New 500 gallon RF trailer build

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eightysecond

Newbie
Original poster
Well guys, I started on this journey about 4 years ago, I am been into smoking meat for quite a long time with smaller rigs, electric units, etc...  I decided I wanted to learn how to weld and build a large smoker.  I built a tandem axle trailer from 2" X 4" tubing and 4" channel that I have been slowly chipping away at as I get a little more skilled at welding.

I will openly admit that k.a.m. aka kam59 has been the source of my inspiration to go on this adventure - so thanks
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  I think I have every single pic from both of your big builds from 'The Smoke Ring' saved and I use them to get my wheels turning on how to do this.

I just recently finished everything structurally on the trailer and got the jack installed so I am ready to start marking & cutting the tank.

The tank is from 1954 and is an old butane tank - it's OD is 41 and OAL is 103.  The heads are .230" and the shell is .344".  I had previously removed the fittings and filled with dawn dish soap and water a few years ago - so it has just been sitting and waiting for me to get off my rear.

I have measured the marked the tank at 3, 6, 9 & 12.   If I use the space between 12 & 9 for my door opening it puts my door height at 32 1/4".  I think I will need to a split door since the counter weight I'd need with one may be a little ridiculous - but that is a bummer since I won't be able to do a large door on the opposite side for a whole hog due to the configuration on the trailer.  Interested in everyone's thoughts on that.

I have a friend with a plasma cutter and that's what I plan on using for cutting the doors, firebox and the firebox cut-out.  My math has the top of my cut-out for the firebox at approx.  14" which includes a 2" grease dam.  Firebox will be 34 H X 38 W X 36 L.

Please let me know if anyone sees any wrong turns I'm making before I go cut the tank, I sure do appreciate everyone's input and wisdom.  Thanks in advance.

Something I am struggling with is how to mark the cut out the firebox opening at a perfect 90 degrees so it fits tight, I am sure there is some special trick I'm not thinking of.

I will attempt to add some pics:

Here is my rough "vision".







 
Good looking trailer Eighty Second I like it. :) 
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Here is what I came up with on the calculator based on your tank dimensions.

Link to BBQ Pit Calculator

For your firebox to cooker chamber opening look at this.

37.875Top width of cut-out.:

17.664Bottom width of cut-out:

12.268Height of cut-out:

378.649

You can look at it here.

http://planetcalc.com/5155/

I would definitely bring my top cut down at least 6.5" not only for weight but so you can reach the handles when opened.

What is the width inside the dome welds?
 
Thanks! I think that 41" measurement is the width inside the dome welds (129" around/ 3.14 = 41.08).  I haven't cut anything yet so I'm not sure what any inside numbers look like yet.

Does the 12.268 figure include any sort of grease dam height, or should I add that to it?

Understood on bringing the top door line down, I'll do it.
 
What is the horizontal distance between the dome welds. IE how long a door could you have?

The 12.26 is the distance between the top of your 2" bridge and your top cut.

Crude drawing but it works lol.

17.66" should be about the width of your bridge.

37.875 should be about the width of your top cut. 

 
When I built my 500 gallon tank smoker I made two doors that overlap that way if you want to put a big hog on you have a nice big opening. Here is a link to my build http://www.smokingmeatforums.com/t/250565/500-gallon-tank-build

Very good idea Smokin Peachey. :)
Left door overlaps the right door


I used a piece of flat gasket on the overlap.

Let me know if you would like more info or if I can help.
 
Thank you both for the replies kam and Smokin Peachey. I guess I just need to do some thinking about the likelihood/ frequency of a whole hog. I typically just cook ribs, briskets and butts.

How close should I be able to cut to the dome welds and still be good to go? Just enough space for the door seal?

I sure do appreciate you guys answering my questions. Trying the best I can not to screw this up. Lol
 
Update, I cut out the doors and the FB to CC opening with a plasma and have started making hinges.  I still need one more 8X4 plate before I can get the FB done and the local steel supplier is ordering it. 

For the hinges I cut out a piece of wood to get the shape and then cut it out of plate.  I took into account that the plasma would add 3/8 all around so I made the template a little smaller than I wanted.

For the doors I ended up doing 2 and they are 26.5" wide, I'll get some better pics.


 
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