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80 Gallon Reverse flow smoker build . new pics 5/17/16
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shadowrunner762
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Joined: 06 May 2016
Posts: 30

PostPosted: Tue May 17 16 5:16 am    Post subject: 80 Gallon Reverse flow smoker build . new pics 5/17/16 Reply with quote

Greetings all,
Originally I was going to wait till this was done next week, but sandblast is saying it will be next tues. when there done. I have been waiting to get a tank to make my own reverse flow smoker for several years now. 3 weeks ago one popped up on craigslist finally. its only an 80 gallon air tank, but i am geared up to make one. To date I have about 15 hours into the project, I am pressed for time on this and am moving as fast as possible. I used Feldons xcell sheet to get my calculations, and went about 5-7% over the listed totals.
Enjoy the pics

[/img]
the tank


in the lab


plasmacaming the firebox with 1/4" plate


more plasmacam


lining up on the cast iron planton table to see how to weld it


working the intake vents into the firebox


dampeners for the firebox


decided to be lazy and spray transfer the inside of the box.


got the face on the firebox


locking down the rest of the outside edge welds


fitting the door on the box


started treating the tank to get it to where i want


more cutting


plasmacamming the main hinges


drilling slightly oversized to make the fittings work


test fit.... it works


straight on view.


plasma cutting under the hinges for welding


another view


laser leveling and magnetically locking down the hinges for welding


locking in the X and Y axis


tack welding into position


welded to the tank


plasma torching the rest of the door out


first look inside


offset view


free cut the interface for the firebox


test fit of the firebox to the tank from the inside.. it fits !


everything is still level and on the mark


cut out the hinges for the firebox, tried to mimic the main hinges in look to be a little artistic


fitting the hinges to the firebox


everything is aligned properly


getting everything lined up for welding


solid fit


reinforcement on the firebox door to limit warpage


door finished

at this point today i got my steel for the base and have to start cutting it out. i have 12" tubeless tires and heavy duty casters. its time to get on the base.

Ill post more as i finish my base to the build.

be safe all.


Last edited by shadowrunner762 on Thu May 19 16 1:59 am; edited 1 time in total
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k.a.m.
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Joined: 12 Dec 2007
Posts: 26019
Location: Southeast Texas.

PostPosted: Tue May 17 16 5:27 am    Post subject: Reply with quote

Very nice work shadowrunner762. Very Happy I could get lost in that shop for weeks. Very Happy
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shadowrunner762
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Joined: 06 May 2016
Posts: 30

PostPosted: Tue May 17 16 5:30 am    Post subject: Reply with quote

Thanks boss..
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castrovillecowboy
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Joined: 26 Nov 2015
Posts: 268
Location: living in VA, heart still in TX

PostPosted: Tue May 17 16 5:32 am    Post subject: Reply with quote

Looking great Shadowrunner. Looking forward to watching the rest of your build.
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-olllllllo-
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PostPosted: Tue May 17 16 12:23 pm    Post subject: Reply with quote

looks pretty shwanky!!!
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Maniac
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Joined: 02 Oct 2010
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PostPosted: Tue May 17 16 3:35 pm    Post subject: Reply with quote

shadowrunner762 she is looking pretty good Exclamation Nice playground you got there Very Happy Really nice to have toys like that to play with Wink
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Smokin Mike
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Joined: 02 Dec 2008
Posts: 3163
Location: Winston-Salem, NC

PostPosted: Tue May 17 16 7:28 pm    Post subject: Reply with quote

Excellent work there shadowrunner762. I could setup a cot in that shop and just live there. Shocked


Question, Are you planning on putting in a grease dam between the firebox and the cooker?
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shadowrunner762
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Joined: 06 May 2016
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PostPosted: Wed May 18 16 7:54 am    Post subject: Reply with quote

Smokin Mike: hey boss, yes something in the works using the 1" drain plug. haven't sorted it out yet tho lol...
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shadowrunner762
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Joined: 06 May 2016
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PostPosted: Wed May 18 16 8:35 am    Post subject: Base Build Reply with quote

Got my measurements locked down today and started on the base for the build.


cutting the radii for the uprights with my homemade jig.


helps when you have not so steady hands lol..


60 ton multi-cutting station. love it..


laid out each side on the table an went to town.


welding my way to BBQ..


bringing the sides together.


"we need bigger clamps.."


45 min of clamping and leveling to make sure its dead nuts on.


the result, base completely flat, uprights were they should be. cant wait for the tanks to come back from sandblasting.


fitting and tacking the front caster bases.


locking them down.


finished up welding into position.


starting to position the casters and the back of the base to figure out how i am going to mount the wheels.


looking good...


only have to use a .250 plate spacer.

A question i have for the group, I have everything level, the only thing i don't know enough about is how much the tires will sink once the entirety of the weight is on it. the tires are rated for 288 # each. the inflation max is 24 P.S.I. the casters are about 175# each. i figure i will be around 500# when this is all said and done. Any advice on this would be appreciated greatly. all in all not bad for 6 hours in the lab today.

be safe all
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k.a.m.
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Joined: 12 Dec 2007
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Location: Southeast Texas.

PostPosted: Thu May 19 16 4:54 am    Post subject: Reply with quote

I would adjust for about 1'' squash. If they do not go that much you can deflate them some.
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shadowrunner762
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PostPosted: Thu May 19 16 5:09 am    Post subject: Reply with quote

excellent!!!... thanks for the intel boss..
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shadowrunner762
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Joined: 06 May 2016
Posts: 30

PostPosted: Tue May 24 16 10:14 am    Post subject: 80 Gallon Reverse flow smoker build . new pics 5/23/16 Reply with quote

greetings all...
got the stuff back from sand blasting finally and started on the reverse flow section of the build.

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/1_zpsxgq0utrj.jpg

brought the laser level back into play to index the plate


this made things so much easier...


worked out the template to make the piece fit... need more practice on those lol


everything still level..

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/5_zpsgqj4lmcn.jpg


located the hole for the exit on the pipe.. my torch hands suck still...

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/7_zpsybvm14fk.jpg

everything sealed in place and no warpage thankfully...

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/8_zpsldrfhfpx.jpg

pipe welded into place inside and out.

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/9_zpsvwhd1yrb.jpg
convex flexion of the upper cut, man it was bad , almost a 1/4" out of place.

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/10_zps0aae1yvo.jpg
after a chain, a 6ton jack and a torch pushed it back into shape... lol

http://i1067.photobucket.com/albums/u440/shadowrunner762/reverse%20flow%20plate/11_zpsjgqxzbby.jpg
everything flat at least.. more to do tomorrow...

made the 1-1/2" drain pipe at an angle to allow to flush out the plate and now get it on the legs or underneath.

btw, the photos are resized, not sure why some look larger.. interesting

be safe all
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Smokin Mike
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Joined: 02 Dec 2008
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Location: Winston-Salem, NC

PostPosted: Tue May 24 16 8:27 pm    Post subject: Reply with quote

Nice! I see I'm going to have to get a laser level. That instrument looks like it's very practical for constructing pits.
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shadowrunner762
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PostPosted: Wed May 25 16 9:11 am    Post subject: Reply with quote

Its made my life much easier. I use it all the time hehe.
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shadowrunner762
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Joined: 06 May 2016
Posts: 30

PostPosted: Wed May 25 16 9:26 am    Post subject: 80 Gallon Reverse flow smoker build . new pics 5/24/16 Reply with quote

Got back to the build today. got on a roll and made a lot of progress by the time i stopped...


cut a 2" dam for the back end of the baffle plate.

http://i1067.photobucket.com/albums/u440/shadowrunner762/PIT%20TO%20BASE%20AND%20FIREBOX/2_zpslwglg8ln.jpg

Using Autocad to design and build it made quick pieces like this a snap. and they fit on top of it lol..

http://i1067.photobucket.com/albums/u440/shadowrunner762/PIT%20TO%20BASE%20AND%20FIREBOX/3_zpsdbitudy9.jpg

All welded in position, now i have 2" water bath if i want to use it that way.



used the laser level to snap a back line to build the grates on.


http://i1067.photobucket.com/albums/u440/shadowrunner762/PIT%20TO%20BASE%20AND%20FIREBOX/5_zpsfst71mgz.jpg

cut and positioned the angle iron and checked all my planes to be level.


http://i1067.photobucket.com/albums/u440/shadowrunner762/PIT%20TO%20BASE%20AND%20FIREBOX/6_zpst9xxsvdt.jpg

1 in square tube cut for the rack bases.


used the level to mark the back of the tank at the lower lid mark.


lowered it into position and monkeyed with it for around 30 min to get all the planes lined up


attached the firebox and 3 bead welded into position so it'll never move.. my fit-up was not as good as i would of liked on this project.


off view of the smoker


a view up into the back of the firebox, fit nicely, i dont think ill be able to get a bead in there tho lol.


i have in the end 5" from the baffle plate to the grate, and from the firebox to the baffle i have a 1.5" air gap.

tomorrow ill get to the smoke stack, and start working on the strapping around the lid area an the fire box. the door to the firebox is a good fit, not sure if i will do anything on it.

be safe all..
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SoCalSmoker



Joined: 09 May 2014
Posts: 24

PostPosted: Thu May 26 16 2:32 am    Post subject: Reply with quote

Very impressed by your fabrication skills. And I need a lazer level now after seeing how well they work. Keep up the good work.

Kyle
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shadowrunner762
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Joined: 06 May 2016
Posts: 30

PostPosted: Thu May 26 16 6:06 am    Post subject: 80 Gallon Reverse flow smoker build . new pics 5/25/16 Reply with quote

got the inside done today, and worked the exhaust pipe on to the pit. The locking mechanism took a bit to figure out what I wanted to accomplish.

http://i1067.photobucket.com/albums/u440/shadowrunner762/Racks%20and%20trays%20and%20exhaust/1_zpscpdhbepk.jpg

got the front to back on the upper level marked out.


starting to lay out the framework for the upper tray.


upper level finished


all the expanded metal inn place.


after a little thought, i cut a section of the exhaust pipe, and tack welded it in position and after checking all axis for level, dropped a ruler to mark the cut position on the compound surface of the pit.

http://i1067.photobucket.com/albums/u440/shadowrunner762/Racks%20and%20trays%20and%20exhaust/8_zps7ucgaxdl.jpg

plasma cut and ground clean the hole for welding


tacked into position, time to lock into place

http://i1067.photobucket.com/albums/u440/shadowrunner762/Racks%20and%20trays%20and%20exhaust/10_zpsdfhiz9b9.jpg

upper tray lock works...


expanded welded into position under the pit for wood storage.
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Smokin Mike
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Joined: 02 Dec 2008
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Location: Winston-Salem, NC

PostPosted: Thu May 26 16 7:19 am    Post subject: Reply with quote

Ok, I'm flunking you for not mitering the corners of the cooking grates. Laughing Laughing Laughing
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castrovillecowboy
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Joined: 26 Nov 2015
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Location: living in VA, heart still in TX

PostPosted: Thu May 26 16 8:32 am    Post subject: Reply with quote

I am with you Mike, and jeezzzz could you not have milled down the tubing so the expanded metal would have been flushed in. Getting lazy at the end. ROFL

Seriously though. That is some awesome work. I wish I was half that good.

Hope you have a perfectly level place to put it when your done. Can't wait to see a cook on it.

Great work.
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shadowrunner762
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Joined: 06 May 2016
Posts: 30

PostPosted: Thu May 26 16 9:08 am    Post subject: Reply with quote

Smokin Mike wrote:
Ok, I'm flunking you for not mitering the corners of the cooking grates. Laughing Laughing Laughing


hehe, time crunch on this one boss... and it didnt help that i wanted to get into the machine shop and they are off this week ...
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