80 Gallon Bid for Excellence

[huntfishgrill]

OK another very specific question, since the port from FB>CC will be boxed, does it necessarily need to be dead same area/cross section all the way through? Or can it start larger(exiting the FB) so long as the actual entry into the CC is the correct square/inch area? basically tapering down, since we're coming at a funny angle into the bottom of the CC. We're talking 12" max run from FB>CC with a little dog leg in the middle somewhere.

[Gizmo]

You only figure the bottleneck in your case. Total area of the SMALLEST one of the openings….
If you like splitting hairs and stacking BBs then you could add the volume of that exchange "plenum" to your FB too since it's really an extension of the FB anyway.

This is one of those subjects that keeps Frank awake nights …..

[Smokeone]

Gizmo is on fire on this one.

[huntfishgrill]

I ain't layin' awake on this one, that's good enough for me! LOL thanks!
Since that factors into the BP exits i just wanted to clarify. sandblaster tomorrow and hopefully heavy fab time this weekend. what's the word on primer? i have quart high heat rustoleum and heard from my buddy that powder coat may enter the equation, at least for the trailer if we can work a deal with the powder coater. either way, what's the standard paint process, is there a thread?

[mofomatic]

for the bp openings, i used a piece of closed cell foam and a piece of tig rod. cut your foam to the desired sq in, and use that to make you template to cut the curved shape.

[Gizmo]

That's a great idea mofo!

I haven't heard the "closed-cell foam" term in years since we used to cut airplane wing cores out of it with a hot nichrome wire … but I guess I'm getting off the subject …. again.

[huntfishgrill]

bummer. the sandblaster didn't call me back, so unless they get right pretty soon tomorrow, looks like we'll have to wait two weeks to get this thing wrapped up.

[huntfishgrill]

just saving this data here so i don't have re-enter it again
Link to BBQ Pit Calculator

and this little slice of awesomeness
http://www.1728.org/circsect.htm

build notes
FB exit needs 65.34 square inches
5.5" baffle plate height= 70.217 square inches
Baffle plate exits need 1.15 x 65.34 = 75.141 square inches/2 = 37.5705 square inches each exit.

*I need to confirm the recommended cooking grate height over the baffle plate.

[huntfishgrill]

Well we finally got to the third day of fab on my first smoker project. after getting screwed by the first sand blaster we managed to get the interiors blasted yesterday. Today we got the FB plenum, the baffle plate and the CC door hinges done. We also got the drain and started the FB intake before finally tapping out for the day.

marking off the firebox for the plenum.

the curve-to-curve template could have been a nightmare, but we used cardboard templates and a little country boy engineering to get it done.

mocked in the first side plate of the plenum

anther shot of the first fitted side plate

the long pieces were pretty easy once the sides were done.

another look at the mocked in main pieces of the plenum.

now to cut the holes for the firebox plenum.

cutting the holes for the firebox plenum.

cutting the holes for the firebox plenum.

the individual pieces cut out and ready to build the firebox plenum.

[huntfishgrill]

welding the interior of the firebox plenum.

welding the interior of the firebox plenum.

welding the interior of the firebox plenum.

welding the interior of the firebox plenum.

firebox plenum all welded in.

drilling the drain hole while installing the baffle plate.

installed baffle plate. two pieces with rounded ends and straight grease fences. insane amount of welds on this thing.

[huntfishgrill]

These hinges are no frills but plenty strong. we had some tube that was exactly the size to fit over 3/8" bolts, so we sut two segments of tubing for each bolt and welded one half to each side of the door/CC.

We needed persuasion to line up the door due to some slight spring, so we used the forklift to "lean" on it until it lined up right.

closer look at our simple hinges. we used three across the top of the door.

welding the hinge on.

the first of three hinges welded on. the door works like a champ.

[huntfishgrill]

can someone confirm what height is preferred for the cooking grate over the baffle plate for me? we're working towards 5 inches.

[Blazer]

huntfishgrill, I think you would be fine at 5''

[Puff]

Awesome. This looks like a great shop to work in also....

[Smokeone]

[huntfishgrill]

Day four is in the books. It felt like slow going today, but we got some major waypoints put to bed. Here's the cook chamber door and the firebox door on hinges.

View of the cook chamber door on all three hinges.

another view of the three hinge CC door. there is a seal/flange yet to be installed. we took the hinge pins out and lightly clearance the edges of the door where they drug on each opposite hinge piece. they work great.

Welding in the hinges on the FB door.

better look at the FB door hinges being welded in.

one FB hinge welded in. the door gaps are super tight from the fenced plasma cut. sealing should be pretty easy.

[huntfishgrill]

What consumed most of today was the firebox grate and air intake. I could have skimped here or spent some money and bought some pre-fab stuff, but we had access to some narrow strips of 10 gauge cold rolled steel so we sheared 1.75" strips and built this grate for the firebox. It's ridiculously overbuilt and just right.
The air intake slider was fab'd from square tubing and angle iron and was notched in similarly to what everyone does with their fireboxes. We made it up, but it ended up looking and working pretty good.

Good look at our country boy engineering for the FB intake. (that's a porta-power hose running through it , but otherwise that's it!

20"x16" 10 gauge fire grate. made from scrap steel strips.

20"x16" 10 gauge fire grate. made from scrap steel strips. here you can see the notches with small rod welded in as cross supports.

welding in the support brackets that allow the grate to stay secure, yet be removed easily.

The grate installed. I added some simple handles from the scrap rod material. This isn't as fancy as some FB grates i have seen, but it should work just fine. here you can also see the air intake from the inside.

[huntfishgrill]

after four days we still have a ton left to do, but we're getting there. We made a list and will do everything we can to knock it out in one more weekend assault.

[Gizmo]

Looks good so far!
Have you considered a pinned release for the tongue jack? …. then just make a small storage location on the trailer to store it for transport - plug it in when you need it….

[The Czar]

Nice....I'm currently working on a similar style build....I like it!!

Sent from my iPhone using Forum Runner

[Rodcrafter]

Nice work guys!

[huntfishgrill]

Looks good so far!
Have you considered a pinned release for the tongue jack? …. then just make a small storage location on the trailer to store it for transport - plug it in when you need it….

Yeah i haven't considered that for the trailer jack. In fact, i knew better than to buy the swing-away due to the short tongue, but the non-swing versions at HF all had low lift distances and were just so cheap. They had a decent non-swing flat foot version that i stared at, but the wheel is soooooo nice when you need it. I'm very much on the fence about the trailer jack issue. It looks like crap where it is right now, that part i know.

[Clover Ridge Smokers]

[SmokinFF]

It's coming along nicely. Keep up the good work.

[huntfishgrill]

any thoughts on clamps to secure the CC door? it's looking more and more like i need to buy a couple of those 500# toggle clamps, but i with there was something better looking that was cheap and effective.