250 gallon cross flow smoker build thread

[workingdog]

Cut out the collector top and bottom on the plasma table out of 3/16. The curve matched really well. Going with square tube for exhaust as it's relatively thin wall and the 6" round tube was 1/4" and very heavy and very expensive.

next is to cut out a pair of matching flanges so the rest of the stove pipe can be bolted on.

 

[workingdog]

One really nice thing about having a plasma table is that the top and bottom of the collector and perfectly straight and identical. I took in place measurements for the sides, laid them out on the plasma, and cut more perfectly straight and square pieces that fit in perfectly. So much easier.

 

[workingdog]

finished - except for the grinding.

 

[greenbeast]

Fire that baby up!!

 

[rkymtnflyfisher]

Sweeeeeettttt.

 

[workingdog]

I can't fire up until I finish the other end. Here's the plasma table cutting 5/16th plate for the inner firebox.

 

[workingdog]

Okay, the bottom and sides are cut and the back is cut with a radius that matches the tank and it's tacked together - and very heavy.

I had been killing myself (in fusion 360) trying to figure out how to translate the intersecting curves of the tank and the firebox onto the firebox so I could cut the top, sides, and back to fit. The back was easy, simple radius, but the top was a nightmare and I never even got to the sides. So, I assembled the bottom, sides and back just to see where I was

And realized that I didn't need to do that at all. If I can project the sides and top onto the tank using something like cardboard or the laser level, then I can cut the tank to fit the box, slide the box into the opening, and then mark and cut the sides and top to fit. So, that's what I'm doing tomorrow. However, I have to go to Harbor Freight and get one of their lift tables, because hanging it from the gantry isn't working. I have to have it dead steady and dead level.

And, this is just the inner box. Once this is set and welded in place, I have to surround it with the outer box. And I'm going to have to do it all in place because if I don't, I won't be able to get where I need to get to weld the box to the tank. Hopefully the lift table will make that easy.

 

[workingdog]

Okay, I committed and cut the end of the tank.

I had been agonizing over cutting the top of the firebox to fit the curve of the tank, and once I had it cut, I realized that I didn't need to cut the top of the firebox at all, I could just shove the full piece in there. In fact, that would be better, because it would be the start of the heat deflector - which it has to have anyway. And, it fit pretty good, only had to widen the opening a little.

Before I can finish attaching the firebox, I have to deal with all the threaded openings that were in the top and that are now in the bottom. turns out they are all in this large plate that's like 1/2" think. So, I have to cut it out and replace with plate that has one hole for grease drain. And then I can put the top on the box and weld it in place.

 

[workingdog]

Progress

Now, a sane person would put a door in the front and call it god, but for some reason I'm going to put another box around this box. I have issues.

 

[workingdog]

So, lots of progress on the firebox. However, this is like 10 steps forward then then like 2 big steps back.

The firebox and door are so heavy, that the whole tank is literally tipping over as it sits on my fixture.

The plasma table did a fabulous job cutting the inner and outer doors and door frames. They came out perfectly aligned with a very narrow kerf.
However, in the end, it did too good a job. I had on my list, that once I made the door pieces into a sandwich, to put them in the firebox and check for clearance.

But, of course, I got into the groove and welded it all up without checking and ... the plasma table cut it way too tight. I really, I should have had the plasma table cut an 1/8" off the outside of each door while it was still on the table, and an additional 1/4" off the inside latch side to allow for swing.

Now, I'm not sure what I'm going to do. At least I have to cut an angle into the latch side so the door can swing, which is going to be brutal. But ... I'm not sure how to handle the rest. I may have to cut 3/16th off the bottom as well. both require put yet another piece in to see the side, welding then grinding. I'm so tired of grinding.

g

 

[mudgudgeon]

Ouch!

Might be easier to cut a new door rather than hack up the one you have made already

 

[workingdog]

Okay, here's the door with one side and bottom cut off. the plasma table did a nice job cutting the plate and I just had to cut the ends off and clean it up. One one side the 1" box tube came out and a new piece went right in. On the other, I had to cut a piece of scrap. But, it worked.

now, with strap for seal, the door is installed and operable. So, now the smoker will actually smoke something.

All that's left is a latch, temperature sensors, and damper for chimney. And there's lots and lots of welding and grinding to do on the outside of the firebox.

 

[workingdog]

Okay, the smoker is done - mostly. I've got it outside and I was thinking of shipping it to my son in Montana - because I can't figure out how to get it hauled to Montana if I put a trailer under it.

But, now that I've got it roughly on the pallet my axle came in, I'm not sure FedEx freight will even take it. They say they will take it by length and and weight (1,000lbs), but ... I don't want to get the entire thing packed and secure only to have them reject it.

anyone have any experience with shipping stuff this size and weight??

 

[mudgudgeon]

How did this turn out?

I hope it's had some use in the last 2 years?

 

[workingdog]

It’s at my son’s in Bozeman. It’s getting irregular use. I was rented for a professional competition and performed well.

 

[ceylonfj40nut]

As a BBQing Texan, i used to have an offset smoker that was the parked at my place for company use. 250 gallon. It required a s*** ton of wood to get it hot, and temp control was also a challenge. One trick I learned was to place the next wood pieces in line go into the smoker on top of the firebox to prevent-heat/ dry for about an hour. Caught fire quicker and less acrid smoke. I was exhausted by the time the meat was ready. Its for those that enjoy “the ride”. Yours is great for a restaurant! I now have a pellet smoker which is a game changer. Got it down to a tee where it is so consistently good with minimal meat prep. I must admit I have adjusted the temperature while grocery shopping .

Great idea to insulate the fire box the way you did. That’s next level.

 

[MadMace]

now have a pellet smoker which is a game changer. Got it down to a tee where it is so consistently good with minimal meat prep. I must admit I have adjusted the temperature while grocery shopping .

This!!! My RecTEQ is the best purchase I ever made. Love BBQ’ing but my stick burner would wear me out…managing temps in the middle of the night..don’t miss it. Almost seems like cheating (and probably is, from a purist stand-point), but some of the best brisket we’ve made has come off the Recteq.