80 Gallon Compressor Build

[akjeff]

Finally found a donor air tank, and got started. Using the SmokerPlans 24" BY 46.5" SINGLE DOOR, 2 ENDBELLS, SQ. FIREBOX RIGHT SIDE plans. Made the door and firebox cuts in the tank, and then took it to a friends shop to be sandblasted/cleaned. Meanwhile, got the 1/4" plate for firebox, and had the them shear to size. I'm working alone, and have no plans to try and muscle a full sheet of plate around. The tank was enough of a handful! Plasma cut the vent holes, door, and opening into the cook chamber. Tacked it together this evening, and will weld it tomorrow. Came out square and everything! Hopefully the tank will be ready on Monday.

Think I'll need to build a small trailer to mount it on, so I can move with my ATV. This sucker is going to be heavy!

Jeff

[ajfoxy]

Good start... clearly you have a thing for alum deckplate...

[akjeff]

You noticed that! I ran it on the wall behind the welding table, lathe, and mill. Figured the sheet rock would just get trashed with sparks, cuttings, coolant, oil, etc....Got a little carried away!

Jeff

[akjeff]

Welded up the tacked together firebox, and flanged the door cutout today. Need to get some door gasket material, before doing the hinges. Also have to make the sliding covers for the draft openings. About crapped my pants when I priced commercially made ones. No way I'm paying $40 a piece! Door latch will need to be made as well.

Jeff

[Big T]

[akjeff]

Thanks Big T! Made the tracks for the air dampers out of $12 in hardware store square stock/scrap 1/4"x3" flat bar, and a half hour on the vertical mill, rather than fork out $80 for a pair of commercially made. Will drill and tap a hole at the far end of the 1/4" thick slider to screw on a knob. I'll let part of the screw pass through so a nub sticks out on the inside, and act as a stop. If I need to tweak the slider due to heat warpage, just back out the screw, remove, adjust, re-install. No welds to cut/re-weld.

Jeff

[Big T]

Nice It just feels better when you build something versus buying it off of the shelf.

[akjeff]

That it does!

Jeff

[ajfoxy]

Yes indeed. The satisfaction of doing it all yourself is hard to beat... more so if it actually works.

[Rodcrafter]

Nice


Making memories!

[Dirtytires]

Looking good.

[akjeff]

All sandblasted in and out! Will be nice to work with clean steel from here on out. Next, will be cutting out the bungs and weld patches in their place, along with welding up a few "oopses" I made while plasma cutting the motor mount off the top of the tank. Going to wait and cut the feet off after I get it on a stand, as they're kinda handy to have for now.

Jeff

[akjeff]

Welded hinges on the firebox door, and have the rolling stand mostly done. Waiting for a day when a buddy of mine can come over and help put the tank on the stand. Then weld firebox to the CC. Didn't take any pictures.

Jeff

[Big T]

[akjeff]

Made a little more headway today....starting to actually look like some semblance of a smoker. Welded the cook chamber to the stand, and then the firebox to the cook chamber. Waiting for it to cool off, and then start making a cardboard template for the baffle plate. Now I can cut the feet off the former air tank.

Jeff

[Big T]

[Dirtytires]

Great progress. Not to be negative but you may need to cut the baffle plate In half to get it in. Many will slide it in from the end before putting on the firebox. No matter....just a bit more work.

[akjeff]

My baffle plate will be in 3 pieces. The main plate is 33" long(full width), and fills the cook chamber from end seam to end seam. Will then scribe the firebox end to fill the end cap of the tank, and then cut a trapezoid to create the required gap at the other end. Weld them in place.....done. Then weld a "dam" ahead of the yet to be drilled drain pipe hole.

Jeff

[mp4]

Don't forget to put a shadow plate in. I don't have one in mine and wish I did.

[Dirtytires]

Baffle plate Gap doesn’t need to be a trapazoid just cause the the firebox hole is. Most just square off the plate leaving the required square inches of gap at the end.

[akjeff]

Just following the blueprint. I have a plasma cutter, so it makes no difference to me what shape I cut it. I'll just stick to the print.

Jeff

[akjeff]

Just a little progress today. Fit the main baffle plate, and the filler for the end bell, and welded in place. Instead of welding the gap filler at the other end, I decided to make it so that it could be removed/replaced. So, I cut out the trapezoid of plate, and welded a piece of 1" angle to it. It then bolts up to the "dam", that will be welded to the end of the main baffle plate. Cut the feet of the donor tank as well. Have some grinding/clean up work to do. Install the drain pipe, shelf channels, and chimney. Can't wait to see some smoke!

Jeff

[Diggerg]

[akjeff]

Thanks all. The more I research, the more I think I'll skip the drain, and just scrape after each cook. Welded the "dam" on the BP this morning. Going to fill with an inch or so of water, and do a leak down test on my BP welds before proceeding. Probably just go with a simple drain plug in the bottom of the CC, just in case some water gets in there.

Jeff

[Big T]

That's a neat design for the BP gap. You could make a larger piece, bolt it on and see how it changes the tune of the pit.