Virginia Oil Tank Cooker Build

[hcallaway]

In Eastern NC, pigs were cooked in old fuel oil tanks. (Resturants had covered pits out back.) As the years have rolled along the cookers have moved towards being custom built. Fabricated with all new materials. Top of the line Stainless Units trimed out with polished diamond plate, electronics, multiple burners and big bucks. Not sure if the BBQ is much better but the presentation is over the top. Even how you open the lids now require an engineering degree from NC State. 40 years ago flipping a pig required somehow laying him on a removeable grate with expanded metal top and bottom and by using steel rods it kept everything in place. Now to flip a pig you have some with gears, chains and the discussions are about motors, reductions, ratios. Big time cookers when I was a kid use to have a handle that when the lid was open one man could flip the pig. Now that was innovation.

I have issues with my little smoker holding temperatures. I found out on this site it has been operator error. (MINE) I love to open the door and add charcoal as the fire is slowly dieing. My cooker is going to use propane.
This is not going to sit well with those that really know how to do BBQ, but it will meet my needs.

[hcallaway]

Giving full disclosure, I did have a really nice custom built Pig Cooker. I sold it the new High School after seeing what they were going to be charged for a custom grill. It ran on propane. I was able to loan it out to anyone, churches, schools, business friends, kids and family. I even cooked for a fundraiser for a Womens Group.

The free oil tank came after having my son in law and daughter convert to a heat pump. A 275 gallon container showing gleaming silver paint. The unit was built in Goldsboro NC home of some of the best BBQ in North Carolina by a Fuel Oil Tank Company. I even know the grand kids of the owner. The business is long gone, but the tank is now going to be given new life.

She is a beaut!
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-18594-1340054297763.jpg

You can see that I am not going the traditional split it in half cooker. I am going to keep the tank on the vertical to use one burner. I could do a small pig, but whole hog is not the direction I want to go.

[hcallaway]

Top out line is for the door to the shelves and the lower door will be for a charcoal/drip pan. I can cook burgers on the grill with it about 7" of clearance. When I use the propane, the drip pan with help with the indirect heating. At least this is the plan.

[hcallaway]

Before I cut the tank, I let it air out for days. You can see the oil pan catching anything left in the tank. I did cut holes for my saw blades. Read on how to do it before cutting. There are many different opinions on cutting any kind of tank. Fuel oil is much better to deal with than gasoline etc....

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-18621-1340054296199.jpg

Even as good as the tank drained you still have to clean it out. I filled it with wood and let it roll. (I had it sitting out in the middle of the driveway. It looked like an oil field on fire at first with thick black smoke.)

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-18609-1340054297248.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-18229-1340054295157.jpg

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-25830-1340054251702.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-25830-1340054251702.jpg
Door metal stressed relieved after cutting. Had to strengthen the openings using flat bar.

[hcallaway]

Sorry for the double post picture. Could not figure how to get rid of one of them.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-25829-1340054249611.jpg
Hard to see the flat bar used on the sides of the door opening.

[hcallaway]

Since the door warped when it stress releived. I have to cut slots in the door and bend it to match the opening. Spot welded it just to hold its shape.

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-26200-1340054253731.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-25676-1340054250641.jpg
This is my drip pan or charcoal pan depending on what I am cooking. Slides in and out. I can take a grate out above and cook off to the side if I want to do it that way. Gennerally I see the heat flow from the bottom, up each end 3" of clearance and in the front and back 2" of space. The drip pan will keep the heat indirect.

[hcallaway]

Finished the expanded metal grills last night for the top rack. I will add a few more racks up higher for ribs.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-665-1340146623198.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-758-1340146602292.jpg

[hcallaway]

I have not grinded any welds so don' look too close. I am getting better at welding as the project has progressed. Heat and Wire speeds have been honed in. Picture above shows how I had to form flat bar to support the openings.

[va92bronco]

Looks like it is coming together. Just finished my oil tank smoker in the winter. Good luck and keep the updates coming.

[hcallaway]

Any links to pictures? Thx

[---k---]

Thanks for sharing. I enjoy seeing build threads like this. It makes me jealous of those that have the tools and space to build something like this. I would love to do it, but I'm only able to live through posts like this. I look forward to seeing how it turns out ... even if it does use propane.

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-26113-1340241390269.jpg
Drip/Charcoal Pan Cover. Still not finished. Have to shorten the catches, install bolt tie downs. I am going to try and cut a hole with a hole saw. Weld a nut to a large washer. Insert into the hole upside down and weld. Then use a bolt with a T handle to hold the plate down. Kind of like the T handles that screw down valve covers on an engine.
Nuts welded on washers. I did this on a pickup bed for hidden fasteners.
http://i83.photobucket.com/albums/j289/hcallaway/DSC00811.jpg
Holes drilled. Flip nut to the inside and weld the washer.
http://i83.photobucket.com/albums/j289/hcallaway/DSC00812.jpg

[Boshizzle]

Nice build, bro! But, there is no reason for a VA BBQ cook to be schooled by anyone in NC.

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-27367-1340241403792.jpg
This is my single burner. 60" 1 1/4" pipe.

[hcallaway]

Nice build, bro! But, there is no reason for a VA BBQ cook to be schooled by anyone in NC.

I could not school anyone on this site. As I mentioned earlier, I struggle with my tiny little smoker.

[mr dirts bbq]

callaway, i need your help i got a friend who has a whole hog cooker that has been messed up by previous owner, he wants me to put 5 burner in her i dont know how to make propane burners can you help? i need 5 adjustable valves also just like a small home grill but 60" wide. oh yeah and an awesome build too!

[hcallaway]

callaway, i need your help i got a friend who has a whole hog cooker that has been messed up by previous owner, he wants me to put 5 burner in her i dont know how to make propane burners can you help? i need 5 adjustable valves also just like a small home grill but 60" wide. oh yeah and an awesome build too!

My burner is off ebay. This one is 1 1/4" sch 40 pipe. A106 Seamless Pipe.
You have to have a air mixer to match the OD of the Pipe. A connector to the hose, regulator and tank. The most burners you would use on a 5' wide would be 2 burners. You would get hoses that go from both burners to one regulator. Single burners are about $160 with all the fittings, lines etc... my tab was just short of $300.

[fatcliff77]

Awesome build! I just recently finished mine, and had my 1st cook on father's day. I really like your tray idea!

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-2978-1340588821816.jpg
Fitted a cover for the Drip Pan / Charcoal Tray opening. Since the Tank is curved I have spent way too much time trying to make tight fits on the doors. I was going to hinge it like the other door, but to get it really tight I used a concept like a barn door brace. Bar fits in the slots. Had to cut them down to allow the pan to slide in and out. Welded washers and nuts on the inside of the grill. Then used the bolts to hold the top of the bar in place. Worked out better than I thought since I could still reach the inside of the tank to weld. Did not use my blind nut concept. Took small diameter tubing that I welded over the bolts as my fasteners/handles.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1949-1340588830862.jpg

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1154-1340588849363.jpg
Cut a small door on the end to fit my burner on the inside. If you do have a burner make sure you can pull it out to service it. The slots tend to get rusty and cut down the gas flow. I took a piece of angle to flow the contour of the burner cover and welded it to the end of the cooker. At the other end I took the left over cut door cut out and tapped it to fit over the burner pipe. The burner can come out in a few minutes and is tight enough to stay in place during transport.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1089-1340588860992.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1007-1340588872980.jpg
Used same fasteners and tie downs as the other opening.

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-22730-1340588888093.jpg
Started to weld up the door. I am trying to build up the welds to cover the gaps. I also cut open the lid for a Temp Gauge.

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1024-1341169717694.jpg
Kind of ugly stacks.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1099-1341169729883.jpg
Started welding and grinding around 5:30 today to beat the heat. Put new closures on the lid. Forgot to take pictures. Added lifting/tie down to the top of the cooker. Now I can pick it up with my tractor. Added strength to the legs on the front and rear. It would be easy to mount on a trailer now.

[hcallaway]

Almost done. Needed a way to open and close the door. Wooden bat should be OK.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1046-1341691320656.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1144-1341691297542.jpg

[twinsfan]

I love that Louisville Slugger handle! Been following the entire build. Looks sick, I just wish you used wood instead of propane, but I get your concerns. :-D

[hcallaway]

I love that Louisville Slugger handle! Been following the entire build. Looks sick, I just wish you used wood instead of propane, but I get your concerns. :-D

The way we have been looking at the cooker, I think we can add a wood box on the back of the cooker. The drip/charcoal pan acts like a diverter as the heat has to travel to both ends before rising up. Not a 100% sure flow but I would guess at least 90% of the heat would have to go that way. The cooker is certainly not air tight on the lid. I do think it will hold heat pretty good with the over lap of steel on the opening using flat bar inside and out. There has to be at least 4-5" of over lap on the sides.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-1037-1341691235521.jpg

[Sillius Sodus]

I really like this idea. Your pictures throughout are much appreciated. The dual heat source idea is great.

Plus, I like that it looks all beat up and not brand new. A real homemade idea. Great job!

[hcallaway]

Fired it up today to see if it will build heat etc...
It hit about 500 degrees in about 10 min if that. My problem is going to be keeping it low.
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-2555-1342284387994.jpg


http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-3104-1342284400586.jpg

[hcallaway]

http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-8125-1342284417670.jpg
http://i83.photobucket.com/albums/j289/hcallaway/BBQ%20Cooker%20Charcoal%20and%20Gas/photobucket-6470-1342284430752.jpg
The tractor makes it much easier to move around. I adjusted the pressure regulator to less than 5 psi and the tem still held at over 300. I did have the vents closed. I will have to play with it.

[hcallaway]

Trip to Walmart and picked up: engine cleaner, spray bottle, Bic lighter, vegetable oil and hours later the grill is ready. Cleaned the grill. Sprayed it with oil. 250-275 for 2 hours and 400 for 1 hour to season it like a cast iron pan. We hope to cook our first butt next week.