A BBQ grill for a customer...

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I built this grill a couple of months ago.   It's the customer's job to paint it.  He's slowing down this time of year and has a few guys standing around with nothing to do but sand and paint.  It was a two stage build.   He wanted to use it for a few times and then do some more work to it.  This is after I got it back before I started stage two. Took it to a friend's restaurant on a Saturday afternoon for a little cookout (hence the "special" wood fired pizza)  More pics to come later.  I am going to take pictures of the finished product. Attached ImagesEsab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:that looks great!  and the food looks even better!
Reply:Those 6 racks were gone in nothing flat.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Looks very nice! But I would say that your firebox is waaaay too small. The general rue of thumb is 1/3rd the volume of the cooking chamber. Do you have any problems keeping up the temps or feeding wood often?When I built mine I actually did the same thing, but its just a tad under 1/3 (maybe 1/4), but haven't had any problems keeping temp (I use a auto draft with alarm also).But like I said it looks awesome.
Reply:The fire box was built to the CUSTOMER's specs against my advice. He wanted to use it primarily for grill cooking.  Not visible in the photos is the charcoal rack under the grill.However,  I'd say the 1/3 size of grill is highly inaccurate given my experience with this thing.  I wouldn't have believed it.   With minimal air flow and with the stack shut down(it has a damper in the stack) to about 30% flow, it managed an even 230 degrees.  Over a six hour run, it consumed one small bag of charcoal for starter and then about 7 or 8 quartered pieces of oak.  When I shut it down and starved the fire,out of the 7-8 pieces, 3 partially burned pieces were leftThe main issue with a firebox this size is loading several pieces at a time requires careful placement of the wood so it doesn't roll out. A fire grate would help, but it wasn't part of what the customer requested....soooo.......I was able to bring it up to about 400 degrees easily with full air flow.  He had already cooked at least twice on it.  The first was for his family.  The next time was for his church on Easter Sunday...full of hamburgers.  This coming weekend, I think its a family reunion, chicken-que that he has to cook for.It pulls great though... I managed a 70 mph run easily through the backwoods for a short distance with no sway or wobble.  Its lightweight.  Most grills this size, are hard to maneuver by hand.   I can move it around by hand with no problem.   The trailer is 2x3  14 gauge sq tubing which makes it strong and light.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:A couple more...I will try to get some pics of the inside and backside.  This is after it was delivered and more stuff added. This is the customer's pic.   Inside I have added a half rack to at the top.  The backside has a prep table. Attached ImagesEsab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Here is a program to calculate the size of things for next time you get to build a smoker...It works real well for me gives you exhuast size and length, smoke inlet from fire box, pretty much everything you need.>>>  smoker size calc.zipthe smoker looks great. Did he ever talk to you about making it a reverse flow ?JerodHypertherm 30Miller Syncrowave 200Millermatic 140and a propane torch and hanger if all else fails
Reply:No,He wanted it  to use it as a grill primarily and wanted on a budget.  I have a "reverse" before, and looked at dozens of them at shows.  I have seen them work good and then I have seen them work awful. The open firebox is about as close to pit style bar b que as you can get.  The reason this unit has two gauges is that the temperature can be monitored all along the length of the chamber.  There was less than 10 degrees difference between the two the whole cooking session.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:WOW! Great job!!!I am planning on making a large pit BBQ type griller, but it most likely will not be mounted to a trailer.DId you build it with the Power Ultra 205? I just ordered one from Everlast and I can't wait to get it in and start welding?What process did you use to create most of the welds? TIG MIG or Arc?Is the PU205 doing its job?Have you done any other projects with the 205?Jeremy
Reply:I used MIG and Stick.  I used plasma for the cutting.The cutting was done with a PowerPlasma 60 and the firebox was welded up and in with a PowerARC 200 with 3/32 and 1/8"  5 P and 6011 rods running around 65-70 amps and about 80-85 for the 1/8" with two passes.    Also, I found use for it with some other welds on the tank, where running the MIG wasn't the best choice.   For the MIG, I used the ESAB MM 250.Tig is too slow for this type work, unless your customer or you are a rich man.  The idea here is production, quick, fast, and strong.  This was too much prep work for the tig as there were heavy, multiple layers of aluminized paint that had to be either ground off or burned through to get a proper weld.  The stick welder shines in this area and can get penetration through the scale and rust.  Of the balance of the remaining welds, the majority were Spray MIG, with a little short circuit for tacking and for the trailer frame.Last edited by lugweld; 05-11-2010 at 03:34 PM.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Thats cool. I def know that time is money!!!Im probably going to use the stick way more than the TIG also on stuff like that.If i may ask, did you come out "ahead" on the grill project for your customer?Again, nice job!!
Reply:Yes I did.  I charged him for it...Can't do that kind of stuff for free.lol.  I didn't make a lot mind you.  A friend of a friend.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Man,  Lugweld now i m really hungry.........nice jobLincoln 255XT Power Mig                                                                    Lincoln Precision Tig 225Hypertherm Powermax 30
Reply:A very fine looking smoker!That will cook some serious "Q".
Reply:We got the ribs from Sysco on sale.  They marinated 24 hours and cooked for about 7 @ 230 degrees.  They were done and pulling from the bone. They were a little tough but tasty.  We saved the uncooked ribs and my friend cooked them later and preboiled them then oven cooked them in a special slow and low style and he said they were still tough.  Didn't appear to be the fault of the cook or the cooker....lolEsab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:One of the ways you can tell if ribs are done, is pick them up by the tongs & if the unsupported end bends at least 45 degrees away from the support tongs, they are done.  The meat should pull from the bones a bit, exposing the rib tips.  In competitions, the meat should pull away from the bone with a "tug" of the teeth, not fall off the bone tender.You can also use a meat thermometer to cook them.  They are done when the temp equals about 190-195 degrees.  Another method is the 3-2-1 method.  3 hours on the grate smoking away, 2 hours in foil, 1 hour naked on the grate again, while you sauce/spray with apple juice.If they are tough, you might try the 3-2-1 method................ oh, no boiling allowed.  No need to brine em either.  Just pull the silver skin from the inside, rub, toss on the smoker.  Yumola!!!!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 MarkBall2One of the ways you can tell if ribs are done, is pick them up by the tongs & if the unsupported end bends at least 45 degrees away from the support tongs, they are done.  The meat should pull from the bones a bit, exposing the rib tips.  In competitions, the meat should pull away from the bone with a "tug" of the teeth, not fall off the bone tender.You can also use a meat thermometer to cook them.  They are done when the temp equals about 190-195 degrees.  Another method is the 3-2-1 method.  3 hours on the grate smoking away, 2 hours in foil, 1 hour naked on the grate again, while you sauce/spray with apple juice.If they are tough, you might try the 3-2-1 method................ oh, no boiling allowed.  No need to brine em either.  Just pull the silver skin from the inside, rub, toss on the smoker.  Yumola!!!!
Reply:Guys, I did follow this method.  I did not brine them, but rather did create a non salt marinade with apple and orange juice, and basted them with apple juice, and put them in the foil.  They were bending and pulling at the tips but they were still tough.  They were good, but a little chewy.  Temp inside went to about 200 degrees.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:That BBQ design is perfect!  I just got re-inspired with mine.  Thank you.
Reply:Only 200 degrees?  That might be the problem.  Ribs need just a touch more heat, say 225-240 degrees.  Maybe at 200 the cooking took so long, the meat turned to leather?  Don't know for sure.Sounds like you did good, just a bit tough.  My first ribs were awful tough too.  But I had airleaks & the temps kept spiking.  2nd ribs cook went much better.  Ribs were great!!!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:No the internal temp was 200 but it was cooked at 230-235 degrees.  I have cooked a lot of ribs on other smokers and grills without them being tough.  These were still on the tough side. We got about 40 pounds of ribs and kept about 3 racks back for him to cook later. When he oven cooked  the remainder of them later in a combination of foil and beer did not improve them so I guess it had to be some hogs that figured out what was coming to them and got tense...lolEsab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:My Bad, misunderstood the 200 temp.I was reading on another website I belong to other have had similar problems when they take the ribs to over 200 internal meat temp.  Could be the ribs were just tough & no matter what you did, they would be tough.Good looking cooker & ribs though.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:nice job!What type/brand paint was used on the BBQ's?Blackbird
Reply:I'll have to inquire on the brand, to make sure, but I think it was 1200 degree hi temp flat.  Customer painted his own...that was part of the deal.  Though I can paint it, it saved him some serious money.  He already had the paint so he saved me the hassle.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:great job. great quality work. I hear a lot of comments about the size of the fire box, but I think the size is not as important as the quality and fit of the seals and the coresponding size of the exhaust.  genetics of the animal do make a difference, but you might try adding an hour to the time spent inside the foil with juice.  Don't go above the 200 deg mark water boils at 212 and the ribs will dry out the longer you keep them above that temp.did you just start out with flat sheet metal? what did you use to bend it into a cylnder?
Reply:The "cylinder" was a retired propane tank...Someone is having a stomach ache thinking about it I am sure.   But I followed proper safety precautions, the tank was empty and washed and filled twice before it was cut into, plus it aired out a couple of weeks.  The smell will remain thanks to the additive that remains in the tank.   But,  quick hot fire will burn off any remaining residue, and rinse down and re season takes care of the rest.  I have another in ready to start again, this time much smaller.I have made others though in times past from 3/16 to 11 gauge material for the tank.  I have a local machine shop roll flat plate for me and press stamp the ends, so I weld it up and cut it to fit my design when I have the ends welded in.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:how much does it weight? i have a 250gallon tank and it weights dam near 2000lbs with everything i put on it plus the frame of the trailer which brings it up to around 3000lbs - mounted on a 3500lb axle kitalso how big of an axle did you use and how big of a spring hanger kit?I break things for a living...
Reply:No,I don't think it weighs any where near that much.  Its quite light.   It is easily maneuvered around by hand.  I'd say its probably a max of 1200-1400 lbs, if that much.  The frame is lightweight 14 gauge 2x3 tubing, and the whole trailer without the tank is maybe 200 lbs.  I could easily pick it up before the axle was installed.  The tank probably weighed in less than 700 lbs, about the same as my engine drive ranger 8.  I could pick up one end and scoot it around when needed.  The counter weight weighed a couple of hundred though.The axle was a 3500 lb axle, that I cut down and welded back together, and reinforced across the weld seam and along the length with a piece of heavy angle to shore it up.  Hanger kit was a typical 3500 lb hanger kit.  But it doesn't even flex or compress the springs, even over a  "bump".  It acts quite light.  My 1/2 ton Dodge didn't know it was back there at 70 mph.   I live in a trailer building mecca, so parts are cheap and fairly easy to come by so a 3500 lb axle is easy and cheap to come by.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Here are a few more pictures of the grill from different angles before the add ons were completed.  I had the pictures on CD for a while, just forgot to post them. Attached ImagesEsab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Originally Posted by dave powelsonnice job!What type/brand paint was used on the BBQ's?
Reply:I believe that is what the customer used on his.  But I think he used several gallons.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:As for ribs being tough. it can be just the ribs!I am a meat cutter, & we get lots of different varieties of ribs in & our best seller is also our cheapest, but you couldn't pay me to eat them things again! I tried cooking many different ways & finally gave up & just pay fifty cents more for good ribs. we get $1.29 a LB for plain ribs, & $1.49 for ribs rubbed with our BBQ seasoning.  its a low grade Gunnoes ribs.Our next best ribs run $1.99& up & are delicious. but then it becomes a choice of back ribs, Hollywood style, baby back ribs, country style from picnic or boston butt. or even riblets from pork chop ends. No cooker here, just a plain store bought square charcoal style bbq grill discounted end of season a few years ago after it had been dropped, $10 for a grill that was dented but new & retailed for $49.95.  Now if only I had some ribs in the freezer! but I am off today & I dont feel like driving 60 mile round trip on my day off for ribs.but I probably will grab a pack tomorrow. plus I can cherry pick through several cases for some real nice ones... lol
Reply:Originally Posted by weldbeadi just left $15 at homedepot for a quart of rustoleum hitemp satin black. quart will do a lot of smokers.unless they are ten feet long trailer smokers.
Reply:Lug good job on the cooker! But let me help you with the cooking a little.....First off for best results on any meats your temperature should be no lower than 250. I prefer 275-280....it is the same as welding good iron, if the heat is not there the penetration is not going to be there either....It should not take over 3.5 hours on spare ribs to be done. they should not be tough cooking them at higher temps either. If they start to get too dark on the bottom side with higher heat, just turn them over halfway through the cook and they will be fine.....Please don't boil any more ribs or BBQ in general.....do it right with Hickory wood and watch your friends smile!
Reply:Joe,I come from the land of BBQ here. I first started before my teen years helping out at church BBQ's.   You can't hit a town with out 2 or 3 BBQ restaurants.We have guys locally that have won Memphis in May and other national shows all over.  225 is the target temps they use and is commonly accepted as a target temp.  I knows of a few,depending on the meat would rather go down to 200.  Hickory, though a good smoking selection has a more eligible relative: Pecan.  It imparts a sweeter flavor and is easy to come by in these parts.  Now fruitewood such as peach and apple is often abundant as well, and some mix it in.  But  Pecan can be the difference between 1st and 2nd place...Nothing better than chicken quarters smoked in an open pit over Pecan wood.  Oak makes a nice smoke too, but it can get bitter, depending upon the type of oak...Old scrub oak does pretty well, which is what I was using since it was already "collected and split"Additionally, many like to have a good, black/dark bark on the meat   The ribs we had were just plain tough.  We got them on special from sysco. Others haven't been that tough..though the whole pile disappeared in less than 20 minutes...something was good.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT