My 100 gallon reverse flow build

[boomhower]

Boomhower,  I have a question....  the firebox to tank cutout......  It looks like the cutout fits perfect inside the radius of the tank end.....  How did you know where to cut the firebox to match the two different radii in the end of the tank  ???  I'm going to assume a compass scribe technique was used....    Anyway, it looks perfect to me..... 

I need to learn something today and you are my "go-to-guy" at the moment....  Dave

  To cut the firebox, you can see in the 2nd picture in post #16 at the bottom of the tank where I marked the firebox with a black sharpie.  I only cut the back of the firebox.  The top of the firebox remains intact and becomes part of the reverse flow plate/water pan.  You can also see in picture #1 of post #16 that the back of the firebox is not welded to the top of the firebox.  (Only 2 little tack welds)  This is because I knew I would be cutting the back off and didn't want to have to cut the weld seam there.

  The hard part was actually before that.  Laying out the lines on the curved end of the tank (smoke chamber).  That was tricky. 

   For that,I first used a framing square (too get the horizontal line of the cut when looking at the end of the tank (smoke chamber).   With the tank sitting flat on its casters on the (somewhat) level concrete floor,I marked the height of the cut and then used the framing square sitting on the concrete and marked the line around the curve of the tank in several places.  Then I connected the dots. 

  For the vertical portion of the cut, I simply measured from the weld seam (the welded seam of the main cylindrical shell of the tank to the formed "domes" on the end) to a point 2" (I think) up on the radius and marked it in several locations around the tank.  Then connect the dots for that line. 

   It wasn't perfect with the first cut, but once I had the main cut, I test fitted the firebox and marked where it needed more material removed on the tank.  Then grind the high areas down until you have a good fit. 

   I'm sure there's easier ways to do it, but that's what I did.

I also "cheated" and had drawn it up in CAD so that I got the area for the firebox to smoke chamber connection correct (according the the smoker calculator I found on this site somewhere).

 

[boomhower]

Firebox reinstalled to the smoke chamber and welded....

Welded on the inside, and the last of the bungs removed from the inside of the tank and ground down.....

 

[boomhower]

Cutout and fitting the reverse flow plate/ water pan....

Reverse flow plate is 1/8" thick plate steel.

Firebox end....

 

Opposite end....

I put a slight slope downward to the right (away from the firebox) and added a 1-1/2" lip and piped a drain on that end, but I don't seem to have any pictures of that....

 

[whittling chip]

This has got to be the fastest build I have ever seen....GETTER DONE!

You're really doing a outstanding job at fabrication. Too bad you didn't get to use the exhaust stack you planned on. I'm sure you'll come up with something great.

I love a lot of things, the pics, the quality, the CAD work. All is fantastic.

Thanks for sharing.

I sure hope you can cook as good as it looks!

Just kidding,

WC

 

[boomhower]

This has got to be the fastest build I have ever seen....GETTER DONE!

You're really doing a outstanding job at fabrication. Too bad you didn't get to use the exhaust stack you planned on. I'm sure you'll come up with something great.

I love a lot of things, the pics, the quality, the CAD work. All is fantastic.

Thanks for sharing.

I sure hope you can cook as good as it looks!

Just kidding,

WC

Thanks for the compliments.  Here's a little secret.  It's actually already done.  The build actually took me almost a year and a half.  (I have two kids under 4 years old that eat up a LOT of my free time.)

I'm simply posting this at the speed that my posts get moderator approved.

 

[whittling chip]

Can I make a suggestion?

Moderators, please give this man the room to work!

 

[dog1234]

Shoney that thing look great. I got lots of good ideas. Can you send me more pictures of it?

 

[boomhower]

Rolled up some 3/16" thick x 2" wide flat stock for the smoke chamber door flanges....

Welding them to the doors....

Door flanges done....

 

[jsoda17]

I was thinking the same thing, this guy moves quick! Excellent quality workmanship. Everything is very well done. I was watching the times the pictures were getting posted and was amazed by how quick you were doing things. It was making me frustrated by how slowly my build is going. Glad you filled us in!

 

[boomhower]

Here's the trailer frame all welded up with the axle (rebuilt) and test fitted....

Frame on jackstands.....

Smoker on the trailer.....

 

[boomhower]

Patching up the bung holes.  Welded in patches and ground smooth.

Firebox end.....

Opposite end...

 

[boomhower]

Chimney welded in....

Cooking rack guide rails welded in.....

Doors welded on......

and you can kinda see the 1.5" lip I welded on the reverse flow plate/water pan here.....

 

[alelover]

Looks great. Was it balancing on only those 3 jackstands?

 

[Dutch]

Great looking build you have going boomhower!  Looks like you have plenty of room to add some upper sliding racks in that thing.

Looking forward to the maiden smoke!

 

[boomhower]

Chimney cutoff parts....

Chimney cutoff done.....

Closed.....

Open...

 

[boomhower]

Looks great. Was it balancing on only those 3 jackstands?

Thanks.  Yes.  If you look at it, the jackstands are placed almost where the wheels support the trailer and the trailer jack goes.  Very stable at this point.  Also, this is an easy way to test what the tongue weight on the trailer is at this point. (Although I had already let the computer calculate it for me in the CAD system)

sq


Great looking build you have going boomhower!  Looks like you have plenty of room to add some upper sliding racks in that thing.

Looking forward to the maiden smoke!

Thanks.  Yes, I might add some more racks later, but my initial thoughts were without the upper racks, I might be able to squeeze half of a small hog in there for a large party.  I haven't decided yet.

 

[barnesski1]

Awesome Build!!  Keep it coming!!!

 

[boomhower]

Entire smoker bead blasted & painted, door seals installed, and meat racks done.....

Racks out....

 

[boomhower]

Firewood box....

Firebox ......

Hatchet handles.....

Ready for a fire....

 

[jsoda17]

Sure you made that?? Looks awesome! Most professional smoker manufacturers dont have products that look that good. Very impressed. Also feeling quite embarrassed of my build quality in the thread below. Looking forward to the next batch of photos.