Here are my questions:
Is my cooker just generally too small for even heating... or a just a well functioning smoker? I know it'll have the capacity for the qty of meat I'd be cooking It's fine if it's large enough for what you want to cook.
Are there any glaring problems with my design, anything from a fabrication standpoint to functional issues? No
This is a small backyard smoker, but should I consider different thicknesses of steel? If so what and where? CC could be 3/16" but why bother
The baffle plate is drawn level lengthwise, should it be slightly lower on the drain end? no
Is it necessary to have the BP bent? No
Where should the top and bottom of the cc door be cut out in terms of 12 o'clock to 3 o'clock, or 11 to 2:30, etc.? (I hope that makes sense) 11 to 4
The firebox is nearly a perfect cube (16"x16"x16"), is this optimal or do I need to make adjustments for baskets, ash trays, etc.? No it's fine
Do I need to make the BP gap adjustable? No, only for tweaking but most are not
Do I need to consider the travel in the elbow when figuring stack length? No
What is a good vert. spacing between grates? ~5"
Anything you would change, anything at all? Please lay it on me! I'd like to be younger.
Finally; I don't see a lot of hexagonal or octagonal shaped CC. It would be cheaper for me to do that than get plate rolled, is there a reason we don't see more 'geometric' CCs (besides a lot more welding)? Make it rectangular and have more room for the upper rack. Tanks reduce a lot of welding.