Building my own need advice

[Type2 BBQ]

I have decided to go all in and build my own smoker. I was going to do the double 55gal barrell smokers, but there is a zoning law due to being in a historical district and so I cannot.

So, I am going to build a 2x2x8' wood smokehouse, and I have a bunch of old wood from some barns locally that I am going to put on the outside to match the local historical structure guidelines.

I have located the needed plywood (http://www.lowes.com/ProductDisplay?...d=3735755&cId=) and 2x4s (http://www.lowes.com/ProductDisplay?...d=3604680&cId=) and so now I am looking into the grates/shelves.

My question is which of these is best to go with:
Carbon steel: http://www.drillspot.com/products/13...Expanded_Sheet
or
Stainless Steel: http://www.drillspot.com/products/13...Expanded_Sheet

I am projecting 3 shelves at 12" intervals for a starting point, and 6 hanging hooks. A water pan about 18" off the top of the heat source. This will let me do moist heat (150-200F) smoking, or fully cold smoke.

The unit will be double walled, with R15 insulation (http://www.lowes.com/ProductDisplay?...d=3388304&cId=) between the walls. I am doing this as where it will call home is in path of some good wind as we live on the top of a ridge and it whips through here. Plus in SouthVA we get snow and cold (it is 16F today) and I would love that baby to just humm along.

So, if anyone has any suggestions for me on the shelves, and fire source let me know. I am leaning toward full log fire inside a claypot for the fuel source. Would create two doors one for the fuel and one for the smoking chamber. This way I can work the fuel without affecting the meat chamber.

[Smokin' Dick]

I would look for a heavier gauge than that #16. The grates on my two larger cookers, a Lang and a Good One, have 3/4" #9 flattened expanded. I think if you use the #16 you will have some saggy grates, and we all know that is not good! Carbon steel is fine to use too. Keep it oiled at you will not get any rust. If cost is not an issue, go with the stainless.

[Trav8300]

I built a double barrel, and now that I'm finished I wish I would have built a cabinet smoker. It's hard as hell to get a barrel to be air tight after you have cut into it. I agree on the stainless steel grates to. But if they are a bit pricy expanded metal works great to.

[eDJ]

Re:

Just curious, if you live in a restricted historic area....will they approve of you cooking outdoors ? You might go ahead and build this smoke house
and house a Brinksman or Masterbuilt metal smoker in it, provided you could find a used one for cheap.

If it proves to not be a problem whether fire hazard or otherwise, then
you could sell the metal smoker and go ahead and finish the smoke house
to suit your needs. Should you get a cease and desist order.....well at least you'll still have a nice storage building for garden tools etc.

I'd encourage you to quietly ask around about any restrictions that apply to day time business hours outdoor cooking. You may have to consider doing this in the later afternoon and evening hours.

When I'm with friends in the town below me and we are running the smoker
people all around seem to know it. Kids ride up on bicycles smelling the air.
It will attract attention.

[nickelmore]

What kind of budget do you have? I am diggin the old wood, my next build will use similar.

Do not use home type insulation, use rock wool.

I would line the interior with tin or stainless sheets.

I thought there was a member here out west that sold soem great looking smokers that look old school. I will try to find the link.

Do you want to use wood, lump, electric or propane?

Any way, welcome you are in the right place.

[PreacherRodgers]

Ash 88 about his plywood smoker

[nickelmore]

You also need to think on how to "control" the fire inside.

Do some searches around here, there are some very good plywood type builds here and folks will pipe in to tell you what works and what does not.

I had a friend of mine that had the fire chief walk in the bar and hand him a ticket for putting out his smoker..... funny thing it was about 15 minutes after he told me how great it was and how much he has been smoking.....and how he can leave it unattended for more than 10 hours etc.....

We still get a chuckle out of it.....

[nickelmore]

I found this one, similar to the one I am looking for, but it gets my idea of what I am thinking.

[L20A]

I have a plywood smoker that I built. Actually it is the 3rd one. It works well. I posted pics of it here a couple of years ago. It is 2X2X6' high. No insulation. It has fire bricks on the "floor" and I made wood trays with 1/2" hardware cloth for the bottom of the tray. The trays slide on 1" runners thgat I attached to the sides. I use this smoker for most of my fish smoking. Lately I have been using my Weber smokey joe which I set in th ebottom for my "fire". It works greta & I can leave it going for hours unattended.

[Type2 BBQ]

I have a plywood smoker that I built. Actually it is the 3rd one. It works well. I posted pics of it here a couple of years ago. It is 2X2X6' high. No insulation. It has fire bricks on the "floor" and I made wood trays with 1/2" hardware cloth for the bottom of the tray. The trays slide on 1" runners thgat I attached to the sides.

This is very similar to what I want to do. Do you have plans for what you built so I can compare to what I am doing.

I do not have to worry about the building being removed as it will be slightly hidden. I have talked to the fire chief, who is also the preservation society CEO and he is ok with it if I build it from wood. They are ok, if I build a brick oven, with a brick smoker on the side. I cannot build a modern metal exterior structure though, or face it so someone could see inside the unit. Stupid laws.

As for a budget, I can spend up to $200.00 on the unit. The reason for the budget where it is that we want to build a brick grill, pizza oven and so I am splitting funds for that. I smoke on my off-set now but it is a pain to do a longer burn.

I considered electric grill plates for the heat source as it is easier to control, and no need to restock the wood etc. The issue is that it will be about 30ft from an electrical outlet and so not wanting to run a cable across the yard and garden for that.

I plan to control the heat, but having a water pan hang about 24" above the heat source. This will act as a damper for the heat. I will drill 1/2" holes on either side of the pans brace to allow for smoke to rise up the sides in the main smoking chamber.

On the expanded metal, I will look at heavier gauge. I guess I could also do a 1x1 cross brace on each tray to beef up the lighter weight metal. It is only a 24" span, so one at center should help.

Thanks to everyone for the help. I am loving this community, and even though I have grilled for years, it is not until the last year that I got into smoking, and it is so much better for many things. Still love to throw a burger and dogs on the grill and have a party :)

Keep the suggestions, critiques coming. I welcome your advise and expertise.

David