BBQ smoker in the works

[zak77]

So i finally pulled the trigger on a new air compressor so i now have an old compressor that was showing it's age. What else am i going to do with it but built a new smoker out of it. The tank dates to 1941 and although the compressor still worked, it was slow and needed attention but upgrading to a new unit was the best choice. I spent the weekend cutting it up and burning the paint off it and a lot of small things got thought out. I had a 20lb propane that was out of date so that'll be the firebox. This will be a reverse flow smoker when done.

 

[DonPowers]

Looking good, will definitely outlast most manufactured smokers. What are you going to use for grates?

 

[PelicanPines]

Awesome... I'm in to see the rest of the project.

 

[pancho400cid]

Neat.

How 'bout a pic of the bottom of the air tank just for reference? How badly rusted is it for being 75 years old?

Take care cutting the propane bottle - or had you thought of that already?

 

[firworks]

Looking cool. Keep us updated. Did you use a plasma to cut that tank? The edges look real clean.

 

[msgross]

cool project... I have a 50+ year old 80 gallon tank, still in use.

 

[930dreamer]

Nice vintage Kellogg American tank, nice fab work.

 

[ZRX61]

I'm trying to get hold of a couple of engine cans for Lycoming T53's (Huey engines) as they appear to be the perfect size for a smoker, albeit a rather large one. I could replace my three smaller ones with just one bigger one.
There's two sitting across the road at the college, but I haven't be able to persuade the right people to part with them yet. I need to get over there with a tape & get the actual dimensions.

 

[gnpenning]

Neat.


Take care cutting the propane bottle - or had you thought of that already?

Looks like it is cut and attached in pic 3.

 

[bad_idea]

Awesome idea! I have an old 30 gallon tank and a propane cylinder laying around. Just what I need, another project..... Curious to see how this goes.

 

[whitetailhntr]

I know you said you already burnt everything off, tho isnt there any concern about food safety once you start cooking in it? Any chance of metallic fumes?


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[zak77]

Cooking grates will be expanded metal and firebox grate will be 1/4"x 1" flat bar that i need to piece together.

The bottom wasnt as bad i thought it'd be but i'll get some pics of it. What was very odd was when i was cutting the top plate off the tank with the round legs, one of the tubes had oil in it but not the other 3. There were no holes in the tank or anywhere else so i have no idea how the oil got in there.

All the cuts were with an angle grinder, just took my time and was careful.

The propane tank has been sitting outside for 3 months without a fill valve so there was no issue of built up fumes. I'm not worried about any possible food contamination with either tank since the temps it's already seen will burn off any possible contaminates considering the max temps this will see when done, will be about 350° but typically more around 250°.

I got most of the parts already so it's just finding the time to put everything together. This isnt my first build of smoker. Here's what i use when i need to feed an army. It's called the "Big Dog".

 

[zak77]

Well i've been making some progress. I've been working with what i have on hand instead of buying new steel so some of it has paint and rust which needs to be cleaned off before welding so that prep time is eating away at fab time so the build has been a little slow. Plus i've been helping my mom with cleaning up my grandmother's house since she's now in an assisted living facility. Here's how she sits after this weekend. What kills me about my garage is that the slab was poured with a crown so that any water would drain to the sides, so of course the slab isnt level side to side. I thought i had leveled the smoker prior to welding the legs on but something happened and the end result is a non-level smoker so i gotta fix that issue. At least it's a "rolling chasis" now.

 

[Richard Cranium]

looks great so far, keep us posted with pictures.

 

[XJPat]

If I may suggest adding a side table, that also doubles as a handle for moving it around.

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[southalabama]

Neat project.

Check out "barbeque by franklin" on pbs. He has an episode where the shows a number of BBQ grills built from tanks. He showed the subtle features that made the difference. Also the sizing and proportions of the air vents.

 

[zak77]

I planned on putting a shelf in front for when things come off the smoker. I gotta make a handle for the side to move it around which I should have some extra 5/8" rod that i used for the axle. After i get things level and back on track i need to put in the reverse flow plates and grease channel, firebox grate, cooking grate(s), chimney, shelf, put the doors on and then i can fire her up. Of course i gotta paint her in the end so she looks pretty.

 

[Bears Fan]

Awesome looks like some great fabrication there and I'm subscribing! I gotta see the finished product now Oh great now I'm on the hunt for a old tank! thanks a lot, another project on my list

 

[Bears Fan]

Oh yeah I really like the size of it, seems like everyone wants to build a monster size grill, but how many time would you need one that big? this looks like a perfect size

 

[JonBoehman]

Loving it! Keep us posted. I am going to do one in the near future myself

 

[TheEquineFencer]

I know you said you already burnt everything off, tho isnt there any concern about food safety once you start cooking in it? Any chance of metallic fumes?


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Yeah, I was thinking both are galvanized.

 

[JonnyMac]

Subscribed to this one.. ive been making a few firepits for friends recently and have been considering a move across into bbq/smokers!!
In terms of cooking, what would you be cooking up and how long will it typically take?

 

[zak77]

This smoker will be for smaller cooks when i dont need a ton of space for a lot of food. Like if i want to cook 1 brisket. I do have a WSM(Weber smokey mountain) which is a great smoker but space is a little limited and there's just something about a stick burner versus a charcoal smoker for taste. It just seems "cleaner". The WSM is great for butts that take 12-16 hours to cook but for a 5-6 hours brisket, this should work great. Even if i want to cook chicken thighs, sausage, pork loins, turkey, bacon(cured bellies smoked=bacon), roasts, etc, etc. Offset smokers do take a lot more baby-sitting than charcoal smokers but that's kinda the challenge of running one. It's not a set-it-and-forget-it, you need to check temp gauge every so often and add wood as necessary while adjusting air flow.

Last night i got it all leveled out, had to cut about a 1/4" out of the legs but she's sitting nicely now so it's on to working on the other parts.

 

[zak77]

I got a little more done on it. I have the reverse flow plates installed and the grease tray that carries the grease/fat down to the grease trap and the exhaust stack got mounted. The stack was a section of lally column that i had kicking around but getting the concrete out was the problem. I had it in a fire for about 6 hours hoping that'd weaken the concrete to the point where it'd easily crumble out, nope. It did go easier than i thought. I used an angle grinder to make a cut length wise which allowed the steel to seperate from the concrete. I just welded the seam back up afterward.

 

[Deadscout]

Subscribed to this one.. ive been making a few firepits for friends recently and have been considering a move across into bbq/smokers!!
In terms of cooking, what would you be cooking up and how long will it typically take?

We recently put a firepit in our backyard. Don't get me wrong firepits are nice but I have been thinking of branching out and getting something bigger as well.

 

[jeepboy4life]

This smoker will be for smaller cooks when i dont need a ton of space for a lot of food. Like if i want to cook 1 brisket. I do have a WSM(Weber smokey mountain) which is a great smoker but space is a little limited and there's just something about a stick burner versus a charcoal smoker for taste. It just seems "cleaner". The WSM is great for butts that take 12-16 hours to cook but for a 5-6 hours brisket, this should work great. Even if i want to cook chicken thighs, sausage, pork loins, turkey, bacon(cured bellies smoked=bacon), roasts, etc, etc. Offset smokers do take a lot more baby-sitting than charcoal smokers but that's kinda the challenge of running one. It's not a set-it-and-forget-it, you need to check temp gauge every so often and add wood as necessary while adjusting air flow.

Last night i got it all leveled out, had to cut about a 1/4" out of the legs but she's sitting nicely now so it's on to working on the other parts.

I know this isnt about BBQ but as a pit master I must ask about your 5-6 hour brisket? Is this just the flat or is it the piont as well. I own and operater a BBQ catering company along with my father and when we smoke brisket (point and flat) it takes between 18-24 hours. the smoker looks good though and revers flow is the only way to go. This is my "Small" smoker, it is made in Gergia by a company called Lang BBQ. It sits on a 16-1/2" trailer, the front is a charcoal grill aprox 43"x23" the smoking chamber has two racks one at 71"x28" the other at 53"x27" it also has a warming over above the fire box that has three shelves at 13"x21". her name is Bertha

 

[zak77]

You've never done a brisket hot and fast?? When i first got into BBQ all i read about cooking brisket was low and slow, and that's what i did for years until i read about cooking them hot and fast. Boy was i impressed when i tried it. Instead of 225-250° kick the temp up to 325-350° and foil when the internal temp hits about 160-170 then put it back on till it's probe tender, maybe another hour or 2. Just as good as a low and slow brisket.

Just google hot and fast brisket for more info.

 

[jeepboy4life]

Can't say I have heard about hot and fast. Guess I just prefer low and slow but will have to try it hot and fast.

 

[mustange70]

Oh yeah I really like the size of it, seems like everyone wants to build a monster size grill, but how many time would you need one that big? this looks like a perfect size

Once you have one that big its hard to go back.

Love the build, I'm due to build another one to replace my current one. I'm wanting to build a very similar style as well.

 

[zak77]

It's all done except for paint, which'll be happening tonight. I'll try to get a pic of it tonight when i'm done painting but it may have to wait till the weekend. I'm spraying it with Rustoleum high temp paint with the cheapo hvlp guns i got from Tractor Supply. I got a 15lb brisket ready to go in this weekend!!!

 

[zak77]

Well there it is, all done. Tried it out on a brisket over the weekend and i'm happy with the way things turned out. Like any stick burner it's needs attention. I had to add wood about every 45 minutes +/-. Still need to fine turn the burn process to eliminate temp spikes but that'll come with time. Unfortunately i had a lot of other **** going on so i there were more temp fluxuations than i wouldve liked but in the end i'm happy and like it.

 

[jhn9840]

Very nice job. Thanks for sharing all the way through. Enjoy it for years to come.

jhn9840
John

 

[Bears Fan]

Nice! Now what time is The Garage Journal members BBQ

 

[ZRX61]

Here's those Huey/Mohawk engine cans I was talking about:
They are 5'6 long. Bottom half is 2'9 wide by 17.5in deep. upper half is 2'9 by 18.5in.
Vent in the end of the upper half is 4in dia. That 90deg Angle on the bottom is 3.5 by 3.5in & is 22in apart.
I figure the hinged door on the front would go between those 2 ribs which are 32in apart.
The flange around the outside is 2.5in on the ends & 1.5in along the sides.The part either side of the door is 17in & I figure that would be easily accessible.
Not much in the way of cutting parts off the outside, but there are some internal parts that would need the attention of the plasma cutter.
The fact that you can simply unbolt the two halves would made internal fabrication a piece of piss. I figure the main cooking surface would be about 2in below the top of the lower half (about 32in by 65in) & an upper shelf could be fabricated in the rear part of the top maybe 12-14in wide & running just a bit longer than the hinged door.
According to the link posted last week, the firebox would need to be 24x24x32 (or thereabouts) 26in cube also works. Size of the engine can is 260gallons.

 

[My Old Tools]

Or you could spring for a real pit built by my uncle. I worked for him 40 years ago in college.
http://anbewley.com/products.html

 

[ZRX61]

I like the designs from Klose. That big square box doesn't look right, but those are intended for commercial outfits. My use would be for home.

 

[JonnyMac]

Yep that looks awesome... any chance of a few internal pics. Im interested in the way the smoke flows through from the burner to the main chamber..

 

[bad_idea]

Looks good. I am building one just like it because of this thread. The inside of my compressor tank had a fair amount of rust. I cleaned it off w/ a wire wheel. Is there any further surface prep I need to do on the inside of the cook chamber? How did you prep yours?

 

[Capt Chrysler]

Or you could spring for a real pit built by my uncle. I worked for him 40 years ago in college.
http://anbewley.com/products.html

Ross, this is the Garage Journal. Not the Home shopping network. We build things! May have been cheaper to buy it. But, now what sounds better. I bought this or I built this?

Ok just poking a little. I did check out your uncle's web site. Very Nice Looking Rigs!!!

Have a great day!

Capt. Chrysler

 

[zak77]

Yep that looks awesome... any chance of a few internal pics. Im interested in the way the smoke flows through from the burner to the main chamber..

The only pic i have of the interior is the one further up on this page. Basically you have a firebox on the right side, then a sheet of steel that prevents the smoke from rising until it hits the other end of the cook chamber then it rises and flows out the exhaust on the same side of the firebox. You can use any gauge metal you want, i just happened to have 1/8" kicking around. It's best to put a piece of angle iron down the middle to act as a grease catcher and angle it to a piece of pipe where the grease can collect. When i'm done cooking i open the valve on the and all the grease goes into a can. If you're not making a reverse flow you're going to want to use baffles to help prevent the end by the firebox becoming a hot spot.

I didnt have to do too much cleaning to the interior of this smoker. I burned a hot fire to get rid of any oils then hit it with a wire brush. I vacuumed all the **** out and the smoker does the rest. You can oil it if you choose just dont paint anything on the inside. Just using it will build up a layer of bbq goodness and that's it.