Build a custom bbq smoker part III

Building your own bbq smoker is no small feat, but it is a lot of fun. This is how I approached it.

This is part III in the series. You can find part I herepart II here and part IV here.

The build continues. It is time to assemble the large food chamber. Since it is made of thin sheet metal it needs a skeleton (sort of) to stay in shape. So I mounted eight angle irons running the length of the food chamber.

Mounting the angle irons

Mounting the angle irons

To make sure the legs won’t bend or flex the outer cylinder I made vertical sections of angle iron also. But in order to bend them properly I cut slots every half inch. This way I can bend them with my hands, shaped to fit perfectly.

Custom bending of vertical angle irons

Custom bending of vertical angle irons

Since I had the original wooden board from which I cut out the wooden frame the size of the circle is just right. You can see three of them welded on to the main chamber below. They are located right where the legs will attach.

Vertical reinforcement angle irons mounted

Vertical reinforcement angle irons mounted

I did a test fitting of the leg frame before welding the outer cylinder just to make sure everything fits. It does 🙂

Test-fitting the leg frame

Test-fitting the leg frame

Now it’s time to remove the wooden frame that everything has been built upon/around.

Breaking the mold

Breaking the mold

I fabricated the two doors today, that was a smaller job. I made them from 2 mm sheet metal, and welded frames out of angle iron.

The two doors fabricated

The two doors fabricated

In order for the doors to fit the main chamber I fabricated adapter frames. I test mounted these below, to make sure the fit is just right.

Test fitting the door frame

Test fitting the door frame

Before the last parts of the wooden frame is removed I welded support braces in place in the middle of the food chamber. I also welded the grill grate ‘bars’ in place, as this was way easier to do now than later when the chamber is welded shut.

Mounting support braces and grate 'bars'

Mounting support braces and grate ‘bars’

Now it was time to finally remove the last parts of the wooden frame.

Breaking the last parts of the wooden frame

Breaking the last parts of the wooden frame

And finally I get to weld the first short end in place. I chose to erect the main chamber to get the best circular fit.

Mounting the short end

Mounting the short end

Follow the build in part IV here.

Posted by Henrik

Passionate food lover and a big fan of traditional barbecue.

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