RF Smoker Build

[jsents]

So I am finally starting. Marked out the door, cut out the door, removed the base ring and removed the valve connectors.

I used k.a.m. advice on the door position for a 30" tank
6" from the top 12:00 position
The bottom is 1" below 3:00
1.25" from the elliptical welds

I cut the door with a grinder and sawzall.

Things went well but there is a about a 1/8" sag in the middle of the door at the top, Wondering if I need to worry about that?


The tank Specs




Tank before starting



Door marked out and ready for cutting




Door cut out and Valves gone



Picture of the top of the door with the sag in the middle.

[k.a.m.]

jsents, that is a pretty cut. Like I have always said it really doesn't matter what you use to cut the tank. If it is going to spring it is going to. You just deal with it down the road.
I would check with a straight edge to see whether it was the door or the tank that moved, it may have been a little of both. Either way that amount is easy enough to cure once you figure out what happened. I look forward to seeing some more pics and updates.
_________________
Always remember slow and steady wins the race.

Hybrid Cooker

[GF]

jsents, nice cuts for a sawzall and grinder.

Looks like your off to a good start, looking forward to following along.

[Maniac]

nice work so far. Good to see you finally got started. looks like you have just a small tweek to do and it should be fine...like kam said use a straight edge to see what moved.
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RF Smoker
20" disc
uds

[jsents]

Maniac, k.a.m. and GF thanks for the compliment on the initial cut.

It was the tank that sprung. The door stayed pretty straight but it looks like the top middle of the tank sprung up by about 1/8". When in the process should I try to fix that?

Made a little more progress this weekend. Cut the whole for the fire box and the Guys at the shop tack welded the firebox together. We set things together so we could figure dimensions of the RF plate and get an idea of what length to make the trailer. We are using 5/16" for the firebox and planning to use 1/4" for the RF plate.

Since the firebox is not wide enough, we are planning to square off the gaps between the tank and firebox with 1/4" steel. Does that sound like a good idea?

Thanks again for all the input and compliments.


Picture of the Tank setting on firebox


Front side Picture of the Gap

Back side Picture of the Gap

[k.a.m.]

jsents, filling in the sides with 1/4" plate will be fine in my opinion.
Very nice work on the firebox and fit up. I will be watching to some more pics and updates.
_________________
Always remember slow and steady wins the race.

Hybrid Cooker

[jsents]

Made limited progress this week. Was trying to avoid 2 trips the sand blaster so I sanded/wire brushed the inside of the tank. I wanted to make sure the area below the RF plate was clean before the RF plate went in. Then I decide I went that far I might as well do the whole inside. If I build another one, I am pretty sure 2 trips to the sand blaster will be in the budget. I am not sure what type of coating was on the inside, but it took a 60 grit flap disc to really take it off. The Wire brush just removed the surface rust and seemed to leave a coating of paint.

I also removed the ledge inside the tank at 6:00 clock position to make sure any liquid that make it to the bottom the tank can get out.

The firebox has now been welded and the hole to the tank has been cut.

Hopefully I can make more progress this week. I spent my extra time last week fixing up a building for the baby chicks that will eventually end up in the smoker.

Inside of tank all prepared


Firebox all welded up.


Update: Images now resized, sorry about that.

[SoEzzy]

Please read PMPNLT650pxOTLS!
_________________
Here's a change Robert.

I still work here!

[GF]

jsents, looking good so far.

The grinding, sanding, and wire wheeling, is time consuming and generally miserable but it'll bee worth the effort later.

Looking forward to updates.

[jsents]

Worked on the smoker a little more on Tuesday. Hoping to make more progress tonight. Here are some pics

Firebox welded on


Some of the welds


The Welder Michael


The rough fit of trailer frame to smoker

[jsents]

Made more progress tonight. Trailer is now rolling, drains for the lower tank is put in, the drain for the reflector plate put in, and reflector plate installed.

After the progress today it raised some questions.
1. I just received the two 6" hinges with brass pins from BBQ Bonanza www.kck.com. I was only planning to use those hinges on the cooking chamber door. After holding the hinges in my hands, I am thinking about getting them for the fire box. Would that type of hinge work for the fire box too?

2. After rough fitting the tank to the trailer, I am ending up with the first cooking rack at a height of about 41 inches. That is with the tank mounted 5 inches off the trailer. I would like to keep it 5 inches off the trailer so I can put wood under the tank while transporting. Is 41 inches too tall for the 1st cooking rack?


3. I would like to have 2 cooking racks. My opening is 14 inches tall. Is that enough space for 2 cooking racks. I feel like 6 inches between grates is going be really tight to fit a full size hog that has been quartered. Our current cooker only has 1 shelf so I have not really paid attention to how tall the pieces of meat. Does 6 inches sound like enough room between cooking racks?



Pictures of the Reflector plate going in.











Tank tipped up to weld out bottom side of tank.


My other helper Josh working on the trailer.


tank on trailer with 5" spacing between tank and trailer.

[Wreckless]

[k.a.m.]

jsents,
1. I just received the two 6" hinges with brass pins from BBQ Bonanza www.kck.com. I was only planning to use those hinges on the cooking chamber door. After holding the hinges in my hands, I am thinking about getting them for the fire box. Would that type of hinge work for the fire box too?
As Mike mentioned the type of hinge you use will mostly depend on the way your firebox door mates up. The bullets will work no doubt. I have made all sorts of strap hinges for fireboxes as well. The hinges on my warmer as well as the R/F cookers firebox and warmer in my signature work well. They are made from 1/4" x 2" flat bar with 1/2" hot roll and 1/2" SCH 80 pipe.

2. After rough fitting the tank to the trailer, I am ending up with the first cooking rack at a height of about 41 inches. That is with the tank mounted 5 inches off the trailer. I would like to keep it 5 inches off the trailer so I can put wood under the tank while transporting. Is 41 inches too tall for the 1st cooking rack?
If a 41" cooking grate is comfortable for you and you can open and lower your chamber door then go for it. After all it is your cooker.

3. I would like to have 2 cooking racks. My opening is 14 inches tall. Is that enough space for 2 cooking racks. I feel like 6 inches between grates is going be really tight to fit a full size hog that has been quartered. Our current cooker only has 1 shelf so I have not really paid attention to how tall the pieces of meat. Does 6 inches sound like enough room between cooking racks?
6" is good for briskets, butts, and butterflied pigs. Turkeys in pans is a tough sell 7" works better. But again as mike stated when cooking a hog pull your top grates, i always shoot for 6" to 7" spacing.
I hope this helps.
_________________
Always remember slow and steady wins the race.

Hybrid Cooker

[jsents]

Thanks k.a.m and wreckless for the advice! Without this sites advice, both solicited and things I have found by reading old post, I am sure I would not be anywhere close to where I am at.

1). I am going to use the bullet hinges on the Firebox and fabricate hinges for the smoker door.

2). I am going to position the tank at 5" above the trailer and let things end up where they end up. The fire box will have over 12" ground clearance and I think the 1st grate will end up at 41". I would have preferred 36" for the 1st grate but trailer and tank are too far along to make that happen without a lot of changes

3). I am leaning toward 7" open between the top and bottom grates and a 5" opening on the top grate. I can then cook the larger cuts on the bottom and smaller cuts on the top. I figure 5" will be enough for the brisket, quartered chicken, and ribs.

[jsents]

Quick update of progress from Tuesday. Tank is now mounted to trailer, firebox door cutout, first Shelf is done and parts for trailer basket around the tank are cut.
Firebox door cut out

Firebox getting welded to trailer

Rear view of trailer and smoker

Side view of trailer and smoker


Me Dreaming of smoking meat on that nice shelf


Firebox intakes marked and waiting for plasma cutter.


Edit** reposted with pictures fixed

[SoEzzy]

Please read PMPNLT650pxOTLS!
_________________
Here's a change Robert.

I still work here!

[jsents]

First off, Thank you to k.a.m. for the advice on how to fix the tank warp. It worked great. We put a 2x4 over the bend and then using a chain and chain binder, we put pressure on it and hit it with the sledge.

Thank you to TuscaloosaQ for the specs of his trailer that I tried to replicate.

Thank you k.a.m. and Wreckless for the advice on the hinges and grate height and space between grates. It is hard to picture the spacing and size of meat cuts. The second opinions really helped things go faster.

Thank you to GF and Manic for the encouragement along way.

Thank you to SoEzzy for the help in posting pics correctly.

With that all said, I think I am going to try the initial burn tonight to see if it comes up to temperature. We pretty much finished up most items last night. Still have finders, firebox guts (charcoal basket and stuff), fire box tools, jack and smoker door handle left to go.

Now for some pics.
Template for cutting air intake slide

Air intakes cut out

Air intake slides put on

Air intake compete

2nd shelf complete

Corner grate getting cut and door getting welded on

Door on and exhaust getting welded on

Rear view with fire box door on

Firebox door latch system that I think I saw in k.a.m. build

Grates pulled out

Temp gauge tacked in with door latches on

A place for my digital meat probe to into the tank with out having to crush the wire in the door.

[k.a.m.]

Josh, your project is looking awesome. Did you get the tank lined out like we discussed? I look forward to seeing some more pics and updates.
_________________
Always remember slow and steady wins the race.

Hybrid Cooker

[Wreckless]

Looking great dude! Those are some nice textbook hinges on that cooker door, good job. Ready to see it finished out. Gotta see if there isn't some advice on here for stretching that level a bit longer tho.
_________________
Backyarder
Smoker Grill
Trailer Rig

[GF]

jsents, everything is looking good, it won't be long now.

BTW, get a note pad so you don't have to write notes on your firebox.