My first attempt at a build.

[kam59]

Here is a pic of my grill it is 20" x 36". I put inset handles on it.

photo213.jpg

• kam59
• Jun 21, 2017

 

[12ring]

Thanks for the pics Kam. My grate will be 18.5" X 37". Do you think the angle still needs to be 1/4"? If so that's fine I'll do it. I just didn't think there was anyway it needed to be that thick.

I got the CC and FB back from being blasted. They look awesome. Should make it easy to paint after I'm done. I also ordered the circles for the end pieces. Ordered the square tubing for the frame and also the flat bar for the door flange. It will all be ready this Friday.

I think all I need now is the pipe for the stack, angle for grates, expanded metal and some scrap to build the plenum. I can't wait to get it done already.

http://s666.photobucket.com/user/Finegans4/media/IMG_3115_zpsfodftlz4.jpg.html

 

[kam59]

You will be fine with the 1/8" just be careful when welding the expanded to the frame it will want to rack or bow on you just jump around as you tack it down.

 

[kam59]

Nice work on the blasting. :)

 

[12ring]

Getting closer. But I should have listened to Kam and went with 1/4" angle for the grates. 1/8" seems a little flimsy. Oh well it's done now. Going to have to make it work.

http://s666.photobucket.com/user/Finegans4/media/IMG_3131_zps1kduwma3.jpg.html

 

[kam59]

The frame will be fine. Just get some 1/2" hot roll to use as bracing underneath spaced equally out. As I mentioned when you weld out the expanded metal move around as to avoid the grate moving on you from the welds drawing the metal.

 

[12ring]

IMG_3154.JPG

• 12ring
• Jul 3, 2017

So I cut the top and bottom and sides of my CC door. I left. The corners uncut. I'm not even sure why I left the corners other than I seem to remember a video I watched a long time ago that said to weld on the hinges before finishing cutting out the door so you keep it lined up straight.

I think my door is going to spring a little and I'll have to bend it some. My question is, should I finish cutting the door out completely or weld hinges on before? Kinda seems like a dumb question because if the door springs, the hinges won't allow me to get it bent back.

 

[kam59]

I would cut out the door and deal with any tweaking on my welding table. Sometimes having the door attached and having to get forceful with it results in damaged hinges.

 

[12ring]

Ok thanks.

 

[12ring]

IMG_3156.JPG

• 12ring
• Jul 3, 2017

The door sprung a tiny little bit. Not bad at all.

 

[brnhornt]

Nice!

 

[12ring]

I'm using a 4" inside diameter smoke stack and making a plenum. When I cut the hole on the side of the cook chamber, do I cut a 4" circle or go ahead and cut a square the size of the plenum?

 

[daveomak]

Match the plenum....

 

[kam59]

I slightly over size my hole because I build the plenum so that I have a weld base at top. My 6" exhaust on my 24" sits on a 6" tall x 7.5" wide plenum making my cut out on my chamber 7" x 5.5".

 

[12ring]

IMG_3170.JPG

• 12ring
• Jul 4, 2017

Got some more done. I cut the football opening from FB to CC, did some grinding to make the circles fit. Getting closer. The plenum and air intake have me worried though.

 

[kam59]

IMG_3170.JPG

• 12ring
• Jul 4, 2017

Got some more done. I cut the football opening from FB to CC, did some grinding to make the circles fit. Getting closer. The plenum and air intake have me worried though.

Looks very nice. :) What are you worried about?

 

[12ring]

Just worried that I'm going to make it right and have the right draft. Last thing I want to do is build it and then it doesn't draft very good.

 

[kam59]

You say you are using 4" pipe as your exhaust. It is probably 4.5" O.D. Make your top plate 5.5" x 5.5" This will give you a 1/2" around the top to weld out. Your top and bottom horizontal cut in the chamber will be 5" if your'e using 1/4" material. Left and right vertical cuts can vary a bit but you want at least 4" tall.  For 4" the bottom plate will be 5.5" x 3.5". Back top plate 1.5" x 5.5". This leaves you with your angled plate being something like 5.5" x 3.25". Something like this. 

001.jpg

• kam59
• Jul 4, 2017

 

[12ring]

Thank you for the plenum drawing Kam. I made one out of poster board so I can see how it will look. Plus it will shiw me hiw much metal I need for it. Then I can trace it out to make my cuts.

Only issue I have now is conflicting reports on stack length. Feldon's calculated says for a 4" stack it needs to be 20.5" above the CC. Others have suggested it needs to be 34" above. There's people that like the stack intake at the top of the CC but I've read people saying it's better at grate level. So what's everyone's opinion on that as well?

Here is a pic of my makeshift plenum and a stack that is 26" above the top of the CC

IMG_3172.JPG

• 12ring
• Jul 5, 2017

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IMG_3173.JPG

• 12ring
• Jul 5, 2017

IMG_3174.JPG

• 12ring
• Jul 5, 2017

 

[kam59]

You could go between 20" and 24" in my opinion. If you like the looks of 24" go there if you like the 20" it will work. 34" is too tall for 4" in my opinion.

As for the plenum placement I prefer my exhausts as hid as I can get them. If you are not planning on a top grate I would move it up to when the left and right corners are 1/2" from the edge this will allow weld surface. If you plan on a top grate position it to where maybe just the top portion will be covered by the grate rail. You are away from the wall anyway's so the flow disruption from your grate rail will be minimal.