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Old 11-11-2009, 09:10 PM   #4468
EvilTwin v2
Found some matches.
Join Date: 11-11-09
Location: Moundsville, WV

I got my barrels the other day. I'm using 2 55 gallon barrels. I cut the lid & bottom out of one to use as the center section. The 2nd barrel, I cut on the top of each center rib to use as a base & a lid.

The 3 sections fit pretty tightly...should seal up nicely.

From left to right: Top, center, lid.

Here they are stacked.

I cut everything with a cutoff wheel on my angle-grinder. I left about 3/4" lip on the inside top & bottom, so that the center section will keep some structure. I may have to grind away some once I get the grills.

Note: They were both a seafoam green color w/ a bit of rust until I burned them out.

Well, other than paint & some sort of damper on the intake & chimney, it's done.

I picked up 2 replacement Weber grates & a Weber bottom grate at Lowes, along with several nuts & bolts. I then stopped at a metal supply place & bought a 12 3/4" x 50" piece of heavy guage expanded metal. Then I finally stopped by Walmart & got 2 thermometers for the smoker, and then 2 remote digital meat thermometers (all on closeout).

On the way home, I stopped at a buddy's house & picked up an old post jack (3" od) to use for intake & chimney (black iron pipe was going to cost over $25 for enough and this was free).

After several hours with the torches, welder, hole saws, etc., we have smoke.

I ended up with the first grate at 24" above the bottom of the charcoal basket, and the top grate about 14" above that. The thermometers are within 1/2" of the grates.

here's some more pics from today:

I put it through it's paces again tonight. I had it up to 800* for about 15 minutes 4 times & then let it sit at 500 for another 1hr. It's been holding 250* with the coals from that for the past 2 hrs w/ using foil as a damper on the intake & exhaust.

I still want to put some handles on it, paint it, and build dampers, but it's at least ready for meat now.
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