So what do you think? would 24 gauge work?

That is pretty thin but I don't see why it wouldn't with the way you described doing it.

what about insulating with a welder's blanket?

That would work as well. I suggest giving it a try and then posting some pics and letting us know how it works out for you.

no problem...but I've got to finish the build my USD first ;)

I like the concept but would probably go thicker. As long as you can compress it enough to fit inside.

As for insulation, its value comes from dead air space between the layers. Thermal eddy currents can form within this space; which lowers the insulation value. That why batting is used versus just dead air space. But some batting can absorb moisture (which acts as a conductor).

I think cutting up a couple of water heater jackets to fit would work pretty good.

All this being said, I only use wood, which is free. so I don't really care about efficiency. If I had to buy charcoal, I'd probably reconsider.

What is your reason for going thicker on the metal?

If I'm going to endure the hassel and expense of building a double-wall UDS, I want it to last.

Why not just section a donor barrel?
Cut off the top and bottom and do the math to see how much of a strip you will need to cut off the side.
Hmmmmm….. I feel a project coming on.

DOH!

The hassle?? Building them is half the fun!! :mrgreen:

FYI for the math challenged: The math is 3.14 times diameter

has anybody ever did a powder coating on one?

Should withstand the heat ok.
I looked into it, the cost is what kept me way, the guy wanted $$80 to do it.
I will stick to paint.

Anybody ever have issues with getting your kettle lid to fit?
I just bent the chit out of mine to get it to fit.