Vertical Stainless Santa Maria Combo Build

[addison363]

Hello all,
The journey begins! I have a stainless steel hull of a test stand that has been sitting in my garage for far too long. It is essentially a 6 ft server cabinet attached to a drain table. I'm starting the smoker portion this weekend. Pictures document starting condition. Steel is ordered! Addison

[Big T]

That should be a sweet build.

[ajfoxy]

Welcome.
That is definitely going to be a very interesting build. I look forward to see how it all unfolds.

[Squiggle]

should be a very interesting build.

[Rodcrafter]

Welcome to the crew!


If we can help just ask.

[addison363]

This is a rough sketch of where I hope this project is headed...but the devil is in the details. I borrowed shamelessly, the pizza oven feature idea, from Pete M. Pure genius! The magic will be to find just the right burner. I will want good control of the entire cooking chamber which is 28,643 cu. in. (temperature target 225 as a smoker and 400 as a big A$$ oven) and also be able to put in temporary ceiling to make a pizza cooking chamber of 5,771 cu. in. and crank that smaller space up to 650 degree F. I have my eye on a LP 2 piece burner from Tejas (LPCAST10-2) that puts out 100,000 BTU but looks like flame can go also really low. Any thoughts on Low Pressure vs High Pressure?

Right now I'm trying to work out the vertical spacing. I'm thinking of putting 4.5 inches between shelf supports, but how many inches above the top of the charcoal basket do I place the bottom of the water/sand pan? Is it just clearance for easy refill or is there more science to it? -- Addison

[addison363]

Progress update:
1. Back cover cut, drilled and attached.
2. Ceiling cut out for server rails, insulated and attached.
3. Back cut, drilled, insulated and attached.
Here are latest pics. -- Addison

[Big T]

[ajfoxy]

Looking like it is all coming together. Can't wait to see it in action.

[Squiggle]

[addison363]

Thanks for all of the encouragement! Good progress continues. Ceiling (except for whole hog hook), back and right sides are done. Left side is in progress...Next up is to finish plumbing the air inlet and cutting in thermocouple access tube to the instrumentation cabinet. I'll post more pics soon.

I've not got a good idea for cooking grates. I bought some 3/4" x 13 GA. MILD STEEL A36 FLATTENED EXPANDED SHEET, but don't weld (...yet). Maybe on my next smoker!

Question: I'm thinking of just cutting it to width (17.5 inches) and then bending down the front edge to create a lip and bending up the back edge. Total cooking surface depth would be 22 inches. They would nest nice for storage and I think the 2 bends would add side to side rigidity and I only have to span a 17.5 span width. I've got pretty full shelf supports and would only be cantilevering 2 inches off the front and the back. Any concerns with this plan? Better ideas for a "No Weld Cooking Grate Design"?

Thanks in advance for the replies. Addison

[Rodcrafter]

Sounds like a great option!

[Squiggle]

very nice work dude, well done!

[addison363]

I haven't posted pics in a while. Here are a few to start catching you up. More to come.

[Rodcrafter]

Sweet!

[Big T]

[temurf]

[addison363]

Next batch of pictures! She is coming along!

More pieces and parts

Air inlet dry fit

hose connection in back

mounted sprayer for filling water pan, fire suppression, and clean-up

Inlet air goesinta

Inlet air comesoutta

Temperature probe access into cooking chamber

Inside done ready for burner cutout

Water pan ready to go!

Bench burn, leak and safety test

[addison363]

Grates and burner cut-in completed last night. Making burner brackets today. Installing burner and drip edges this weekend and then she should be ready for a good clean and burn.

[Big T]

[temurf]

Looking good.

You'll be posting Q-View before you know it.

[ajfoxy]

That is definitely looking great. Good strong work, well done!

[Squiggle]

Looks awesome dude!

[addison363]

Well it was bound to happen...I hit a snag. I got the burners cut in and mounted. Got all the paint pen removed and gave the inside a nice bath with mineral spirits followed by soap and water. I rolled it out into the drive way, hooked up the propane and prepared for the first burn. Pilot and burners lit just fine but wouldn't stay lit for very long. At first I thought it was just the breezy day we were having today. Now I think it is definitely an air problem. I just watched the burners with the door open for 5 minutes. I then closed the door and burners and pilot went out in less than 2 minutes! At least my safety valve has gotten a good test! I couldn't smell even a hint of propane gas when I opened the door after pilot and burners went out.

The exhaust is a 2" x 7.5" rectangular hole in the top of right side wall with a slider damper over the top on the outside. It was fully open.
Inlet air is 2 ways. The first is a 2" pipe and ball valve arrangement that was fully open during the test. The second is the oversize cut out and burner mounting. 7" x 13.25" rectangle opening in bottom with (2) 6" diameter burners below. Burners are mounted under the unit with top of burners being flush with the floor.

My hunch is that somehow my exhaust is not working like I expected and she is filling up with combustion gasses that are extinguishing the flame just haven't figured out how to confirm or have any ideas to fix it. Any troubleshooting advice? -- Addison

[addison363]

Drip edges and water plan in place.

All set up in charcoal configuration

Burners mounted

Ready for first burn -- if only propane would stay lit!