i just built a smoker out of a 55-gallon drum (barrel).
i cut my door out with a plasma cutter. i welded flat stock (2" wide) along the top and bottom of the door opening (wire-feed). i then made my food rack by welding a frame out of 1" angle iron, and welding expanded metal in it for the rack itself (arc welded). i used 1" square tubing for legs, with the same for front to back leg support (wire-feed). i welded the legs to 4" square flat iron pieces (wire-feed) and used 2 SS 5/16" allen head bolts (with stainless washers and nuts) to hold each one the the drum. i used 2" angle iron to make my firebox support. i bought a firebox from lowe's ($55, Char-griller brand). i made a cover for the hole in the firebox (where it mounts to the char-griller grill) and welded (wire-feed) 2- 3" diameterx4" length pipes on it. i used the plasma cutter to cut the plate from inside the holes. i welded (wire-feed) the pipes to the end of the drum, cutting out from inside the pipes again (plasma cutter). that is how the heat and smoke gets in the food chamber. i used a sawzall <sp?> to cut a 4" diameter hole on top for the smokestack. i bought a 4"x24" "pipe" from lowe's, along with a 4" rain shanty- that is my smoke-stack. it is not heavy pipe. galvanized vent pipe type stuff. i bought a thermometer from academy for $8- old smokey brand; 2 1/2" diameter. i robbed the handle off my old char-broil lp grill. i already had the hinges for the door. i used the same kind of ss bolts/washers/nuts for the hinges that i used on the legs. i replaced all visible bolts on the firebox with the same kind. (i am ocd, and anal about all bolts and such matching if at all possible.)
i am going to add a shelf to the front as soon as feasible. i am going to put a heat deflector on the firebox end if it needs it.
simple, i have $80 in it (the firebox, smoke-stack, thermometer). i got all the metal, and drum, from work. i will get another drum when i can and make a burn barrel (for my wood). for the burn barrel, see this link:
http://www.smokingmeatforums.com/viewtopic.php?t=661
i will post pics in the charcoal section, in my thread on making it, as soon as the camera gets back home.