First Build - 40 Gallon Propane Tank

[cancerboyuofa]

Been reading for a while, finally pulled the trigger. Thanks to DuayneB for the tank hookup and the help! About 40% done with the build so far, will post more pics and plans soon. Its a 40 Gallon old propane tank that is about 40" long by 18" wide. Not a good welder, nor a fabricator. Built a few ugly drums, but never any welding. Been quite the process, but thanks for all of the knowledgeable people and posts on the forums!

Firebox is going to be 18"x14"x14"
Smoke stack 2.75" x 30"
2 Cooking Grates: 17.5" Deep on bottom & 14" Deep on top


Plans drawn up.


Tank, measuring and getting ready for the door cut.


Door and firebox notch all cut out and cleaned up.


All flanges welded up on the door, fit is perfect, no warping.


Grates are welded up, just need to clean up a bit.

Thoughts on a 26" Across cooking expanded metal needing supports in the middle? I'm afraid of sag.

Getting back to work finishing firebox and grinding all welds down, more pics and plenty of questions

Let me know what you guys think and if it all looks good in the plans.





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[Gizmo]

Nice build - looks like you got a great start on this one.

If you're nervous then just add another piece of square tube in the middle.

Egor uses 3/4 - 9 flat exp. steel for the grates at a 40 inch span rail to rail. I just added an intermediate cross member of square tubing in the middle of the grate halfway between the front and back edge of the grate for added support - I've had over 50# of PB on those grates with no sag.

[Clover Ridge Smokers]

[cancerboyuofa]

Thanks. I'm using 3/4 x 9 expanded, but adding the square tube is a great idea.

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[Rodcrafter]

Good job and welcome to the crew.

[Rev.Mike]

[bluecatfish]

Great that the door fits perfect! That doesn't happen very often!

[cancerboyuofa]

Very pleased. Lets hope it stays that way when I get to hinging and painting.

For legs, what size tubing do people use? Thinking 1x1 is too small? 1x2s? What wall thickness?

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[cancerboyuofa]

Baffle Plate snug fit, needs some notches cutout. Had to make it 2 pieces to fit it...just barely.


Firebox pieces cut and starting to weld my firebox up.


Throat cutout and setting up for the tedious cut with the cutoff wheel on the front panel of the firebox and the door. Door size is going to be 16" Wide by 12" High,. hopefully this is large enough to put a slideout charcoal basket.


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[DUAYNE B]

You are moving right along witth that build, your gonna like that size for small groups, nice job

[Big T]

I think you'll have plenty of room for a basket for your FB

[Grabber70Mach]

Looking good.

From infinity and beyond

[cancerboyuofa]

So what is the thought on supporting this thing? 1" Square? 1x2" Any consensus?

its about the only thing I have yet to figure out in my head or paper.

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[Big T]

I would go with the 1''x2'' if that were my options, I think the 1''x1'' will hold it but it just looks too skinny to me. jm2cw

[cancerboyuofa]

That's what I was thinking. What about wall thickness? Matter much?

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[DUAYNE B]

Wall thickness can be .065, it will hold the weight just fine. I use 1 1/2 square on smaller builds, big build gets .095 2 in. Mainly for the look .

[cancerboyuofa]

Wow, cant believe I didn't do any updates! it is finished. I'll post a few pics at a time to show the progress until finals.



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[cancerboyuofa]

Firebox tacked up ready for seams

Firebox ready for front and final seams.

Smoke stack

After a bad weld and clean up job, got the smoke sack welded up.

Tacking baffle plate

Baffle plate fits and tacked

Intake cut and tacked

Took some welding, cutting and rewelding, but got the intake done

[cancerboyuofa]

Got tired of dealing with the HF 90amp welder. Upgraded to a new Hobart Handler 140. What a difference!

1/8 inch flange done on firebox door

Flanges and hinges welded onto door

Frame welded. Went with 1x2 .065 as per the referrals on this site. Thanks! Also 1" angle form horizontal legs.

[DUAYNE B]

Coming along nicely, did I mention when I sale a tank to someone, part of the deal is half the first batch of Q cooked in it?

[cancerboyuofa]

Test fit and tack up firebox. Like a glove, thanks for the cut Duane B!

Final firebox layout. Works, possibly not the best idea on the latch?

All set, just minor prep work left on paint. Caster and handles all set. Damper handle in place.

It works!!

First Q, mesquite chicken thighs.

[cancerboyuofa]

Painted.... finally complete.

Finished pic after test cook.

Took the new smoker to my first KCBS comp. Rhythm and Ribs in Cottonwood AZ. Didn't get paid in anything but the smoker cooked like a champ. Did two pork butts and a brisket on the bottom shelf, didn't use the top self.

[cancerboyuofa]

That about wraps up the whole build. Would have been easier to do it the whole time. Thanks formal' your help. Its time for another build now...

[cancerboyuofa]

Coming along nicely, did I mention when I sale a tank to someone, part of the deal is half the first batch of Q cooked in it?

Haha, I wasn't aware of that. Maybe next cook!

[Big T]

Nice rig !