First Time Build 100# Propane Cylinder (Help Please)

[Fishgod]

Here are a couple of crude drawings for the fire box. Please forgive my drafting skills.

This is my idea for the fire box, 16H X 12 Wide X 14 Deep. I drew 2 inches higher since the fire grate would be at the 14 in mark. The air would come from under the fire grate. Good idea? Also I was thinking of picking up some 1/2 in sq. tube and circle the entrance of the firebox to make a door stop/seal. The 1/2 seal would sit back 1/2 in. The firebox door would have the same 1/2 tubing welded to it to seal the door. Good idea or overkill? still trying to figure out the vents. Not sure how I would seal them up except for a long slide or a double slide (half going left, half going right). Let me know what you think

[Big T]

I wouldn't say that it's overkill because it'll help keep the door from warping. Make sure that you have a little wiggle room when the door is cold or it could expand and not open or close when you fire it up. The overall design looks fine, as far as the intake goes you could use one large rectangle with a slide over it.

[Fishgod]

Thanks Big T.
I see your point on the intake. I have reduced it to two rectangles It will be easier to to put the slides on there. Went to the metal shop and ordered up the steel for the firebox. They are cutting the pieces to size for me. I didn't want to have to cut them all out with an angle grinder.
I have another question. What size metal for should I use for the band around the CC door? 1.5 x 1/8th or something thinner?

[Big T]

That'll work fine for banding the door.

[Rodcrafter]

Yeah what BigT said


Making memories!

[Fishgod]

Well I picked up the steel. Now I just need to get some time to make my cuts on the cylinder and start welding up the firebox. Seeing how this is my first welding project I'm going to do some practicing on some of the scraps


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[ajfoxy]

Excellent idea on getting some hood time in on scraps. And always remember at the end of the day an angle grinder can clean up most welds...

[Welder10]

What kind of welder will you be using?

[temurf]

Howdy Fishgod. Welcome aboard.
Sorry to be so late to the party but I built my reverse flow out of a 100# propane tank. Here is a link to the build thread: viewtopic.php?f=124&t=5218 I used the calculators from this forum and she works perfectly. We are still getting to know each other, but so far, the only issue is that there just aint enough space for everything that I want to cook on her.

[Fishgod]

Welder10 sorry to say but it's 120v Craftsman. Hoping to pick up one of my own this summer.
I opted to go with 3/16 plate for the firebox in hopes of getting a better weld.


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[Fishgod]

Howdy Fishgod. Welcome aboard.
Sorry to be so late to the party but I built my reverse flow out of a 100# propane tank. Here is a link to the build thread: viewtopic.php?f=124&t=5218 I used the calculators from this forum and she works perfectly. We are still getting to know each other, but so far, the only issue is that there just aint enough space for everything that I want to cook on her.

Thanks for the link


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[Mankussm]

Get a circular saw with a metal blade!

[Fishgod]

Well, I did some welding tonight. Fist off my I say. You welders, machinists are true craftsman. Wow it is not easy to do. I believe it will hold up fine for a smoker but man I would not trust my welding on a critical part. I plan on doing some more practice before I start. Once again you people that lay down those beautiful welds are artist

Below are is my practice on an outside edge weld I had to do two passes After grinding down it looked pretty good except for a few small pits. This is 3/16th steel. Pictures are front and back.

[Squiggle]

Watch as many YouTube videos on how to weld as you can & then practice, you'll be a pro by the time you finish the smoker.

[Rodcrafter]

Practice may not make perfect but it will help you weld better.

[Big T]

There's no substitute for practice.

[Welder10]

Welder10 sorry to say but it's 120v Craftsman. Hoping to pick up one of my own this summer.
I opted to go with 3/16 plate for the firebox in hopes of getting a better weld.


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I'm not familiar with that particular welder. I was gonna check to see if I could help any with your welding experience. Some of those machines have auto set on them. From the looks of your welds, it seems to be welding plenty hot enough to hold. Good luck with your smoker build, enjoy building it. You are at the right place for addressing any problems you may have during your build. The guys on here are fabulous about going above and beyond to help any way they can.

[Fishgod]

Thanks Welder10. I will most likely have some questions. I got a bunch done today.

I cut the threaded end off with my saws all.

Firebox cut out made with angle grinder

Cut the base off and ground it down

Top of door cut in.

Bottom of the door cut in.

Top band tac welded in place.

Bottom band tac welded in

Hinges welded tac welded in

Door cut free

[ajfoxy]

Making good progress there.

[Squiggle]

Awesome work dude, well done!

[Rodcrafter]

Here we go


Making memories!

[Big T]

[Fishgod]

Thanks all,
I got a bit carried away with welding the hinges and straps. The top corners curled up a bit on the door. Its not to bad, thinking about putting a little heat on the backside and tweaking it a bit. Am I no the right track? It's lifted about a quarter of an inch.

[Big T]

There's several methods of tweaking a warped door but a lot of guys use the chain and jack method viewtopic.php?f=148&t=3344

[Big T]

I would take the time to get the fit as tight as I could. another thing is if you're going to put a gasket on the CC door, you'll need to shim the door out half as thick as the gasket you're going to use before you weld the hinges in place.