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Insulated reverse flow vertical build (BWS-style clone)
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Thu May 16 13 5:30 am    Post subject: Insulated reverse flow vertical build (BWS-style clone) Reply with quote

After the hard, cold winter this year and not being able to keep temps in my redneck setup, I decided to do an insulated build.

Here's the old setup for reference. It's small firebox attached to an old oven and a Stoker for fire management.


Plans are for a BWS-style clone. The 26x30 racks are made to hold two hotel pans side-by-side with room to spare. The firebox is 30x12x26. The inner smoke chamber is 30x36x26. There's a 1" air gap between the false inner wall with a total firebox to smoke chamber area of 70 sqin. Instead of a deep waterpan, I went with firebrick to separate the firebox and smoke chamber. I may add a shallow waterpan later if needed.

Here's the initial CAD design:
https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/945862_10151331913590876_1536722579_n.jpg

Just started by noon on 5/11. I use a carbide blade in the chopsaw for the rollcage fabrication I do on the side, so I figured why not use it for 14ga steel tubing?


Forgot to take pictures until about 6pm. Cousin Alex running the grinder. Says from the first time he welded, he always knew he'd be a good grinder.



Had to get somewhere by 9pm, so we closed up shop early.


By Tuesday evening, all the intermediate walls were tacked in place.


I'll probably have a few questions and I plan on asking them as I go along.


Last edited by joefarmer on Sat Jun 29 13 12:44 am; edited 1 time in total
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Maniac
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Joined: 02 Oct 2010
Posts: 2432
Location: Pa

PostPosted: Thu May 16 13 8:08 am    Post subject: Reply with quote

joefarmer welcome to the ring Exclamation

Looks like your off to a great start...looking forward to more pics of your progress
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smittybuilt
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Joined: 11 Sep 2009
Posts: 37
Location: danville,ky.

PostPosted: Thu May 16 13 7:38 pm    Post subject: Reply with quote

you never know where you are gonna show up! glad to see you over here showing off the redneck set up.

jimmy
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Kave Dweller
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Joined: 12 Nov 2012
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PostPosted: Thu May 16 13 11:46 pm    Post subject: Reply with quote

nice keep em coming.
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Fri May 17 13 7:30 am    Post subject: Reply with quote

smittybuilt wrote:
you never know where you are gonna show up! glad to see you over here showing off the redneck set up.

jimmy


Mr. Smith! Howdy! Laughing wow, I can't believe I ran across you here! This weekend is TS, so no progress until Saturday night.

Forgot, the expanded metal for between the firebox and firebrick showed up on Wednesday night.


Last edited by joefarmer on Sat Jun 29 13 12:45 am; edited 1 time in total
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Sun May 19 13 2:09 pm    Post subject: Reply with quote

Cleco's are for more than just racecar panels, who knew? Laughing


The inner false walls are spot welded on 4" centers.


Inner false wall fully welded and floor partially welded.




Last edited by joefarmer on Sat Jun 29 13 12:48 am; edited 1 time in total
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smittybuilt
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Joined: 11 Sep 2009
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Location: danville,ky.

PostPosted: Mon May 20 13 7:36 pm    Post subject: Reply with quote

looking good man, i'll let you build me one when you get done! Very Happy
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Thu May 30 13 12:18 am    Post subject: Reply with quote

Timbo and Blake Weaver wanted one too. Laughing

Cut the steel for the door; made it an inch too wide. "measure once, cut twice" works for me.


inner skin and the insulation retaining pins are welded to the door.


2" rock wool.


outer skin. Will be replaced with a stainless cover eventually.


it's HEAVY as Jeremy demonstrates.


haha, poor jeremy. We weighed just the door- 54 lbs.


Last edited by joefarmer on Sat Jun 29 13 12:52 am; edited 1 time in total
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Fri May 31 13 10:10 pm    Post subject: Reply with quote

working with a carbide blade and chop saw is excellent.


TIG'd the firebox door together


added hinges


picked up a new bottle of argon and was surprised at the pressure.


Last edited by joefarmer on Sat Jun 29 13 12:55 am; edited 1 time in total
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Sun Jun 02 13 12:53 pm    Post subject: Reply with quote

Jeremy asked what was burning. apparently a rag soaked with lacquer thinner will catch on fire?


Brian says it's straight.


firebox firebrick is cut and installed


you can see the false wall in the smoking chamber that ends 1" below the roof.



teflon tadpole seal






Last edited by joefarmer on Sat Jun 29 13 12:59 am; edited 1 time in total
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Untraceable



Joined: 16 Mar 2013
Posts: 16

PostPosted: Sun Jun 02 13 9:55 pm    Post subject: Reply with quote

How was it working with the tadpole gasket? What size did you use?
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Sun Jun 23 13 3:00 pm    Post subject: Reply with quote

it's 3/8" tadpole gasket. It's very easy to work. In fact I made the lower gasket 1" to short and I was able to unscrew the side and stretch 1" from either side with room to spare. McMaster Carr 88255K11

exhaust stars.


removable ash pan and fire grate rails are in


firebox wood grate


measuring for the racks


Cummins 12v pushrod handles



2 of 9 racks installed


door jambs painted


fully painted & primed


thin blue!!!


seasoned and ready for first smoke.


roast potatoes in the drippings pan
https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/999545_10151393313965876_475028650_n.jpg

had pork and beef seasoning left over in the cupboard. mixed them together and tested on chicken. had some good heat to it.
https://sphotos-b.xx.fbcdn.net/hphotos-frc1/297524_10151393313975876_1134907636_n.jpg

trailer door latch. worked better than expected.



test biscuits




betty lou probe was 2" off the floor. ribs probe on lower rack 12" from floor. cooker probe is dead center under top rack at 21" off the floor.
https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-ash4/1005251_10151404617850876_1248357435_n.jpg

what could be better than sausage gravy with the test biscuits. Rolling Eyes Laughing


Last edited by joefarmer on Sat Jun 29 13 1:21 am; edited 2 times in total
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k.a.m.
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Joined: 12 Dec 2007
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PostPosted: Sun Jun 23 13 9:42 pm    Post subject: Reply with quote

Welcome to the ring joefarmer, looking forward to seeing some pics of your cooks. Smile
Very nice work on your cooker she looks fantastic. Very Happy
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Wed Jun 26 13 12:48 am    Post subject: Reply with quote

k.a.m. wrote:
Welcome to the ring joefarmer, looking forward to seeing some pics of your cooks. Smile
Very nice work on your cooker she looks fantastic. Very Happy


Thanks! I keep forgetting to take pics until the meat's disappeared. I'm doing 15lb of butts on Thursday and then 45lb of butts on Friday. I can't wait to see how it does!
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joefarmer



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PostPosted: Sat Jun 29 13 1:23 am    Post subject: Reply with quote

6 hours in.
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smittybuilt
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Joined: 11 Sep 2009
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Location: danville,ky.

PostPosted: Mon Jul 01 13 10:18 pm    Post subject: Reply with quote

what happened? you start drinking or did the battery go dead on the camera? Lol.
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Wed Jul 03 13 2:59 am    Post subject: Reply with quote

smittybuilt wrote:
what happened? you start drinking or did the battery go dead on the camera? Lol.


Laughing I went on vacation and then came back.

https://sphotos-b.xx.fbcdn.net/hphotos-prn1/1011714_10151412362445876_1222169434_n.jpg

it was a little more dry than normal. I should have put both smaller butts in the front. Overall it was a success and everyone had favorable things to say.
https://fbcdn-sphotos-d-a.akamaihd.net/hphotos-ak-ash3/945012_10151412362450876_443654422_n.jpg
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RLane22
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Joined: 09 Jul 2009
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Location: Valley View TX.

PostPosted: Thu Jul 04 13 1:46 am    Post subject: Reply with quote

joefarmer this is a very nice build for sure sir. thanks for sharing. i may have to try and build one like this when i finish my latest project.
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joefarmer



Joined: 16 May 2013
Posts: 19

PostPosted: Thu Jul 04 13 4:44 am    Post subject: Reply with quote

Thanks! If there's interest, I can post either a solidworks file or post drawings for this size.
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BigC_BBQ
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Joined: 28 Feb 2012
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PostPosted: Tue Jul 09 13 3:49 am    Post subject: Reply with quote

I'm contemplating building a smoker very much like this one. I was curious, and if you feel it's an inappropriate question, I'll fully understand, but What is the ballpark material cost on something like this? Convincing wifey to let me build another pit will take some research, and This is very near exactly the type of build I have in mind.
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