BBQ Smoker, Cooker Grill, build page 1

The finished painted page BBQ cooker smoker.

THIS PAGE IS Build page 1. BBQ offset smoker built in St Augustine.

Build page 2. BBQ offset smoker built in St Augustine.

Build page 3. BBQ offset smoker built in St Augustine.

BBQ Cooker Smoker Grill

My customer Jamie brings me a large metal box with two doors he got from the railroad. He says he wants a meat smoker made out of it. He asks can it be done?

So I stare at it and the wheels start turning in my head and ideas start bouncing around and multiplying.

BBQ Cooker Smoker Grill
It was an amazingly well built box that already lasted 20-30 years of outdoor service for the railroad before they decided to upgrade to higher tech electronic housings.

BBQ Cooker Smoker Grill
He's explaining what he wants in features and I'm explaining how and what I can do to deliver his wishes. Ideas are bouncing around a mile a minute.

We solidified a plan and intangible design in our heads, and go ahead and buy material to make his dream come true.

BBQ Cooker Smoker Grill
Brand new 1/8" steel plate full sized. Now we have to accurately cut it down to assembly size pieces so we can put them back together the way we want them to fit.

BBQ Cooker Smoker Grill
For those customers of mine that want to be involved, I allow them. Jamie is also saving some build money by being my labor for me. I teach him how to accurately cut plate steel and off he goes.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
He couldn't believe my toys. He didn't know a circular saw existed that cuts plate steel like others cut plywood. He was having fun with my high tech toys.

BBQ Cooker Smoker Grill
The cut is perfectly straight and amazingly smooth. So much better than a torch cut as he expected. Out build accuracy typically is within 1/64th of an inch on average.

BBQ Cooker Smoker Grill
Jamie was stunned how fast my saw cuts plate steel. 20 second cuts left him with his mouth hanging open in amazement.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
Precise sized pieces begin accumulating.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
Now Jamie really falls in love with the accuracy. The pieces fit together perfectly exactly like we wanted them to.

BBQ Cooker Smoker Grill

On the firebox there will be doors to load the firewood into. We are building reinforcements on the door and door opening so the hot metal cant warp and flex.

We want air tight sealed doors without having to use gaskets as the sloppy fabricators, welders have to.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
The bottom one is the wall of the firebox that has an opening that fits the door into . The top one is the door. They both get reinforcement to stop heat warping.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
Now we are beginning to weld the walls of the firebox together. It will have five closed sides and one open side to mount onto the cooking chamber.

BBQ Cooker Smoker Grill
Now you can see one of the walls has the door opening built into it already and the reinforcement is already welded inside because it would be hard to get to later.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
You can see how amazingly precise the fit was after cutting the large plate into smaller pieces.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
Now you can easily see the reinforcement welded on the inside of the door opening. It gives it tremendous stiffness and rigidly so the door ends up with a perfect air tight fit.

BBQ Cooker Smoker Grill

BBQ Cooker Smoker Grill
The five sided firebox is done waiting for the door to be mounted into its opening. At this moment its tach welded in place so there was still room for adjustments. Now it will receive the last of its permanent welds.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
In one day it went from brand new steel flat plate to a fine perfect five sided firebox.

BBQ Cooker Smoker Grill
Jamie is smoothing out the weld splatter to make the joints invisible.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
When Jamie finished grinding the edges of the firebox, you could not tell it was welded. You could not tell it was made from multiple individual pieces put together. It looked like it just slide out of a mold. Every seam was invisible.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Now I'm welding temporary tabs on the door so I can put the door into its opening and it will sit in perfect plane, not too deep nor too high, as I wiggle it around to get its perfect alignment for welding the hinges on.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Jamie is holding the hinges tight to the box so I get good tight welds.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
One tab is knocked off already so we can test the door swing.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
I was really surprised. I've had many customers help me before but Jamie was amazing. He was smart, knew what he was doing, learned super fast and worked non stop.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Now we are adding outside lips on the door that will make flush contact with the wall when the door is closed for a nice tight seal.

BBQ Cooker Smoker Grill
I cut slots in the lip so I can weld through the slots holding the lip perfectly flush and very strong to the door.

BBQ Cooker Smoker Grill
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Now its time to start making some sort of handle and door latch system for holding it tightly closed.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Drilling a hole/pivot point in the handle so it can rotate open and closed.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Cooling the hot welds down quickly so we get the least amount of heat distortion in the door and its lips.

BBQ Cooker Smoker Grill
Grinding down the welds through the lips so the weld becomes invisible and leaves people wondering what's holding the lips in place.

BBQ Cooker Smoker Grill
Welding the bolt pivot place, in place so the door handle can freely swing as we intend for it to do.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Cutting out the latch mechanism the door handle will lock tight into.

BBQ Cooker Smoker Grill
Some of it was saw cut and the last piece had to be cut with a torch as it was too short to fit any blades into that short of a  space.

BBQ Cooker Smoker Grill
Now the lock is welded in place that holds the handle and door tightly closed. The more you push the handle, the tighter the closure becomes.

BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
BBQ Cooker Smoker Grill
Ok, enough pictures on this one page. Go to build page 2 to see more progress.

The finished painted page BBQ cooker smoker.

This page is "BUILD PAGE 1" BBQ offset smoker built in St Augustine.

Build page 2. BBQ offset smoker built in St Augustine.

Build page 3. BBQ offset smoker built in St Augustine.

Remember, I work by appointment only. 904-638-8338  Call me, 9 Am to 7 Pm, any day of the week




 

 


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