My First Reverse Flow Build - 125-Gallon Propane Tank (Plenty of Pics)

Discussion in 'Reverse Flow' started by bluffton smoker, Aug 29, 2012.

  1. Thanks RibWizzard for the help and direction...

    I got the firebox door cut and flanges on. To bend the flanges for the radius of the tank I marked them every inch...

    And used the table of my drill press as a brake...

    they turned out pretty good...

    Now its off to ACE to see what I can see.
  2. nice
  3. roller

    roller Smoking Guru SMF Premier Member

    Looks great !
  4. Thanks all...   So far I only had to re-engineer the chamber opening, the legs, the door flanges. Come to think about it, so far I have built this smoker TWICE... I finished up welding & grinding on the doors.

    Still haven't figgered out the hinge thing. I want the hinges and handles to match.. We will see where it takes me. Still haven't make it to ACE..
  5. daveomak

    daveomak Smoking Guru OTBS Member SMF Premier Member

    BS, afternoon.....  Nice job on the radius.... Professional looking and they fit perfect.... [​IMG].....  Dave
  6. Yep, I was pleased with the radius bends on both doors. ACE had weld-on hinges, BUT they were not what I was looking for. I want the hinges (4), door handles (2) and dampener handles (2) to be uniform anyway. So I'm gonna go with the 1/2" pipe over 1/2" round bar for the hinges and 1/2" pipe over 7/16" round bar for the handles. I'll post pics as everything evolves.
    Last edited: Sep 12, 2012
  7. Are you going to install spring handle on the round bar handles? I used 1/2" round bar and slid the spring handle over it and tack welded a washer on both sides to keep them centered. I used to use sections of hickory hoe handles and drill them out, but they would get grungy looking after time. This time I went with the spring handles and I am happy how they look. They are made of stainless and I taped them up before painting the smoker and the stainless looks cool against the black smoker.
  8. I'm gonna try the 1/2" pipe over 7/16" round bar. If I don't like it I will go with the spring handles... I can't let the handles be the only thing that I do correct the first time, right...  I'll know in 2 hours what I'll end up with.. 
  9. Okay I completed the hinges on the cook chamber. I can't believe it took 3 hours... I ended up using 7/16" round bar and 3/8" pipe to make the hinges. The 1/2" pipe I planned to use looked too big once I got the hinge mocked up. The lid fits tight. 

    Dave - I did not make the hinges both right or left handed as it just didn't balance out for me. Oh well, I can just take a victor wrench to it if I need to do any adjustments or upgrades...

    Here's the pics...

    I used my drill press as a brake again to bend a radius in the round bar & flat bar.

    When all is said and done, this is how they turned out.. I still have a bit of welding and grinding to do to make them pretty, but here they are...

    Last edited: Sep 13, 2012
  10. daveomak

    daveomak Smoking Guru OTBS Member SMF Premier Member

    Nice job on the hinges.....  they look very good.....  the blind welds on the air seal look really good too...  beats laying a bead for 20' and warping stuff....  [​IMG]  .....
  11. Yeah the blind welds are the way to go...  THANKS!
    Last edited: Sep 13, 2012
  12. I'm done with the structural welding on the doors, I have a little finish work to do, but that's gonna wait 'til later.

    Here's a few more pics..

     I'm pretty happy with the handles as well. When I was heating the round bar to make the 90-degree bends I could grab the handles bare handed.  AND I don't need latches as the weight of the doors keep them tightly closed. The door stops are welded in big time as they will do double duty as lift points.

    Next Step - Burn Out #1  I'm kinda rushing this build as I was approached to smoke 4 briskets for a business in 2 weeks. My little smoker can't handle that kinda load..  I sure hope this thing cooks like it is supposed to.

    I can smell it already.
  13. jarjarchef

    jarjarchef Master of the Pit OTBS Member

    Taking notes...........

    This looks great.....
  14. Thanks jarjar, I appreciate the good words... It kinda makes the time spent to stop and take pics worth it.. I know there are many views on many threads, but not many folks actually take the time to acknowledge others work. That is what a forum is all about, isn't it?
  15. daveomak

    daveomak Smoking Guru OTBS Member SMF Premier Member

    Don't forget the exhaust stack before you fire it up !!!!!!   [​IMG]  .....
  16. This burn is gonna be just a 'burn it out' kinda thing. I plan on blocking the doors about 1/2 way up and pour the wood to it. I have a bunch of old lumber & pallets. Gonna burn in both chambers. Watch me warp the hell out of a perfectly straight smoker. But I've smelled that propane residue long enough... Flame on..

    Once this burn is done, I still have plenty of work on the inside before doing the finish work, stuff like welding up voids and grinding everything down. Then comes the paint and seasoning run. All this has to happen before the end of the month. Good thing I don't have a day job, huh?
  17. Got a question to throw out there... How many of you actually use the dampener on the stack for control? Me, I use the air dampener to control the fire and leave the stack wide open. I sure would like to hear from you. About half of my smoking buddies don't use the stack dampener and the other half swear by it. I was just curious...  Thanks
  18. jckdanls 07

    jckdanls 07 Master of the Pit Group Lead OTBS Member

    I don't have a RF just a cheap chargriller...Yes.. I have to use the exhaust damper to get it down to 225`.. the intake is closed all the way and the exhaust is only open about 1/4 or less
  19. daveomak

    daveomak Smoking Guru OTBS Member SMF Premier Member

    Jack, evening....  Try and seal up those air leaks....  your smoker control will be so much better...  when you close the damper on the firebox, the fire should go out..... that is the ultimate goal...  then you will have perfect control....  Dave
  20. My opinion is to never use the exhaust dampner to control anything but rain from entering the smoker when your not using it.  Exception would be my last build where I installed two to switch from reverse flow to conventional.

    Dave is right, all control should be done at the firebox end.

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