Smoker Build

[Aaron Mathis]

After several years of being completely addicted to smoked meat, I have finally decided to build a smoker. The motto of my life is to either "Go Big, or Go Home!" That means I often bite off more than I can chew, which makes for some awesome projects, and meeting some amazing people who help me along with that journey.

I've been cooking meat on a filled cinderblock Santa Maria style cooker. After several whole pigs(200#+), numerous birds, and various hunks of animal flesh, while it's been fun, it is now time to move onto the big boy toys.

My plan is to build a 550 Gallon reverse flow smoker out of a propane tank with a 3'x3'x3' firebox. On top of the firebox will be a vertical smoker/warmer, made specifically to fit the foodservice sized trays.

This smoker will be on a tandem trailer. I'll add to it a smoker about half the size of the 500 that I will acquire from a friend. That smoker is complete with a large firebox. Eventually I want to build a roof over the top and awnings that raise on the sides.

My goal is to be able to work from the trailer rather than standing on the ground. The trailer will be equipped with sinks and water supply and work areas in the front so that it will all be up to health codes.



The virgin tank: I purchased it from a guy who had intentions of turning it into a smoker but got lazy. Sold it to me for $150. Perhaps that was a bit steep, but it had been already purged and all fittings pulled. Peace of mind is worth a bit to me. As a precaution, I slowly drilled a three inch hole in the uphill end, and I ensured it was empty from a safe distance.



I cut the small door off finally after running through 10 cheap grinding wheels. The tank is thick being 3/8th of an inch. I eventually moved over to using sawzall with a decent blade on it. Makes me think I was stupid for using the wheels. On the next door, I will score it with the wheel, then with a fine cutting wheel make a starting hole then use the saw for the rest.



Using KAM's technique I cut the door slowly leaving sections at the corners. It worked pretty well and the door only sprung 1/4 inch. I'll tighten it up with the threaded rod welded to the nuts that I have seen on the forum somewhere.



Even though it was clean, I wanted to make sure, plus I wanted to see if heating the tank would boil the paint off the exterior surface.



It did well on the top coat, but not so much on the thick primer coat. I refuse to spend another 3 days using the wire brush on the grinder, or spend the money to rent a blaster. I think paint stripper will be my friend.

My plan of attack now is to cut off the bottom half of the upper end. I will wait until I have the firebox tacked on before cutting out the big door. I really want to ensure the cylinder won't warp by cutting out that much material.

Once I get my steel supplies here, I'll move from my house down to the shop. I wanted to keep it at the house until I needed the welder.

[GF]

Aaron Mathis, That is going big.

Good luck with your build, looks like your off to a good start.

[Aaron Mathis]

I was able to get a little work done on the smoker this afternoon.

Much to my surprise the paint did boil off. I hit it with the wire brush on the grinder and in 20 minutes I did more than I had done in 4 hours.



I also took a few minutes to grind off the top valve and remove the old info plate on it.





I took some time today and figured out all the steel I need for the project. I don't think the CFO is going to be happy when she sees the cost of the 1/4" steel plate. Hopefully I can buy her silence with smoked meat.

[TankerTom]

Sure looking good! I'm glad to hear the fire saved you the hassle of grinding off all the paint with a wire wheel. Keep up the good work.
_________________
Cheers, Tom

[Aaron Mathis]

Well I got back a quote today. Much to my surprise everything was cheaper than I thought it was.

My big concern item was the 1/4 plate for the firebox.

I need 6 pieces, 3'x3'x1/4" for the box. Doing some looking online I was fearing each piece would be around $150. My local supplier quoted me $70 and that was with the cutting fee.

Now I just need to convince the CFO to give me the credit card.

[Aaron Mathis]

As life would have it, today was the first day I got to work on the project since earlier this week.

One of the things I was lacking to complete the project was a trailer. On a whim I decided to check out craigslist. For the last 2 months, I had been looking there for an 18+ foot 7000 pound trailer to haul my smokers and supplies.

Well rather than hit the utility section, I did a search for an RV.

I found one about 20 miles down the road. A little bit of horse trading later, and I believe this one will be mine tomorrow for around $300. The interior is absolutely crap, but the frame looks solid.



I've got a guy who will strip it down for me in trade for the metal on it, so I'll be left with the trailer, frame, electrical, and water tanks.

[Aaron Mathis]

As of yesterday afternoon, the trailer I mentioned before is now mine.

A little air in the tires, some grease on the hitch and she was good to go.

[Maniac]

Heck of a parts trailer you got there. Good luck on your build.
_________________
RF Smoker
20" disc
uds

[k.a.m.]

Aaron Mathis, this looks like a fun project. I will be watching for more pics and updates.
_________________
Always remember slow and steady wins the race.

Hybrid Cooker

[Jamdawg]

This looks like it will be a good one.

[Aaron Mathis]

Trailer is currently being ripped down by the neighbor.

Today I am hopefully going to cut the firebox hole.

[Aaron Mathis]

Well for the last week or so the trailer has been at the neighbors. He's supposed to have been tearing it down, but has been taking awhile to get it done. Either way, it's getting done.

An uptick in work and rain has prevented me from working too much on the actual tank. I've been amassing ideas and drawing plans.

On the few good days my other hobby flying has been distracting me.



Hopefully tomorrow I can get back to work on the tank.

[Aaron Mathis]

Finally the trailer is stripped. I was able to get the two water tanks from it and also the power cords and such. The frame is solid, and looks like it will make a great platform for the project.

The last few days I have been working on a side project. I decided to find a few drums and build 2 UDS's so I wouldn't have to take my big smoker to smaller family events.

These are food grade barrels previously containing purified strawberries. My only issue is getting the ridiculous red paint(perhaps epoxy or high temp paint) out of the interior. I've done two burns and the outside burned right off, but the interior is being more of a challenge.

Will the weed burner technique work on this? I saw that I can get one from Harbor Freight for rather cheap.

[GF]

Aaron Mathis, that liner may give you a run for your money.

You could try a wire wheel in a grinder, I'd check into having it blasted or look for unlined drums.

Good luck with it.

[missionsusmc]

Man that looks like an awesome project. I love both your hobbies. Where abouts do you live? Kinda looks like Southern Appalachian mountains in the background.
_________________
"Never trust a skinny cook."
"Real men pass gas and use hickory."
"Happiness is...a belt-fed weapon."

Mary had a little lamb, a little brisket, a little ribs, and boy she was full!!!

[Aaron Mathis]

Thanks for the tip GF. I was trying to avoid the wire wheel The wire wheel will take it off but will be a lot of work. I may just get the weed burner for giggles.

Missionusmc, I'm located in the Champlain Valley in VT just south of Middlebury. Those are the Green Mountains, part of the Appalachians.