Uahi Ahi: Rib Smoker Rack

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Completed a custom design/build for a local client.  2ea 18" X 36" Rib Rack assemblies to integrate to his existing {mobile} smoker unit.  Client initially desired 2ea rib rack assemblies sole-to provide real estate for smoking ribs.  Convinced the client to augment his approach and allow the racks to be used for instances other than rib racks (e.g. smoke'n pigs, chickens, lamb, other).  Client agreed. The Build.  Used the following materials to fabricate the rib racks: 1-1/2' x 1/8" A513 square tubing, CFXM 3/4" - #9 mesh, 1018 3/8" square bar, Horseshoes (Size 00, 1), and 1/4" CRS round bar (handles).   17ea rows of horseshoes @ 2" O.C.  The two assemblies consisted of a frame and a horseshoe grid.  The horseshoe grid is removable.  Flexibility. The Processes.  All welding completed using GMAW on BLUE XMT 304 and 74DX Feeder & Bernard 300A Q-Gun.  Short-circuit w/ C25 shielding and axial (spray) arc with 98/2 Oxy.  Spray arc used only because ran out of C25 gas yesterday.The Result.  2ea heavy-duty framed rib rack smoker units for grill action or fire pit ops.  SaWeet.  Client's doing cheetah flips and now requesting an upgrade {strengthening} of his existing smoker unit.   No prob.  Will post in-action photos of the pork ribs being cooked at the future event.  Shakah! Attached Images"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Great design! 32 racks of ribs at one time! Where do you put the bacon? GravelThe difference between theory and practice is that in theory there is no difference.
Reply:NICE !  Man that is a whole lot of horseshoes too.
Reply:Those look great Kai.  Great job.How did you like spraying?  Use the optima?
Reply:@ Gravel - thanks brah.  Bacon goes anywhere you can find space.  You could drape the 'shoes, wrap the ribs, or lay the grid with bacon.  Ha!@ BD1 - cleaned out a local ferrier supply of their iron shoes.  Mahalo.@ Drf255 - mahalo Al.  Spray arc was acceptable.  Not my first choice due to increased HAZ and potential over-fusion on the 3/8" square bar.  However, axial transfer made easy work of the grid build & all horseshoe-to-grid welds.  No issues.  Short circuit used to weld both frames and the CFXM-to-frame tacks. Optima used for some of the vert up work.  Gun'a further experiment with the Opt's settings and test the limits in prep for another heavy-metal fab.  You need to (re)rip an Optima brah. Last edited by ManoKai; 05-31-2014 at 07:36 AM."Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Nice Job!Miller Multimatic 255
Reply:You know, I was just being funny about the bacon but I bet it would be good to drape bacon on top of the ribs while they cook. I usually wrap my boudin stuffed pork loin in a bacon weave.Sent from my SAMSUNG-SGH-I497 using TapatalkGravelThe difference between theory and practice is that in theory there is no difference.
Reply:Excellent work bro ...like that designBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:One of these days i need to go see my friend in HiloBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:mano; even though no swine in my house (wife's orders) i'm getting hungry looking at those racks. nice work.i.u.o.e. # 15queens, ny and sunny fla
Reply:Originally Posted by 7A749You can just shut up right now........ Damn, already thinking about grilling. Just got the ok from the wifeMaybe ill even get some bacon!!
Reply:Originally Posted by docweldermano; even though no swine in my house (wife's orders) i'm getting hungry looking at those racks. nice work.
Reply:Looks like a fun thing to clean after it is used."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:@ Louie1961/ killdozer11/ docwelder - thank you for the looks and nice comments .  Really stoked the client is stoked.@ Gravel - there's only one thing better than bacon.  Guess?  Think hard.  Answer:  Nothing.  Ha!  Can tell you enjoy grill'n action like me.@ 7A749 - Steve, on the DL.  There may or may not be 102ea 8oz horseshoes missing from the acclaimed BudWeiser Clydesdales show team.  The iron was stamped "Grant's Farm, St Lo, MO."  Don't say nut'n to no one.  Ha!  Glad the build whett'd your appetite to light fire and rip some grill'n action. Last edited by ManoKai; 05-31-2014 at 08:34 PM."Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Did someone say pic???Sent from my SM-G900V using TapatalkGravelThe difference between theory and practice is that in theory there is no difference.
Reply:Smoker looks awesome although I would hate too foot the bill on filling that up. Gravel, the ribs look awesome. Lots of time and work but well worth the effort.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.
Reply:Sorry for the hijack Manokai!Sent from my SM-G900V using TapatalkGravelThe difference between theory and practice is that in theory there is no difference.
Reply:Mmmm me like ribs Gravel!!!!!
Reply:For any of you that don't want to invest heavily in a smoker, Bass Pro has a wide, propane Masterbuilt that works well. Can't wait to have the time to work on my big.ish smoker though. Sent from my SM-G900V using TapatalkGravelThe difference between theory and practice is that in theory there is no difference.
Reply:That looks really nice.  Did you have to treat the horshoes with anything to keep them from rusting?
Reply:Originally Posted by docweldermano; even though no swine in my house (wife's orders) i'm getting hungry looking at those racks. nice work.
Reply:Originally Posted by Drf255No wonder you wouldn't let go of that bacon when it was time to leave the hotel for tig clinic!I get it now Joe.
Reply:Awe He!! yeah Kai, AWESOME!!!"Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:@ Gravel - thanks for the lead.  Just today, two local dudes contacted me inquiring about "strengthening" (think:  MIG repairs) to their existing smokers.  Thinking re-skinning and hole repair action, with an allowance for drainage.  Will check out the rigs @ B@$$Pro.@ cbones62 - mahalo. For intermittent oxidation control, using what 7A749 stated.  Light coating of doing oil / Pam spray.@ Stick-man - mahalo loa nui bro!  How's your Hougen treat'n you?  And, when you gun'a rip some of your dakine 'excess' SMAW rod stash out here.  Ha!"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Great job Kai! Eatin some BBQ right now and wishin they were ribs! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys@ weldermike - thanks for the props.  Hope your foot is healing on-track.  Still look'n for a project to integrate the 'sliders' you gifted me last year. In good time brah.  In good time.  Aloha "Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:This Bass Pro one I have is not going to last forever but in the 15 months I've had it I've run it about 20 hours a month with no signs of decay. Not bad for less than $200.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Mano that is very clean and flat looking, how did you fight warpage on the square stock with a jillion shoes welded to them?Ranger 250 thick stuffHobart Handler 140 not thick stuffthe pane and oxy setup
Reply:@ KineticWeldingServic - mahalo.  Never fought warpage.  Instead, used the design and welding 'flow' to minimize HAZ and mitigate any geometric "deltas".  Explanation.  First, the build esssentially consisted of two subassemblies: frame (w/ CFXM) and grid (w/ horseshoes).  The frame.  All long/short sections for each unit were precision cut, with ends mitered and edges beveled along all four mating surfaces for exacting fitup pre-welding.  Diagonals confirmed square/true within 1/32".  In MIG short-circuit each long-to-short leg interface was tacked (in order) outside corners, inside corners, top, bottom.  The top welds were ground flush to accept a flat/clean surface for the CFXM.  Next,  the CFXM was Hypertherm'd and the mesh was skip-stepped tacked symmetrically in 5ea locations (per short side) and 8ea locations (per long side).  Frames complete.  No warpage.The grid.  The 3/8" square bar was welded in a similar manner.  First, the outer perimeter was cut, affixed to the CFXM/Frame with c-clamps, and tacked. Welded joints (in order) outside, inside, and top (except for the spray arc'd unit).  Checked diagonals.  Solid.  HAZ controlled.  Next, cut each 3/8" square bar comprising the 17ea traverse rows of the grid per unit.  Now, set and tacked (fillets, grooves). As the grid was being welded, four C-clamps on the outer perimeter maintained geometry and aided in keeping the grid flat against the CFXM/Frame. Periodically, the grid was unclamped from the CFXM/Frame IOT to ensure the grid did not become fused to the CFXM. Had a few minor errant shots during the spray arc'd unit build, and lightly pried the grid from the CFXM.  Grid established and all diagonals aligned. Time to CowBoy Up.The horseshoes.  Recall, 17ea rows of 3 horseshoes per row per each unit. Prior to arclight'n the horshoes onto a given row, made sure the local/global geometry of the grid was maintained.  The 3/8" square bar rows, at 15" length, are very stiff.  In fact, each grid morphed into a highly stiff ladder-like structure.  After the pitch (vertical alignment) of a 'shoe was held on a row, the 'shoe tines were blasted with .035 ER70S-2 wire.  Moved quickly between shots on a given 'shor to maintain pitch.  To fuse two adjacent 'shoes, the tines were MIG'd and then quickly the vertical joint.  Note: two sizes (00, 01) of horseshoes were incorporated into the build.  Believe the key to maintaining the overall geometry of the units was joint fitup, minimizing HAZ per shot, and not chasing the clock.Last edited by ManoKai; 06-03-2014 at 03:36 PM.Reason: verbiage"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:To extend the life of my client's existing (inception date, c. 2005), installed a false floor in the work chamber today.  The chamber's existing floor was shot out and holier than swiss cheese.  Plasma'd 3ea sections of 1/4" HRS @ 24" x 36" ea.  No welding.  Gravity assist set and fit up.  Steel will be re-purposed for a sweet future build {Octagonal Offset Smoker}.  Hypertherm "45" and Metabo Grinder action only.  The "45" continues to cut like a laser and the Metabo dressed the edge chamfers on the plate like butter.  Sampled some dry-rub ribs from the initial burn-in.  Dakine x 10.  Attached ImagesLast edited by ManoKai; 06-07-2014 at 05:27 PM."Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Action shot:  dakine ribs get'n smoked at my client daughter's graduation party.  ~ Tasting so sweet ~ Attached Images"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi