Project "HUMPTY" — Kamado/BGE Restoration, Vancouver, Canada

[MayDay]

The reason I didn't load very much coal for the cook was I was afraid to overheat the Kamado and crack it again.

For yesterday's first cook, the cooker was loaded with about 1 gallon of Hard Coals Lump for the pork. Then, an extra 2 quarts lump added for the chicken. Wasn't enough for either cook.

Another problem is ash buildup. The ash suffocates the coals and chokes off air flow before the coal burns out. I think the ash is not able to fall through my rusty coal grate as easily and cleanly as it would with a smooth grate or one with different configuration (?).


Am keeping my eyes open for something I could use as a new grate, but have not been able to find anything up here. Thought about buying a commercial drain cover, but they are costly up here at ~$60. Needs to be 7" diameter.

Here's a picture of the ash pattern and unburnt lump from the overnight bakeout. Only used about a gallon of lump and choked down to ~280F. Damper open ~1/2" and smoker top ~1/4" for the night. Quite a bit of unburnt coal left.


Will try Nam-Char next time (higher quality, low ash). Have a small stash left, but the local shops have not been able to bring it in lately.

If I load the firebox up to the fire ring, how do I manage the ash issue so that the coals don't suffocate?

Suggestions?

May

[jonboy]

I like the color of your cooker. It looks like the great pumpkin,charlie brown.
I think that you need a wiggle stick for the ash. It is a small wire with a L
bent into the end. You insert in thru the ash door and up into the ash grate and wiggle. I need to make myself one for my next cook. It seems that you can make them from a used bbq fork. Remove one side and bend.
jon

[MayDay]

Thanks Jonboy. Will definitely make myself a wiggle stick. My Kamado didn't come with an ash tool, so I'll also find something suitable for sorting and cleaning the ash.

Yah, I really like the copper color too! Looks totally different under different lighting. Very cool!


Thanks to you, "The Great Pumpkin" of Charlie Brown fame has now been added to the Copper Cooker's pedigree (in addition to Humpty).

As for a new charcoal grate, my sweetie may be able to weld something up for me.


May
Project Humpty: SLIDESHOW, PHOTO ALBUM
____________
Kamado/BGE
Cobb Barbeque

[Professor Salt]

Great job on the refurb, May. I really enjoyed your photos and the updates throughout the process.

Thanks for adding much to the community. Great to have you aboard.

What's that fish in your avatar?

[Brauma]

Yes, that color is kickin! Very nice job.

[MostlySmoke]

Mayday,
You are the only kid on the block with one of those!! Looks great!

[swamprb]

Originally Posted by MayDay

The reason I didn't load very much coal for the cook was I was afraid to overheat the Kamado and crack it again.

For yesterday's first cook, the cooker was loaded with about 1 gallon of Hard Coals Lump for the pork. Then, an extra 2 quarts lump added for the chicken. Wasn't enough for either cook.

Another problem is ash buildup. The ash suffocates the coals and chokes off air flow before the coal burns out. I think the ash is not able to fall through my rusty coal grate as easily and cleanly as it would with a smooth grate or one with different configuration (?).


Am keeping my eyes open for something I could use as a new grate, but have not been able to find anything up here. Thought about buying a commercial drain cover, but they are costly up here at ~$60. Needs to be 7" diameter.

Here's a picture of the ash pattern and unburnt lump from the overnight bakeout. Only used about a gallon of lump and choked down to ~280F. Damper open ~1/2" and smoker top ~1/4" for the night. Quite a bit of unburnt coal left.


Will try Nam-Char next time (higher quality, low ash). Have a small stash left, but the local shops have not been able to bring it in lately.

If I load the firebox up to the fire ring, how do I manage the ash issue so that the coals don't suffocate?

Suggestions?

May

Get an ash tool and keep the mousehole clear. Try a Lodge cast iron trivet or find a cast iron floor drain cover from a plumbing supply for a coal grate.

[Smokin Gator]

Here is the Amazon link for the Lodge cast iron trivet:

http://www.amazon.com/Lodge-Pre-Seas...4488893&sr=8-1

I really like mine.

[h20loo]

Maybe sand blast the piece and use a wiggle rod. I would want it to work- but if it works with the original pieces than that would put a grin on my face. If you have time and want to try something different then I would try electrolysis .
http://www.antique-engines.com/electrol.asp

I often do this with my antique parts. Kind of like smokin" - takes time, neat to watch(beer) and the end result is amazing.

[MayDay]

Great ideas for the coal grate. Will check them out.

Thanks Waterloo. Didn't even occur to me to try home electrolysis. I removed the rust the old-fashioned way, with wire brushes, knives, files and a few skinned knuckles. A few curses too. Wish I'd seen the Rust Removal Using Electrolysis writeup before I painted all the other rusty bits.

May
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Project Humpty: SLIDESHOW, PHOTO ALBUM

[MayDay]

I'm forgetting my manners. Wasn't sure how to respond at the time, so am giving my belated appreciation for all the advice and encouragement EVERYONE gave (on and off this thread)....

• Waterloo - I may just do some electrolysis yet. Thx.
• Smokin Gator - Thanks for the Lodge trivet link. And yes, HE does look great!
• Swamprb - Brian, THANKS for all the great advice! Your Imperial Kamado Restoration posting was what I studied before jumping in to do my own repairs. Took a lot of the unknowns out.
• MostlySmoke - Yep, only one Copper Cooker out there; he's not part of any lemming pack!
• Brauma - Mark, still kind of wishing the copper to be that "new copper" color, but it still came out great. Humpty is looking quite dapper!
• Professor Salt - Thanks for the kind words. Glad you enjoyed the photo documentation and slideshow as I didn't want to overpost on the pics. The fish avatar is one of few allowed for newbies. As a newbie, I'm not able to post my own avatar (yet).
• Jonboy - One Wiggle Stick coming up this weekend! The Great Pumpkin is now one of Humpty's aliases.
• Crome - Glad you like the copper!
• Thillin - Ok, will be loading the firebox more. Was too timid before.
• Cabntmkr1 - Thanks for the pat on the back.
• CivilWarBBQ - The restore turned out better than I expected. A piece of cake compared to TomJax's Extreme Makeover. Even though I didn't use furnace mortar over the JB, everything is still holding together after the bakeout and first cook. Keeping my fingers crossed.
• Browser - When I first saw the Kamado, there was never any doubt in my mind that I would restore it. Some of my buddies did think it was an eyesore and better off in the landfill.
• CaptGrumpy - I'll be sure to watch my temperatures!
• FatDaddy - Hope you can get to your restore soon - I sure enjoyed mine.

You guys are all great!!!

May
Project Humpty: SLIDESHOW, PHOTO ALBUM
____________
Kamado/BGE
Cobb Barbeque

[swamprb]

Originally Posted by thillin

Looks good. Add coal all the way up to the fire ring.

PLEASE DO NOT fire a clay Kamado like a Big Green Egg!

I can't stress enough for anyone with a claypot to download the manual for the pre 1976 BGE from the Naked Whiz!! You risk overheating and damaging all the fine work you've put into this. Start out with the suggested amount of briqs/lump and add as you cook.

I just got a Medium Sakura Hibachi Pot Kamado from my BIL's brother that will be my next restoration project and when he told me that he filled up the firebox EVERY time he cooked it was no wonder the thing is in pieces.

I would suggest using furnace cement over the JB-Weld joints. I only say this because I was using the claypot base mod in my WSM and it cracked-I pieced it back with JB-Weld and after a few cooks it cracked at the reapair. It was not in direct contact just the heat sink in place of the waterpan. A little insurance as I see it.

[jeffjenkins1]

Very nice pot and finished product!

Jeff

[MayDay]

Originally Posted by swamprb

PLEASE DO NOT fire a clay Kamado like a Big Green Egg!

I can't stress enough for anyone with a claypot to download the manual for the pre 1976 BGE from the Naked Whiz!! You risk overheating and damaging all the fine work you've put into this. Start out with the suggested amount of briqs/lump and add as you cook.

I just got a Medium Sakura Hibachi Pot Kamado from my BIL's brother that will be my next restoration project and when he told me that he filled up the firebox EVERY time he cooked it was no wonder the thing is in pieces.

I would suggest using furnace cement over the JB-Weld joints. I only say this because I was using the claypot base mod in my WSM and it cracked-I pieced it back with JB-Weld and after a few cooks it cracked at the reapair. It was not in direct contact just the heat sink in place of the waterpan. A little insurance as I see it.

Brian, FUEL OVERLOAD warnings duly noted. Thought I had overly skimped on lump for the initial bakeout and first cook. As suggested, will be referring to the original Kamado manual for fuel loads. Thanks for the extra emphasis.

Funny thing about the furnace cement.... I had actually returned the unopened product for a refund yesterday. Ok, it's back to the store to buy the stuff again.

Last week, I just got lazy and didn't want to go the extra step of furnace mortar. Sounds like I had better do it ASAP. However, will only be able to mortar the JB-welds on the inside, seeing how the outside is already painted. OK?

The Kamado was to star this weekend in 2 cookouts (Sat & Sun) with company coming over....

1. If I apply the cement tonight, will I have enough time to let it dry and cure in time to use for tomorrow's dinner? !!!
2. What does curing involve? A low-temp bakeout?
3. How can I minimize cracking or flaking?

Thanks!

May
Project Humpty: SLIDESHOW, PHOTO ALBUM
________________
Kamado/BGE, Cobb

[MayDay]

Didn't notice this before, but apparently the previous 2 fires (bakeout & 1st cook) caused some thermal stress. The JB'd bottom, firebox and fire ring are all fine. But new cracks have propagated from the original ones that were JB'ed in the dome.


Crack growth in dome - close up.


DRAT!!! I thought the two previous firings were low and slow. Maybe not?

This calls for new JB-epoxy application PLUS FireStop furnace repair cement ! ! !

However, Humpty has been committed for tonight's dinner (and tomorrow too)!!! Invitations have been issued and accepted. Food has been bought and prepped.

*** So, I'm going ahead and cooking on Humpty anyways. ***

As precaution, the dome will be reinforced with wire around the neck so that it doesn't collapse. Will also be careful to keep the temperatures below 400F.

There will probably be more crack growth due to thermal stress from the additional firings. If the dome cracks right to the edge, JB application next time should work better because the epoxy can then be applied INTO the cracks (instead of on the surface).

I will deal with all this AFTER the weekend, after all the guests have left.

Moral: Look at things in the day(light).
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Project Humpty: SLIDESHOW, PHOTO ALBUM