Build a custom bbq smoker part IV

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

The build continues. It is time to weld the outer cylinder air tight. The pieces of tape you seen on the end is to mark where all the angle iron is located, so I know where to cut holes for the doors, as well as where to mount the legs.

Outer cylinder being welded

Outer cylinder being welded

Once that was done I started mounting the leg frame. The angle is key here, so the smoke stack doesn’t point sideways like the tower of Pisa.

The leg frame is being mounted

The leg frame is being mounted

Here you can see the leg frame from another angle.

The leg frame seen sideways

The leg frame seen sideways

Before flipping the whole smoker upside down the drain pipe for fat and juices must be mounted. I made a small square hole in the bottom of the food chamber and mounted it:

The fat drain mounted

The fat drain mounted

The time has come to cut a hole for the fire chamber. I used the jigsaw and steel grinder for this, it didn’t take long.

Hole for the fire chamber

Hole for the fire chamber

It is finally time to flip it right side up, so work on the doors can commence.

Ready to raise it upright

Ready to raise it upright

So this is what it looks like when standing on its own frame for the first time.

It's standing upright for the first time

It’s standing upright for the first time

I’ve been meaning to fabricate hinges for the fire door for a long time, but never gotten around to it. Well, I built them today.

Fabricating fire door hinges

Fabricating fire door hinges

While at it I built hinges and handles for the food doors also.

Door handles and hinges in place

Door handles and hinges in place

In order to mount the doors I cut two large rectangular holes in the main tank. It took a while, but I managed to get a snug fit.

First door being mounted

First door being mounted

Once I had the second door tap welded in place, it was time to start sealing all welds.

Both doors tap welded in place

Both doors tap welded in place

After working hard to cut hole for the firebox it was time to see if it fit.

Time to mount the firebox

Time to mount the firebox

To make sure there are no air leaks in the main chamber I mounted gaskets in the doors. These are replacement gaskets for the Kamado Joe. I chose them since they are 1 inch wide.

Closeup of the gasket mounted in the lid

Closeup of the gasket mounted in the lid

Some finishing touches: I added support ‘legs’ to the doors so one can leave them open.

Support 'legs' for the doors in place

Support ‘legs’ for the doors in place

I also fabricated four grill grates. They are easy to take out for cleaning.

Grill grates manufactured and mounted

Grill grates manufactured and mounted

After welding a bevel frame where the firebox is mounted, it was time to slide it in place.

Firebox mounted

Firebox mounted

I proceeded by mounting the smoke stack, and then came the time to fire it up!

 

Posted by Henrik

Passionate food lover and a big fan of traditional barbecue.

Leave a Reply

Your email address will not be published. Required fields are marked *