Woody - My first BBQ Smoker Build

[Mechanic of Smoke]

Thank you!
I'm so glad you're so enthusiastic about the smoker.

 

[Abigail4476]

Hey guys,
On various trips to different corners of the USA, I became increasingly addicted to BBQ.
I love to cook myself, and I enjoy working with metal both personally and professionally.
This led to my desire for my own smoker.
Having already experienced the quality and flavor of BBQ in the States, it was clear:
I needed a smoker that could offer the same level.

Below, I'd like to shed more light on the story behind its creation and the highlights of the finished smoker.
After a lot of research, the plans became more concrete.
A complete CAD model was created, accurately depicting many details.
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But even here, it became clear that every element required further research.
The calculation principles from @daveomak were a great help, and virtually all dimensions are based on these rules.

Standard Reverse Flow Smoker Calculator... by DaveOmak and others... Ready to use.. rev5.. 6/19/15.

Here's to "Alien BBQ" and the folks that first put the calculator together and "1728 Software Systems" for this great "Circle Calculator" and all the folks at "SmokingMeatForums", with a special shout out to Ribwizzard, that contributed their ideas and feedback while this thing was coming...

www.smokingmeatforums.com

Reverse Flow Smoker... How to calculate build tutorial...

> Reverse Flow Smoker... How to calculate build tutorial... By DaveOmak This is a tutorial and you will need a calculator and paper to note desired dimensions... This tutorial has been proven to make an excellent operating Reverse Flow smoker... Here's to "Alien BBQ" and the folks that first...

www.smokingmeatforums.com

Since building a smoker was completely new territory for me,
I often had doubts about whether I was still on the right track.
The sheer number of reports and videos didn't make things any easier.
But after careful consideration, you just have to go for it!

So, I started with the first work on the pipes.
Wall thickness 10mm (~3/8") - Diameter 500mm (~19 1/2")
I had the sheets laser-cut, after deburring, I could begin the first welding work.
I welded the thicker sections using MAG, and the more delicate work using TIG.
Below are a few pictures from the construction phase.
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Now I'd like to highlight the smoker's features.
The firebox has a very sturdy grate.
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The top is also flattened to allow for preheating wood or heating a pot.
This flat surface is heated directly by the fire and isn't just placed on top.
And of course, the matching poker is a must.
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From a mechanic's perspective, the adjustment mechanism for the two air inlets is certainly a highlight.
As described by @daveomak, one is at the top and one at the bottom.
Both are positioned as close to the wall as possible, extending laterally.
They are also infinitely adjustable and can be completely closed.
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The door latch features a fold-out catch.
This allows you to control ventilation (heating up) by opening the door.
When not needed, it simply disappears and is out of the way.
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An unexpected challenge was... Wooden Handles.
I had no concerns about finding a woodturner for the handles.
I live in the Bavarian Forest, where working with wood is commonplace.
However, no one could or wanted to make these handles.
After a long search, I finally found a woodturning workshop that did a very good job.

The wood comes from an American walnut tree, which I thought was very fitting.
I also really like its appearance, and it's weather-resistant.
I treated it with Timberone to ensure it lasts as long as possible.

Speaking of the handle, it's free-spinning and ball-bearing mounted.
The side table is made of the same wood and is removable.
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Another unexpected challenges was the grate.
While readily available in almost every hardware store in the States, flat-rolled expanded metal mesh in the required thickness isn't really available in Europe.
Ideas for buying and importing a large board, I quickly dismissed.
After a lengthy search, I found a supplier in the UK and ordered it from there.

There are a few more details inside the smoker.
- An additional rack or, alternatively, a steel plate can be inserted in the upper section, which also has space for a water pan.
- A drip bar is mounted on the inside of the lid to prevent condensation from escaping.
- A Tel-Tru thermometer is integrated into the lid, with its probe positioned approximately 3cm (~1 1/5") above the rack, which is roughly in the center of most cooks.
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- There's also a small barrier to prevent liquid from running into the fire.
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- A permanently welded threaded fitting, covered with a malleable cast iron fitting, serves as a drain.
It also has a hook for holding a bucket.
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On the left side, behind the removable table, are three openings for sensor cables.
They have the same malleable cast iron design as the drain.
A modified seal is used...Wine corks.
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The chimney is foldable, allowing for the use of a more compact cover.
The connection point has a groove for a stove sealing cord.
A damper is also installed, as well as a scale indicating the percentage of remaining airflow.
German Overengineering :-)
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The firebox is coated with avocado oil, the cooking chamber with linseed oil.
Oxyblocker-S was used for areas that remain relatively cold (frame, table frame, etc.).

Last but not least, the name.
Since "Smokey" seemed too unimaginative
We've chosen the second most unimaginative one.

"Woody"

Besides, Woody from Toy Story is a great character :-)
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The first test run was recently, and we made pulled pork.
After a bumpy start, the temperatures were relatively easy to control.
They are easy to manage, and the smoker is running quite efficiently.
I think this is a very good result, considering that the outside temperatures are currently around freezing and the weather isn't very consistent.

All in all, I'm very happy to finally be able to complete the project.
I'm also very pleased that all the assumptions and research led to the correct proportions.

At this point, a huge thank you again to @daveomak, who left behind a fabulous collection of knowledge here.
Rest in peace.

Also, thanks to YouTube channels like https://www.youtube.com/@mysticsmokers3014 and https://jgbbq.com.au/offset-build/ for further valuable input.

Wow, this is amazing