Insulated Cabinet Smoker Build

[carlosh]

Well, the time has come and I have started building my smoker. I've changed the plans I don't know how many times! I've asked questions from members of this forum and have gotten valuable input. I changed the dimensions so that I would make the most of 2 sheets of 4'X10' steel with little or no waste. It will look surprisingly a lot like the ones built by BBQ Engineer. It is also similar to the design by Pit Maker's "The Vault." http://www.smoked-meat.com/forum/new...newthread&f=51

In the end, I've come up with the following "must have" features in the design:
1. Upright cabinet style
2. Efficient in high wind environments and cold weather
3. Reverse flow smoking
4. Cover exterior and interior (except fire box) with 14 gauge steel
5. Inside of fire pit will be lined with 1/4" steel
6. Three “slide in” racks
7. Heat will be provided by charcoal and firewood (no electric coils after all).
8. Two doors. One for the fire pit and one for the oven.
9. Two inch thick walls for insulation
10. An electronic temperature sensor will determine when the temperature begins to drop and a fan will turn on until a desired temperature is achieved.
11. Wheels so that it can be rolled around
12. Automotive paint on the exterior

Pictures will follow shortly.

[GOT14U]

sounds like your on the way....2" insulation I think might be over kill if you use Kaowool...I have had mine going in negative degrees with one inch insulation. just a thought to save ya some money.

[carlosh]

I went out a couple of days ago and purchased two 24' 2"X2"X1/8" square tubing for the frame. I will be using the diablo Freud ferrous cutting blade for cutting the steel. Here's a guy at the steel supply place bringing down the square tubing, which he will cut roughly in half so that I can carry it in my truck.


Here's a jig I made for cutting the square tubing at 90 degrees using the Freud blade on my circular saw.


Here's the same jig for cutting at 45 degrees.

[carlosh]

Got14U: I'm pretty much committed on the 2"X2" square pipe, especially since I already cut it up. Do you think that I could get away with using 1" insulation in a 2" wall spacing? Hmmmm.....

OK, so here's the first side I tacked together. It is about 37"X28". I used plywood spacers to ensure that when I build the other side, it will be fairly close to the first one.

[AJ]

Nice work. I like the jig for the mitered cuts. How many cuts do you get out of the blade before it needs to be replaced?

I am just starting my build. I went the other route and just bought a Evolution Rage-3 Double Bevel miter saw to cut my tubing. I also ordered a Strong Hold 3-axis clamp to make things go a tad quicker and smoother.



Looks like a fun project.

[GOT14U]

you are committed, I wouldn't do the 1" in the walls but I would take a look at mineral insulation...I have not used it but I believe other builders do. it may be cheaper but then again I am guessing......word of advice when tacking pieces together....you can make it a tad out of square then tack the "inside" so it pulls into being square...hope that makes sense ....and rock on!

[BBQ Engineer]

you are committed

I agree...you have set your path...continue on and don't look back...don't second guess yourself either. You have done your homework and know what you are after...Give it hell, and take lots of pictures!

word of advice when tacking pieces together....you can make it a tad out of square then tack the "inside" so it pulls into being square...

Jerod, that's one of the most difficult things for a hobby welder to wrap their head around...Welding has to be planned out so you can apply heat to MINIMIZE the effects of warping and bending of the base metal. You weld one side and bend the hell out of your project, and then if you weld on the other side and it pulls back in line...I actually threw a set of doors away after I just went to town and welded all the way around them. They were so tweaked they never would have sealed properly.

[ChadRat6458]

Here is my favorite saw for cutting tubing.

http://www.harborfreight.com/horizon...saw-93762.html

Search slickdeals.net for a 25% off coupon

Throw away the blade that comes with it and get a good one.

[redruff]

wow! That should be bullet proof...literally!

[carlosh]

Well, the Freud Diablo blade is really working well for cutting the 2"X2" frame pieces. This morning was nice and cool and I got a lot of welding done. I'll post some pictures later tonight.

Redruff: Let's hope the bulletproof part of it won't be needed. LOL

[carlosh]

A. J.: That jig looks awesome. Wish I had it when I needed it.

Well, I cut all of the 2"X2" pieces that I will need for the frame. I joined the 2 sides together and to my horror, the whole thing rocked about 1/2" on one corner due to warping even though I took extreme caution to tack weld and hold pieces down with clamps. I was using 3/32" 6013 rods at about 70 amps.

I used the Freud Diablo blade to cut most of the cross members and left it hanging by a thread. I made darned sure that the 2 sides sat flat on a surface and started tacking again. This time it all worked out.

Here's one of the tacked joints and one that I grinded down.



Here's another one of my weld joints. By the way, I'm using a Lincoln AC (crackerbox) stick welder.


The lower part you see is where the fire box will be located.

[AJ]

Looking good. Sounds like it's weld a little - check for square/plum, weld a little more - check again. Can't wait to see the end result.

This is the insulation I was recommended to use in my build.

Very High Temp Mineral Wool 9328K42

[carlosh]

Wow AJ, I like that insulation. It's not very expensive either.

Carlos

[BBQ Engineer]

Looking good. Sounds like it's weld a little - check for square/plum, weld a little more - check again. Can't wait to see the end result.

This is the insulation I was recommended to use in my build.

Very High Temp Mineral Wool 9328K42

You may try these guys for a ceramic fiber blanket...I got good service and good prices from them. First roll I bought on Ebay, and they were the sellers...called them direct and they sold it to me over the phone for my next order at the same price. That way I didn't have to jerk around with Ebay, I went directly to the source. They sell blankets from Morgan Thermal Ceramics.

I usually reserve McMaster for the one off type of things simply due to pricing. Mcmaster has awesome service...Next day ground shipping to my house and I love that...I do seem to buy a lot of stuff from them too.

On Edit: I see that the insulation from McMaster is a ridgid mineral wool green board...I can't really compare the two because they are different products...Ridgid mineral wool boards and the ceramic wool blanket.

Good luck.

[carlosh]

Well, I've been working on it a lot, but haven't had time to update this post. You see, I'm also a wildlife photographer and a new souvenir and gift shop took up my line of photos and I was busy supplying them.

I started trying to put the 14 ga. sheets on and kept making little blobs on the chassis or making holes in sheet metal. After some discussion with a friend who's a welder, he recommended that I buy the Harbor Freight MIG welder and use flux core. After a few days of frustration, I finally started to get the hang of it.

So, I start putting on the inside skins and the back false panel.