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July 9th 2012
I picked this smoker up from a fellow smoker Chef Jimmy from Harrisburg.
If all works out well this will be Frank Jr. (Mini Me)
This is Frank,
July 9, 2012
We got to Jimmy's and had a beer, yes a Killians, what can I say, the man has good taste in beer.
My brother Jim and I went to secure the smoker and Jimmy tossed a few brats on his smoker.
Brother Jim securing the ropes, I drag my poor brother into all kindsa CHIT!
Jimmy smoking his brats.
I had given Jimmy some of my Hot Sauces, he seemed to like them or maybe he was just being polite?
He also gave us a Chimney Starter, 2 brand new handles for the New Braunfels, 3 bags of charcoal and a Mecco Water smoker.
After everything was secure Jimmy, Jim and myself sat and had another beer and tossed around a few stories.
Well the trip home was uneventful except for when I pulled out of Jimmy's driveway.
I almost took out his telephone pole.
When I was making the left out of the Driveway, I thought the smoker had shifted and was watching it through the rearview and misjudged the road, I would say I missed the pole by maybe 6 inches, I'm pretty sure he seen me swerve Ha Ha OH WELL.
I was going to start the restore in the fall because of financial reasons and I don't like the hot weather, any how I am the type of person that cant just wait, so I started on it last night.
July 10th 2012
Ok, now that the introductions are out of the way, lets see what we can do with this smoker.
Well I hit my first snag, the bottom is completely rusted out on the side opposite the firebox, after pulling off all the loose stuff it was not looking good, it's so bad in some spots that it cant be wire brushed and is through to the other side, its solid rust completely through.
My initial plans were to clean it up and play around with it before painting and making any modifications.
This is the metal plate that was in the firebox.
I lost a lot of metal in the firebox as well.
My wife came out last night while I was working on it and said, "whats wrong you look bewildered".
I told her the condition of the smoker and she said, "well if it's no good toss it".
Sad, but she don't understand what a classic this smoker is. After all she doesn't want to see me getting frustrated over something like this when I already have a functional reverse flow and a Newish GOSM BB.
After she said that, I said, "NO I have to figure out a way to save it", (Visualize me giving the smoker CPR), so out came the tools.
So in order to try and not overwhelm myself, I'm going to tackle this, "one problem at a time".
I played with it last night and may have a few ideas on saving it.
I had a few compressors and small 30 pound propane tanks at work that I had brought home in case I needed the metal for tuning plates or a reverse flow plate.
After looking at the rusted out hole in the bottom and trying not to get discouraged I looked at the compressor and thought they looked to be the same diameter.
So I took some measurements and yes, they are the exact same diameter, so I started hacking up the compressor.
Dry fitted the new piece, I cut this so the grates would rest right on top of the new fitted piece.
After I get both pieces dry fitted and aligned properly, I'll take off the bolted legs paint them and drill the holes for the legs through the new metal.
I will also cut a piece to fit the side you see to the right.
As of now I plan on mudding the bottom with Rutland Hi-Temp Stove & Gasket Cement. I'm not sure if welding would be a good idea because of the condition of the bottom portion of the smoker.
After I was satisfied that a restore was possible, I played around a bit to watch and see how this thing works.
I stared with a full chimney on top of a half of a basket I borrowed from Frank and checked temps in different areas of the smoker then added wood to get the temp up real high to dry it out real good and try to eliminate the possibility of any immediate rusting.
Well it appears to have good flow and the doors all are a pretty good fit and leak slightly, I will use some RTV to fix that when the time comes.
The heat recovery is really good and heats up pretty quick, Guess I'm used to heating up Frank.
I see why these type smokers are modded with baffles I could probably use this as is but my smoking area would be limited to the side away from the firebox.
I can also see why folks use just charcoal or lump on theses smokers.
So my plan is to fix what needs to be fixed and start with the modding later.
I think I'm going to use tuning plates as opposed to a reverse flow.
July 12, 2012
I figured it be better tearing the smoker down completely and rebuild from the ground up.
First I removed my dry fit plate, (need to make another one).
I started by removing the firebox, all the screws came out fairly easy using vise grips. There was a coating on them from the fire that kept them from rusting too badly.
Then I removed the exhaust pipe, again no problem.
Next step was to remove the bolts holding on the legs. No problems with the nuts except with one. I had to knock it down a bit with the angle grinder. I didn't want to grind it down too much because it appeared the bolts protruding from the legs are welded in place. Cap screws are usually able to be removed with vise grips, sometimes if they are rusted out too bad the bolt will twist and snap, the fact that these were in a layer of grease was a big help.
After I removed the legs I noticed that the bolts are indeed welded in place so hopefully they will be long enough to go through the existing smoker body and the new plates I will be adding.
Removing the bolts from the legs that held the supports in place proved to be more difficult (Phillips head machine screws), I hit these with an angle grinder and popped then through.
Now that everything is in pieces I can see what needs to be fixed, beefed up or replaced.
Evaluating the extent of the rust.
I'm a little concerned taking a wire wheel to close to the thinnest part, note the Pliers in the hole.
I got hold of some type 316 SS 1/4-20 caps screws, bolts and Lock Washers.
I'll probably start with the legs this weekend, sanding and painting.
I decided to do this as a reverse flow and acquired a 14 gauge shelf that I feel should be thick enough for a reverse flow plate. My only fear is the downward piece getting hammered with heat, its a pretty good drop from the top of the inlet to just below the grates.
Boykjo's reverse plate mod below.
I have a few ideas for this, I may add a second plate from the firebox angled downward towards the reverse flow plate like I did on frank to reduce the hammering effect, or may do something as simple as placing a piece of granite on the firebox side, I really wont know till I start putting it back together and get a better Idea on what I am up against.
July 9th 2012
I picked this smoker up from a fellow smoker Chef Jimmy from Harrisburg.
If all works out well this will be Frank Jr. (Mini Me)
This is Frank,
July 9, 2012
We got to Jimmy's and had a beer, yes a Killians, what can I say, the man has good taste in beer.
My brother Jim and I went to secure the smoker and Jimmy tossed a few brats on his smoker.
Brother Jim securing the ropes, I drag my poor brother into all kindsa CHIT!
Jimmy smoking his brats.
I had given Jimmy some of my Hot Sauces, he seemed to like them or maybe he was just being polite?
He also gave us a Chimney Starter, 2 brand new handles for the New Braunfels, 3 bags of charcoal and a Mecco Water smoker.
After everything was secure Jimmy, Jim and myself sat and had another beer and tossed around a few stories.
Well the trip home was uneventful except for when I pulled out of Jimmy's driveway.
I almost took out his telephone pole.
When I was making the left out of the Driveway, I thought the smoker had shifted and was watching it through the rearview and misjudged the road, I would say I missed the pole by maybe 6 inches, I'm pretty sure he seen me swerve Ha Ha OH WELL.
I was going to start the restore in the fall because of financial reasons and I don't like the hot weather, any how I am the type of person that cant just wait, so I started on it last night.
July 10th 2012
Ok, now that the introductions are out of the way, lets see what we can do with this smoker.
Well I hit my first snag, the bottom is completely rusted out on the side opposite the firebox, after pulling off all the loose stuff it was not looking good, it's so bad in some spots that it cant be wire brushed and is through to the other side, its solid rust completely through.
My initial plans were to clean it up and play around with it before painting and making any modifications.
This is the metal plate that was in the firebox.
I lost a lot of metal in the firebox as well.
My wife came out last night while I was working on it and said, "whats wrong you look bewildered".
I told her the condition of the smoker and she said, "well if it's no good toss it".
Sad, but she don't understand what a classic this smoker is. After all she doesn't want to see me getting frustrated over something like this when I already have a functional reverse flow and a Newish GOSM BB.
After she said that, I said, "NO I have to figure out a way to save it", (Visualize me giving the smoker CPR), so out came the tools.
So in order to try and not overwhelm myself, I'm going to tackle this, "one problem at a time".
I played with it last night and may have a few ideas on saving it.
I had a few compressors and small 30 pound propane tanks at work that I had brought home in case I needed the metal for tuning plates or a reverse flow plate.
After looking at the rusted out hole in the bottom and trying not to get discouraged I looked at the compressor and thought they looked to be the same diameter.
So I took some measurements and yes, they are the exact same diameter, so I started hacking up the compressor.
Dry fitted the new piece, I cut this so the grates would rest right on top of the new fitted piece.
After I get both pieces dry fitted and aligned properly, I'll take off the bolted legs paint them and drill the holes for the legs through the new metal.
I will also cut a piece to fit the side you see to the right.
As of now I plan on mudding the bottom with Rutland Hi-Temp Stove & Gasket Cement. I'm not sure if welding would be a good idea because of the condition of the bottom portion of the smoker.
After I was satisfied that a restore was possible, I played around a bit to watch and see how this thing works.
I stared with a full chimney on top of a half of a basket I borrowed from Frank and checked temps in different areas of the smoker then added wood to get the temp up real high to dry it out real good and try to eliminate the possibility of any immediate rusting.
Well it appears to have good flow and the doors all are a pretty good fit and leak slightly, I will use some RTV to fix that when the time comes.
The heat recovery is really good and heats up pretty quick, Guess I'm used to heating up Frank.
I see why these type smokers are modded with baffles I could probably use this as is but my smoking area would be limited to the side away from the firebox.
I can also see why folks use just charcoal or lump on theses smokers.
So my plan is to fix what needs to be fixed and start with the modding later.
I think I'm going to use tuning plates as opposed to a reverse flow.
July 12, 2012
I figured it be better tearing the smoker down completely and rebuild from the ground up.
First I removed my dry fit plate, (need to make another one).
I started by removing the firebox, all the screws came out fairly easy using vise grips. There was a coating on them from the fire that kept them from rusting too badly.
Then I removed the exhaust pipe, again no problem.
Next step was to remove the bolts holding on the legs. No problems with the nuts except with one. I had to knock it down a bit with the angle grinder. I didn't want to grind it down too much because it appeared the bolts protruding from the legs are welded in place. Cap screws are usually able to be removed with vise grips, sometimes if they are rusted out too bad the bolt will twist and snap, the fact that these were in a layer of grease was a big help.
After I removed the legs I noticed that the bolts are indeed welded in place so hopefully they will be long enough to go through the existing smoker body and the new plates I will be adding.
Removing the bolts from the legs that held the supports in place proved to be more difficult (Phillips head machine screws), I hit these with an angle grinder and popped then through.
Now that everything is in pieces I can see what needs to be fixed, beefed up or replaced.
Evaluating the extent of the rust.
I'm a little concerned taking a wire wheel to close to the thinnest part, note the Pliers in the hole.
I got hold of some type 316 SS 1/4-20 caps screws, bolts and Lock Washers.
I'll probably start with the legs this weekend, sanding and painting.
I decided to do this as a reverse flow and acquired a 14 gauge shelf that I feel should be thick enough for a reverse flow plate. My only fear is the downward piece getting hammered with heat, its a pretty good drop from the top of the inlet to just below the grates.
Boykjo's reverse plate mod below.
I have a few ideas for this, I may add a second plate from the firebox angled downward towards the reverse flow plate like I did on frank to reduce the hammering effect, or may do something as simple as placing a piece of granite on the firebox side, I really wont know till I start putting it back together and get a better Idea on what I am up against.
PCa Sucks - But I WILL, No DID beat this!!
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