40 Gal build

[soccerguy83]

So this guy followed me home yesterday!



It's a heavy beast and took 4 guys to load it on my trailer, though I think most of that weight was coming from the pump and motor sitting on top! It's not quite as thick walled as I would have hoped at 5/32" (was hoping for closer to 1/4"), but it was the perfect size for what I wanted. This will be converted into a backyard offset smoker, al la Aaron Franklin style! The tank is roughly 48"x20" at 40 gallons and using Feldon's calculator will require aprox. a 20x15x15" firebox putting it at 145% (too big?).

I'm excited to get going on this project, but there are a few things I need to do first. I need to put together the shop hoist I got from HF to get it off the trailer and generally be able to move it around. I need to take the pump and motor off. I need to get a grinder. And lastly but most importantly I need to learn how to weld haha. Some may say that I should know how to weld prior to taking something like this on, but I have confidence in myself and figure that this is the perfect kind of project to learn on! Worst case I farm it out to a local welder. I am shooting for it being completed sometime next summer or fall just working on it as I have a few spare mins.

I'm sure I will have a ton of questions as this thing progresses!

[Smurf]

So the fun begins. And yes it will be fun. Nice project to hone your welding skills. Best of luck and post pics. 145% seems a bit big. 105 to 110 seems to be the sweet spot.

[Big T]

You wouldn't believe how many guys on here learned to weld while building their smoker.

[Puff]

AND, spent even more money on more welding gear in the process!

But with a big smile

[soccerguy83]

Hey guys thanks for the warm welcome! I'm really looking fwd to getting this thing underway this winter!

[The Czar]

It's a good thing

[soccerguy83]

Yesterday I got my 2ton lift put together.

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[Big T]

That'll save your back

[Puff]

Oh yeah!

[soccerguy83]

haha That was the idea! This for the most part will be a one man show, so gotta work smarter not harder!

Ok first question of many to come. I'm thinking I want to remove all the plugs on the tank and weld in blanks to make a clean body. I'm assuming that Oxy/Acetylene will be the easiest manor to remove them. As I don't have an O/A torch, is there another method? I thought about using a bi-metal hole saw, but with the plug removed, there would be no way to center the bit. If needed an O/A torch will be on the Christmas list this year.

I will be stealing this idea for how to fill them in though! Click here : plugging holes in tank

[Bkndsdl]

I'd stay away from the torch as much as possible. Too much heat input = warping. If you tack weld a piece of scrap material over the hole, you can use that as your center.

[soccerguy83]

Another great idea!


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[soccerguy83]

It's now off the trailer, the lift did a great job!

Next steps are to remove the motor, clean up the pump and remove it. Then clean up the tank a bit.


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[Fishless Mickey]

I just use a 4" grinder with an abrasive cutting disk. Doesn't make the prettiest hole but you dont notice that after welding the patch and the grinding/polishing is done. You could keep one of the threaded nipples for a grease drain.

[soccerguy83]

Fishless, I was planning on doing just that with regard to the grease drain. There are currently two on the bottom that would work well for that.

[soccerguy83]

Thoughts on a 4.5" vs 6" angle grinder?

[mp4]

Split the difference and get a 5". [WHITE SMILING FACE] personally I like the 4.5" because it's a little easier to manage in small spots.

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[Bkndsdl]

4-1/2" is all you'll ever need. 6" will be too big to get into some spots, plus it'd be heavier.......

[Rodcrafter]

You can do it, we can help.


Making memories.

[forty_creek]

Welcome


Drankin, Smokin and Dreamin

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[soccerguy83]

Pulled the motor and pressure switch off tonight.

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[Puff]

I'm no professional but I used my 4.5" grinder and my 3" air power cutoff wheels. By cutting a small square around it, you can accomplish a similar end result and use square pieces instead of round. I like that link photo however. The 3" disc is a verymanageable small cut if needed ( harbor freight $20. )

Forgot to add... I used the small pressure switch hole as a pass thru to send my temperature probes through when cooking. With a few small cap plugs, I can close them up as needed and another thing I did was to use a small 1" sq piece of the Nomex gasket to wrap around the probe wire and slip into the pressure hole if I REALLY NEEDED to seal it up

[soccerguy83]

Great ideas Puff! My pressure switch hole might be a good spot for the tel-tru I need to look at their site and see what the mounting options are. I plan on running a maverick, but would like the tel-tru to be able to glance at from afar (out the window haha). For the maverick, I'm thinking about running a slot in the side of the door opening, like I have set up on my WSM's. Also thinking about leaving one of the plugs and using that as you described.

I'll know more once I get the pump off and cut off the brackets to figure out what I want facing up.
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[soccerguy83]

Making progress, shoulda used the lift to remove the pump, it was very heavy.

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[Rodcrafter]

Yeah it looked like a good pump, I wouldn't throw that away.