Mailbox mod question

[hinds90]

I have a rangemaster electric smoker and will be doing the mailbox mod this weekend. My smoker doesn't have the hole for the chip loader. How would you guys go about cutting and setting the hole up for the duct with the double walls?

 

[cmayna]

A hole saw to make the hole. I would then get some aluminum ducting which would match the diameter of the hole or something near it.  This would then line the hole.

 

[tallbm]

I have a rangemaster electric smoker and will be doing the mailbox mod this weekend. My smoker doesn't have the hole for the chip loader. How would you guys go about cutting and setting the hole up for the duct with the double walls?

You are kind of in luck that I've looked into this kind of thing before.

I personally would buy this 3" exhaust flange:

https://www.carid.com/walker/flange...kD3xMav0W3sFg6YS1ucd-682PBEgyiXEaAhinEALw_wcB

3inchFlange.png

• tallbm
• Jul 28, 2017

I would cut my hole, insert the flange, sheet metal screw the flange lip to the smoker, then use 600F RTV High Temp food save silicon to caulk the edges of the smoker and the flange so it was sealed and air/water tight .  

Then it would be ready to have the 3" elbow joint of my mailbox mod ready to insert into the flange hole.

This way you have a completely food safe sealed system and you could always jury rig up a plug to close the hole should you decide to detatch the mailbox mod.  

I hope this info helps :) 

 

[hinds90]

Would a galvanized 90 degree elbow for the connection between the mailbox and smoker be okay?

 

[redoctobyr]

People seem to prefer avoiding using galvanized parts when possible. Certainly by the time the smoke leaves the mailbox, it shouldn't be very hot, and would therefore be unlikely to cause a problem.

But if something unexpected happened, like the pellets started burning, instead of smoldering, it's possible the temperatures could climb enough to make the zinc on the galvanized elbow become a health risk.

I just ordered a toolbox, to try and do a "mailbox" mod. The toolbox isn't galvanized, unlike most steel mailboxes. I'm going to try and find aluminum duct components if I can, to avoid using galvanized parts.

With that said, I'm sure plenty of people use galvanized duct components, and it's probably fine. I'd just feel better avoiding it.

Not sure what size duct you're using, but Amazon has 3" 90-degree aluminum elbows, including this one for $7 shipped with Prime:


I had an easier time finding 4" 90-degree aluminum elbows on HD and Lowe's sites. But Home Depot would ship this 3" one ($4.50) to my store, for pickup:

http://www.homedepot.com/p/Speedi-P...Degree-Adjustable-Elbow-EX-26A90-03/202907324

 

[hinds90]

Cut a hold on the bottom instead to get around cutting into the double wall on the side. Probably would have took the same amount of time but this should work just as good.

20170729_175821.jpg

• hinds90
• Jul 29, 2017

 

[pagraybeard]

0729171943.jpg

• pagraybeard
• Jul 29, 2017

This is my mailbox mod on an old little chief. I cut my hole in the lower back.
I like hinds90s idea of the bottom if you can

 

[tallbm]

Cut a hold on the bottom instead to get around cutting into the double wall on the side. Probably would have took the same amount of time but this should work just as good.

20170729_175821.jpg

• hinds90
• Jul 29, 2017

Looks good.  Just ensure you don't get meat drippings going into it.

I look forward to seeing how it all turns out and I look forward to seeing your first smoke with it all :)

 

[hinds90]

I still have to run to Walmart tomorrow to hopefully get a steel mailbox and a short amount of ducting to connect the 2

I Have a pork shoulder seasoning overnight just not sure what I'm going to use to smoke it. I also finished up my mini Weber smokey mountain and really leaning to using that it.

20170717_192759.jpg

• hinds90
• Jul 29, 2017

 

[dr k]

Cut a hold on the bottom instead to get around cutting into the double wall on the side. Probably would have took the same amount of time but this should work just as good.

20170729_175821.jpg

• hinds90
• Jul 29, 2017

You can use a T sideways instead of an elbow so grease can drip into a soup can with water in it when slid over the bottom of drain part of the T and smoke can come in at a right angle to cover both grease and smoke. A little water in the can seals the joint between the can and T, keeping all air coming in through the smoke part of the T.
-Kurt