bbq reverse flow smoker contest entry

Here we have a reverse flow BBQ smoker made out of 1/4 in material. We first started with a 4x8 sheet of 1/4 and cut the door panels leaving 2 in sections throughout the cut allowing it to stay attached to the sheet and be rolled at the same angle as the smoke chamber which also in turn made the doors easier to cut using the hand plasma. (Final piece cut was 78.5" x 4').

From a second sheet of 1/4 we then cut out the fire box with the same style door (final cut 62.8"x20). next we had them rolled at 25" dia and 20" dia. we then made the end caps for the smoke chamber using the leftover material from the previous cut, 1 with a 25" diameter circule solid and another 25" with a 3" hole cut out for the smoke stack. Next, we cut 2 20" diameter circles for the fire box ends pieces 1 with a 6" diameter hole with a damper for a vent the other had a 10" x 7" rectangle cut from the upper part of the piece to allow the smoke to travel into the smoke chamber.

From there we took the end caps and welded them into postion. Next, we designed flanges and hinges. The hinges were made with the same 1/4 material consisting of 3 pieces (see hinge picture for design). The flanges were designed to cover the door gaps with a border width of 1.25". Using the hand plasma, we cut the top of the doors all the way through keeping the sides and bottom attached we then tacked on the hinges and tops of the flanges. Once the hinges and flanges were set we proceded to cut out the rest of the doors then clamped down the flanges sections at a time to help bend the flange to fit the door contour. Once we were happy with how the flanges were placed we then finshed welding them to the doors along with the hinges.

Next we propped up the smoke chamber to the height we wanted, marked the center of it along with the fire box making sure everything was aligned before weleding them together. Once the two tubes were together it was on to the legs. The legs were made of 2" x 2" 1/4 tubing which we got 16' of. On the side where the fire box is located there are 2 12" wheels and located on the other side sit 2 legs on 4" x 4" base plate. (you can make legs to desired height) To get the legs to match the contour of the smoke chamber we took a drop piece from one of the 25" diameter circles and traced the cirlces angle to the leg. Using the hand plasma we then cut the legs and butted them up to the chamber, tacked and checked to make sure they were level and finished the weld. Using the same process we set the other legs as well. From there we mounted a 40" x 25" log rack under the smoke chamber using 2"x2" 1/4 angle iron and 3/4 expanded steel.

Next we finshed cutting through the 10" x 7" rectangle on the fire box so it opened into the smoke chamber (using the hand plasma) Next we found level inside the smoke chamber and welded 1" x 1" on either side for the cooking racks. Next we designed the baffle system/ drip drain using 12 gauge material, 44" of 1" x1" angle iron, 1' of 1/2" pipe, and one ball valve. The 12 gauge material was cut into 3 pieces, the first (5" by 25 ") went level right above the hole between fire box and smoke chamber angled slighty down into the 44" 1" x 1"angle iron that runs down the middle and at the end of the angle iron we drilled a 1" hole for the pipe to insert to (we also drilled a 1" hole in the bottom of the smoke chamber for the pipe to come through) . Once the angle iron is set we welded the other two pieces of 12 gauge (12'' x 43'' ) to the first one (cutting angles to fit) leaving a gap in the middle where the anlge iron is, making sure the pieces are pressed together tightly.

Next we finished the welds. Oppiste end of the wheels we added a 20" by 10" mini prep station out of 1"x1" angle iron and expanded steel. Then added a handle at the end of the prep station with 2 inch gap between the two to allow room for your hand to grasp the handle. We cut the same design as the hinges (downsized) to use to add handles to both doors. Then welded on the 3" exaust tubing just under 3'. Once we were happy with all the welds and placements of everything we ground the corners round and sanded everything smooth preparing to paint. We used a high heat paint in matte balck, and applied it using a spray gun. after two coats it was completed.

 

Ok now post a pic of the finished item so we can drool over it

Larry
NZ

 

I'll have to post a pic later for some reason it wouldn't let me.

 

Also do you have a CDL of the whole project?

 

Yes I'll upload that and a pic tonight. I was having trouble adding some of the files

 

Here are some of the pictures. Having troubles uploading some of them still. I'll try again later with some more.

 

Baffle drip tray with drain.

 

Nice! Those grates are awesome - Congrats!