Smoker out of a 80 gallon compressor tank

[WHeydet]

I'm going to start off saying that this is my first time building a smoker. I am not new to machining and fabrication though. I have about 17 years experience in the aviation repair industry. That being said everything I usually work with is thinner and lighter metals but I think I can figure out a smoker! And have some fun doing it!
I'm starting out with a old compressor tank that has been given to me so I'm already ahead of the game. I have cut off the brackets that I don't need or want on it. Ground off the fittings on the top with a electric grinder.
Leveled out the tank and laid out the door, cut that with a plasma cutter and cleaned up the edges. The door did spring a little but not too bad.
I am going to weld on the straps today hopefully and cut out pieces for the legs and frame.

[Big T]

It looks like you've got it figured out

[WHeydet]

I put the straps on the door this afternoon. I'm going to have to grind down a few welds. Not the best welder but by the end of it I should have it down! Any tips would be greatly appreciated! Using a Miller 250 mig setup. Here it is with the door tacked.
Also I ground for a while on the inside of the door and tank trying to remove some of the rust from it. How much of it need to come out. Everything down to shiny metal or take off all the lose crusty stuff?

[Bricklayer2]

[Squiggle]

[Big T]

I would knock all of the big chunks of rust out with a grinding disc and the hit the rest of it with a wire wheel.

[WHeydet]

Ok that's what I've been doing.
Link to BBQ Pit Calculator
Here is the link for the feldon calculator. Any other suggestions for tweaking anything here based on experience? Also the dimension for FB to CC opening is a diameter for half moon. I'm planning on putting the FB 6inches up from the bottom with a 1.250 grease dam. Will that give me the size needed? I'm thinking it will be more then the square inches needed. Is it better to half a smaller opening or larger then needed?

[Pete Mazz]

http://planetcalc.com/5155/

[WHeydet]

That's awesome. Just what I was looking for! Thank you

[Pete Mazz]

[WHeydet]

Making some more progress. Stand is well under way. Need to grind down a few ugly welds nothing major though. Fit it up under the cook chamber, looks good to me! Next week is going to be the firebox!

[WHeydet]

I want to go with two cook grates. How high above the main grate should I put the upper cook grate? 5" good enough?

[Big T]

5'' will be fine for most cuts of meat but some of the larger pork butts might not fit.

[Rodcrafter]

[Squiggle]

Double you can always take out the top shelf for the bigger stuff.

[WHeydet]

What size expanded metal are you guys using for your cook surface?

[Big T]

3/4 X 9 carbon steel and I prefer the flat over the raised surface.

[Rodcrafter]

Me too


Making memories!

[WHeydet]

Thanks for all the advise this project is going great! Going to start on firebox next week. This is where I'm at as of last night.

[Rodcrafter]

[WHeydet]

Thank you. Already thinking of "the next one" I build!

[Big T]

It sounds like you'll fit right in around here!

[WHeydet]

Is it necessary for me to do a burn out on this tank? I was thinking that I was going to weld the stack on, weld expanded metal for cook grates in, cut the hole for the firebox. Then throw some wood inside the cook chamber and fire it up. Is it needed or just wait until it's all welded up right before I'm ready to sand blast the outside?

[Rodcrafter]

No it's not needed.

[WHeydet]

Welded on my stack and the expanded metal. Fire box next week or so. This has been a great project so far! Only have maybe an hour after work each day, it would go faster if I had all the equipment at home! Dreaming there!
Going to sand blast the outside after the firebox is welded on then it's time to paint. Since it's going to sand blasted. Do you guys spray a primer before paint or just go with high temp paint?