Double pan GF build from South Africa

[BBQChris]

Purchased my plans and converted some of it to metric. Today I had all the 50mm x 50mm tubing delivered. Dropped firebox plans off with the laser cutter and started cutting the tube this evening after work.




Always knew I must keep my weber box for something lol.

[ajfoxy]

Ahh the old trusty Weber saw stand.

[Big T]

There's no turning back now!!

[Squiggle]

You're on your way now dude

[BBQChris]

I need to order some rivnuts for the latches. What sizes did you guys use for them?

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[ajfoxy]

Whatever size fits the bolt holes in your latches. Depending on which latch I'd hazard a guess at around 4 to 6mm

[BBQChris]

Can the outer sheets just be tacked on or is it important to seal the space?

[Roamingbirdbbq]

I would say sealed. Don't want the insulation absorb moisture.


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[ajfoxy]

But stitch weld it. Don't try to weld a single bead in one hit. It will warp. Ask me how I know

[Squiggle]

Me too!

[BBQChris]

Quick question. I've ordered a 2" ball valve. What size and type of pipe will I use?

[mp4]

I used black pipe.

[Rodcrafter]

Me too


Making memories!

[ajfoxy]

Black pipe.

If you are unsure of what size take your ball valve to your steel supplier and tell him you want a piece of black pipe to fit. Now if you are lucky they will also sell pipe nipple. This will have the threads on both ends. Get a couple long enough as well as some pipe connectors, also with thread on the inside though. What I did was weld a connector to the firebox then when assembling turned the nipple into the connector (Squiggle stop now!) If it all works out you should have a bit of pipe with thread sticking out the front of your smoker. Screw the valve onto this. And you are done and dusted.

Now if your supplier does not sell pipe nipple, then get a suitable piece of black pipe and go around to an engineering type works and see if they can put a thread onto your pipe both ends. Obviously after you have measured and cut it to size.

[BBQChris]

I ended up welding a fitting on. Will get some pipe and have a thread put on

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[BBQChris]

Another question. I got some 700C fireplace paint. Do you think it will be ok to paint the inside of the firebox with it?

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[BBQChris]

Some more pics

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[Rodcrafter]

The fitting you welded to the ash box is galvanized. You never paint the inside of any part of the smoker.


Making memories!

[ajfoxy]

Don't paint the inside of the firebox, chute or cook chamber.
And don't use galvanised on the smoker. Always use black pipe. Although it probaby won't get hot enough to actually vapourise the zinc coating but when dealing with food it is beter to err on the side of caution.
Now that you have welded it on already you could use a wire cup brush on the outside and a wire wheel on the inside. Or leave it and just use black pipe on the rest of it.

[BBQChris]

What if I use a torch and burn the galvanising off?

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[Squiggle]

Looks awesome dude, well done!

Agree with the others on the gal, not a good idea to use it & I think it will take a hell of lot of heat to burn it off

[BBQChris]

Thanks. Hopefully getting the sheet metal cut this week so it should start looking like something soon.

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[Rodcrafter]

I know you may not want to hear this. But cutting that fitting off and putting the right one on couldn't be that hard. I would fix it right while you can easily, and never think about it again.


Making memories!

[Weldun]

The other issue with your coupling aside from being galvanized is that it's malleable iron which is not typically very receptive to being welded with a ER70 type wire. Beyond the chemistry differences between the carbon steel fire box and the malleable (cast) coupling they possess different heat coefficients, this means they expand and contract at different rates which make that set up prone to cracking. I think you'd be doing yourself a huge favor to remove that malleable coupling and use either a standard carbon steel coupling or a forged steel coupling. Looks like you are on your way to a fantastic looking cooker, nice work!

[ajfoxy]

Yep, probably the best all round solution. Get yourself the following: "Nipple Steel Steam Barrel 50NB" and a couple of "socket steel steam full 50NB"
Grind the original off and weld the socket to the firebox and screw the nipple to the socket (don't go there Squiggle). You won't regret it.

If you can't find steam pipe then go for bog standard ungalvanised black pipe, get the one end threaded to accept your valve and weld the other end to your firebox.