Offset Firebox Question

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westofsouth

Newbie
Original poster
Feb 25, 2025
6
1
I'm building a offset from a 120 gallon propane tank. I'm going to cut the tank in two parts and use the longer part for a cook chamber and the smaller end for the firebox. The problem I'm running into is that if I cut the tank so that I've got about a 20 inch long firebox, the volume of the firebox is about 55% as big as the cook chamber. The rule of thumb I've read is that it should be about 33% ... so my firebox is going to be too big. Is that a problem? Why wouldn't a too large firebox be good?

I'd appreciate any help. I'm not sure I'm posting in the right spot ... this is my first post here.
 
Read through this and see What you come up with...


The rule of thumb I've read is that it should be about 33%

This is true... But bigger doesn't hurt... Smaller will...
 
Read through this and see What you come up with...




This is true... But bigger doesn't hurt... Smaller will...
Thank you sir! I will read through the tutorial on design of reverse flow smoker builds. I'm sort of leaning towards a vertical baffle offset. (I know nothing but this seemed like a simpler build than a Reverse Flow ... I used to own an old style Klose offset (no tuning plates ... just a deflector plate as I recall ) ) I'm thinking that bigger might be OK ... I appreciate it!!
 
I'm building a offset from a 120 gallon propane tank. I'm going to cut the tank in two parts and use the longer part for a cook chamber and the smaller end for the firebox. The problem I'm running into is that if I cut the tank so that I've got about a 20 inch long firebox, the volume of the firebox is about 55% as big as the cook chamber. The rule of thumb I've read is that it should be about 33% ... so my firebox is going to be too big. Is that a problem? Why wouldn't a too large firebox be good?

I'd appreciate any help. I'm not sure I'm posting in the right spot ... this is my first post here.

Howdy and welcome aboard!

You are correct that the recommended volume of the FB is 33% of CC volume. Like JckDanls 07 JckDanls 07 said, it's generally OK for the FB to be bigger than that. 55% is a lot bigger, but would probably still be OK. Can't say this for sure, but I expect the main issue with such a large FB could be fuel consumption. It may require lots of wood to keep temps up...but the air flow should be OK as long as you get your other numbers correct (exhaust stack diameter and length, intake damper area, and throat opening area). Make sure you use one of the reputable online pit calculators to get those measurements correct.

Couple things you could consider if you're worried about the FB size:

You could look for a smaller-diameter tank or pipe to use for your FB...or you could build a square FB out of plate steel. With either of those options, you could ensure that your FB was on that 33% number exactly.

Either way, I hope you'll post your build here so we can follow along! Sounds like it'll be a fun project!

Good luck with it!
Red
 
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Howdy and welcome aboard!

You are correct that the recommended volume of the FB is 33% of CC volume. Like JckDanls 07 JckDanls 07 said, it's generally OK for the FB to be bigger than that. 55% is a lot bigger, but would probably still be OK. Can't say this for sure, but I expect the main issue with such a large FB could be fuel consumption. It may require lots of wood to keep temps up...but the air flow should be OK as long as you get your other numbers correct (exhaust stack diameter and length, intake damper area, and throat opening area). Make sure you use one of the reputable online pit calculators to get those measurements correct.

Couple things you could consider if you're worried about the FB size:

You could look for a smaller-diameter tank or pipe to use for your FB...or you could build a square FB out of plate steel. With either of those options, you could ensure that your FB was on that 33% number exactly.

Either way, I hope you'll post your build here so we can follow along! Sounds like it'll be a fun project!

Good luck with it!
Red
Thanks! I also figured out that I could cut some of the volume if necessary by adding some refractory bricks to the firebox. I could reduce FB volume by 10% by adding 10 bricks. I'll try it without to see if I need to do this.
 
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All good options... You could also just put a piece of plate (1/4" minimum) in the bottom of the FB/tank up to the height needed to get you to that 33%+ ... This will also give you a flat bottom inside the FB ...
 
All good options... You could also just put a piece of plate (1/4" minimum) in the bottom of the FB/tank up to the height needed to get you to that 33%+ ... This will also give you a flat bottom inside the FB ...
This is a really good idea. I like this better than the brick idea. And I can easily do this as a mod if the firebox is too big ... thank you again
 
The 33% number is just a guesstimate that someone made years ago and put into a formula. It isn't a hard and fast rule. Some people think it's gospel and your smoker will run like s*** if you don't follow that - nothing could be further from the truth!

I built a 60-gallon tank out with a 30 gallon firebox - people said, "Oh that firebox is WAY too big for that smoker, it's going to be way oversized and isn't going to run well." BS. It ran awesome. Great little backyard/patio smoker!

1740656572109.png


Conversely, I've run my friend's big pit, which is a 230-gallon, with a 32-gallon firebox, which should be drastically undersized according to the 'conventional wisdom'. Now, it took me a little while to figure out how to run his pit best, a couple of cooks, no more. It's dead simple now.

1740656807254.png


Bottom line is, you work with what you've got. You can make anything work, the key is good airflow and minimizing obstructions, nice big throat opening and decent sized, plenty long exhaust stack to help generate draw.

However, all that being said - I'm with seenred seenred , I'd suggest keeping your tank whole and waiting, looking and being patient to find a piece of pipe to use as a firebox. It'll most likely be thicker walled AND you won't be cutting down your chamber and having to cap 2 ends and you will never regret having more space. What you're planning now, I think you may wish later you had a more than 20" deep firebox (for managing splits, etc) AND you may someday wish you had a little more space in the cook chamber. You will never regret keeping it full size, I don't think. You MAY regret cutting it down later. I know 120-gallon and 150-gallon tanks around here are rare as hen's teeth.

Anyways, that's my thoughts.

<edit> The caveat to that is a reverse flow smoker - they seem to be much more 'iffy' on firebox size. I have not got experience with those personally, so if that is your plan, I'd talk to someone who has built a bunch of those.
 
The 33% number is just a guesstimate that someone made years ago and put into a formula. It isn't a hard and fast rule. Some people think it's gospel and your smoker will run like s*** if you don't follow that - nothing could be further from the truth!

I built a 60-gallon tank out with a 30 gallon firebox - people said, "Oh that firebox is WAY too big for that smoker, it's going to be way oversized and isn't going to run well." BS. It ran awesome. Great little backyard/patio smoker!

View attachment 713911

Conversely, I've run my friend's big pit, which is a 230-gallon, with a 32-gallon firebox, which should be drastically undersized according to the 'conventional wisdom'. Now, it took me a little while to figure out how to run his pit best, a couple of cooks, no more. It's dead simple now.

View attachment 713912

Bottom line is, you work with what you've got. You can make anything work, the key is good airflow and minimizing obstructions, nice big throat opening and decent sized, plenty long exhaust stack to help generate draw.

However, all that being said - I'm with seenred seenred , I'd suggest keeping your tank whole and waiting, looking and being patient to find a piece of pipe to use as a firebox. It'll most likely be thicker walled AND you won't be cutting down your chamber and having to cap 2 ends and you will never regret having more space. What you're planning now, I think you may wish later you had a more than 20" deep firebox (for managing splits, etc) AND you may someday wish you had a little more space in the cook chamber. You will never regret keeping it full size, I don't think. You MAY regret cutting it down later. I know 120-gallon and 150-gallon tanks around here are rare as hen's teeth.

Anyways, that's my thoughts.

<edit> The caveat to that is a reverse flow smoker - they seem to be much more 'iffy' on firebox size. I have not got experience with those personally, so if that is your plan, I'd talk to someone who has built a bunch of those.
Thank you. I'm going to give it some more thought. Your comments are very helpful.
 
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