Aluminum smoker

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With the drop from a past project, I have decided to make an aluminum BBQ/smoker (this is the smoker part).  So I grabbed a plate that was 8" longer than the diameter that I needed because of the flat ends after rolling.  Then I sawed off one of the flat sides and started tacking each of the round plates. I worked them equally so I wouldn't end up with the rolled plate walking more to one side than the other. I used a wratchet strap to pull it a bit tighter since the flat ends of the plate were preventing me to form it in a perfect round. A pipe clamp helps quite a bit when you are real close. Just make sure that you aren't going to pull it past where you want things to meet up or it will make things alot more difficult when you get to the end.Once I got it close to where I figured the ends would meet up, I sawed the other end off with a little overlap.When they were touching I could draw a line and cut the end so I had a little gap so I could work the seam with a screwdriver, but not enough to mess with my finial weld.With rolling and fitting, it took me about 1 1/2 hours until it was welded out.I'll post more as things progress..-Mike Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:That's gonna be one unique lookin cookin' machineI sure wish I could make a weld that looked that nice."Any day above ground is a good day"http://www.farmersamm.com/
Reply:That is going to look nice when you are finished. I know it will be a lot easier to roll it around do to the light weight. Has anyone ever seen an aluminum smoker before. ??
Reply:How did you roll the plate? Great job,I wish I could do that.
Reply:That looks nice. What kind of heat source are you going to use?
Reply:But, but, why do you want to smoke aluminum?    Are you going to smoke aluminum chips, or extrusions, or wrought pieces?  Scraps, or cast pieces?I know of some folks who have smoked cast aluminum engine blocks.  It didn't look or smell tasty at all.    The best laid schemes ... Gang oft agley ...
Reply:I have some s.s. perferated plate that I am going to use in the smoker box for the chips or whatever I figure works best to sit on.Why do I want an aluminum smoker?  I think it's all about being one of a kind I guess.  Assuming that it's a first.  I have seen aluminum bbq's before... I think on this board there is a post about them.I rolled it with a hand roller.  I posted a pic of it the other day on this thread: http://weldingweb.com/vbb/showthread.php?t=24412-MikeCommon sense in an uncommon degree is what the world calls wisdom.
Reply:I wonder what the coefficient of thermal expansion is for an aluminum smoker. City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:I think it might go though a bit more fuel than it's metal cousins.  Tonight I welded the smoker to the main unit and didn't notice until I had it on it's supports that they were not lined up to eachother correctly.  It's after 8pm here, so I'm ready to call it a night and work on it tomorrow or saturday.Another thing that I'm kinda questioning is the footprint of the legs.  they are 18" deep and 18" from end to end.  I might have to take another approach because it might be a bit tippy.  Any suggestions on this would be much appreciated.Mike Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:That is turning into quite a smoker. I agree it will take more fuel than a steel one just because aluminum is such a good conductor. You should be able to keep the birds warm with it this winter.
Reply:That's an awful lot of drop from the last project would you mind if next time I just come by and pick up all the drop from your projects?It does look reaally nice and I picked up an idea here so the wife won't complain the next time I build a project. I'll just tell her it was drop from the last job.
Reply:I had the 22" diameter x 18" shell laying around from a diesel tank job.  And there was 5 pieces of 12" x 48" plate from a recent job that I used for the sides and smoker.  It's pretty nice when the material is already paid for.  -MikeCommon sense in an uncommon degree is what the world calls wisdom.
Reply:Just add some Feet- and make as long/wide as neededEd Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I had a chance to work on the smoker today.  When I welded the ends on the large can, they sucked inwards after cooling.  So in order to attach the side tables, I had to tap out a hole to accept a pressure regulator.  It's the same area where my stack is going, so it's no big deal.  I pumped it up until it puckered out in the middles of each side, then I tacked the sides on.  I had to wait until it cooled and depressurized before the sides sucked back against the can.The next step is to tack a few more spots and weld it out.  Then I can start cutting again.It's finally starting to look like something.Oh yeah.. I havn't addressed the leg issue.. I'm not sure I like the idea of ski's under it.  It's just not something that you see on bbq's. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:I hope i can tig weld as good as that someday. Thats a nice smoker ya got there.
Reply:I managed to weld on the smoke stacks, a hinge(copper tube core with aluminum tube on the outside(all I could find that would work nicely)), a handle and I cut it open.  Then I drilled a hole between the cooking area to the firebox.  I cnc'd out some plates so I could add some style to my 1/4" s.s. round stock for the grill.  I ran out of material so I couldn't do the bottom or top grills.  With the stops set on the metal muncher, they round stock came out pretty consistent. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:That's the neatest thing how ya made the dies to bend the grill runners"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Very nice job Brainfart!Miller Thunderbolt 225Millermatic 130 XPLincoln HD 100 Forney C-5bt Arc welderPlasma Cutter Gianteach Cut40ACent Machinery Bandsaw Cent Machinery 16Speed Drill PressChicago Electric 130amp tig/90 ArcHobart 190 Mig spoolgun ready
Reply:Great work!  I like your jig for shaping the grill grate!Here is what I have so Far:Miller:Shop Master 300 A A/C D/CS 22a Wire FeederRFC-14 Tig PedalHF-251D High Freq. UnitProfax 250 A Mig GunVictor RegulatorsHarris:63-2 torch Cutting Attachment 49-3making home built tig cooler
Reply:I'm nearly finished.  I have a few details to iron out, but I'm ready to test it out for lunch tomorrow.  I ended up using perforated plate on the smoker side.  I think I can use pellets.  A friend wants to give me a pellet auger, but I'm not sure I want a motor hanging off my smoker. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:Here are some more pictures. Attached ImagesCommon sense in an uncommon degree is what the world calls wisdom.
Reply:That thing is sharp! I really like the SS grill, nice work! Originally Posted by farmersammThat's gonna be one unique lookin cookin' machineI sure wish I could make a weld that looked that nice.
Reply:Brain farth,I have built several grills.  This is very nice looking... But,  the temperatures reached in the fire box to establish a fire will MELT it down... I am afraid.  I saw someone who has one and it is an indirect smoker and he has to keep water in a special box surrounding the flame to keep it from falling apart.  Addtionally,  he has omitted the water a time or two and everything looks like it all rippled and sagging in the heat area.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:Maybe I can line with with some 316 or asbestos.Common sense in an uncommon degree is what the world calls wisdom.
Reply:This is from US forest service:Wood burning is broken down into four rudimentary stages. In the first stage, the surface of the wood releases vapors, gases, and mists, some of which are combustible. This stage of combustion exists up to 395�F. In the temperature range of 395�F to 535�F, the majority of gases--which yield from 60% to 80% of the heat content of the wood--are driven off and "burned" through liberating reactions, though no flaming occurs until higher temperatures are attained. Once the temperature rises from 535�F to 935�F, the gases that are released are subject to secondary reactions, become combustible and ignite, producing flames. What remains after the gases are emitted is pure carbon or charcoal. This char is combusted in the fourth and final state at temperatures in excess of 935�F. I have read flaming temps with an air "draw" can exceed 1500 degrees.Aluminum melts around 1200 degrees.My steel smokers have turned a dull cherry red in the fire box while the meat was smoking on about  225.Last edited by lugweld; 01-23-2009 at 12:22 AM.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 255EXTAny chance of seeing that smoker in action?
Reply:Sure.. I'm having a BBQ today in about 30 minutes. Your more than welcome to join. Common sense in an uncommon degree is what the world calls wisdom.