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New Stumps clone underway - Finished!! pics on 6/13
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dfess1
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Location: Philadelphia, PA

PostPosted: Mon May 23 11 10:07 am    Post subject: New Stumps clone underway - Finished!! pics on 6/13 Reply with quote

So I have been wanting to upgrade from my Brinkman SnP for sometime now. I do not know how to weld at all, but luckily my father does, and has most of the tools we'll need. So I figured this would be a great father/son type project. Only problem is, I now live in Philly, and my parents are still up in Rochester NY. Luckily my boss is pretty cool, and is allowing me to work remotely for however long it takes to finish this off.

So, last summer I was kicking around a R/F design on a trailer. Well, a year has passed and the only thing the same will be the trailer theme. We've decided to go with a Stumps clone, looking for cold weather efficiency, ability to get sleep at night with a long cook, and just the overall coolness of the cooker. The cook chamber will be 42" wide, 2' deep, and 4' tall. We're also going to take a shot at a way to line the fire box to hopefully negate the burnout inherent with the design. So this past friday, I packed up my stuff, and headed north.

Now, not only do I enjoy bbq, but my wife and I are also avid homebrewers. We're also ready to take the step up to all grain brewing. What's that matter? Well I wanted a single tier brewing rig, that would be loaded on the trailer with the smoker, and allow the brewing related pieces to be easily stripped off the rig, so it can double as a 3 burner gas stove. My father, being a mechanical engineer, came up with the designs based on my requirements, and went to town on the rig. We figured there is going to be more than enough welding going on with the smoker, and he needed a side project at night to work on that wasn't "work". So when I got up here on friday, this was already done.

Here is a shot bare. The pumps are in the front, and that's about it.



The top collar is extruded aluminum, with stainless grates on the top. The extruded aluminum allows for countless mounting points. This is/will be key.



This is a shot of just one burner. The piece in the front is a heat deflector for the sight glasses and thermometors. You'll notice a nut on the back rail. Turning this nut raises or lowers the actual burner. Without knowing how close I wanted the burner to the bottom of the pot, and not knowing how much different that would be for a normal fry pan, I wanted it to be adjustable. This works like a charm, with the burner assembly riding along another post of extruded aluminum, as shown in the pick below.




In the shot below, you can see the pump assembly. Follow the post up to the top of the extruded collar. The pumps sit on a platform that is welded to the post. The top of the post is a piece of angle iron, that has two pins that ride in the channel of the top of the extrusion. The bottom of the post
sits in a cup that is attached to the bottom shelf. All i have to do to remove the pumps is to lift up on the handle, and pull them away. Also, just behind the pumps is the gas rail, that has flow controls for each burner. They rail is fed by a 0-40 psi regulator, and the flow controls work great.

Still to attach are the starters. We're using just a normal bbq push start, so you don't have to have your hand in there with a fire starter to get her
lit.



Again, the extrusion is great for mounting points. Just need to rig up a bracket, and it's easy on, easy off.



And here's a shot with the pots on top.



Yes, these do fit underneath. Everything can be stripped off of the rig quite easily, so that it can double as a three burner stove at a bbq
comp/camping/tailgating, etc. The unit that houses the switches will also hang on the front of the rig, with pins holding it in place that sit in the
top rail of the extrusion. Still need to pick up some lids so we can put the returns in them for transferring liquids among vessels. The brackets for
the Hop Rocket (hop back) and the water filter are drying right now (paint). Will have those ready to go in a day or two. And I need to get to HD and pick up a contractor pack or two of hose clamps. Need to cut the hoses to length and attach the cam and groove fittings. Then we can get on to a wet test.
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dfess1
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PostPosted: Mon May 23 11 10:11 am    Post subject: Reply with quote

Today, sunday 5/22 (yes, we made it through the rapture), I started to learn to weld. After running some sample beads on a piece of scrap, I graduated to these two pieces.



They didn't come out too bad for only a half hour in!

Then it was onto the fire grate. This is a shot of it still "warm". Tomorrow morning I'll be back out to grind down the welds. These aren't quite as nice as the test pieces, but Dad says they should hold no problem. Maybe once they are ground down, they'll look a little nicer.



Should start on the shelving tomorrow, or possibly the frame, not sure yet. We'll see, but I"ll be updating this (hopefully daily, all depends on how tired I am, and whether I remember to take pics along the way).
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mwells
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PostPosted: Tue May 24 11 1:04 am    Post subject: Reply with quote

Thats a great start. There will be enough grinding along the way, I wouldn't worry about the grate. No one will ever see it. Unless it is hanging up when you mount it, I would move on.
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dfess1
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PostPosted: Thu May 26 11 8:29 pm    Post subject: Reply with quote

Ok, time for an update. We have the frame welded up, and the angle iron for the trays. I will be welding up the expanded steel for the trays as time permits, and we aren't working on the frame itself. We're still waiting for the firebox to come back from the fabricator, as Dad doesn't have the equipment to weld 1/2" plate.

Here's a shot of the frame:



The lower piece in the front (the really crappy looking one) is just tacked to hold it square. We are keeping the bottom support to do towards the end so that we can get in and weld in the cook chamber skins. This way it isn't completely in the way.

Saturday we pick up a trailer and try to modify that to suit our needs.
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mwells
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PostPosted: Thu May 26 11 8:37 pm    Post subject: Reply with quote

Coming along. Where are you planning to mount the firebox? Left, right, back? When you get some skins on it, it will really start to look like a cooker.
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dfess1
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PostPosted: Thu May 26 11 8:39 pm    Post subject: Reply with quote

the firebox is going in the middle of the back. We need that to come in so that we can pattern the hole for the transfer tube. We need to also weld in the supports for the firebox. We're going to attach it with angle iron, so that it is easily removable in the case our design doesn't work out, or burns out. The fire area itself is going to be lined with firebrick (same stuff used for fireplace's). Hoping this helps prevent the burnout.
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mwells
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PostPosted: Thu May 26 11 8:47 pm    Post subject: Reply with quote

I know guys have used firebrick before. Not sure it prevents burnout more than the 1/2 inch plate will. I think you will be fine either way.

I would definitely suggest waiting to get the chute and firebox in to build the mounts. That is the way I did it the first time. The second time I thought I would do it the other way. I ended up cutting out tubes and rewelding them to fit the firebox.

I had a trailer clone planned. I was going to do the firebox on the back too. When I changed and decided to build another porch pit, I went back to a side chute.
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dfess1
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PostPosted: Tue May 31 11 7:18 pm    Post subject: Reply with quote

Ok, It's tues 5/31, and we got some more accomplished this weekend.

First off, let me start by correcting a mistake. The firebox is going to be 1/4", not 1/2". And we're using the firebrick in hopes that it will prevent the burnout and not need to use the 1/2". Also, we were waiting for the material, but that's because it was being cut to his drawing specs.

Anyway, on to the pics.

I got all 6 shelves made up. 2' deep by 3' wide.



Here is the firebox, about 75% complete. Still to weld to it (at this point) are the angle iron pieces. Since we aren't sure that the firebrick is going to hold, we're making it so you can unbolt the firebox if we need to make changes. That small hole there is for the transfer tube.



Here's a shot from the other side, with just the grate poking out.



Saturday morning we got up early and hit the public market. Then, this little fella followed us home!



So the trailer is wider and longer than we are going to need, but at the price we/I was willing to pay for a trailer, it was the best we could find. After half of saturday and half of sunday (needed time out to go fisihing), this is what the trialer is reduced to:



Monday saw the arrival of my brother (for only the day, he is leaving today to head back to Philly). With his help we got the rest of the angle iron tacked onto the firebox, the metal cut that will hold the brew table in place on the trailer, and we got the inside ceiling welded into place (no pic of that at the moment), as well as the inside and outside backs cut out for the transfer tubes and the exhaust stacks. I'll get pics of those tonight.

Here is my brother and father with the frame, and the firebox mounted to the frame. My brother is holding the frame level while dad finished the welds holding the mounting bars for the firebox to the frame.


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dfess1
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PostPosted: Thu Jun 02 11 10:25 pm    Post subject: Reply with quote

So here's the progress from last night.




The inside is done with welding! All of the interior skins are welded in place.



This hole is where the transfer tube will come into the smoke chamber from the firebox. The supports above it are for the heat deflector and the grease deflector. These pieces are cut, just need to be bolted in.



The ugly bar that was there previously has been removed. The front bottom rail is welded in place. It's a U channel with a 2" drain in the center. The grease pan will be mounted below the hole. The floor has a bit of a slope to it. Hard to see in this pic, but it should carry the grease to the front rail, then out the hole.



All of the shelf rails and stops are welded in place. 4" between each shelf.



Here's just two shelves in place. Need to clean up the welds a bit on the rest of the shelves to get them to slide nice.



The stops work great. No sag to the shelf, and it isn't going anywhere when full extended.



Here is a shot of the backside. These were the firebox mounts from an earlier pic. The firebox will bolt to the back of the smoker. This way, if we need to modify the plan at a later date, we can. And we won't need to do a buttload of grinding to fix anything.

Tonight we start cutting insulation and putting on the outside skins!
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dfess1
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PostPosted: Fri Jun 03 11 7:16 pm    Post subject: Reply with quote

Work from 6/2:

Last night we were able to get the insulation in place, and get the outside sheet metal welded on. Dad did most of those welds, mainly because you are going to see them. I am definitely not to that level yet, but welding is pretty fun. Already have a used one scoped out to pick up on the trip home!

Anyway, he did the welding, I cut the insulation, then ground down some of the welds after he was finished. Also packed the legs full of insulation as well, and ground down some of the welds on the shelves so that they slide easily on the shelf rails. Don't have a lot of pics this time around though.



You can see with all of the racks in, it's going to hold a ton of ribs. This thing with the insulation and outside skins, now weighs a ton. Actually, when we're all done, we figure a little over half a ton (1300 lbs give or take).

The firebox that was so heavy before, was mounted to the back of the chamber to make sure if mated up. Before my brother had to stand on the frame so it wouldn't tip over. Not anymore! The firebox feels light compared to the cook chamber!



The top holes are for the two exhaust stacks. Need to make those. Ran out of the smaller diameter wire last night, and used up the bottle of gas too. Getting more tonight so we can make it through the weekend.
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bmarley5780
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PostPosted: Fri Jun 03 11 10:07 pm    Post subject: Reply with quote

can ya give a round about estimate on cost so far on clone?
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dfess1
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PostPosted: Sat Jun 04 11 1:52 am    Post subject: Reply with quote

unfortunately, not at the moment. My father has been picking up the metal on his way home from work. He'll give me the final bill at the end. in the beginning it was something around 650 for the sheet and the tubing. But we've needed to make a run here and there for other pieces.
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dfess1
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PostPosted: Mon Jun 06 11 7:26 pm    Post subject: Reply with quote

Ok, the weekend saw two solid uninterrupted days. So we got alot of work done, but not neccearily a ton of pictures of the work in progress. More like we're done with this piece, here's a pic. So..

The heat deflector plate mounts were welded in. If you recall in an earlier pic, there are two pieces of angle welded across the back. The heat deflector and the grease deflector utilize pins to hold them in place.



Here's a crappy shot of the heat deflector. You can see the rests that are mounted on the walls for the front of the deflector.



Here is the grease deflector on top. It's hard to see, but the pins for this piece poke up through the rear angle. Then there are two cotter pins that hold the deflector in place. They can come out easily so that you can pull the whole thing out for easy clean up. The grease deflector is also larger than the heat deflector, and had angle iron along the edges to catch grease and funnel it towards the front of the smoker and into the grease trap.



Here's the door getting stuffed. This is the only shot we took with insulation going into it. Need to find a handle for the door, and order a thermo and we'll be good here.



Hey look, our trailer is back together! A little shorter and a lot narrower than before!



And it's about the length of a mazda3 hatch! So it won't take up a ton of room in the driveway.



So a bit has happened by this pic. We cut the legs down on the smoker, and welded on some feet. The smoker is going to be bolted to the trailer now, instead of being welded in. This way in the future, if we decide to take it off the rig, we can. A couple of grade 8 bolts and she won't be going anywhere. We also had the smoker jacked up and on blocks. Had to get the trailer under there somehow. Not like we were going to dead lift it.



Have the trailer slid back and in place. Now it's time to slowly set her down on the frame.



Stacks cut, welded up, and cleaned up.



Just resting in place. Need to weld on some rod so that we can put dampers over them.



At this point, the trailers new feet (well their mates actually) have been welded to the frame and the the smoker is securely bolted to them. The trailer is now up on jack stands. Will be picking up the pieces for the springs tonight, so we can get those and the axle back on.

Now, the frame in the front is where the brewing rig/3 burner stove is going to go. It's just laid on there at the moment. Need to put in some supports for that, but that will come once we get the firebox bolted on and finished up. The firebox door will be opening toward the rear of the brew platform, so we need to account for allowances.



And here's a shot of the rear of the trailer. This is pretty much it's final height. I'm 6' and I can see over the top of the smoker. So it'll be nice not to need to get on a step ladder to get at any of the racks. And the majority of the weight will be distributed over the rear axle.

We're getting there. Still on the to do list:

1. weld up ash pan
2. weld up chimney
3. cut fire brick to fit inside firebox
4. weld up supports for brew platform and weld brew platform to trailer
5. weld on rear jack/leveling supports
6. put on springs/axle
7. install light kit
8. weld on fender supports and fenders
9. finish up stacks
10. paint

there's probably more in there, but I'm forgetting at this point.[/list][/list]
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dfess1
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PostPosted: Wed Jun 08 11 10:20 pm    Post subject: Reply with quote

We're getting down to smaller stuff to get done. Between monday and tuesday, we got some more accomplished.


Last night we got the smoker door hung. Before we could do that, we needed to screw down the gasket material. Then get it lined up, hinges welded, and then the latches. Also have a coupler for my thermo that is coming shortly. On the outside it's a 1/2" female fitting, on the backside it's a 1/2" male threaded into the female. So the thermo will screw in on the front and the end of the termo will sit nicely between the two racks.



man these latches are heavy duty. Really sucks in the door, and gets a good seal on the gasket.



When we opened the door to see if it swung freely, we noticed that it was hitting on the corner of the trailer, and making it stop a little over 90 degrees. So we cut the corner off the trailer, and will be welding in a stop so it can't cam up on the corner that is there. Going to add a little rubber bumper as well so it doesn't chew up the paint.



Everything is now back in the smoker, deflectors and grates.



Here is the grease catch pan and assembly. The pan is not designed to travel here, hence no stops or pins/clamps holding it in place. Also below that is a reciever for the bike rack. yes, I wanted to be able to take the bikes with us as well.



Firebox is bolted on, and the firebox door is mounted. Have a piece of 2" nipple for the 2" ball valve that arrived yesterday. Also have the smoke stacks welded in place.



Have another fitting welded in place in the rear of the smoker, same as the front door. This is so that we can feed the probe wires for the Stoker unit (digital temp controller). Will make for a nice clean look.



Brew rig platform is welded into place, with additional supports for the decking. Remember, I won't be brewing beer while this is mounted to the trailer. Will only be using it as a 3 burner stove, so it won't see much weight on it at all. When brewing beer, the rig will be on solid ground, as 3 15 gallon pots are quite heavy.



The dogs weren't the only ones dieing of the heat yesterday! That lake (Lake Ontario) is still a brisk 65'ish. Wasn't in for long, that's for sure.
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dfess1
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PostPosted: Mon Jun 13 11 8:16 pm    Post subject: Reply with quote

Well, it's 6/13 and I'm back home in PA, with a smoker in tow. The last few bits when pretty quickly, so there may be some holes in the picture timeline. There are some cool tricks that I forgot to take pictures of, but will get those later on. Anyway, without further ado...



Frame and smoker are painted. The springs are on, the axle is mounted, and the tires are on. You can see the coal chute in the background. It's also all welded up and painted.



Here is an empty firebox.



First layer of firebrick is in. The white bricks in the corners are a soft brick. I cut it with a hacksaw. These are there just to take up the space in the corners, to try to keep the firebricks from moving around.



And the top layer is installed. We ran out of the soft brick, so the top layer has a piece in each corner, but it's only half the height of the final firebrick layer. Holds them in place no problem.



The decking has been installed on the platform at this point. There are D rings welded in around the outside of the platform so that they can be used for tiedowns. In front of this platform is the propane bottle holders. I didn't have any up there with me, so these remained empty for the trip home. Also in this picture, the last time we saw the handle for the third wheel.



The dampers are on top of the stacks. They have some repurposed hairpins that secure them when under tow. The hairpins came from my camlock fittings for the brew setup.



The firebox has been buttoned up. Now that's alot of toggle clamps! The trained eye may notice a couple of empty bolt holes. We miss counted by 5. Picking them up on the way home tonight to finish it off.



Here's a shot from the back. We installed some nice LED lights, so they should be pretty bright. The fenders are on, and the thermometer is installed. I used a Tel-Tru thermo, which I thought was fitting.



It's tough to see, but the bottom of the face says "Rochester, NY". Since we made the whole rig in Rochester, NY, I thought it was a nice touch!



Bikerack and the Bike have been mounted. This ended up towing pretty well. The bike did bounce a decent amount, but it made it home unscathed.



The brew rig is mounted and securely in place. It didn't move at all on the way home.



Getting packed up for the trip back home. Can't believe 3 weeks went by that fast.



Good thing I could fit most of the stuff INSIDE the pots. Allowed for the big stuff to still have a place in the back of the car, and for the dog to have the full backseat to himself.



Overall shot of the fully loaded trailer. It wasn't too long, and will be even shorter minus the bike rack.



It's pretty hard to see in this picture, but this is the door handle. Here's the background. Every summer my wife and I throw a "Caveman BBQ", no talking (only pointing and grunting allowed), no utensils (eat with your hands), no napkins (use your shirt!). Last year, it was our 5th annual BBQ, so I had T-shirts made up that have "Caveman BBQ" in what looks like stone block that has been chisled out, with Captian Caveman at the end of it. So, Dad took an old bat, put this really nasty looking wheel in the grinder, and went to town. The bat now looks like it's a hand carved club. Once I get a coat or two of stain, and some laquer on it, it'll have a permanent home on the door.



And here is Dad and I, in front of this beast. It was a blast being able to spend time with him, and learn all that I could from him. I enjoyed welding, and am currently looking for a used one I can add to my stable of tools. More of a problem would be where to fit it in my garage now. But we'll find a way.

There was one thing we weren't able to finish up before I left. We picked up a big electrical box to house the Stoker unit and a wireless router. Just ran out of time to mount it, but I wasn't sure where I wanted to do that anyway. So once I play around with it, we can mount it over the July 4th weekend (when I'll be back up there). It's really more of a rain shield for the units for an overnight cook. Tonight I need to give it a test fire, also ran out of time to do that up in Rochester. Sure we could have done it, but I wouldn't have gotten home until super late sunday. SWMBO has been pretty good with the fact that I was gone for 3 weeks (and took the dog mind you), didn't want to make her wait any longer.
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GreenSmoker
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PostPosted: Mon Jun 13 11 10:18 pm    Post subject: Very nice........ Reply with quote

If it cooks as well as it was made, and I'm sure it will, you are gonna run on it till pork runs out. Love the compact design and the 3 burner setup. Enjoy.


P.S. The Caveman idea is great. Love to see some imagination going on in the world. And your better half is in on it as well.


GreenSmoker / Steve C.
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PostPosted: Mon Jun 13 11 11:28 pm    Post subject: Reply with quote

That is incredibly cool, thanks for the pics!!!!

Where did you purchase those red latches for your cooker?
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dfess1
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PostPosted: Tue Jun 14 11 12:27 am    Post subject: Reply with quote

Got the latches off of ebay. Just did a search for "Toggle clamps".
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Tom C
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PostPosted: Tue Jun 14 11 1:24 am    Post subject: Reply with quote

Nice job! The firebrick approach on the firebox is a cool idea. That should really keep any burnout away that you can see in these type of smokers.
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PostPosted: Tue Jun 14 11 10:46 am    Post subject: Reply with quote

Got a test burn/seasoning going now. Been really happy with the smoker and the stoker unit. Got her up to temp really quickly. Been holding it quiet nicely.

Now I just need to figure out what to smoker in her this weekend to break her in! Suggestions??
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