Char-Broil Reverse Flow Conversion

[Tom_Heath]

Thats one heck of a basket, nice work.

[Smokeone]

[The Czar]

That is not a small basket!!!

[maccas66]

Hey Buck, nice job mate!, can I just say one thing, from my own experience with my basket, I`d cut one side down so you can add fuel during a cook without having to pull the basket out to do it!. I hope to cut mine down this weekend

[Buck]

Thanks for all the kind words everyone. I think that basket is going to end up being a parts bin. I started freaking out because I was looking at my old firebox and was thinking this new one isn't much bigger (when I calculated the total area it is MUCH bigger but the illusion between cylinder and cube did me in) and since the cooking chamber metal is so light weight, I wanted to get as much charcoal in, at one time, as I could to minimize re-fills. So I decided to make the basket as big as possible, put a handle on the front and some stops on the back so I could lean it out and fill it when it needs it. So I got it done, stuck it in, and immediately knew it was a mistake making it that big. So now I have a basket that only has 1/4" clearance all the way around and is a pain to move in and out ... can't imagine it will get any easier when it's hot LOL. I already considered just cutting the front down but if I re-purpose the basket, I think it would be better the way it is. Gonna test it like this first and make a new, smaller, lower front basket if I need to. Only took me about 1.5 hours and less than 20 bucks to make it so not the end of the world.

[maccas66]

It will make a hell of a basket for a UDS!

[Buck]

Well I'm kinda anal so my UDS basket would, of course, have to be round LOL. I'm finding it makes a good, sturdy stool if nothing else ... So could someone tell me how you guys are posting more than 3 pics ... it's telling me I've reached my limit when I try to post a 4th one.

[Smokeone]

I do most of mine with photobucket.

Sent from my iPhone using Forum Runner

[Frank_Cox]

I will hafta look into it, I have never had that problem

[Buck]

Maybe I have to have more posts? Sometimes forum newbies are limited in what they can do to prevent spammers going crazy.

[Buck]

Alright guys. Firebox is mostly done and mounted. Did a nice 6 hour 250 Degree minion method lump charcoal burn without refueling (firebox dampers about 1/3 open) so I think I'm about done with the mods and am pretty happy with the improvement. about 35 degrees from side to side and very stable once the vents are set. I still need to put a gasket between the 2 halves of the cook chamber, decide what to do with the firebox closing lever, build a side rack/handle/counterweight opposite the firebox, and install some sort of stack damper but I think she's about as good as she's gonna get. Might add a firebox to cook chamber damper if I decide I need one. I've pretty much scrapped the idea of using the firebox on another build since it will be too small for most anything I would build but I can get it off pretty easy If I need to. 10 tacks and grind off the weld I laid down to seal the firebox to cook chamber opening. I'm glad I did this ... learned a lot of things not to do on the next one .

Welded this mounting plate on first. Made mounting the firebox a snap.

Got the baffle plate gap to recommended size, drain pipe mounted, and drip edge in. Nightmare welding the thick stuff to 20 gauge and have it sealed (hence build up welds on sides of angle) but it does hold water. Can also see the 1" angle I added to seal the cook chamber (gasket coming soon) ... more nightmare welding.

New Hinges ... SO much better.

[Buck]

Can only post 3 pics/per post ... here's some more.

One of these on each side. Holes are staggered. Didn't figure the basket would block 1/2 of one of them (DOH!). One more on the bottom for cleanout and extra air if needed (got 475 and climbing with full basket and all vents open). Not crazy about the handles but they were easy. Might try ironwood later.

Better view of partially done vents.

No idea what to do with that handle (so made it extra long) but it sure does close her up tight.

[Buck]

OK ... one more.

New, smaller, easier loading, charcoal basket. Notice old firebasket (in background) is now just a charcoal starter rack LOL.

Just threw some engaged charcoal in. Put some stops to keep the fire basket from falling out. Can't see them here but just nuts welded to a plate and bolts screwed into them.

[Gizmo]

That's a nice set-up Buck!
Sometimes I wish I had done that with my Charbroiler too...

[The Czar]

Wow man....that is a serious looking fire basket!!!!!

Sent from my iPhone using Forum Runner

[Buck]

THX Rick ... about $225 total into it (including lots of extra material for the "real build"). Don't think I'd be able to get anything that works this well for even 4x that price from a store. I didn't know what else to do about the basket dcman ... I just used what was laying around. I didn't want to open the door and have hot coals fall out on my bare toes (flip flop country here). At least there's no worries about it getting hot and falling apart. ;)

So I was thinking about how my cook chamber is made from pretty thin material and how I'm probably loosing a ton of heat out of the top of it right now. Has anyone ever put a radiation plate in the top of the cook chamber? I could easily weld one in and it would insulate the top, put some more weight on the lid so it would close tighter, and maybe even get the top of my chicken a little more crisp. Only drawback I can think of is that I'd loose some headroom. Anyone ever try/see this?

I'm going to compile a list of tools used, materials, and what I discovered about reverse flow cooker dynamics during my test burns after I get it 100% complete ... maybe in a different thread. I did this in a small area of my backyard and I think if people see they don't need tons of money, a huge shop, and a bunch of tools, they might be inspired to get out there and build one. More people smoking some good Q on something they made has got to be good a thing!

[Smokeone]

I think a new thread on your technique and lessons learned would be great!

I have not seen or heard of the radiation plate. Would seal it tight and insulate between the two?

[Tom_Heath]

I concur with S1 that it would be great to have another thread about the logistics of the build. You are 100% correct that there is a ton of folks that hold off thinking they need more stuff to build.

Made me laugh with the flip flop comment, LMAO still. I used to read on a welding board and there is a member over there called HOTFOOT. Go figure.
Guess he was welding with tennies on and well, caught a hot spark.

Nice looking build

[Gizmo]

I would suggest you concentrate on getting the whole thing air tight. Most of the improvements you want will come from that using the parts you have.

[Buck]

I hear ya rick. Just thinking out loud. I just put the cook chamber gasket on and still have to test it but the only place I could see smoke last cook was from the stack and around the cook chamber/lid gap so I think it will (amazingly/finally) be air tight. From the looks of it, I might have to add some weight to the lid to keep it sealed no matter what. That lid *might* weigh 3 pounds so not much pressure on the seal.

[Gizmo]

Stop by your local hardware store and pick up a pair of "draw catches" - the kind you "buckle" shut like a mason jar - sort of. You might have to do a little bracketing to get them right where you want them but it's a cheap way to pull that lid shut and compress the fire rope.

Let us know how you do - I think you'll be amazed how much better it works after these improvements....

[Rodcrafter]

Looks like you can get ur done with that!

[Bulldog BBQ]

I have.a char griller offset smoker that i turned into a reverse flow. It was easy and chap and the differences are night and day. I can cintrole heat within 2° and never have to move the meat around. The smoke ring it punches are 3/4 in!!.

[Frank_Cox]

awesome!