275 Gallon BBQ Smoker Trailer Build

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I think this will be the first big project that I'm posting here on WW. Actually, now that I'm thinking about it, the only project I have posted so far. This is still in the design phase, but the customer told me he had about a budget of $500 to $1000.  This is just a rough sketch of what it will look, what nearly every smoker looks like. It will be a reverse flow. I don't have any pictures of the trailer yet it will mount on, but the tank and the trailer will both be supplied by the customer. This won't be my first smoker though. I made one last summer, but it did not turn out well. So, after making that smoker, I figured out what I will make different. The first problem is the back door didn't seal up that well. To fix that I was thinking of making almost a 2 part door. The first part will be welded into the box. I was thinking of putting a 2" lip around the inside edge of the box. The second part will be the actual door. It will have either flat stock or angle iron coming off the door so when it is closed, it fits inside the 2" lip. I think I am explaining this correct, let me know if I need to reword it. Also, has anyone tried this before? Another problem was slight warping. The easy solution is to make the steel thicker. After looking through my steel catalog, I was thinking either 9 Gauge, 6 Gauge or 1/4". In this case, thicker is usually better, but of course I have a budget. For making the firebox overall, has anyone made a shell out of angle iron then welded the plate onto it? Also, should I sand blast everything before painting? Before, I only blasted the trailer. I think those are the only things I really have questions about. It will probably be a couple months until I lay a weld though.Millermatic 200Miller Spectrum 2050
Reply:Framing the box is only useful for fitup. Get some good 90 degree angle clamps to help with that.Nothing thinner than 1/4" for the fire box. Thinner will rot out faster, warp, and doesn't hold the heat good enough. Sandblast the whole thing for the best paint adhesion.GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Hey Gravel, 1/4" for firebox, how about the main body thickness?Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:http://www.thesmokering.com/forum/Here is a great web site for smokers. Look in the smokers section. Use their on line calculator to figure fire box size, stack size, air flow and such.  I would also use adjustable tuning plates if I were doing another reverse flow.I build a reverse flow a couple of years ago.  As well as mine works my next one will be a Diamond Plate clone.  The fire box is on the rear and the heat controls better. Dan D. Attached ImagesManipulator Of Metal
Reply:Originally Posted by MinnesotaDaveHey Gravel, 1/4" for firebox, how about the main body thickness?
Reply:Originally Posted by DanD78Not Gravel but my fire box was made with 3/8" and the tank was around 1/4".  1/4 for both would probably be fine. I had a bunch of 3/8 hopper car bottoms so that is what I used. Tanks like to spring when you cut the door out.   Dan D.
Reply:Originally Posted by MinnesotaDaveHey Gravel, 1/4" for firebox, how about the main body thickness?
Reply:Originally Posted by DanD78http://www.thesmokering.com/forum/Here is a great web site for smokers. Look in the smokers section. Use their on line calculator to figure fire box size, stack size, air flow and such.  I would also use adjustable tuning plates if I were doing another reverse flow.I build a reverse flow a couple of years ago.  As well as mine works my next one will be a Diamond Plate clone.  The fire box is on the rear and the heat controls better. Dan D.
Reply:Originally Posted by DanD78Not Gravel but my fire box was made with 3/8" and the tank was around 1/4".  1/4 for both would probably be fine. I had a bunch of 3/8 hopper car bottoms so that is what I used. Tanks like to spring when you cut the door out.   Dan D.
Reply:Originally Posted by MinnesotaDaveMan, I better look for some scrap sheet - guy looking for one from me will get sticker shock with new iron.
Reply:Originally Posted by GravelOne of the great thing about smoker builds is that pitted steel doesn't make it look bad. Just adds character.
Reply:Originally Posted by MinnesotaDaveI suppose I'll still have to paint the outside though....damn...lol
Reply:Originally Posted by M J DNo paint is needed, just charge twice as much and call it"Patina" .
Reply:That will work and perhaps marketing it as a "green" product that doesn't harm the environment with harsh chemicals
Reply:Originally Posted by M J DThat will work and perhaps marketing it as a "green" product that doesn't harm the environment with harsh chemicals
Reply:http://weldingweb.com/vbb/showthread.php...s-post-em-hereMight want to look here as well.  Searching Welding Web may pop up even more projects.I re read your entire post and have a concern.  If he has a max. budgt of $1,000 you are not going to make any money.  Paying your self $50 an hour for 20 hours will eat that $1,000 in labor alone.  I know for sure you will have more than 20 hours in the build.  Then you need to add materials, sand blast and paint.  If he is a buddy and he is supplying all materials go for it.  If you are doing it for profit you might re think a little.Is this one of those oval fuel oil tanks?  Dan D.Manipulator Of Metal
Reply:So, after reading people's replies, I will probably go with 1/4". I'm not sure how thick the cooking chamber is, but I have heard some of the older 275 Gallon tanks are 1/4". Dan, this is one of those oval fuel tanks. I'm a good welder but I don't think $50 an hour good. For most projects, I charge $20 but most of the business I have done is with family and friends. The customer is kinda a friend of mine, but he is not someone I just met. If he would pay $1000, I was going to put $300 to go to labor, $200 for sandblasting and painting (It was $100 for my 4 x 8 trailer so I dont think the extra tank on it will cost another $100), and the rest will go towards steel. For those who have made smokers, what do your guy's intakes look like and what does the inside look like?Millermatic 200Miller Spectrum 2050
Reply:Originally Posted by TypeSo, after reading people's replies, I will probably go with 1/4". I'm not sure how thick the cooking chamber is, but I have heard some of the older 275 Gallon tanks are 1/4". Dan, this is one of those oval fuel tanks. I'm a good welder but I don't think $50 an hour good. For most projects, I charge $20 but most of the business I have done is with family and friends. The customer is kinda a friend of mine, but he is not someone I just met. If he would pay $1000, I was going to put $300 to go to labor, $200 for sandblasting and painting (It was $100 for my 4 x 8 trailer so I dont think the extra tank on it will cost another $100), and the rest will go towards steel. For those who have made smokers, what do your guy's intakes look like and what does the inside look like?
Reply:Originally Posted by TypeSo, after reading people's replies, I will probably go with 1/4". I'm not sure how thick the cooking chamber is, but I have heard some of the older 275 Gallon tanks are 1/4". Dan, this is one of those oval fuel tanks. I'm a good welder but I don't think $50 an hour good. For most projects, I charge $20 but most of the business I have done is with family and friends. The customer is kinda a friend of mine, but he is not someone I just met. If he would pay $1000, I was going to put $300 to go to labor, $200 for sandblasting and painting (It was $100 for my 4 x 8 trailer so I dont think the extra tank on it will cost another $100), and the rest will go towards steel. For those who have made smokers, what do your guy's intakes look like and what does the inside look like?
Reply:Originally Posted by MinnesotaDaveI suppose I'll still have to paint the outside though....damn...lol
Reply:Originally Posted by roadkillbobbyour gona loose a ton of money on this deal, old oil tanks are not 1/4 inch , there should be a metal tag that tells you what gauge it is, I just pulled a tank out of a basement and its gota be at least 50 years old and it is stamped 14 gauge...you are only figuring 15 hours labor for fabrication and welding, its gona take you at least double that if you figure all your time on the project...tell your friend $1000 isnt gona make it....
Reply:Originally Posted by Arctic98zSays who!?