Constructing a BBQ Smoker

Raymond · Posted: Jan 03 2012 Post subject: Constructing a BBQ Smoker

Hello Folks,
I have been bitten by the BBQ Smoker Bug. I am in the process of setting up my first BBQ Smoker. I used my regular BBQ to smoke some trout on and I am hooked. I have a wood furnace that I have just removed from my house, and it is still in fine shape. I think it will make a perfect BBQ Smoker. It has a fire box at the bottom and on the top of that is where the smoke comes up into the smoke box and goes out the stove pipe opening at the back. I think I will weld a steel box on top of the furnace and will put a cap on the stove pipe opening. I will drill holes along the top of the smoke box on the furnace to allow the smoke to enter into the smoker that I am going to weld on top of the smoke box of the furnace. I will then install a chimney on top of the smoker with a damper inside of the chimney pipe. And I will need to install some heat gauges also. I have all of the furnace controls and the thermostat and I think I will connect them all back on the furnace. I need to gather some racks and some rods so I can hang larger pieces of meat like bacon sides and sausages and so on. What else do I need to complete this BBQ Smoker other than the door hinges and the obvious stuff? All your ideas and recommendations and help will be very much appreciated. This BBQ Smoker will sit under a lean to roof. It will have wheels on it and will be able to load it on my trailer and take it to the camp or where ever else I want to go with it. For a cold smoker, would it work if I covered the holes over that I plan to drill in the furnace smoke box and uncap the stove pipe opening and attach another box and stove pipe onto the stove pipe opening? I hope that makes sense to you all what I am asking.
Thanks,
Raymond

232mako · BBQ Fan Joined: 27 Apr 2010 Posts: 266

Howdy Raymond, sounds like a cool build all I would suggest is welding 1" to 2" high pieces of pipe in the bottom holes to keep the grease from entering your firebox and causing a grease fire, other than that you need to post Pic's of the build. Very Happy

Raymond · Posted: Jan 04 2012 Post subject:

Hello 232mako, that is an excellent suggestion about welding the 1' to 2" pieces of pipe to keep the grease from entering the firebox. I just thought about welding a 1" to 2'' frame around the outside edge also and have a small section with a channel so the fats and greases can run off into a holding container. Do you think that would be a good idea also?

Raymond · Posted: Jan 04 2012 Post subject:

Will post picks when I start the build also. Thanks for the ideas.
Raymond

Raymond · Posted: Feb 06 2012 Post subject:

I have started this build. Here are some of the photos. The OD are 20" wide by 42" long and 4' high walls. Here is the framing of the smokehouse,

The two side wall are studded.

Now for the front and back walls.

Now to join the four studded walls together.

Now to start the boarding of the walls.

I figured before I made it to heavy to lift that I would take it and put it on top of the furnace.

Raymond · Posted: Feb 06 2012 Post subject:

Here is the walls sitting on top of the furnace. I will continue to board up the walls.

Now I add some slow slopping roof rafters that I salvage from an old tent trailer.

Now to board in the roof.

Now to build the double doors and install them.

I just realized that I have to change the lower hinge on the left hand door,. I installed it on the bottom of the line I made instead of on top of the line where it should be.

Raymond · Posted: Feb 06 2012 Post subject:

Now to do the work on the inside. I need to get some more wooden dowels to put inside the smokehouse and I have racks inside my basement for the smokehouse also.

I now need to rip boards to make strip of wood to screw over each crack between the boards and I am going to install tin of the roof. I decide to make a fire in the firebox to dry things out a bit. The smoke pipe is not connected into the smokehouse yet either. I need to install a damper into this smoke pipe also. I was planning on drilling holes in the smoke chamber but have decided to put the smoke pipe through the end and install a chimney with a damper out through the roof on the other end. Here is a few photos of the fire in the furnace.

My back is screwed right now so there is not much worked getting done on the smokehouse lately.

Raymond · Posted: Feb 06 2012 Post subject:

Here is a view while looking down at the furnace top. where I was going to drill holes through the top to allow smoke to rise up from the holes. But I plan on putting the smoke pipe from the furnace into the bottom end of the smokehouse.

It is getting wet when it rains because the roof needs to have tin installed on the roof. That is what will be done next.

Raymond · Posted: Feb 06 2012 Post subject:

This furnace was removed from my home and I had it saved for this purpose. There is small of creosote on the inside of the furnace but I plan on using my power washer to wash out the inside of the furnace. Is there anything in particular that I can use as a cleaner that would be good to use for this purpose? Any and all responses and answer will be much appreciated.
Thank you,
Raymond

daddywoofdawg · Posted: Feb 06 2012 Post subject:

Get some of that fireplace cleaner you throw it in the fire and it burns the cr@p into ash.or contact a fireplace store and see what they have.
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Raymond · Posted: Feb 07 2012 Post subject:

Good idea, I will do that.
Thanks,
Raymond

k.a.m. · Posted: Feb 07 2012 Post subject:

Raymond, your cooker is looking Great. Very Happy

What are you going to use for a stack? I look forward to seeing some more pics and updates. Very Happy

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SWP5767 · Posted: Feb 08 2012 Post subject:

This is one of the most interesting smokers yet. I really like the idea of a wooden smokehouse style cooker. Great use of the resources you had around.

Great job!! Cant wait to see your first cook in it.
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Raymond · Posted: Feb 08 2012 Post subject:

Raymond · Posted: Feb 08 2012 Post subject:

TrailerBuilder · Posted: Feb 08 2012 Post subject:

Very unique cooker for sure Smile

I like it and look forward to its finish and seeing some food pics from it. Nice Job Very Happy

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Raymond · Posted: Feb 08 2012 Post subject:

Raymond · Posted: Feb 22 2012 Post subject:

Hey Folks,
The smokehouse build has been on hold for a while because of a back problem and I am having a fair amount of pain and I am awaiting to receive an Epideral injection in the spine on March 10th. I do have a question that I could use some advice on. Is a 5" chimney stack with a damper to large for the roof pipe, and also do I need a damper in the pipe coming from the firebox to the smoke house.
Thanks,
Raymond

ChuckieD · BBQ Super Pro Joined: 07 Oct 2009 Posts: 1129

Raymond,
I like your smoke house! Cool

I have back/neck problems also, and know what you are going through. There is nothing like having a project staring you in the face every day that you can't work on because of pain. Wintertime is hard, but spring is around the corner and if you are like me things will start to get better. Wink

Take your time and get better, the smoker will be there when you are ready to finish it. I hope you get well soon bro and nice work on the smoker. Wink

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Chuckie D.

Big Green Egg XL
UDS build
The Old Brick Barbecue Project!

fallywhacker · Posted: Feb 22 2012 Post subject:

Interesting concept. I also have a similar furnace that heats my house. My question is what kind of wood is the smokehouse built from? Also what is going to keep it from catching on fire or are you expecting the furnace jacket to prevent this?
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