View Full Version : Recent Kettle Modification
landarc
03-11-2010, 10:09 PM
So, based on Woodreaux's comments on a now forgotten to me thread, I made some modifications to my kettle to increase cooking times, improve temperature stability and control, evenly distribute heat and add versatility to my already super versatile kettle. Here they are about 50% done.
http://i166.photobucket.com/albums/u105/landarc/P3110092.jpg?t=1268365055
The smaller Smokey Joe charcoal grate sitting on One-touch vanes, this will change soon. It gives me more distance from the grate and will eventually have a firebasket to allow better Minion method cooking.
http://i166.photobucket.com/albums/u105/landarc/P3110094.jpg?t=1268365059
A cast iron skillet provides thermal mass and a baffle all in one to force heat to the edges, provide thermal mass and prevent flare-ups. I am now looking for a slightly larger, no longer good for cooking, CI skillet to use. I would like to find a skillet closer to 14" or so in diameter.
http://i166.photobucket.com/albums/u105/landarc/P3110099.jpg?t=1268365069
Chickens sacrificed to see how they work, a few days ago a bunch of baby back ribs were also cooked on this setup. In both cases, once the heat was settled in (270F for chicken, 225F or so for ribs) it was rock solid for the entire cook.
http://i166.photobucket.com/albums/u105/landarc/P3110100.jpg?t=1268365073
Chickens done with a rub of Todd's Dirt and my own medium grained top rub riffed off the Dirty Dalmation. One hour and 10 mins or so at 270F. These did not suck and served as proof of concept of my new modifications.
texman02
03-11-2010, 10:22 PM
Very interesting! Nice thread.
Woodreaux BBQ
03-11-2010, 10:25 PM
thanks, landarc!
I haven't found a smokey joe grate for sale. Have you tried an expanded steel basket i saw on this link?
http://www.bbq-brethren.com/forum/showthread.php?t=56577
landarc
03-11-2010, 10:34 PM
So, my top secret plan is to find some expanded metal, steel, no galvanizing or MSG, roll it around the inside of that fire grate and tie it down with steel wire, no galvanizing or MSG on wire either. Create a basket with a depth of about 3", or more if I can get away with it. I am also going to use threaded rod (not galvanized, no MSG) across the grate to get it off the vents. And I will be cruising the Goodwill looking for a 14" or 16" diameter cast iron griddle instead of using my chicken frying skillet. Although, the seasoning on that sucker is spectacular right now.
timzcardz
03-12-2010, 05:45 AM
It would probably work better for you if you placed all of the "K"s up.
Yleekyoti
03-12-2010, 06:53 AM
Thanks for the pics. That will be usefull for future cooks on the weber!!
bigabyte
03-12-2010, 07:32 AM
Interesting setup. How long do you think you can get on one load of fuel?
jeffjenkins1
03-12-2010, 07:41 AM
Looks awesome!
Jeff
Desert Dweller
03-12-2010, 07:47 AM
thanks, landarc!
I haven't found a smokey joe grate for sale. Have you tried an expanded steel basket i saw on this link?
http://www.bbq-brethren.com/forum/showthread.php?t=56577
Try Home Depot for the grate.
bigabyte
03-12-2010, 07:53 AM
Ooops, I just saw your other thread where you mentioned you got 5 hours burn time with the ribs!:biggrin:
Smokey Al Gold
03-12-2010, 09:12 AM
Hmm this is very interesting I like the setup. I'd definately like to see more of this in action. On that small pile of coals you got that long of a burn? I too use my kettle for everything and I'm gonna look into this more. Academy sells a square grill wok that would work I think as a charcoal basket.
tommykendall
03-12-2010, 09:18 AM
Interesting - post pics of the final design. I'm wondering about your ability to still get an indirect effect in your cooks.
Smokey Al Gold
03-12-2010, 09:28 AM
I'm thinking something like this for a charcoal basket?
http://i178.photobucket.com/albums/w278/alramirez_82/412285e.jpg
landarc
03-12-2010, 12:44 PM
I'm thinking something like this for a charcoal basket?
http://i178.photobucket.com/albums/w278/alramirez_82/412285e.jpg
The only issue I have with a grill wok like this is that I find ash evacuation could be better. It is good enough for sure. I like the ability to whack the side of the kettle and get the ash to fall through the grate.
Yes, I got 5 hours out of this setup, the photos here show the chicken cook, it ran for 2 hours. I needed more for 5 hours under ribs. But, I do believe I can get more with a larger fire basket. Bigabyte, I am really wanting to get 7 hours at 280F out of one basket, so I can do briskets and butts without grill gymnastics to add more coals, I really think I can get there. The biggest benefit so far, which was unexpected, is with the cast iron skillet thermal mass, this setup has been rock solid on holding temps. I hope this continues with the larger charcoal loads I am plannning.
thomasjurisd
03-12-2010, 12:49 PM
Have you guys tried the baskets sold by webber that sit on either side of the kettle allowing room for a drip tray/water pan in the middle? I use a dual hinged grate (to allow adding coals or wood chips without having to lift the entire grate) and it has worked great for me for years. Many a brisket done on this setup....
landarc
03-12-2010, 12:56 PM
I have a set of those and they work great. I am just looking to address a couple of ideas that kept working at me.
Woodreaux BBQ
03-12-2010, 01:18 PM
I'm thinking something like this for a charcoal basket?
http://i178.photobucket.com/albums/w278/alramirez_82/412285e.jpg
That is what i use
sfbbqguy
03-12-2010, 01:23 PM
Have you guys tried the baskets sold by webber that sit on either side of the kettle allowing room for a drip tray/water pan in the middle? I use a dual hinged grate (to allow adding coals or wood chips without having to lift the entire grate) and it has worked great for me for years. Many a brisket done on this setup....
First...GREAT IDEA lando! Certainly going to give this a try.
I've done a number of cooks the way thomasjurisd describes and it's worked good...but I like the way this method looks and the thermal mass with the cast iron to help hold temps could be real beneficial.
suprfast
03-12-2010, 01:26 PM
I was just looking through harbor freight and they have a 3 pc cast iron set for 14.99. I could have sworn the large skillet was 14". They even had a dutch oven too
kris
deguerre
03-12-2010, 01:30 PM
Just checked - the large was 10".
mbshop
03-12-2010, 02:21 PM
sooooo, what are ya trying to accomplish/change ? what is the issue that needs changing. really want to know as most of my cooking is on a kettle and this is interesting but hard to follow without knowing what you want to accomplish. thanks,
landarc
03-12-2010, 02:33 PM
It started with just wanting longer cook times and more grate space. When I am in Humboldt with family, or doing the odd cook for groups, I often need space for 6 or more racks. This is an attempt to get back the entire grate for cooking. Also, this new configuration should give more room for charcoal was my original thought.
With the cast iron skillet/griddle I think I can get even heat, from all sides of the kettle, which I hope will allow a very even cook on butts and brisket, although this was not the original intent.
suprfast
03-12-2010, 04:46 PM
sooooo, what are ya trying to accomplish/change ? what is the issue that needs changing. really want to know as most of my cooking is on a kettle and this is interesting but hard to follow without knowing what you want to accomplish. thanks,
Its turning the kettle into an indirect cooking surface(ie oven) instead of having direct flames(or potential flames) underneath food
Philly-QueMaster
03-18-2010, 09:44 PM
You have any pics of the ribs you did? I'm going to be cooking up 3 racks of St. Louis spares and 1 small 5lb spatched chicken and I'm debating on if I should just use my UDS or my new weber performer I'm dying to try out. My concern with the kettle is that there wouldn't be enough room for 3 racks and 1 chicken...even if I used a rib rack. With this tenique I may be able to make it work.
Patrick
Meat Burner
03-18-2010, 09:51 PM
Patrick, I think you are right. There isn't enough space to do that on a kettle. We all want to do more but at some point it just isn't practical. I use my Weber, a lot, but you can only put so much on and cook well. Lucky for me, I have two Webers and 4 UDS's. LIFE IS GOOD!!!
Philly-QueMaster
03-18-2010, 09:56 PM
Patrick, I think you are right. There isn't enough space to do that on a kettle. We all want to do more but at some point it just isn't practical. I use my Weber, a lot, but you can only put so much on and cook well. Lucky for me, I have two Webers and 4 UDS's. LIFE IS GOOD!!!
So you think I should take the safe route and use the UDS? Either way I'll be happy that its finally nice out and get to cook outdoors.
Meat Burner
03-18-2010, 10:14 PM
Brother Philly, I'm with you about the days getting better. I think you folk have had some nasty weather happening there. Don't be passive on this forum about what and how you cook. All I would ask is be honest about what was good and what wasn't so good. We all like to brag about out great cooks but we all also appreciate honest responses about what didn't go so well. Stay with us and we will learn from you as well.
landarc
03-18-2010, 10:26 PM
I would do the chicken on the performer cause you have it. Do the ribs on the UDS cause you have it. And since you now are using two cookers, throw on some fatties and MOINK balls too. By the way, with the new kettle config. I can do three racks of spares, tips and the chicken on the kettle, if I had two cookers, I already told you what I would do.
Philly-QueMaster
03-18-2010, 10:31 PM
I would do the chicken on the performer cause you have it. Do the ribs on the UDS cause you have it. And since you now are using two cookers, throw on some fatties and MOINK balls too. By the way, with the new kettle config. I can do three racks of spares, tips and the chicken on the kettle, if I had two cookers, I already told you what I would do.
I actually told my wife jokingly tonight I should just use both the kettle and the UDS. I'd like to preserve charcoal so I'll only be using one or the other. I guess i'll decide tomorrow.
peppasawce
03-19-2010, 10:45 PM
I like this so much that I subscribed
Paulmark
03-19-2010, 10:59 PM
What about the grills that sit obove the original grill by way of extending legs,
http://www.fredsmusicandbbq.com/RACKS_EXTENDERS_CAST_IRON_AND_PORCELAIN_COOKING_GR ATES_s/65.htm
I don't have any experience with these but it seems like an easy way to go. There is also a 14 inch cast iron griddle at this site.
Desert Dweller
03-20-2010, 09:17 AM
I wondered how big of a CI skillet I would need to create the same effect in my (36.5 inch) Ranch Kettle. I don't think they make them that big...
JiveTurkey
03-21-2010, 12:29 AM
http://i178.photobucket.com/albums/w278/alramirez_82/412285e.jpg
Home depot had these on sale for $5 this past week so I bought two. I tried this method with some chicken and ribs but I made the BIG MISTAKE of leaving in the middle of this experiment to help a friend move a dresser "real quick" (I forgot I promised him I'd help, oops). Well real quick turned into about 4 hours and when I got home the fire was out. That's the last time I leave in the middle of a first time test!
What I found was that this SS box doesn't hold very much lump since the rack sits right at the top of the box but still enough to do ribs and chicken if you keep an eye on it. My fire went out for reasons unknown, I still had a little bit of unburned lump so it didn't burn completely. It probably could have used a good shake at some point so it's my fault not the method.
Also I added a water pan above the coals to act as a heat diffuser ala WSM-style mod. The water obviously accounted for some of the lump burn. Next time I'll try to pack the lump a little better but the key word here is "next time" because there will be one, I like this mod. Thanks again guys for at least giving us something new and fun to try.
landarc
03-21-2010, 12:43 AM
I wondered how big of a CI skillet I would need to create the same effect in my (36.5 inch) Ranch Kettle. I don't think they make them that big...
Bo, I don't see how you would be able to lift the skillet if it was a manhole cover. Oh wait, a 30 inch manhole cover would work perfect. Preheat would take about 12 hours I suspect.
landarc
03-21-2010, 12:47 AM
Jive, the biggest issue I am working on is charcoal capacity, but, I am pretty sure I can solve that once I find the round cast iron griddle or a steel plate I have in mind.
JiveTurkey
03-21-2010, 12:57 AM
I don't have any way to draw this out visually so bear with me here, let me see if I can explain what it's my mind here.
So take the box like I have or even one made out of a smokey joe charcoal grate with a ring of expanded as the new fire box.
Now you know how all the UDS owners put 4" bolts down from the grate so it sits 4" from the bottom? Just picture most every UDS fire box.
My thinking is take longer bolts and make them point up from the grate with fender washers at the top. Then you can put the existing kettle charcoal grate to rest on the washers. Now the existing kettle charcoal grate can be 3" or 4" under the cooking grate, just enough room for the cast iron skillet. This will make more room between the bottom of the kettle and the CI skillet so you can fit more charcoal in the box. It could work.
EDIT: I just fired up Paint and here is a basic idea:
landarc
03-21-2010, 01:10 PM
Yes, that is similar to what I am planning. I am also looking at different ways to eliminate the cast iron in favor of some other flatter heat sink.
JiveTurkey
03-21-2010, 04:29 PM
The UDS crowd uses pizza pans for heat sinks. Lots of cool ideas in the UDS thread.
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