Making a smoker.

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Hey everyone, decided I would do a nice project to keep me busy. I have been semi smoking ribs on my BBQ for a while and I think whats holding me back from the "fall off the bone results" is not using real indirect heat. I have been looking at other folks smoker projects and they look amazing. Im just a dumb pipefitter (wanna be welder) so bear with me, lol. If you have any tips or lessons learned from your projects PLEASE say something.I recently picked up a Syncrowave 180SD about 2 weeks ago and it really has gave me the bug to try and come up with some projects knowing I can weld any metal my garage can handle, lol.. I have a had a Miller Dialarc 250 for about 3 years, and have had a Maxstar 150 STH for a year or so, but Im starting to collect welding machines, LOL. I like the 180 because of the AC TIG welding features, and is the real reason I bought it. The maxstar is just an amazing machine and can weld just about anything DCEN a hobbiest would ever ask of it (highly recommended).But on to the smoker. After looking at a ton of production smokers and home made projects, I decided to go with a real simple "classic" style. Not just because of the tried and true design, but also it seemed very simple to replicate. Here is the basic design on MS paint. Its 12 gauge steel rolled at a local metal supply (S&K steel in Sacramento, look them up they are real great). The smoke box is a tad over 13" diameter and was the tightest they could roll steel sheet, but its perfect for what I need it for. The main BBQ body is 20" diameter X 3 ft length.Here is the pieces back from S&K steel. And I flapper wheeled the edges and tacked the smoke box. Here is as far as I got tonight. Welded the seem on the smoke box and ghetto laid out the end caps to cut out.Tell me what you think!!
Reply:Don't put a pipe between the firebox & smoke/grill chamber.  You will lose too much heat & will use a lot more fuel.  Most of the offset smokers have the firebox welded directly to the end of the cooking chamber.Go here http://www.thesmokering.com/forum/vi...b0d772255fefea & look for offset smoker's.  There's lots of info there.Here are a couple of calculators to determine the size of your firebox to cooking chamber.http://webpages.charter.net/tomchism...alculators.htmOtherwise it looks like you have one heck of a start.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by MarkBall2Don't put a pipe between the firebox & smoke/grill chamber.  You will lose too much heat & will use a lot more fuel.  Most of the offset smokers have the firebox welded directly to the end of the cooking chamber.Go here http://www.thesmokering.com/forum/vi...b0d772255fefea & look for offset smoker's.  There's lots of info there.Here are a couple of calculators to determine the size of your firebox to cooking chamber.http://webpages.charter.net/tomchism...alculators.htmOtherwise it looks like you have one heck of a start.
Reply:Here are a few more ideas on your smoker:Most of these are self explanatory.  I built a Upright Drum Smoker a few weeks ago & it turned out nice.  Your's looks nicer though. Attached ImagesMarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Here are a few pics that match the last drawing. Attached ImagesMarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:I ran some calculations (using the calculator link) & came up with the followingCook chamber = 3768 cu in (20"x36")Firebox = 2122 cu in (13"x16")  I guessed at the length of the fireboxUsing the 1/3 rule (Firebox should be 1/3 the size of the cook chamber) = 1254 cu inChimney size should be 3"x15.02"Air intake should be (if you want 4) 1.5", if you want 6 air intakes should be 1.25"Then you just need to weld the firebox to the cooking chamber once you have sized it to 16.98 sq inches.Show us your build pics & how things turn out.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:That's a real nice set-up there, MarkBall2!  I know this isn't considered a tradional "smoker", but it works really well. It's not nearly as nice as your fellas, but I'll share it anyways. heck,even for a laughI throwed it together about 5 yrs ago. The bottom of it is an old S.S. 3-bay sink(freebie), the racks inside are made of 1/2" sq. bar / expanded metal. The hood is bridgin angle / 9/16" decking.   Havin some wings with 'taters and onion. I use wood only, mostly cherry, walnut,oak and hickory. Ain't bought charcoal in 15 yrs.http:// Attached ImagesDon't let that iron in your lungs, turn to lead in your @$$!!!!
Reply:Ironman, that looks pretty good too.  The smoker photos above aren't mine, I got the ideas from The Smoke Ring.  Mine is only a upright 55 gallon barrel on wheels as there are only the two of us here.  Use of scrounged materials is what it's all about.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by IronmowerThat's a real nice set-up there, MarkBall2!  I know this isn't considered a tradional "smoker", but it works really well. It's not nearly as nice as your fellas, but I'll share it anyways. heck,even for a laughI throwed it together about 5 yrs ago. The bottom of it is an old S.S. 3-bay sink(freebie), the racks inside are made of 1/2" sq. bar / expanded metal. The hood is bridgin angle / 9/16" decking.   Havin some wings with 'taters and onion. I use wood only, mostly cherry, walnut,oak and hickory. Ain't bought charcoal in 15 yrs.http://
Reply:I love the smoke ring website.  I have learned a lot from them and have built several smokers as well as fixed a couple.
Reply:A few new pics from last night. Got the smoke box ends cut out and one side welded on. Im gonna leave the other side off so I can weld some flat bar (that I still have to cut) in there for the firebox grate to rest on.
Reply:Awesome info MarkBall2!The tuning flaps are just what I need. I have been planning to build a small smoker for just two to four people. I currently own an old 1979 Weber model but I could only control the heat by counting the charcoal brick-etts and hickory chunks used in the lower fireplace -- very little control. And it usually averaged about 230 degrees which is too hot in my opinion. So I thought I would build my own with a way to control heat better. THANKS AGAIN!SteveJunkYard Tools .com
Reply:For good Que, 225-250 degrees slowly cooking the meat works the best.  Beef/Pork anyway.  Chicken/Turkey needs more heat about 300-325 to keep the skin from turning to rubber.Low & Slow is the motto for good fall off the bone Que.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Hey, got a new 720p HD video camera so I thought I would give it a wirl and see how it recorded. And it did very well actually. I thought because of the brightness of the arc it would wash everything out but it didn't.Here is a video of me doing a cover pass on my smokebox. The weld in the video is pretty subpar IMO, but its hard to weld and talk, and I took a long break to set-up the camera (excuses, excuses I know).Tell me what you think!!
Reply:Video above doesnt work anymore. Here are the video's I shot last night in order. I ended up getting the best results from no pulse and around 85 ish amps. Im pretty happy how it turned out, and Im really enjoying the time behind the hood.This one is HD, I don't know why the others aren't.
Reply:I only watched a small portion of the videos you've posted and quickly came to the following conclusion. Stop using the pulsing feature on your machine. Unless you've experimented with different frequency, pulse length, background current, and peak current setting, the pulsing feature will only add confusion to the whole mix. In order to create the nice stack of beads you're looking for, a certain rhythm is required, and if you're pulse setting are not spot on it'll only mess up your rhythm. If you really want to pulse, practice on some scrap until you achieve the look you really want. Otherwise, use your foot and your natural rhythm to create a nice weld.Good work on the smoker so far!
Reply:Originally Posted by TigWizI only watched a small portion of the videos you've posted and quickly came to the following conclusion. Stop using the pulsing feature on your machine. Unless you've experimented with different frequency, pulse length, background current, and peak current setting, the pulsing feature will only add confusion to the whole mix. In order to create the nice stack of beads you're looking for, a certain rhythm is required, and if you're pulse setting are not spot on it'll only mess up your rhythm. If you really want to pulse, practice on some scrap until you achieve the look you really want. Otherwise, use your foot and your natural rhythm to create a nice weld.Good work on the smoker so far!
Reply:Got some more pics from what I accomplished today. Welded in some support bars for the firegrate, and cut the firegrate. I cut it in two pieces so I can easily remove and replace it if I need to through the firebox lid.Whadayathink?
Reply:You're going to need to frame your grate to keep it from sagging when it gets hot. I used some 1x1x.125 angle on mine. Even still, it sags a bit in the middle, but not enough to make a difference.Miller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:Originally Posted by bratkid63You're going to need to frame your grate to keep it from sagging when it gets hot. I used some 1x1x.125 angle on mine. Even still, it sags a bit in the middle, but not enough to make a difference.
Reply:I'm really sorry that I haven't had time to look thru this.  My problem, not yours.  My bad.For some of the best built, most elegant() smoker/cookers.........look at some of the ones that Oldtimer has put up.Very simple, and very functional.He's got a tendancy to feel funny about his welds, bein' as he's retired.  But take a close look at the stick welds.  They are very good, and I mean very good.  His welds are the quality I'm aiming at trying to copy.  Good stuff.  Better than most I've seen on here.For cool stuff on the grill, design artsy stuff, there's another guy you might wanna look at.Gizzardguts, or something like that .  I have to go look up his name, but he's good, real good. I know the guy's posts, and they're good, but I can't think of his name.  BBL"Any day above ground is a good day"http://www.farmersamm.com/
Reply:that filler rod should be flying though your fingers when welding1/16 e70 rod dont use the pulselooking good what kind of vid camradid you use
Reply:Originally Posted by ed macthat filler rod should be flying though your fingers when welding1/16 e70 rod dont use the pulselooking good what kind of vid camradid you use
Reply:Originally Posted by bratkid63You're going to need to frame your grate to keep it from sagging when it gets hot. I used some 1x1x.125 angle on mine. Even still, it sags a bit in the middle, but not enough to make a difference.
Reply:I personally would be a little more concerned about a frame around the perimeter of the expanded metal than the support smack in the middle.  With a perimeter frame, you will develop a slight dip in the middle, but not enough to matter.  Without said frame, I am thinking the edges will start to sag down, significantly further.  Expanded metal, especially when heated, has very little strength of it's own, but when attached to a perimeter frame on all 4 sides, it suddenly becomes a much more sturdy.Who is John Galt?You are going to want to support the front & back side of that expanded also.  It will sag after your first burn.  Might wilt over 1/2 way to the bottom.If you make it out of small angle (1"x1") then a 3/8" rod down the middle - welded to the angle -  that will prevent the sag.  Then build your hot fire.  Your also not going to like the uprights in the center when you try to clean out the ash.  Now an ash door, air inlets & fire door, looks about ready to fire it up!!MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Here are some vids of me and my buddies screwin around. I told my buddy who is doing the TIG welding that I could do my side faster and better using crappy *** SMAW, lol. We were pretty even actually, I thought I would be much faster. Enjoy.
Reply:hope it turns out well, nice work so far. check out thesmokering.com for more info
Reply:Have the day off today and tomorrow (Army veteran here!) so more work continues on my smoker.Here, im welding my cooking chamber. Although I tig'd my firebox, I think it would take too long and cost too much (in argon) to do this in TIG. The only problem is the very thin 12 gauge steel, I have already blew 2 holes that I had to fill trying to weld it vertical up to flat, now Im running VERY cool at 72 amps with 3/32 7018 semi downhand. Its turning out so so. Im gonna grind it anyways and run a nice thick pass one there is more metal there.
Reply:Pic of 7018 weld. Not the best by any means. But I really feel I have to travel pretty fast to keep from burning through. Im keeping most of my time on the thick edge (10 gauge) and kinda washing into the 12 gauge. Any tips on this guys?
Reply:More pics, got the firebox tacked on last night. Ran out of zip wheels so I had to use my 1/8 150 amp 6010 torch to cut the hole for the firebox entry, lol it cut through very easily.Weld ground down on the cooking chamber to even out all the highs and lows of the torch cut end plate.
Reply:Here are some vids and pics from today welding the firebox on. First couple of beads looked like crap and I had a few pinholes, but one I got in a rythym it went very nice.
Reply:haha you're on the smoke ring aren't you
Reply:Originally Posted by Nickoshaha you're on the smoke ring aren't you
Reply:I think K.A.M was a pipeliner before he discovered his true calling as a cook/chef.  He has some good eats he displays & has written several cookbooks too.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by SR20steveI am. I found out about the smoke ring from this forum. I have identical post on there as well. KAM over on thesomkering is real good welder, and Im getting allot of good smoker building tips from him.
Reply:Its starting to look like a smoker! Good work so far
Reply:304ss stack material came in the mail. I decided to go with 2.5" so I could get alittle more length for the "cool factor" . Im gonna polish it up nice when I get it welded together and on the cooking chamber.
Reply:Got picks of my SS smoke stack welds. They weren't perfect by any means, I used a file on the edges to define the weld if your wondering.
Reply:Good job on the pipe fittings. I've seen turbo manifolds being sold with welds that didn't look half as good
Reply:Originally Posted by TigWizGood job on the pipe fittings. I've seen turbo manifolds being sold with welds that didn't look half as good
Reply:I know its a bad picture, everything is still a mess under the hood, and everything is powder coated black to look OEM, but is this want you're looking for?2.5L Gt3076R Air-water Intercooler... I'll get better pics up when its complete. Hope you dont mind Jenn
Reply:Originally Posted by TigWizI know its a bad picture, everything is still a mess under the hood, and everything is powder coated black to look OEM, but is this want you're looking for?2.5L Gt3076R Air-water Intercooler... I'll get better pics up when its complete. Hope you dont mind Jenn