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[JoeGrilling]

I finally finished months of doing CAD drawings and started building my own pellet smoker.  Here's what I have so far in terms of design criteria:
1. Two grate surfaces that will be 39" x 24".   Each surface will be in three sections for easier cleaning and handling.  The plan is to build my own grates from 5/16" 304 SS. 
2. Upper grate surface has two height options.  One at maybe 4" above the lower to accommodate a drip pan for turkeys and another a few inches higher to allow basting ribs on the lower level.
3. The frame is in two sections.  The upper contains the cook chamber and bolts on to the lower cart section.  The cart is made from 2" .120" square tubing and the cook chamber is made from 1" .120" square tubing and 1"x2" .120" rectangular tubing.
4. Cart section is TIG and MIG welded.  Cook chamber is all TIG welded to allow easy weld grinding for fitting inner and outer sheet metal skin.
5. The plan is to use ceramic insulation between the walls.
6. Outer and inner sheet metal will be 11 gauge steel.  The outer skin will be TIG brazed on and the inner skin will be bolt in.  The inner skin will sealed with high temperature RTV.
7. Smoke Daddy pellet hopper.
8. Smoke stack(s) is something I am still thinking about.  I am currently looking at dual stacks with dampers based on all the grief folks have had with the refrigerator pellet smokers and trying to get the minimum temperature down.

Yeah I know this is a lot of work but it makes for a great retirement project.  I just got the framing complete this week.


 

[ylr]

Amazing. Can't wait to see it finished!   

[Bobitis]

Oh my... Do you think the RTV will hold up to the temps you may experience?

[dk117]

Anxiously awaiting updates on this thread.   My for all it's worth as I have zero fabrication skills:

1) You'll be very happy with a smoke daddy hopper assembly.   get the 35 pounder if you haven't already purchased.
2) try dual stacks. 

I'm new to both smoke daddy and dual stacks and am very pleased with my first few months of cooking.

DK

[JoeGrilling]

Oh my... Do you think the RTV will hold up to the temps you may experience?

It's what everyone else uses.  I always wondered if it is used to allow for expansion joints.  It's not a problem with cylindrical grills but it could be with the boxy ones.

[Bobitis]

Oh my... Do you think the RTV will hold up to the temps you may experience?

It's what everyone else uses.  I always wondered if it is used to allow for expansion joints.  It's not a problem with cylindrical grills but it could be with the boxy ones.

Not sure why that would even be an issue. Round vs square makes no sense to me.

From what I've read, RTV is good for 400 deg F or more. What is 'more'? I can't find the variables.

All I know is that baking often calls for 400 deg +. Pizza being a primary culprit. I'm sure there are many other cooks that would require higher temps.

Love, the design and effort. Just wanting to not sell yerself short.

[JoeGrilling]

Anxiously awaiting updates on this thread.   My for all it's worth as I have zero fabrication skills:

1) You'll be very happy with a smoke daddy hopper assembly.   get the 35 pounder if you haven't already purchased.
2) try dual stacks. 

I'm new to both smoke daddy and dual stacks and am very pleased with my first few months of cooking.

DK

I did a lot of reading over the weekend on various forums on insulated grills including the fridge ones.  Getting low temperatures is their biggest problem and adding venting always seemed to be the solution.  Some added additional fans and that really messed things up since this reduces airflow to the fire pot.  I am leaning toward dual stacks after seeing Gator Pits videos and reading some of your posts.  The PID controller to be used is still up in the air.  I have been using the Savannah Stoker on my Traeger Texas 34 and have been happy with it.  They allow you to tweak just about everything.

[Mikro]

Use the High Temp RTV for exhaust manifolds, temp is 750* if I remember correctly? I used that on my build years ago. never had a problem.
mk

[GREG-B]

You are obviously a very skilled craftsman with beads and fit like that.

[litzerski]

I'm interested on how you like the Smoke Daddy pellet hopper.  I have a propane vertical that I eventually plan on converting to pellet using the Smoke Daddy. 

[Ralphie]

Wow.  Very impressive.

[Canadian John]

 That is good old fashioned CRAFTSMANSHIP.

[JoeGrilling]

Thanks for all of the compliments everyone.  I figure this will take me another couple of months to complete.  This thing is starting to get pretty heavy.  My biggest challenge is going to be getting the bottom covered and painted.  I started buying Harbor Freight material lifting equipment when my last two kids went off to college.  Their 1/2 ton lift table and 2 ton engine lift have really saved my back.

[JoeGrilling]

Anxiously awaiting updates on this thread.   My for all it's worth as I have zero fabrication skills:

1) You'll be very happy with a smoke daddy hopper assembly.   get the 35 pounder if you haven't already purchased.
2) try dual stacks. 

I'm new to both smoke daddy and dual stacks and am very pleased with my first few months of cooking.

DK

I am curious about the dimensions on your GP's smoke stacks.  The things I'm interested in are pipe size (thickness and pipe size) and height.  My guess it uses 4"x4" tubing with 1/8" wall thickness.  The height seems to be about 24".

[dk117]

4"x4" yes,  20 inches from bottom to top, then the bird house stack on top, so sure 24".   1/8" steel.   

Remember, I have no fabrication skills, your eyes from a picture are better than mine hands on.  I had to go measure to confirm.

DK

PS mine was 565lbs shipped, about 500 as it sits.