After you've got the tubing tacked in and insulation in place you can complete the firebox by covering the insulated sides with some thinner steel. From: $ 4,100.00. I shoot for a number between 103% and 110% with 107% being the sweet spot for the firebox volume. Once you've got the doors mostly cut out you're ready to weld on your hinges. The easiest way to attack a smokestack is to cut a hole in the top of the cook chamber and weld a pipe to it. You want just enough insulation that you can be efficient with you fuel but not so much that you're under-smoking your meat by not being able to add enough wood. Question Now that the smoker is complete and its got some wheels you're all ready to cook but there are some final finishing touches that you may want to add on to the smoker. The entering air below the wood has a greater density than the hot air above the wood, this creates a difference of pressure (draft) and the only possible way is to go up through the wood. Next you'll want to cut a notch into your pipe that is the same height as your opening. The biggest expense will be the steel to build the firebox as you want to use thick steel. Grate made of metal pipe 1/2”-1” diameter. on Introduction. This is the way fireplaces work and though all air seems to bypass the wood, enough of it reacts with fire to maintain combustion. I marked a line half way down the tank at the same width as the firebox. I used 14 gauge sheet to save weight and cost. There are any number of ways to design and build a BBQ Smoker. Still don't know what it is.. Plan to do a buff with an angle grinder after as well. Small holes 1/8” diameter supplying secondary hot air. 2 months ago. While drawing and designing firebox decided to add a small grill and lid to cook steaks or grill veggies or fish. Incoming air is preheated in a confined but hot area before being divided into two separate streams: the primary (lower) and the secondary (higher). Firebricks and refractory fire clay is an acceptable and commonly used solution. Quick View. Secondary combustion can be employed in any of the fire pit arrangements as long as there is a baffle and secondary air coming close to the flue as shown in the following drawing. The 250-has a small footprint, but can handle a pretty sizeable workload. It is also a good idea to weld your hinges onto the door before you finish cutting it out so the door remains in alignment. Place the flat piece inside the tank, then build a hardwood fire inside the tank. It can be welded or threaded and secured with nuts. I am planning one within the next year! Did you paint over this? Rule of thumb. By the same token the amount of smoke created will be decreasing. The axle placement is the most important part of the build as it determines how much weight you have on the tongue, you want about 10% of your total trailer weight to be on the tongue. This is one of the tricker parts of the build because of the weird geometry involved between the two shapes but shouldn't be too difficult if you approach it incrementally. Our Mounted Double 500 is a show stopper, This double unit is perfect if you’re wanting to run 2 different pits for 2 different temps and cook a whole lot of protein while doing so. The hole should be 18 – 24” wide, the bigger diameter the more wood can be burned inside and more heat will be produced, which may be needed when cooking at low outside temperatures. The three classical ways of placing wood in a fire box follow below: The drawing below shows the most common way of positioning wood when smoking. 1 year ago. I would recommend looking for an old utility trailer to mount it on but I decided to build my own trailer because I couldn't find one that quite suited my needs. If you're making your own hinges you can cut some tubing and round stock to length using an angle grinder and a cut off wheel or a metal cutting chop saw if you have one. Reply It does look great natural and if you want to keep that look I would recommend hitting it with one of those paint removal wheels for an angle grinder or just some scotch brite to try and remove the chalky substance. Build a Professional Barbecue Smoker: This Instructable will show you how to build the ultimate backyard barbecue pit. Firebox 250 Gallon Propane Tank Smoker. The smoke cannot go straight up the flue anymore and has to return to sneak through the only available opening where it picks up fresh and hot secondary air and burns cleaner now due to much higher temperatures. A good rule of thumb for sizing your firebox is to make it roughly 1/3 of the volume of your cook chamber in order to provide enough heat for you cooker. You can make door handles in much the same way you made the hinges. 1 year ago. 1. a smokestack that is 6”x 34” 2. Answer 288 Gallon Tank Smoker. Let the fire burn for a couple of hours, keeping it very hot. Depending whether a grate is employed a pipe can be connected to the baffle on the bottom of a fire box or can run over the grate. 250 GALLON PROPANE TANK!!!!! Doors have 1-inch x 3/16-inch flat stock around the edges to seal up the pit; no counterweights are needed because they were cut 8" down from the top, dead center, which also cuts down on the weight. Question The easiest way to build a cooking surface would be to weld a piece of expanded metal directly to some supports in the tank but making your grates removable makes cleaning much easier and you'll thank yourself later. Once you've got all the sides ready you can tack weld all the sides together and then run welds along every edge. While not entirely necessary, adding trim along the doors helps to keep smoke and heat from leaking out the cracks while you're cooking. The air for secondary combustion is delivered in a higher part of the fire box, just before smoke enters the flue. Building a trailer is pretty straightforward and there are several tutorials already online so I won't go into too much detail here but may post another tutorial for building a trailer in the future. Yours seems shorter and fatter. In the above drawing the pipe travels through the flame area and the air inside gets heated and escapes through a series of holes drilled in the end section of the pipe. Build 250 Gallon Reverse Flow Smoker – See the process of building a large smoker trailer. The first step is to mark out where your doors are going to be. My goal was to make a simple, traditional offset smoker that was very fuel efficient and maximized airflow in order to maintain a clean burning fire. If we want to control the burning process by using fresh air dampers, how we place wood controls the rate of burning and temperatures in a fire box. In old times the blacksmith was manually pumping more air into the fire to create high temperatures that made metals softer and pliable and that was excactly secondary combustion even though the air he supplied was not pre-heated. This requires the installation of one or two baffle plates. If proper rules for efficient combustion are observed the wood becomes a very clean fuel. Going off the advice or Mr. Aaron Franklin (who cooks on big a$$ pits-500 gallon LP tanks usually) I know he typically takes a a 250 gallon LP tank and cuts it in half for his firebox on a 500 gallon LP tank cook chamber. The rate of combustion is easiest to control in the stool-grate design and most difficult in the hearth bottom-grate type. I am nearing the finish line and did my big burn. 60 Gallon Reverse Flow Smoker Build. Great Build! You want your firebox to be roughly ⅓ of the volume of your main cook chamber and should preferably be made of ¼" steel. Use a level and soft tape to ensure your lines are straight. 55 gallon drums can work well for cook chambers but tend to be made of pretty thin metal so I think you're on the right track with insulating the cook chamber. I used a cutting torch but you could also use a cut off wheel for this step. Answer The tube has an ID of .560, think that will work pretty well? For this firebox I used ¼" thick steel plate for the interior box and 14 gauge steel for the exterior skin covering the insulation. I am selling my 250 gallon offset smoker. I'd recommend a smokestack that is 6" - 10" in diameter. You can pick up a brand new 55-gallon drum for around $150 or a used one for approximately $20. Now you want to season the cooker in order to get it ready for cooking. I saw that you put wood on the firebox end of the cooking grate is that to deflect heat? Did you make this project? I wouldn't shy away from using a propane tank if you can find one, they make for great smokers and can cut safely if can remove any residual gas from the tank. Hopefully this calculator will help you with the calculations. You can use a piece of cardboard as a template to get the shape to match the curvature of the cook chamber and the pipe. Note: bluish flames indicate complete combustion. The biggest trick here is maneuvering the smoker around in order to get it onto the trailer. However after it cooled this color is kind of a chalky, maybe oily I am guessing primer? 2 years ago. This Instructable will show you how to build the ultimate backyard barbecue pit. I cut these pieces out with a jig saw but you could also use a cut off wheel on the grinder if you don't have a jig saw. Carter, Love this post. Finally I notched out the back of the trailer and welded the firebox sides directly to the trailer. You should consider making the firebox larger. I would recommend using ¼" for the whole firebox unless weight is a big issue for you. Make sure your bottom plate is welded in well enough to support the weight of the tall smokestack. In this case the rate of combustion can be easily controlled by adjusting the air supply under the fire. My smoker was going to have a round firebox simply becasue I got this half a tank for cheap and didn’t want to spend $400+ for … Remember, cook low and slow, be patient, keep a clean burning fire and you'll wowing your friends and family with some amazing barbecue as well as your beautiful craftsmanship. Propane Smoker Grill Smoker Cooker Bbq Pit Smoker Fire Pit Grill Barbecue Smoker Propane Smokers Fire Pits Grilling Custom Bbq Grills. 2 years ago. The holes at the top of the tank should be standard pipe thread so you can buy plugs that will screw on, you just need to find the right size. This burns off oil residues. A fire pit can be a 2 - 3 ft deep hole in the ground, it can be round, square, rectangular, whatever, but it has to be covered with a sheet of metal. Share it with us! This is as easy as welding on a piece of pipe with a valve onto the bottom of the tank. From that line you want to cut straight down and around the tank to create a half moon shaped opening. Even know what I am talking about? 1 year ago. Here the coal bed physically separates fresh air below from the warm air above, a natural draft is created and all air has to flow through burning coals or wood. IMPORTANT: Cutting into a propane tank can be very dangerous if not done safely so I'd recommend having a professional clean and cut the tank for your if you're not comfortable doing so. Can not decide if I am going to paint or leave natural. Once you've got your opening marked you can cut it out with the angle grinder. 29"x58" cooking surface. There are many different methods for creating a cooking surface but I like to keep it simple with with two removable cooking grates located in-line with the bottom of the doors. I realize you didn't provide much instruction on the trailer build (your reason is vary valid) but can you provide the dimensions for the trailer? Once you got a good fit you can weld the firebox on along the edges around the tank. So could do a box with about 2" of space on all side in my firebox. Now that you've got your hinges ready you can start to cut out the doors but be sure not to cut out the whole door until you've got your hinges fully welded on. If you want to increase your cooking surface you could easily add more shelves above the bottom ones. For these cooking grates I used expanded steel (#9 thickness and ¾" opening size), ¾" x ⅛" angle iron, and ¾" square tubing. Introducing a compact, yet powerful offset, which is the smallest commercial offset smoker we build. Hope that helps! My firebox is 30x26x26 It is made of 3/8" steel. Some smokers come with a temperature gauge to help you monitor the level of heat. With a 24”x 60” cook chamber made out of 3/8” thick steel, this beast holds heat for hours! The smoker itself is pretty big, being 64” long, 34” wide, 66” tall and around 450 pounds. For this smoker I used a much larger and taller smokestack than is traditionally recommended in order to maximize airflow through the cooker and ensure a clean burning fire. If you are going to paint it you'll need to get some high temperature paint so that it won't start peeling away from all the heat. For years, these hunka-hunka smokers—a.k.a., offset barrel smokers, horizontal smokers, pipe smokers, or “stick-burners”—have dominated the competition barbecue circuit. I got the smaller tank and started making plans for the firebox of the smoker. (not pictured) The Chudpit 115 gallon offset smoker is the big brother to the 65 gallon and is more robust in every way. For the firebox I used 1/4" plate steel but also included 1.5" of ceramic insulation to help retain heat and improve fuel efficiency. Get some vegetable oil in a spray bottle or on a clean rag and coat the entire interior of the cooker. Our 288 gallon offset smoker is built in the traditional Texas style, with upper and lower racks on casters or skids. The burning coals will deprive the streaming air of its oxygen and that sets the temperature as no more fresh air is available. If a fire pit will occupy the bottom part of a barrel some steps must be taken to slow down the flow of the smoke and evenly distribute it inside of the chamber. The simplest secondary air delivery system is just a covered hole located near the upper part of the baffle. Water smokers, box, barrel, and pellet smokers do a fine job smoking meats and seafood.But nothing establishes your street cred as pit master who means business like an offset smoker. Wood rack, grease buckets, and water pan included. Cooks within 5 degrees side to side. For my firebox, I'm considering a 1/4" steel for the roof and door, but 14 gauge on the 3 sides and bottom, with firebricks on the inside bottom. Placing wood on a grate permits the introduction of primary air below the burning wood and better combustion. Once your firebox information is entered, you will see recommended volumes for the chimney, the air intakes, and the throat. NOW With a Warming Cabinet! My buddy had been working on his first homemade offset cooker for the past few months and just wrapped it up. When smoking, the bottom damper has to be shut tight and the top damper open. I have some pictures of building my firebox. Its on a trailer and is in good condition. What do you do with the holes at the top of the tank? Make a rectangular frame with the square tubing to support the expanded metal then weld it all together. The way most smokers operate is to have an unrestricted flow of the incoming air into the flue (pipe) and the smoke is rushing from the fire pit into the smoking chamber with some unburned particles. What size round bar and tubing did you use for the handles and hinges? You'll want to block up the smoker until you find a height that feels good. This is the most effective solution permitting a great deal of control. These types of handles are nice because the tube rotates on the round bars as you lift the door which makes opening the doors much easier. The drawing below depicts a smaller amount of air flowing through the burning wood and the larger portion blows over the wood increasing the rate of burning. Question Note warm air or smoke will always go up. The biggest challenge with building a trailer is getting everything square and straight so that the trailer tracks straight when driving with it. It can be used for restaurant operations, catering and pop-ups, etc. Thank you for the quick response! Of special interest is a collection of 200 recipes which were chosen for their originality and historical value. 7-ft, 250-gallon tank, 1/4 inch thick steel, 28 inches in height. Now that you've got the main chamber complete it's time to build the firebox. Finding a large piece of steel pipe or a smaller fuel tank is the easiest way to build a firebox but I chose to fabricate my own box so I could insulate it and get the exact size I wanted. I ended up hitting the whole thing with a wire wheel and then painted over it with a high temp paint. A correctly designed stool-grate fire pit will allow to switch from smoking to cooking by opening the fresh air damper located below the grate level. This first major design choice you must make when building a smoker is what you're going to make the cooking chamber out of. Design and 3D Print Your Own Phone Case (in Fusion 360), https://www.homedepot.com/p/Mueller-Global-1-in-Black-Malleable-Iron-Plug-521-805HN/100165402, Square Tubing (firebox and cooking grates). This is a complete, ready to use firebox, simply Weld on or Bolt on to your homemade cooker, tank, drum or modify to fit your existing cooker.. I estimated the center of mass and the total weight of the trailer and did some math to figure the axle placement. Thank you in advance! The angle of that triangle is determined by the manufactured coupler. However… Perfect fit. The above drawing depicts a very clever solution where the baffle acts as a pre-heat air delivery vehicle. I had a 250 gallon propane tank and decided, using the spreedsheet, that I wanted a little larger firebox than was required. I too am interested in a 250gal tank smoker. I bought some expanded metal 44" long and 7" Tall. The heat conduction will also be slowed down and the whole smoking and cooking process will be easier to control. Using concrete blocks or masonry bricks will only make a temporary arrangement as they will start cracking. The deeper the hole the better the draft will be. The average temperature range for this type of smoker is 220-250 degrees Fahrenheit. Hearth bottom grate and the secondary air. Was planning on doing a linseed oil cure and keeping the rustic look. Yes, you are correct. I built the door for the firebox using the same method as I did for the cook chamber doors. It may be made of reinforced concrete or from firebricks. That sounds like it will work great, you really don't need much slop between the pipe and round bar and you can always oil the handles/hinges if they start rubbing too much. Seems like most of the 250 gallon tanks around me are 90+"long and about 30" diameter. I'm having a hard time locating a propane tank large enough, not to mention a professional service that can render it safe to cut open and weld. Note in order for the dampers to perfom their designated function, the fire box and its door must be made tight. A metal box of suitable dimensions can also be used. First you'll want to weld in some angle iron into the cook chamber to support the grates. If you use thinner steel you will loose a lot of heat out of the firebox causing you to burn more fuel and risk warping over time. You may also want to add a grease drain somewhere in the bottom of the cook chamber with a valve so you can make clean up easier. It exclusively uses wood for fuel and goes in the 20” x 20” firebox. This smoker is a beast! You might consider using something other than a domestic propane tank for your firebox since I think the steel on those tends to be pretty thin which isn't great for the efficiency or longevity of a firebox. You can get this paint at most hardware stores in rattle cans. Once you've got all your pieces cut out you're ready to weld them onto the tank, starting with the bottom plate, the pipe, then the side pieces and top. You want to use thick steel is it will keep the temperature stable and easy to maintain. When wood is placed directly on the ground the whole air enters frome above. The raised stool grate type can be an effective tool for switching over from smoking to the cooking process. This is to ensure that the hot air and smoke flows directly across the grates where the meat is instead of pooling in the top of the cook chamber. You can also paint your smoker to protect it from rust but you definitely don't need to. Grind the sharp edges off the cut-out. Cheap thermometers are an easy way to screw up some great bbq. i NEED some dos and don'ts about this idea. However, the design principles and manufacturing process could be easily applied to any size pit. Related products Quick View. Anything deeper than 3 ft will make it impractical to clean up the ashes. Now that you've either purchased or built a trailer you're ready to mount the smoker on to the trailer. Yes, the rectangular frame of the trailer is 4' x 8' and the tongue extends 36" out from the end of the rectangular frame. I've been looking at 1/2 inch round bar and Schedule 30 3/4 inch tube. I had a friend brake a couple of pieces so I didn't have to weld everything. Start to finish build of a replacement firebox for smoker. It’s a popular model with 784 square inches of cooking space, and a … I was wondering about putting the metal floor at the highest point of the firebox so it has to travel all the way across both sides of the meat . For this project that turned out to be 31" from the back of the trailer but if you want more information on how to calculate the axle placement let me know and I'll post a tutorial. I think barrels are only 20 or 22 gauge thick. If you're going to insulate the firebox the next step is to weld some square tubing along the sides your going to insulate. I found that Mineral Spirits sort of liquefy it, making it easy to rub off with lots of old towels. Measurements and blueprints would be great for us interested. July 25, 2014. El Cucaracho Smokers, ECS, ECS pits. First, you'll likely want to add some thermometers to the cook chamber so you can maintain a consistent temperature. However, anything you weld onto the door that you can grab will suffice as a handle. Secondary combustion means adding pre-heated fresh air above the burning wood which will add fresh oxygen into the flames and the temperature will rise allowing cleaner and more efficient combustion. This smoker is a 87" long by 30" diameter Reverse Flow Smoker with a Square Fire Box on the left side. Thanks, I have seen several guys doing it and have not gotten or seen an answer anywhere. The first step is to cut an opening in the cook chamber. There is a negligible amount of information on Spanish sausages in English, and even the Spanish books offer only a few recipes with general information, very skimpy instructions and hardly any explanations. The idea behind secondary combustion is to recover some of the heat that will otherwise go up the chimney by more efficient and cleaner burning of the wood. However, when you only have one door you have a greater risk of distortion when you cut out the door. Using concrete blocks or masonry bricks will only make a temporary arrangement as they will start cracking. Now you'll want to get a nice hot fire going in the firebox and let it cook for several hours. Runner Up in the First Time Author Contest 2018. Full 10 page set of smoker plans drawn with Auto Cad for you to build a smoker. All smokers employ a very simple system of draft control as the the main purpose of smoking is to create smoke at low temperatures and that can be often accomplished without any draft system. Now your cooker should be clean and ready for cooking! Full 10 page set of smoker plans drawn with Auto Cad for you to build a smoker. A metal box of suitable dimensions can also be used. That's a fantastic piece of kit. 24x24x24 = 13824 or only 71.8% of what you need. firebox size by: chas . This calculator is a wonderful resource to use when thinking through your design and deciding on the different dimensions. Made from 1/8" scrap steel sheet, and MIG welded together. It can be an integral part of the smoker or free standing separate unit connected to a smoker by a pipe or digged out trench in the ground. The design of this smoker was largely inspired by the smokers used at Franklin Barbecue in Austin, TX considered by many to be the best barbecue in the country. The temperature is set by the rate of burning wood and the excess fresh air is rushing into the pipe together with the smoke. Sandblast? You could then use a clear coat over the whole thing to try and preserve that look but I’m not sure if they make high temp clear coat or not. Please no low ball offers, I know what its worth and am firm on the price. The grate significantly increases the efficiency of combustion. I found some 1/2 inch schedule 80 pipe that works with the hot rolled 1/2 inch round bar. Then I'd make some slabs of 1-2" thick rocket stove cement (concrete and vermiculite mix) in place of the insulation...Unless that insulation works REALLY well, and I can save the weight. No Pipes!. It has a gas assisted fire box, which enables you to get your fire started quickly or use the firebox as an oven. Cut a 4-foot by 2-foot rectangle out of a flat side on the oil tank. I would recommend using at least 3/16" steel for the firebox as anything lighter will loose heat quickly causing you to burn more fuel and will warp and burn out over time. Looking for ideas, tips advice for anyone who has designed this feature into their smoker. This is a welcome scenario as this fresh air brings moisture with it into the smoker preventing the drying out of sausage casings. It could be a smaller barrel or a metal box. The tank is five feet wide, with two rounded sides and two flat sides. A highly insulated smoker, like the green egg, ends up working more like an oven than a traditional offset and the meat might not get enough smoke from the convection or may get too much white (dirty) smoke, in the case of the green egg, which causes bitterness in the meat over long cooks. Call or Email for Pricing. I was able to easily bend the round stock in a vice using a piece of tube to increase the the bending force but you could also use a torch to heat the material and make the bending easier. It comes on skids, three style of trailers and a wagon. There is a small gap between the two doors which I later welded a small piece of expanded directly to the angle iron in order to increase my cooking area. Wood burns from front to back. Grind? The firebox becomes the hearth bottom-grate type and by adjusting the top damper we can choke down the air supply and the wood will start smoking. The air intakes are critical factors to providing the fire with enough air. After the burn I had this orange/pink hue that I love. The ceramic insulation works very well and I don't think I would want anything that insulated the firebox more than that. Once you've got your expanded metal welded on you're ready to install the grates. I also chose to insulate my firebox with a layer of ceramic insulation of the top and sides to help with heat retention and fuel efficiency. I place the firebox here so that the hot air and smoke enters the cook chamber right at the grate level and travels straight across the tank to the stack opening. 2 months ago The hole can be drilled in the required area and the pipe can be directly inserted into the hole. 2 months ago. The combustion efficiency inside the fire box depends on the ways fresh air is supplied into the burning wood. This might be overkill so let me know guys, not sure how much charcoal/wood it takes to keep a 55 gallon drum at 225-250 degrees for extended periods of time. "Spanish Sausages, Authentic Recipes and Instructions" fills this void and the readers will know not only what is a chorizo, longaniza, salchichón, fuet, morcilla, butifarra, salchicha, sobrasada, fiambre, androlla, butelo, morcón as well as many others, but also learn how to make each sausage. I'm considering using a 55 gallon drum for my cook chamber, and lining the exterior with ceramic insulation, and wrapping that in a 14 gauge skin. Dyna-Glo DGO1176BDC-D Charcoal Offset Smoker – This isn’t your typical wood-burning offset smoker as it has a cabinet configuration with a firebox that’s more designed for charcoal. If the tank still full of water this part can get quite messy! It is built using a 250 or 330 gallon propane tank. Simply slide the L shaped round bar pieces into the tube and weld them onto the door. 250 gallon reverse flow offset cooker. Reverse Smoker Design. Along with the firebox the Throat opening, Baffle Plate Gap, and the smokestack in an RF Smoker are very important in this balance. Great job!! If you're going to take the time to post all this, why not take it to the next level! Looks awesome! This step is necessary for burning off any debris or chemicals that have been left from the tank or the manufacturing process. Raised stool grate stove a baffle and the secondary air. I used 1 ½" thick ceramic insulation which I ordered online and 1 ½" square tubing to capture the insulation. When you finish you can scrub the smoker with detergent and scouring … I will shoot a final when I finish. Now that you've got your doors finished it's time to start on the smokestack. I find the part of the cook chamber right next to the firebox gets pretty hot and also gets a lot of direct radiant heat which can easily over cook the meat. Even if you use the PitCalc you can still get these out of balance. Next I set the large tank aside and let it air out since it still smelled like propane. ... Like a 250 but way better. For these pieces you can use 1/8" sheet or match whatever wall thickness your pipe is. $2800 Now comes with Firebox top grill! I will be doing this myself in the very near future.My question is, where I am we only have access to the domestic and smaller commercial sized propane tanks. However, do not cover the top of the firebox yet as you'll need the ¼" plate exposed for welding onto the cook chamber. This trailer mounted smoker was built using an old 250 gallon propane tank and is the perfect size large parties, catering, competitions, or whole-hog barbecue. Now the hard work is done and you're ready to enjoy the fruits of your labor. Once it has cooled you'll want to wipe it down and repeat this process. First, mark on the tank where you want the opening for the smokestack to be. 1 year ago A 250 gallon tank has about 57750 cubic inches in it. The next step is to make the cooking grates. Too much insulation can also be a bad thing as you will end up not needing to add much fresh wood to keep your temperature up and you'll end up not giving your meat enough smoke. Thanks in advance. Where is the link for the blueprints? Next, make the hinges that will slide into the tube by bending some round stock in a vice. Once your done welding the hinges you can finish cutting out the doors. 1 year ago Nice work. Question Question I like to measure a quarter of the way around the tank for the bottom of the door and then have the top of the door a few inches from the top of the tank. Smoking can be easily done with an open fire (hearth-bottom grate) and adding more sawdust to kindling fire allows for some control at least in respect to smoke. Making headway on my 72 gallon propane tank reverse flow smoker. Now that the firebox is finished you're ready to attach it to the cook chamber. Baffle plates should be made of a thicker material. The next step is to measure size of your grates and and cut out your expanded metal and square tubing for the frame. That’s great! However, as I mentioned before, you will get much better results by moving your smokestack to be in-line with your cooking grates at the middle of the cook chamber. While this is a large project, it can easily be completed in a backyard or garage a few basic tools. A piece of firewood or a water pan seems to work pretty well when you’ve need have meat right up to the firebox. You also want the opening to be wide enough so that it collects air from the whole width of the smoker and not just the center. It is achieved by placing a baffle in the rear of the fire pit to prevent smoke from rushing directly into the flue and to re-direct it into the area where a secondary air is entering the chamber. Let it burn for a few hours and thoroughly clean out any debris. I like to have the grates roughly at waist level for the most comfortable use. Make sure to jump around with your welds on the expanded metal so you give the metal time to cool and don't cause any warping in the grate. The efficiency will further improve if the secondary air in C is preheated. A metal barrel of smaller size can be used for a fire pit or a large 55 gal (200 l) barrel can be cut in half and imbedded in the ground. I have another question. This is also a great replacement firebox for many cookers where the firebox has oxidized and burned through or fallen off. Welcome to the pros. No mention of measurements,size of the doors,gap measurements, smoke stack size, As the overall execution is clear. Would it be possible to use the regular domestic cylindrical one for the fire-box and a bigger 5ft small commercial one for the cook chamber?Looks like attaching the two will be the most headache.Many thanks for the inspiration and congratulations once again on an excellent smoker. There will be less soot and other unburned particles and less smoke as well. Reverse flow baffle is tapered and drains all grease to waterbox to avoid fires and smoldering grease. I marked a centerline and went a few inches above and below it to get a big enough opening. (VERY GLAD I DID). I used 1/4" mild steel plate for the firebox and baffle plate and had the steel shop cut it to size for me with their brake. The less clearance between the top of the baffle, the more heat will be supplied to the top of the fire box. The rate of combustion and temperature is controlled by the amount of wood placed in a fire pit and as the air is consumed, a new fresh air comes into its place. You'll also notice that the smokestack draws from the side of the cook chamber rather than the top like many other cookers. I had the firebox overhang 11" off of the trailer and placed the axle 31 ½" from the back of the trailer. Use a flexible tape measure to calculate the length of the curves or just leave the piece long and trim it once it's welded in place. The drawing below is an example of a closed fire box used in a heating stove. It is obvious from the drawing that a strong draft has very little influence on a combustion process as the air will only stream faster over the fire. ... (or firebox to cook chamber opening) which forces the air mass upward to the top of the cooking chamber where it cooks from the top down. I can't exactly remember the size of the round bar I used but I'm pretty sure it was ½". I used 1" x 1/8" flat stock for these door seals and progressively clamped and welded down the door to match the curvature. First, tack weld the tube just above where you will cut out your door. When a smokestack is too short it doesn't create enough draft causing incomplete combustion in your firebox which leads to thick smoke and bitter tasting meat. ... Post with 10689 views. A good method for cutting into a propane tank safely is to fill the entire tank with water and dish soap in order to remove any residual propane and safely cut into the tank. It does not wipe off very easily, I have not tried removing yet becuase I like the look, but have a feeling it will need to be sanded off. Thanks. I was making one based on the Franklin cook book and your post was very helpful. The firebox holds the fuel source for smoker and slowly transfers heat over to the main unit. To be able to control burning, the air opening has to be greatly decreased and a damper will start exercising control. In Episode 4 of BBQ with Franklin, from 2015, he walked through the process of turning a 250-gallon propane tank into a smoker. I am gonna try to build this smoker! Equipment for Making Alcohol Type Beverages, Directly on the ground, known as the hearth botom-grate, Above the ground on a grate, known as a stool-grate, Above the ground on a grate, known as a raised stool-grate. Once you've got the box all welded up you can cut out the opening for the door and the connection to the cook chamber. You'll likely have to do some grinding to get the right fit. The firebox design is further enhanced by sloping the floor of the firebox from the sidewalls down to the grate. Then you'll cut out pieces to form the rest of the smoke collection. The plan here is to turn a 55-gallon food-grade drum into a smoker in just a few hours, with minimal work and no welding. BBQ Trailer for Food Vending – Nice series on the topic of starting a BBQ trailer that you could use for a business. This is not needed during the smoking process but may be of use when we start cooking meats. My friends, Charlie and his son Levi did most of the cutting and welding on this project and I for sure could not have done this without their help. DESCRIPTION. That would be totally possible, you just would want to make sure that the volume ratio between the firebox and cook chamber is right. There are many different types of hinges you can buy but you can just as easily make your own using some tubing and round stock. I'm in the process of building one and I would like to know the dimensions of the firebox. For the frame I used 2" x 3" tubing because it is very sturdy and easy to weld but you could also use angle iron or C channel. A fire pit or fire box is the area of the smoker where we burn wood to produce smoke or to generate heat to cook meat products. It is much harder to make a stack taller than it is to shorten one. Build your own smoker using a heavy duty 11 gauge LavaLock® Fire Box for Offset, Horizontal or Cabinet style cookers. How well does that ceramic insulation work? Congrats! The biggest size, the 24x48x22, is best for those cooking for a larger party or even those that are doing competitive barbecuing. If you're building a smoker for cooking lots of whole hogs you may consider having just one door instead of two. on Step 14. You'll want the firebox to be roughly a 1/3 the volume of your cook chamber. This smoker is a 87" long by 30" diameter Reverse Flow Smoker with a Square Fire Box … Something like this: https://www.homedepot.com/p/Mueller-Global-1-in-Black-Malleable-Iron-Plug-521-805HN/100165402You could also just cut around the holes and weld a piece of plate in to seal the hole. Reply Answer For this build I used an old 250 gallon propane tank because they're made of thick 1/4" steel and relatively easy to find but any other kind of steel tank or pipe will work just fine. Yeah I had the similar chalky residue left over and I assume it’s just burnt primer. Needless to say we still need to add sawdust or wood chips into the hot coals. The first step is to fill the cook chamber and the firebox with a bunch of charcoal or wood and get it as hot as you can. How did you determine the throat size (hole from firebox to cooking chamber). Would like to here from you guys. The insulation is not necessary but definitely improves the performance of the smoker. Smoker options and pricing. Maybe look for a larger piece of pipe or get some plate that you could weld into a box. Call us to find out why! Be sure not to but the edges completely together so that you have a gap you can fill in with your welds in order to achieve a stronger joint. Franklin was something of … Once you've determined the height you can weld some supports onto the trailer to accept the smoker. putting a sub floor by: chipster . If you go with a 19250 cubic inch firebox, you will need the following. Had a quick question. The unit will have higher efficiency and less wood will be consumed. The general rule of thumb for a horizontal smoker is that the firebox should be 1/3 the size (volume) of the cooking chamber. Seasoned in … I'd recommend buying Tel-Tru thermometers or another high quality brand. Octos 110 Gallon Octo Smoker. When placing wood on the ground in a firebox with fresh air flowing in freely, the higher temperature will be in the back of a firebox or the barrel. All the internal stresses in the steel are released when the door is cut from the rest of the tank and the doors can flatten or distort heavily making fitting them much trickier. The first thing you need to do is source your drum. However, it can be hard to find them in some states so you've got to work with what you've got. The ugly drum smoker is about as basic and easy to build as it gets. A metal barrel of smaller size can be used for a fire pit or a large 55 gal (200 l) barrel can be cut in half and imbedded in the ground. Another useful addition is adding a grate to the firebox to help air flow around the fire or adding a layer of firebrick to help with insulation. You'll want to mount these at grate level so get an accurate reading of the temperature where the meat will be. These are just guidelines based on years building smokers but your mileage may vary! Cut along the lines you marked with an angle grinder and a cut off wheel. You don't have to worry about cutting into the trailer as welding the smoker onto the frame will make up for any structure lost from cutting into the frame. The first step is to cut all the sides of your box. Now that you've got the smoker mostly completed you need to do a burnout and season your cooker. The rate of combustion is independent of the draft and the fire burns as if no chimney existed. It always takes some time to get used to a new smoker and how it cooks but the more you use it the better you'll get and the better your results will be. This trailer mounted smoker was built using an old 250 gallon propane tank and is the perfect size large parties, catering, competitions, or whole-hog barbecue. 250 gallon propane tank!!!!! I used the same rectangular tubing to support the bottom of the tank and angled pieces to support the sides. I don't think these are really necessary as I can easily control the temperature by opening and closing the firebox door and controlling the size of the fire but many people like having these features to fine-tune their temperatures. What size charcoal box should I build? You can have a steel supplier do this for you to make it easier but you could also cut it yourself using a metal cutting circular saw or a cutting torch. For this entire project I used a chain hoist which I got from Harbor Freight for around $50. Particularly on the bottom and top of the firebox which are exposed to the most direct heat and can burn out over time when thinner steel is used. The 1/3 rule would require that the firebox would need to be at least 19250 cubic inches. The book is a highly recommended addition to personal and professional culinary additions. Now that you've got a finished smoker you'll need to get some wheels on it. They can be expensive but are very accurate and consistent. Gary Smith BBQ pits and smokers. Make sure these supports are parallel to each other and perpendicular to the door so your grates will fit properly. building a 250 gallon reverse flow smoker This is the building process that friends and I used to build a 250 gallon reverse flow smoker and put it on a trailer. Text show contact info if … If you want to build your own trailer you can buy trailer kits online that include the axle, wheels, springs, hitch, and lights so all you've got to do is weld up a frame. 250 gallon reverse flow smoker, (2) 30 x 60 slide out racks (3) rack warmer, holds 6 pans 1/4” firebox non insulated $2,200.00 500 gallon reverse flow smoker, (3) 35 x 77 slide out racks (3) rack warmer, holds 6 pans 1/4” firebox non insulated $2,700.00 Insulated firebox $200.00 LP gas assist on firebox $100.00 Firebox size should be 1/3 the volume of the cook chamber. I used a simple jig to create a relief bend in the hinges to leave room for the door seal at the top of the door. For the smokestack I'd recommend finding a large steel pipe (5" - 10" in diameter) and leaving it long as you can always cut it down to length once you know how your cooker performs. After welding the top edge you can put in the insulation and weld on the cover sheet to complete the firebox. A baffle can be placed vertically and it will direct heat in a different direction now. .250" firebox, glow in the dark tell tru guages, 15 gallon waterbox and 1.5" drain. I’ve tried using baffles to deflect the heat but found that they restricted the air flow too much. To control combustion and temperatures when cooking, a bottom damper can be adjusted to provide more air which will increase the burning rate and will create more heat and higher temperatures. The cut-out will be your smoker door. You could also take your smoker to an auto shop to get a more professional finish if you'd like. What are the length and diameter of that cook chamber? 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2020 firebox size for 250 gallon smoker