The rebuild begins. New Braunfels bandera. Update at top with pic

[radio]

Finally got most of the rebuild done. Still need to make a new wood shelf, charcoal basket and paint the front door and seal it a bit better.


 

Picked this one up off of Craig's list for $20.  It was left outdoors uncovered and rain mixed with the ashes in the firebox slowly eating a hole in it.  A new sheet of steel, some welding rods, elbow grease and hi temp paint will have 'er going again in no time

I had been wanting an electric smoker for Bear's beef logs, but I think this baby will be just the ticket.

I'm thinking of just welding the FB to the CCand welding the gaps between the bottom of the CC and the bottom edge of the uprights.  If you look closely at the bottom of the CC directly above the belt sander, you can see a gap.  I could use silicone I suppose, but think welding would be the best route

Anyone have experience with modding these?  I will build a baffle of some sort over the heat inlet, but doubt if I ever use a water pan in it

Didn't even get it unloaded before I started working on it :-)

Update:

Finally got most of the rebuild done. Still need to make a new wood shelf, charcoal basket and paint the front door and seal it a bit better.

After a thorough cleaning inside, I sprayed a liberal amount of PAM on everything and fired her up to re season. The fire brick will go in the bottom of the cooking chamber, but for now makes an ideal weight to hold the fire box lid down snug to form fit the stove rope I used as a gasket.

I have the horizontal New Braunfels going in the background smoking some more Jalepeno and Cheddar beef logs  A La Bear Carver.
Would love to have used the vertical, but didn't have her seasoned in time. Looks like temps are going to be pretty easy to control now that I have all the factory installed gaps sealed up

bandera1.jpg

• radio
• Jun 26, 2015

 

[pc farmer]

I have heard great things about them smokers. Looking forward to the rebuild.

 

[radio]

I have heard great things about them smokers. Looking forward to the rebuild.

Thanks.  The steel isn't as thick as my horizontal offset New Braunfels, but it was a chore to load!  I'm kind of thinking this one might take a bit bigger fire, but will have to do a test run anyway to re season it after it gets a thorough cleaning inside and out.  I will also build a charcoal basket for the FB and maybe put fire brick on the bottom of the CC

 

[pc farmer]

Sounds like a plan

 

[radio]

Started tearing it apart this afternoon and the rust was worse than I thought.  The entire bottom of the FB will be replaced and fresh metal overlaid on the sides and end 6 to 8 inches high.  The air inlet damper/louver is too badly rusted to reuse and is no longer available.  Not sure how I am going to fashion one to control air flow.

 

I also discovered the door hinges had seized up at some point and someone had tried to force the door open and broken them at the weld.  They had then bolted on a couple of dinky hinges which were not letting the door fit properly.  It took me over an hour using lots of penetrating oil, vise grips, nail bar and a 4 pound hammer to get the old hinge pins freed up.  I will lay the CC down and align everything up as it should be and weld the hinge pins back on the door

On the positive side, the CC is in pretty good shape with only light rust in the bottom..  before going back together, everything will get power washed, seams welded, painted and new bolts as needed.  I'm seriously considering welding the FB to the CC instead of bolting it back on

If anyone has any hints or tips to make this thing better before it gets reassembled, post 'em up

 

[radio]

Spent about 4 hours this evening cutting, welding and sanding.  Discovered one of the square tubes is toast and will have to be replaced.  Firebox is at the neighbors who has a cutting torch so he can cut some new steel to scab onto the bottom and sides of the FB where the rust ate through.

There was a pretty good gap all the way around the bottom of the CC, so I welded a bead all around to seal it.  Figured that was better than silicone.  Tomorrow I will weld the hinge pins back on the door, sand the CC and get it painted and possibly get the stove rope around the door if I have time.

Thinking the FB lid really needs a flat piece of steel welded in so the heat doesn't congregate at the top so much and make a smoother transition into the CC.  Not sure what to use to help seal the gap between the lid and the FB.  Might try some of the stove rope and hope it don't burn out

Has anyone tried a perforated heat baffle above the FB inlet on a Bandera?  I was going to make a deflector extending to about the center of the CC, but a baffle with graduated size holes might work better

Still pondering how to make a new adjustable air inlet for the FB.  any ideas are appreciated

 

[pc farmer]

Sounds like it is in rough shape. At least you have the knowledge and skills to bring it alive.

 

[radio]

The firebox is reinforced on the outside with 3/16 steel on bottom and sides and on the inside at the back where the heat outlet is.  all the gaps around the bottom of the CC are welded, so no air leaks to deal with.  I also welded the gaps at the corners of the FB where the metal was bent at angles.

Still trying to figure out a decent solution for the FB inlet damper as the original damper is toast.  I picked up 2, four foot sections of steel strap, so may be able to fabricate something using those.

Still looking for opinions on using a perforated heat baffle like the pic above rather than just using a piece of steel as a deflector

 

[wade]

I too have a Bandera that has given me great service over the past 15+ years. Keep at it - they are lovely smokers

 

[radio]

 
I too have a Bandera that has given me great service over the past 15+ years. Keep at it - they are lovely smokers

Thanks.  Have you made any mods to yours?

 

[wade]

To be honest no - other than making a better seal around the fire box lid. I will get round to replacing the missing wooden "table" this summer though. The steel in the bottom "shelf" by the wheels has rusted through in one spot but I am not too worried about that. I was looking to fit an automatic temperature regulator on it though, but that may not be till after the summer.

 

[radio]

Didn't get it finished for a smoke tomorrow, so the pork butts go in the horizontal

It's mostly reassembled and got it over half painted before it got too dark to see.  Got a FB air inlet damper made but still need to weld in a plate in the FB lid and make a heat deflector for the fb opening.  Most of the grunt work is done, so things will go pretty quickly now.  Cant wait to fire her up for re seasoning and temp checks