My Custom Vertical Offset is Getting Close...Big Daddy Bandera!!!

peeps

somebody shut me the fark up.
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I have posted this in some other threads, but since it is getting close to finished I thought I would make a dedicated thread.

A few years ago, after having a couple gas grills, I was introduced to the chimney starter at a friends BBQ. The ease and quickness of starting coals with a chimney eliminated the only real roadblock I had with charcoal cooking as I had never had good luck getting the coals going consistently and in a timely enough manner in my previous attempts while camping or picnicking.

About 2.5 years ago, my wife bought me my first Kettle (22.5 OTG) and from that day for the next year or so, it sat beside my Wal-mart special SS gas grill as it rotted away, never to be used again. The gasser would eventually be sold in a garage sale at a bargain basement price just to get it out of the way of my Kettle.

I had moderate success turning out steaks and pork chops while grilling on the Kettle but it wasn't until I figure out how to configure it for smoking that I really began to love that little guy. The food, the process, the smell, the satisfaction!

I had never done cooking on it for more than a handful of people though with large cuts like butts and briskets. Once I tried ribs on it I started to realize I was going to need something bigger if I ever wanted to make ribs for a decent sized party.

Thus began the search for a smoker with enough grate space but a small enough footprint to not monopolize my new grill space we had made when we did a patio cover and patio extension. (see link to patio discussion)

I knew I wanted to learn an offset, so I began looking for a vertical offset. As I looked for local fabricators to minimize shipping costs, I stumbled across Lone Star Grillz and really dug their designs for the vertical smokers. I didn't love the price tag or the potential shipping prices from Houston! :O I was just getting into this game and never dreamed the prices of some of these rigs. To the back burner this went and I started looking at WSM's and UDS's but never liked the idea of rack-trapped food. I had borrowed an ECB for a while and just learned that, IME, it was a pain in the ass.

A few months ago, another new Brethren member, bvbull200, who I know from a new era GTO forum we are members of, found a NB Bandera for a steal and in need of some TLC. He posted about it on the GTO forum and it caught my eye. It was the style I was looking for and at a low price of entry. We both searched CL for a while and found some decent candidates but all required a bit more TLC than I was equipped to handle since I have no welding equipment. I also found a nice custom smoker in a similar style but with a bit smaller firebox but without the grill top on the firebox side and a shallower smokebox. It was nice, just didn't have everything I wanted.

That same day I looked at the custom one above, I stumbled across a CL ad for a local fabricator (AJ's Custom Cookers). I checked out the pics of stuff he had done and like what I saw, so I shot him an email describing what I wanted and what my budget was. He emailed back and said we could work within or around my budget and get me exactly what I want, so we met up, and worked up this design based on the features I liked from the rigs I had been looking at for about half to 2/3rds of the cost. I did decide to go with 3/16" plate instead of 1/4" and that was a nice chunk of the savings. I'm in Texas...that's all the thermal mass I need, right!!!! :)

The build is 3.5 weeks in from the sketch and down payment and looking at another 1.5 to go.

The pics below show the sketch we worked up together and then the progress pics he posted up last night.

I am super excited as you can guess and have been spending WAY too much time on this site trying to learn as much as I can about cooking on an offset since I have NEVER experienced it. I am thankful for the experience that everyone has shared on this forum and I think it has given me a good foundation to start from once this bad boy gets picked up next weekend!!!

He told me no more pics until it is finished...the tease!

new_smoker_design.jpg


The small shelf on the outside of the smokebox and the holes for temp probes will be on the non-firebox side, it was just shown on that side so he didn't have to draw the other side elevation.

smoker1.jpg


smoker2.jpg


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smoker5.jpg
 
Im Sure it's just the pic but the smoke chamber looks CaddyWhomped....... That guy did have a refurbished Bandera for sale a few weeks back but he wanted too much for it.
I bet that thing will be a good smoker and last a long time (long as it ain't CaddyWhomped LOL). :thumb:
 
Very nice indeed! Having flogged and modded a Bandera for years I would suggest a partition between the firebox and the grill so that you could have a separate bed of coals for your grilling. They lose way too much heat out of the top of the grill to smoke efficiently. I have thought of making a super Bandera myself. Very well made!
 
Im Sure it's just the pic but the smoke chamber looks CaddyWhomped....... That guy did have a refurbished Bandera for sale a few weeks back but he wanted too much for it.
I bet that thing will be a good smoker and last a long time (long as it ain't CaddyWhomped LOL). :thumb:
I think it is just the pic...the pic I have of the 2 chambers sitting on the table prior to joining them, they look squared up.

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You talking about AJ having a refurbished bandera for sale? He has cloned one from 1/4" plate and sold it for $950. Perhaps that is the one you are referring to? I have attached the pic he sent me of that one...
 

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Ya that's the one.... I made an offer but he didn't like my offer. - are you having a deflector or baffle put in where the smoke box and firebox meet (in smoke box)?
 
Very nice indeed! Having flogged and modded a Bandera for years I would suggest a partition between the firebox and the grill so that you could have a separate bed of coals for your grilling. They lose way too much heat out of the top of the grill to smoke efficiently. I have thought of making a super Bandera myself. Very well made!
The griddle guy! :)

The lid on mine will be much heavier than the Bandera and should make a much better seal. I will run it for a while and see how it goes.

I don't plan on grilling AND smoking at the same time other than maybe reverse searing. If I need to grill AND smoke, I will use my 22.5" Kettle for the grilling so I don't lose the heat.

I do plan on having AJ make a removable SS griddle top inspired by yours, just it wasn't in the budget for now...
 
Ya that's the one.... I made an offer but he didn't like my offer. - are you having a deflector or baffle put in where the smoke box and firebox meet (in smoke box)?
Tuning plates. You can see the rails for them in the head on shot.
 
That's awesome!
My only thought, is that those wheels are going to rust and stain your patio, even if they're painted, the paint will scratch off as it's rolled around.
Maybe some of that rubber coating used for tools might help?
 
That's awesome!
My only thought, is that those wheels are going to rust and stain your patio, even if they're painted, the paint will scratch off as it's rolled around.
Maybe some of that rubber coating used for tools might help?
Noted...

Are you referring to Plastidip?

I doubt I will move it around much once it is set. It is going to be HEAVY! I will see what happens when we get it moved into place and see what measures I need to take.
 
Also that's going to be a lot heavier than a Bandera, so you might want wheels on the other end as well or a little wagon handle arrangement w/ wheels that would pick it up on that end to move it around. Looking good!
 
Also that's going to be a lot heavier than a Bandera, so you might want wheels on the other end as well or a little wagon handle arrangement w/ wheels that would pick it up on that end to move it around. Looking good!
There will be a handle on the non-wheel side per the sketch in the OP.
 
Yea, Plastidip. Thanks, I couldn't remember the name.If nothing else, once you get it in its home, you could get a floor jack and raise it up, then you could put a nice pretty coating on the wheels, let it dry and drop it down.Either way man, that's an awesome looking build. Well done, and thanks for the pics.
 
Yea, Plastidip. Thanks, I couldn't remember the name.If nothing else, once you get it in its home, you could get a floor jack and raise it up, then you could put a nice pretty coating on the wheels, let it dry and drop it down.Either way man, that's an awesome looking build. Well done, and thanks for the pics.
Yeah, that's the process I had in mind should it be an issue after you raised it.

Glad to share the pics of the build. I will keep this updated with the final pics and how the learning curve is for me once it arrives. I am HOPING I will be able to burn sticks sometimes and use the charcoal basket/minion style approach at other times depending on what I have going on on the particular day. I will experiment a fair bit to see how I can do either efficiently.
 
Yeah, that's the process I had in mind should it be an issue after you raised it.

Glad to share the pics of the build. I will keep this updated with the final pics and how the learning curve is for me once it arrives. I am HOPING I will be able to burn sticks sometimes and use the charcoal basket/minion style approach at other times depending on what I have going on on the particular day. I will experiment a fair bit to see how I can do either efficiently.
I thought about the rubberized paint used for bed liners and such, I guess it's probably the same kind of stuff as the Plasti Dip just marketed differently. I don't know how well any of that stuff would hold up though with all the weight that your monster Bandera will have. It might just rip and peel off the first time you tried to move the pit but I guess it's worth a shot anyway! At any rate, she's looking good and I'm looking forward to seeing the final product! I know you're about to wet yourself in anticipation!:p
 
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