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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 22 2012 Post subject: "Biggy" sized WSM clone |
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I have this laying around. Little brother has suggested turning it into a super sized WSM clone.
DSCF0618 by jsmootz, on Flickr
Oddly enough, at 60" tall and 30" diameter it is nearly exactly proportional to his 18-1/2" Weber. Could it be so simple as to make a scale replica? I am guessing no but am seeking input.
Could be a fun project. _________________ 150 gallon vertical
propane pig
180 RF |
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k.a.m. BBQ Mega Star

Joined: 12 Dec 2007 Posts: 26020 Location: Southeast Texas.
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Posted: Oct 22 2012 Post subject: Re: "Biggy" sized WSM clone |
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smootz wrote: | I am guessing no but am seeking input |
All I have to offer at this time is will it come with custom steps and a engine hoist to raise the lid?  _________________ Always remember slow and steady wins the race.
Hybrid Cooker |
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Huntin Smoke

Joined: 06 Oct 2012 Posts: 15 Location: St. Louis, MO
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Posted: Oct 22 2012 Post subject: |
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I made something similar and it works really well. It was cheaper than building a horizontal somke at the time and it is a big space saver.
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 22 2012 Post subject: Re: "Biggy" sized WSM clone |
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k.a.m. wrote: |
All I have to offer at this time is will it come with custom steps and a engine hoist to raise the lid?  |
That was my first thought as well. Actually at 6'1 I can reach halfway down in it pretty easily. (The photo makes it appear larger than it really is). And hinging the lid and adding a little assist seems feasible too. A clean-out port on the bottom would substitute for the removable bottom on the WSM.
Biggest unknowns are intakes, exhaust, distance to grates, water pan. etc. I know enough from lurking that uprights don't really relate to the available calculators. Since this thing will probably stay in the family or my garage I can experiment and play with it. Maybe the logical thing would be to put in oversize fittings and start choking it down until it works right. _________________ 150 gallon vertical
propane pig
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 22 2012 Post subject: |
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Huntin Smoke wrote: | I made something similar and it works really well. It was cheaper than building a horizontal somke at the time and it is a big space saver.
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Very cute - I like it.
My hope is to build something that looks so much like a WSM that people will think I pumped one up on steroids.  _________________ 150 gallon vertical
propane pig
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MacEggs BBQ Super Pro

Joined: 20 Dec 2010 Posts: 1740 Location: Barrie, Ontario, Canada
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Posted: Oct 22 2012 Post subject: |
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Based on what you have built so far, I don't think you will have any worries.
If you are not satisfied with it,
then I will cross the border and dispose of it immediately.  _________________ "If the women don't find you handsome, they should at least find you handy."
Pickled Eggs
The cookers (so far).
Some Weber kettles of various age, color and size
UDS & Mini UDS
Abby Normal ECB
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k.a.m. BBQ Mega Star

Joined: 12 Dec 2007 Posts: 26020 Location: Southeast Texas.
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Posted: Oct 22 2012 Post subject: |
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smootz, if you put hinges and a counterweight on the door then it is no longer a clone it is just another upright.
At 6'1" you should be able to handle the lid with no problem I would however see about a fireman's suit in your size they can handle those temps. Oh and go with spinners on the intakes not screw outs. The screw outs will further detract from the WSM clone process.  _________________ Always remember slow and steady wins the race.
Hybrid Cooker |
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 22 2012 Post subject: |
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k.a.m. wrote: | smootz, if you put hinges and a counterweight on the door then it is no longer a clone it is just another upright.
At 6'1" you should be able to handle the lid with no problem I would however see about a fireman's suit in your size they can handle those temps. Oh and go with spinners on the intakes not screw outs. The screw outs will further detract from the WSM clone process.  |
Yep - spinners for sure - gotta do some thinkin on the lid. This is probably not going to be marketable, more of a toy but with this much effort invested I do want it to cook. Thus the concerns about intake and exhaust volumes. _________________ 150 gallon vertical
propane pig
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M Phil Newbie
Joined: 27 Aug 2012 Posts: 79
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Posted: Oct 22 2012 Post subject: |
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Huntin smoke, that thing is freakin awsome looking! |
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Pappy BBQ Fan

Joined: 29 Mar 2011 Posts: 131 Location: Granite City, Illinois (Near St. Louis)
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Posted: Oct 23 2012 Post subject: Re: "Biggy" sized WSM clone |
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smootz wrote: | k.a.m. wrote: |
All I have to offer at this time is will it come with custom steps and a engine hoist to raise the lid?  |
That was my first thought as well. Actually at 6'1 I can reach halfway down in it pretty easily. (The photo makes it appear larger than it really is). And hinging the lid and adding a little assist seems feasible too. A clean-out port on the bottom would substitute for the removable bottom on the WSM.
Biggest unknowns are intakes, exhaust, distance to grates, water pan. etc. I know enough from lurking that uprights don't really relate to the available calculators. Since this thing will probably stay in the family or my garage I can experiment and play with it. Maybe the logical thing would be to put in oversize fittings and start choking it down until it works right. |
Instead of lifting the lid like a WSM, you could rotate the lid with a barrel hinge. It could lift and rotate off to the side. _________________ 22.5 WSM, 120 Gallon Offset, Weber Performer, IQ-110, ET-732 |
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 23 2012 Post subject: |
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One thing is becoming obvious. Though it is possible to build an EXACT replica it may be smarter to build a WSM "based" clone. I will try to limit and/or hide as many of the changes as I can.
First part is a compromise:
Bottom clean-out instead of a removable bottom dome. It would just not be feasible to go get the forklift every time I need to empty ashes.
DSCF0713 by jsmootz, on Flickr
DSCF0715 by jsmootz, on Flickr
DSCF0717 by jsmootz, on Flickr
DSCF0719 by jsmootz, on Flickr
Bolts will be replaced with some sort of wing nut/bolt later.
Oh CRAP KAM !! I've barely started and have already contaminated it with bolts.  _________________ 150 gallon vertical
propane pig
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TrailerBuilder BBQ Super Pro
Joined: 08 Feb 2010 Posts: 3151 Location: Springfield MO
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Posted: Oct 23 2012 Post subject: |
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smootz wrote:
Quote: | Oh CRAP KAM !! I've barely started and have already contaminated it with bolts. |
Typical  _________________ X2 Finished Build
Disco Time
Fire Pit |
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 23 2012 Post subject: Re: "Biggy" sized WSM clone |
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Pappy wrote: |
Instead of lifting the lid like a WSM, you could rotate the lid with a barrel hinge. It could lift and rotate off to the side. |
Nice thought Pappy and thanks for the input. However the lid (dome) would have to lift off the flange and another 8 - 10 inches before swinging to clear the food on the top grate. Maybe I'm not seeing what you're saying.
KAM, I'm pretty sure you were teasing me but a little dedicated hoist may be the ticket.
Anyway there is a lot to do before I get to the lid.
Right now I am a little surprised at the Weber vents. Most every build I have seen here aims to place the vents below the fire grate. This Weber 18-1/2 has the three holes just above the grate. Is this an older cooker, a Weber engineering flaw, or is this how it should be?
BTW - I guess I am going to just up-size the vents to scale. If they are too big I can close them down. If too small I can weld the holes and start over. _________________ 150 gallon vertical
propane pig
180 RF
Last edited by smootz on Oct 23 2012; edited 1 time in total |
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k.a.m. BBQ Mega Star

Joined: 12 Dec 2007 Posts: 26020 Location: Southeast Texas.
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Posted: Oct 23 2012 Post subject: |
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smootz, I wasn't kidding the lid is gonna be a pita to manipulate. Hinges and a counterweight make more sense if your base can stand the offset weight and not tip over. That is a big concern of mine, what the lid does to the cooker stability once it moves off center, couple that with the added weight to raise it and you could have a mess on your hands.
As far as intakes yes they are above the grate but the ring places the coals at and above the three intakes. Everything works together to complete the burn slow and steady. _________________ Always remember slow and steady wins the race.
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 23 2012 Post subject: |
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The lid is definitely the biggest (no pun intended) obstacle but surmountable.
Thanks for the input on the intakes. I was seriously considering lowering them slightly until you spoke up.
I ran the numbers on this size tank. Up-sizing the vent holes by 67% would change the 3/4" holes to 1-1/4". Actual combined si of all three vents would be very close to the calculator's advise for a horizontal of this size so I should have a surplus of O2 while staying physically proportional to the WSM. In short, I will have more than enough flow and the capability to cut it down to zero.
I'm getting a little excited about this project. I had better come down to earth and finish the horizontal that is 90% done  _________________ 150 gallon vertical
propane pig
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Maniac BBQ Super Pro

Joined: 02 Oct 2010 Posts: 2433 Location: Pa
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Posted: Oct 24 2012 Post subject: |
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smootz have a slide gate suggestion for you. we use them on ash conveyor systems. since you all ready have it welded out i'll give you a modified version. in pic #717 top plate gets same hole as bottom plate. in between both plates is what we call a frying pan. flat plate with handle. cap screws get longer with springs on them......don't need heavy compression just enough to make a seal. your mod will be a hole for your fourth bolt thru pan since it is already welded and tapped. ours have the tapped holes wider so pan slips between them.......sorry for the long post. _________________ RF Smoker
20" disc
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Charro Newbie

Joined: 13 Oct 2011 Posts: 48 Location: San Antonio, TX
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Posted: Oct 25 2012 Post subject: |
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How about splitting the dome - think orange segments. Half the dome opens right, the other left? I've seen your work, you can do it. _________________ Is it still art if you can't smoke it?
Back yard offset
Last edited by Charro on Oct 25 2012; edited 1 time in total |
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Maniac BBQ Super Pro

Joined: 02 Oct 2010 Posts: 2433 Location: Pa
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Posted: Oct 25 2012 Post subject: |
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Charro wrote: | How about splitting the dome - think orange segments. Half the dome opens right, the other left? I've seen you're work, you can do it. |
+1 would like to see a telescope observatory look  _________________ RF Smoker
20" disc
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smootz BBQ Super Fan
Joined: 12 Nov 2011 Posts: 451 Location: Kitts Hill, Ohio
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Posted: Oct 25 2012 Post subject: |
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Ha! Ha! Ha! Let's challenge Scottie!!!!
The slide gate gave me one of those "Why didn't I think of that" moments. I'm going to have to see if it is easier to adapt to the flange I already put on or cut it off and start over. BTW - Maniac I havn't figured out how to view your photo.
Splitting the dome is a really cool idea and would probably be an attention getter. It will be a trick to get everything to seal. Swinging out like an observatory would be so trick but I am think that splitting it and hinging each side to lift individually from the center might be more feasible. May even have minimal merit as a way to check food without opening all at once.
.Let's see - hydraulic power unit and cylinders, a few solenoids, limit switches, stepper motors, ----- Just kidding!
 _________________ 150 gallon vertical
propane pig
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4ever3
Joined: 17 Apr 2012 Posts: 15
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Posted: Oct 25 2012 Post subject: |
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I'm with Charro! Split it!
Oh and what about instead of hydraulics why not use steam generated from the fire box? Hmmmm?  |
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