Red's Newest Build: A Direct-Heat Smoker/Grill

[seenred]

Well, time for an update!

I got back in the shop today, and made decent progress.

First off today, I started fabricating a flange for the top of the cabinet opening. Just tacked in place here:

I was happy with how it was all fitting up, so I went ahead and welded it out, then had to spend a while with an angle grinder and flap disc, making all the fitted edges and corners smooth. There will be a matching flange on the door assembly. There'll probably be some Nomex gasket between the two flanges to seal it up nice and air tight.

You can see a notch I cut out of the front-facing part of the flange. That's to allow the cooking grate to slide through.

To ensure that the door assembly and the cabinet flanges match up perfectly, I built the door frame in place on top of that cabinet flange.

Just tacked together here, then I'll move it over to the welding table to weld it out.

Door frame all welded out. Again, I ran a flap disc over all surfaces where it matches up with the cabinet flange...and where the outer skin of the door assembly will be welded to the frame.

Test fit. It matches up with the lower flange real well!

And just to get an idea of what it'll look like when I get the outer skin all welded to the door frame, I laid the top panel in place.

Last thing I worked on today was the FB access door. Got it all framed out with 1 1/2" flat bar. I forgot to get a pic of it, but I did test fit it in the door opening, and it fits good

This build is moving along faster than I expected! I've still got a bunch of little jobs to complete, but I don't think it'll be long until I can build a fire in it!

Still on the To-Do list:

Get the door assembly skinned out; Make a cut in the top of the door assembly and install an exhaust stack and damper; Cut out the openings for the intake dampers in the side of the lower cabinet, and get those dampers installed; Fabricate a bunch of handles (CC door, ash pan, coal basket, cooking grate); Fabricate a handle and latch system for the FB door; Weld on the hinges and get the doors hung; Build a cart and mount it on casters; Install a thermometer; Build a FIRE!!

That's all for tonight - it won't be long now!

Red

 

[speedmetal]

Looks fantastic! Definitely looking forward to more. If you ever want something laser cut feel free to hit me up. Handles, caster plates, standoffs, logos. I have access to metal, lasers and entirely too much interest in fabrication and cookers.

 

[DRKsmoking]

David, if I'm really gonna sell it, I wish I could figure out a way to get it to you that wouldn't cost more than the smoker costs LOL!

I know there are several pit builders here in the lower 48 that sell something similar...but I don't know any Canadian builders...but there are sure some guys up there who do it!

Thanks Joel, it would be nice . I have a feeling that you might keep this one in your stable with your other working smokers/cookers.
And it would be nice to own one of your masterpieces, as the other 2 that i have seen and heard the reviews about make them winners. I would be a lucky person. But I know that is just dreaming on my part. I know when I decide to get a unit like the one you are building. I will find one closer to home. As the shipping would end up being probably the same as the build.

It is a pleasure and fun to watch a great build in progress.

David

 

[seenred]

Looks fantastic! Definitely looking forward to more. If you ever want something laser cut feel free to hit me up. Handles, caster plates, standoffs, logos. I have access to metal, lasers and entirely too much interest in fabrication and cookers.

Appreciate the kind words sir...and thank you for the offer! Its a shame you're so far from me - or I might just take you up on that! I do need to cut out some caster plates and some handles from scrap plate, but I've got plenty of scrap laying around, and it just take a little more time to do it by hand. I have a hand held plasma cutter, which helps some on cutting odd shapes.

Thanks Joel, it would be nice . I have a feeling that you might keep this one in your stable with your other working smokers/cookers.
And it would be nice to own one of your masterpieces, as the other 2 that i have seen and heard the reviews about make them winners. I would be a lucky person. But I know that is just dreaming on my part. I know when I decide to get a unit like the one you are building. I will find one closer to home. As the shipping would end up being probably the same as the build.

It is a pleasure and fun to watch a great build in progress.

David

Thanks again David! And you may be right - maybe I'll end up keeping this one after I use it. But if it stays, something else will have to go LOL! I keep all my cookers in the garage...and I'm out of space! Plus, the only way I continue to fund this hobby is by recouping the money I spend on materials when I sell it. It is never my intention to make a profit selling these pits - just get back what I've spent so I can afford the next project!

Red

 

[Brokenhandle]

Coming along nicely Red! And DRKsmoking I think all you need is a welder and some fabricating tools and you could follow seenred step by step builds!

Ryan

 

[DRKsmoking]

Coming along nicely Red! And DRKsmoking I think all you need is a welder and some fabricating tools and you could follow seenred step by step builds!

Ryan

Ha Ha , thanks Ryan . I could follow but not sure if they sell enough grinder wheels around here to clean up my pretty welding work.

Maybe I will fab a few out of wood. It could be a one time smoker/cook type of deal. LOL

David

 

[seenred]

Coming along nicely Red! And DRKsmoking I think all you need is a welder and some fabricating tools and you could follow seenred step by step builds!

Ryan

Good mornin' Ryan! Thank you sir!

Red

 

[JC in GB]

Really coming along nicely. I envy your machine shop. Would love to have a set-up like that. Eagerly anticipating the pics of your finished unit.

JC

 

[seenred]

Really coming along nicely. I envy your machine shop. Would love to have a set-up like that. Eagerly anticipating the pics of your finished unit.

JC

Thank you JC! It has taken years to acquire all that stuff on a budget. And the shop itself is very spartan...just a little 20x20 uninsulated metal building. It's nothing fancy, but it was what I could afford at the time. But I'm proud of it!

Red

 

[seenred]

End-of-the-week update!

Made more progress the last 2 days. I'm to the stage in a build where most steps go pretty slow. Lots of fabrication of small, hand-made parts that just take time to get right.


I finished framing out the main door.

Then started tacking the skin on the door frame.

All the skin of the door is tacked together.

Test fit the door assembly with the main cabinet body. Fits pretty good!

Since I'm pretty happy with how it's fitting up, I'll be ready to fully weld out the door assembly next time I'm in the shop.

Then I started working on fabricating handles. I bent some 3/8" round bar to make a pull handle for the cooking grate.

And I used civilsmoker 's idea and used a short piece of 1x1" angle iron to make a pull handle for the ash pan.

Next I fabricated a handle for the main door, with a cool touch spring handle.

I'm not ready yet to weld it to the door yet, but here's about what it'll look like when it's welded on the front of the door.

Only handles left on my To-Do list are handles for the top of the coal basket. I haven't figured out yet if there's enough clearance on the top cooking rails to do these handles - I'm still studying that one...

That's all for tonight - more to come!

Red

 

[civilsmoker]

Nice finishing work! That handle looks as though you were inside my head!!! lol.

Can’t wait for it to sizzle

 

[seenred]

Nice finishing work! That handle looks as though you were inside my head!!! lol.

Can’t wait for it to sizzle

Thanks Brother! And if you were channeling the design of the handle to me, thanks for that too lol!

It won't be long til I'll be ready to build the first fire in it! I have a pretty full day of welding left to do - all the door seams, and some outside corner welds on the main cabinet body...then cutting some vents and mounting the hinges, and I think it'll be ready to test!

Red

 

[Winterrider]

Looking good, Can't wait until you fire it up

 

[seenred]

Looking good, Can't wait until you fire it up

Thanks man! Looking forward to it myself!

Red

 

[DRKsmoking]

Coming along at a fast trot now, I can smell some quick chops happening very soon.

Great work Joel

David

 

[seenred]

Coming along at a fast trot now, I can smell some quick chops happening very soon.

Great work Joel

David

Thanks David! Chops...wings...party ribs...can't decide what to do first! I'm thinkin' something hot n fast for sure!

Red

 

[DRKsmoking]

Thanks David! Chops...wings...party ribs...can't decide what to do first! I'm thinkin' something hot n fast for sure!

Red

I think you decided ...... all three, HOT Fast and tasty lol

David

 

[sandyut]

WOW that looks great! Amazing work!

 

[Rafter H BBQ]

That is looking real nice buddy. You are definitely going to have a very nice cooker there. I can almost smell the ribeyes cooking now!

 

[seenred]

WOW that looks great! Amazing work!

Thank you David!

That is looking real nice buddy. You are definitely going to have a very nice cooker there. I can almost smell the ribeyes cooking now!

Justin! What's up Buddy! Thank you my friend! Yep - ya know I love some ribeyes! I'm hoping this thing will be able to get screaming hot with the coal basket raised up right under the grate!

Red