad software to make it perfect.

 

[seenred]

That's an interesting, outside-the-box idea S speedmetal

I'm definitely interested in hearing and seeing how that setup performs! First that went through my mind was, it might be difficult to keep temps down to low-n-slow range...but that's a total guess. chopsaw 's idea of a diffuser plate could mitigate that considerably. Please let us know how it works!

Red

 

[speedmetal]

I would also make them a bit more narrow in the future. That way they can fit between the grate supports. I removed two of them in the process of installing this since I decided to make the connection 15" wide. Nothing some sheet metal and rivets can't fix though.

 

[chopsaw]

it might be difficult to keep temps down to low-n-slow range..

I was also going to move the lid handle , and run a stack in its place . Center of the lid with the diffuser . Thinking heat would even out around the outside and back to the center and out .

 

[SmokingUPnorth]

Looks cool. I really like the cart the one kettle is on. Did you make that?

 

[speedmetal]

Still early, but holding temp well so far! Going to do a pork loin for dinner tonight.

 

[chopsaw]

Awesome .

I wanted the slot big for ease of removal

Yeah , I figured there was a reason . Wasn't dishing your cut at all .
Keep posting the results .

Funny . All my kettles that are dialed in for a long smoke like to run at 260 .

 

[speedmetal]

Funny . All my kettles that are dialed in for a long smoke like to run at 260 .

Yeah, this thing is chugging right along in that range. I am playing with split sizes and logs vs chunks as I go to see what does what. It is always fun to find out.

Pork loin went on seasoned with Lawry's, coarse salt, coarse pepper, chipotle powder, chili powder and is currently at 180~ for a bit so the cook doesn't end too quickly before it can get much smoke on it.

 

[speedmetal]

Well, that was delicious. Cubed it up and had it with white rice. The rest will make for fantastic meal prepping. Took about 5 1/2 hours and held temp quite well. Once I get better at managing the fire in the box and work out the perfect split size this thing will be a monster. I think some wings will be next.

 

[Redicans]

Pork Loins look Awesome!! Fun Project!

 

[seenred]

Nice! I notice the air gaps in the corners where it slides into the kettle. Was that intentional? After watching your first cook and thinkin' about it a bit, I'd say those "air gaps" might help keep temps more manageable. Allows some air flow into the kettle that's not wood-fire heated.

Red