My UDS Build

Built myself a UDS this weekend. Got a 55 gallon bare steel drum, some expanded metal, and put it all together with an angle grinder and nuts and bolts.

For the grates and the bottom of the fire box I got 3/4" #9 expanded metal from a local shop and cut it to size with my angle grinder (went through and entire cut off disc). I rolled up a 1'x4' piece of the expanded metal and held it together with nuts and bolts for the body of the fire box. Drilled some 1/4" holes for the bolts to support the grates and a 1/2" hole for the thermometer.

The drum body and lid both had 2" bung holes so I decided to use those for the air in my initial run and adjust it from there, if needed. For my first cook I loaded it up with about 6 lbs of lump and 2 pieces of hickory. I spacthcocked and brined 2 5 lb chickens, dried in the fridge, and rubbed with salt and pepper. I lite the charcoal and put the fire box in the drum and it got up to about 375 or the next 30 minutes or so. I brought the air intake down a bit at this point and the temp stabilized. After a bit though it started dropping slowly over the duration of the cook even with the intake wide open. Needed to use more charcoal?

After about 1 hour and 40 minutes the birds were about 150 breast. I flipped them over and let them finish up a bit, the skin didn't get quite as crispy as I would have liked but I didn't have them flipped over for long, was getting hungry and they were at 160ish breast. They were really tasty and super juicy so overall quite pleased with the result. Some corn on the top rack and it took about 45 mins at 275.

1. Any thoughts on declining temps? Just needed to use more charcoal or do I need more air?

2. Flow control for the 2" bung? I tried a magnet sheet but it was too thin and didn't work well. I could try a ball vavle but I'm not sure I'll get enough air flow.

http://imgur.com/a/mVFBh

Thanks. Anybody else? Was hoping for more feedback on my build. Added some pics of the fire box.

yakdung said:

The fuel basket needs to be elevated enough off of the bottom of the drum, and above the air intake holes to create a constant flow of air. I utilize stainless bolts, washers and nuts screwed into the basket as legs for elevation. Do not try and change too many variables at once. I would recommend using briquettes until you get the air flow under control.

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The firebox is 12" high with a grate 2" from the bottom for air, can't really see it in the picture.

pbj said:

I use this for my intake.
http://www.bbqsmokersupply.com/index.php?main_page=product_info&cPath=6&products_id=100

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That looks perfect and far cheaper than a ball valve. Thanks!

funugy said:

How full was the charcoal basket at the beginning and end of the cook? How long did you let the UDS warm-up and stabilize before you put on the chicken?

I always use a full basket of coals for every cook and let the UDS stabilize prior to putting anything on to cook, normally about 45 min, sometimes longer if I want higher cook temps. When I am done cooking I just close the intake and exhaust and reuse the leftover coals for the next cook, just add to it to top off the basket.

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Hmm. I'd say it had it about half full, say 5-6 lbs. I let it warm for a good 30 minutes before I put the birds in. There didn't look to be alot of charcoal left, the picture of the firebox is what was left after the cook. I suspect I just need to fill the box up all the way.