First Build MACK.....

[Zimbomike]

Hi all, after having to abandon my initial project due to a "Non Galvanized" pressure tank turning out to be galvanized I have decided to attempt to build a large MACK. I will post pics as things progress. I have managed to put together the racks for the warming and cooking chambers as well as for the firebox. wanted to get started while my steel was being delivered. I Attached are a few pics of my first day..humble beginnings. During which I felt obligated to fire up some ribs on my BGE.

I do have a question about the wall thickness of the chimney pipe, schedule 40, at 6 inch ID calls for around 1/4 inch steel. Is this really necessary to have such a strong stack, as there will be no pressure. Would like opinions either way please.

[dacolson]

Racks look great. I love the BGE. My first smoking addiction started there.
On the stack, I wouldn’t think .25” is necessary but I’ll let others w more experience comment. My current build has a 5” stack w .125 wall thickness.

[Dirtytires]

Congrats on the project start. The Mack is a great pit and will serve you well for many years.quite a few have been built here so plenty of good information is available.

No real need to go heavy wall on the chimney. Heat loss is not important at this point. A lot of guys find schedule 40/80pipe easier to find than big tubing but use whatever you can get at a reasonable price. Keep in mind that smokers are big and heavy and sometimes get some rough use over the years and a thin chimney is real easy to bend or damage.

[Big T]

[Zimbomike]

A good day today.. Managed to get the warming chamber/firebox structure together, and one CC door framed. Using 1 Inch fire bricks for insultion.
I did the tacking up. The nice beads were done by a very talented steel fabricator, working with me on weekends and some evenings. Helps with the heavy lifting as well.Hopefully get that side completed tomorrow. Having a tough time sourcing the right angle iron for the door jams/FB door frame. Will end up making them with steel plate think.

[dacolson]

Coming along nicely

[Zimbomike]

Managed a few hours today, succeeded in getting both cabinets together, top plate and baffle plate welded in. Put some temp legs so we could work upright. Still trying to figure out the legs/wheels. Want to first put it on wheels to get work out the ins and outs of the operation. Then fabricate a trailer. Here are some pics from today.

[Dirtytires]

Always fun when all those little pieces and sub-assemblies start to come together and look like a smoker. Keep at it!

[dacolson]

Nice to have some professional help on those beads. Looks great

[towtruck]

Looking good!

[Big T]

You're making some great progress.

[Zimbomike]

Hi All, thanks for the encouragement. Been a while since my last post. Things progressing now, just fitting the doors and then we are on our way. I've run into a slight snag with the firebox, in relation to the door jamb size, per the plan.

I am having some issues reconciling the firebox dimensions, in relation to the firebox door jamb. As per the plan, I have 2.5 x 1.5 inch angle for the jamb, however there is only 2 inches space available for the jamb. I have measured the firebox plates and they are all correct, inside FB dimensions are 21 x 22.5 . Am I missing something? My option will be to trim the door jamb to the 2 inches, and also decrease the door width by ½ inch. Which is ok, as my insulation is quite thin. Or, I could trim the firebox by .5 inches, but afraid that might mess with the proper volume.
I've attached some pics.
Any suggestions appreciated.

[Dirtytires]

Either of those options would work...trimming down the door probably easier.

You might send a PM to Frank tho as something is wrong. We have had a lot of these built and the dimensions seem to be correct on the plans so I have to wonder if you might have an issue that needs to be found before you continue.

[Zimbomike]

Thanks, I did send a message off to Frank. Lets see what light he can shed.

[Zimbomike]

Hi All, Spoke too Frank and managed to figure out the firebox dimensions issue. Just a matter of doing a bit of trimming, and leaving a bit of overhang for welding. It's been a productive few days, cooking and warming chamber doors mounted, handles and latches on. I am using a temporary (may keep it) latch for the cooking chamber doors. I am having big issues trying to get the latch kit cut to proper dimensions , leaving way too much tolerance in the screw and bolt holes, of all pieces. I did manage to put the stock latch on the warming chamber though, with a bit of reverse engineering. Remaining items.

1. Firebox Door
2. Chimney's installed
3. Weld Drain Pipe
4. Put Rack guides in Cooking Chamber
5. Place unit on trolley

While I am rolling it around my yard, I will start building a trailer. Then off to powder coat for a paint job. Was thinking Burn Orange Smoker with a Black or dark blue trailer.

This forum has been invaluable during my build, often went back and look at others posts for help and clarification. Thanks all. Here are some updated pics.

[Big T]

I'm glad to hear that you got it sorted out.

[Dirtytires]

Making some good progress....

Just a note on the powder coat—the normal powder won’t hold up but my shop tells me they have a high temp powder now. It should be obvious that it’s needed but make sure you specify or you will be re-doing it in short order.

[dacolson]

Looking awesome.

[Zimbomike]

Making some good progress....

Just a note on the powder coat—the normal powder won’t hold up but my shop tells me they have a high temp powder now. It should be obvious that it’s needed but make sure you specify or you will be re-doing it in short order.

Yes, spoken to the shop and they have High Temp powder.

[Zimbomike]

Got in a good days work. Drain pipe in, firebox door mounted, temp gauges in, and made it mobile toady. Much easier to move around... Tomorrow's tasks: Chimney's, food and firebox chamber rack guides, begin remove all the splatter marks and tidy up welds. Looks like it's burn day on Sunday....

Light spray on the inside with cooking oil I guess is the way forward, kinda like seasoning a cast iron skillet.

Thanks again for all the encouragement.
Question: Should I put wood directly in the cooking chamber for the seasoning part, or just let it flow normally from the firebox.

Progress pics attached

[Dirtytires]

Nice work...looks great.

And yes on the “light spray” of oil. One way to avoid overdoing it is to spray it then wipe over with a lightly oiled cloth/paper towel. It will help spread everything and clean up any puddles.

To season you just run a normal fire in the firebox....never put a fire in the cook chamber. This is a good opportunity to try maintaining temps before you put food in it as well.

[Big T]

[dacolson]

Looks awesome. Bet you don’t miss that galvanized tank for a second.

[Zimbomike]

Nice work...looks great.

And yes on the “light spray” of oil. One way to avoid overdoing it is to spray it then wipe over with a lightly oiled cloth/paper towel. It will help spread everything and clean up any puddles.

To season you just run a normal fire in the firebox....never put a fire in the cook chamber. This is a good opportunity to try maintaining temps before you put food in it as well.

Thanks for the advice.

[Dirtytires]

You bet...let us know how it turned out.