How to Build a Smoker

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How to Build a Smoker - Preview of the book

Are you ready to become "Master of the BBQ Pit?" Learning how to barbecue can be a bit overwhelming, but I will guide you step-by-step through the whole process. The detailed information and pictures in this guide to building the smokin’ barrel will make learning how to barbecue, well..simple.

Around my neck of the woods, Barbecue isn't just a way to cook or smoke meat...it's a way of life. For us, BBQ isn't just part of the party, it is the PARTY!

There ain't NOTHING better than being with friends and family, hanging around the BBQ smoker (that you built), having a few drinks while smelling the beautiful aroma of a wood burning barbecue pit and hearing the faint sizzle of the fat slowly rendering into liquid love and gently rolling down the sides of the meat, basting it as it adds a hypnotizing flavor to the smoke and air....only 1 word properly describes it: "Heaven"

Picture this conversation with your best friend, while having a cold beer next to your Homemade BBQ Pit...

Him: "Wow, it sure smells good. What's in the smoker?"

You: "It's a 10 pound Pork Butt, I'm using a blend of hickory and pecan wood for a nice smoky flavor."

Him: "Man, that sounds delicious. How long does it take to BBQ something like that?"

You: "Oh, 'bout 12 to 16 hours or so. I keep the bbq pit at 225 degrees and just baste her a little every once in a while."

Him...(in total amazement. You are his new hero at this point) "WHAT! How in the world do you keep the bbq smoker going so long and keep the temperature steady? My BBQ grill will NOT do that! What kind of bbq pit is that?"

You...(Trying to hold back a huge ear-to-ear smile from that tingly feeling of pride and joy) This is the part where you really shine as a beacon of BBQ light. Watch his face when you tell him this: "Simple. I needed a barbecue pit that would be able to cook slow and low, be easy to use, be fuel efficient, and not need constant attention. So I decided the best option was to build my own BBQ Smoker!"

As you can see from this little conversation, you quickly become a BBQ Super Star in the eyes of everyone you cook for. And this is even before they see and taste the barbecue pork butts, ribs, briskets, chicken, and other succulent barbecue foods you have blessed them with. When it's time to pull that beautiful piece of meat off the BBQ pit it seems to always become more of a ceremony, in YOUR honor. People start coming out of the wood work to get a closer look and smell. To the untrained eye, it might look as though you were bringing a new born baby home to see the family for the first time. Now comes the best part....

When everyone starts eating, you won't hear a sound except for lips smackin', moaning and groining of pure ecstasy, and a bunch of random "Oh my God's!". You might want to close the windows, because ....well we won't go there.... :)

It is hard to describe the joy and pride knowing how to barbecue brings, so for now you will just have to trust me. We have some work to do, before you will be ready to experience this yourself though....Before you can be the "BBQ Guru" you need to learn and understand how to barbecue properly and how to build and maintain your BBQ Pit. Ok, keep that mental picture I just unfolded in the back of your mind, and let's get started!

Now is a good time to take a peek at the preview of the book :)

As you can see from the preview (please take a look at the book preview) snippet of the book…this is a very detailed instruction guide that will guide you through the BBQ pit building process. You will gain tons of BBQ knowledge and pit design and engineering concepts along the way…………

This book is a 110 page detailed step by step guide to build what I would consider to be the best darn BBQ Smoker on the planet. These are NOT the run of the mill bbq blueprint style plans that are all over the internet. This is a full blown nuts to bolts, 110 page with pictures instruction guide that will walk you step by step in building your dream bbq smoker.

Think of the sense of pride you will have when you have that backyard bbq with your friends and family and you pull those bbq ribs off this smoker that YOU built. You will also have the engineering knowledge relating to EVERY component of this bbq pit, since I wrote these plans as a guide. I actually describe the who, what, where, why's of each of the components of the pit. This is NOT one of those cheezy bbq pits that folks make by cutting a drum and tossing in a cooking grate. This is a well thought out, engineered bbq smoker that is made up of many components that all work together in harmony to produce championship quality bbq...every time.

Why do I think the plans are so good?

Well...I have spent the last 5 years designing and building the ultimate BBQ pit based on readily available 55 gallon drums and with NO welding, since the average joe doesn't have a welder. I have spent COUNTLESS hours perfecting the design, so that it does the following:

1. Maintains steady BBQ temperatures for LONG periods of time. This pit was designed for both backyard bbq and for competition bbq. It is critical for a bbq pit to maintain steady bbq temps (225* Fahrenheit) for 10 to 20 hour long cooking sessions. This bbq pit DOES it! If you have ever tried to BBQ a Pork Butt or Brisket on a bbq pit or smoker from a department store or a big warehouse store......then this means something to you. It is pretty much impossible to maintain steady BBQ temperatures in a pit that was not designed to do it.

2. Fuel efficiency. I don't want to spend a ton of money on charcoal for a 20 hour long brisket. This pit is VERY fuel efficient! I can consistently get 20 hour cook times from 13 pounds of charcoal and a few chunks of smoking wood. That is a little more than HALF a bag of charcoal. That is down right crazy :) You will never see that type of fuel efficiency in a store bought smoker or a big off-set type smoker. Period!

3. Even heat distribution and NO direct flame touching the food! Smoke is channeled through the chambers and forced directly across the meat. This means that your meat will have that perfect BBQ smoke ring and bark every time. Whoo-Hoo! Smoke Ring and Bark!

4. Weather-Proof. This BBQ pit works rain or shine, wind or rain!

5. Inexpensive to build. This pit uses a 55 gallon drum and hardware store parts. Why spend 2K on a pit, when you can build (a better one) for a fraction of that.


** BBQ Smoker features - Precise air flow control mechanisms to maintain perfect bbq temps, one of a kind charcoal chute for easy loading, removable charcoal basket and ash pan, folding side tables, steel casters for easy mobility, precise temperature gauging, etc, etc. This pit is designed to be air tight, so fire control is in YOUR hands. No more raging fires means no more tough BBQ meat :) Also included is the Operations guide to the pit. I walk you through actually using it to create AWESOME BBQ. I include a lot of unique operating info that makes using this bbq smoker so darn easy and consistant. I walk you through bbq'ing my award winning ribs. You will fall in love with them. Period.You will not be dissappointed with these plans. You will be able to create Championship BBQ with this pit. Every time. Plain and simple.

Please take a look at the book preview to get an idea of how detailed this book is and how simple it will make it to build the ultimate smokin barrel of your own.


*** By the Table of Contents below you should be able to tell that this is a very detailed easy to read and understand book. The level of detail I have put together in this book will make building your own Smoker a breeze.


HOW TO BUILD A SMOKER 1
LEGAL DISCLAIMER 1
SMOKIN’ BARREL PART LIST 6
MAIN BARREL PART LIST: 6
ACCESS DOOR PART LIST: 6
BARREL LID PART LIST: 6
AIR VENT PART LIST: 6
PAINT PART LIST: 6
BARREL HARDWARE PART LIST: 6
FIRE BRICK PART LIST: 7
COOKING GRATE PART LIST: 7
CHARCOAL BASKET PART LIST 7
THERMOMETERS 7
WOOD SIDE TABLES (SEE SECTION FOR DETAILS) 8
CHARCOAL CHUTE PART LIST 8
TOOL LIST 8
STEP 1 - SELECTING THE CORRECT DRUM 9
FIGURE 1-1 A GOOD BARREL 10
FIGURE 1-2 LID AND LATCH 11
FIGURE 1-3 - BARREL TOP CLOSE-UP 12
STEP 2 - CLEANING THE DRUM 13
FIGURE 2-1 BARREL CLEANING (PAINT SCRUBBING) 13
FIGURE 2-2 BARREL CLEANING (PAINT SCRUBBING) 14
STEP 3 - CREATING THE ACCESS DOOR 15
FIGURE 3.1 ACCESS DOOR LAYOUT AND MEASUREMENTS 15
STEP 3-1 - CREATE A DOOR TEMPLATE 16
FIGURE 3-1.1 - ACCESS DOOR TEMPLATE 16
STEP 3-2 - CUTTING THE ACCESS DOOR 17
FIGURE 3-2.1 - DRILL HOLES (STARTER HOLES) 17
FIGURE 3-2.2 - JIGSAW CUT 18
STEP 3-3 - ATTACHING THE HINGES 19
FIGURE 3-3.1 - DOOR HINGE LAYOUT 19
FIGURE 3-3.2 SHOWS HOW THE HINGES ARE TAPED AND READY TO BE DRILLED AND SECURED WITH THE SCREWS AND NUTS. 20
FIGURE 3-3.2 - TAPE THE HINGES 20
FIGURE 3-3.3 SHOWS THE COMPLETED HINGES. ONCE THE HINGES HAVE BEEN SECURED FINISH CUTTING OUT THE REST OF THE DOOR. 21
FIGURE 3-3.3 - HINGES COMPLETE 21
STEP 3-4 - BUILDING THE DOOR COVER (OPTIONAL) 22
FIGURE 3-4.1 - DOOR COVER DIMENSIONS 22
FIGURE 3-4.2 - DOOR COVER CUTTING 23
FIGURE 3-4.3 - COVER CLAMPED TO DOOR (LOOKS GOOD) 24
FIGURE 3-4.4 - DRILL HOLE PLACEMENT 24
FIGURE 3-4.5 - DRILL HOLES COMPLETED 25
FIGURE 3-4.6 - DOOR COVER PLACEMENT 26
FIGURE 3-4.7 - DOOR COVER CLAMPED AND READY TO DRILL 27
FIGURE 3-4.8 - DOOR COVER AND ACCESS DOOR DRILLING COMPLETED 28
FIGURE 3-4.9 - DOOR WITH FURNACE CEMENT APPLIED 29
FIGURE 3-4.10 - FINISHED SEALING JOINTS 30
FIGURE 3-4.11 - ACCESS DOOR BACK ON THE HINGES 31
STEP 3-5 - INSTALLING THE DOOR GASKET 32
FIGURE 3-5.1 - DOOR GASKET AND SEALANT 32
FIGURE 3-5.2 - DOOR GASKET 33
FIGURE 3-5.3 - STEEL DOOR GASKET 34
FIGURE 3-5.4 - GASKET COMPLETE 35
STEP 5-1 - BUILDING THE CHIMNEY 36
FIGURE 5-1.1 - TUBING AND LID 36
FIGURE 5-1.2 - CLOSE-UP OF TUBING BOTTOM 37
STEP 5-2 - TUBING AND LID ASSEMBLY 38
FIGURE 5-2.1 - LID READY TO BE MARKED 38
FIGURE 5-2.2 - LID MARKED AND READY TO BE CUT 39
FIGURE 5-2.3 - HOLE COMPLETED 40
FIGURE 5-2-4 - CHIMNEY TUBE INSERTED AND TABS BENT DOWN 41
STEP 5-3 - CHIMNEY CAP ASSEMBLY 42
FIGURE 5-3.1 - L-BRACKET POSITIONING 42
FIGURE 5-3.2 - ATTACHED CHIMNEY CAP 43
STEP 5-4 - SEALING THE CHIMNEY TO THE LID 44
FIGURE 5-4.1 - COMPLETED CHIMNEY SEAL 44
FIGURE 5-4.2 - COMPLETED CHIMNEY 45
STEP 6 - INSTALLING THE AIR INTAKE VENT 46
STEP 6-1 - OPTION 1 - INSTALLING THE AIR INTAKE VENT 46
FIGURE 6-1.1 - STAINLESS STEEL INTAKE VENT 47
FIGURE 6-1.2 - VENT PLACEMENT DIAGRAM 48
FIGURE 6-1.3 - VENT PLACED AND MARKED 49
FIGURE 6-1.4 - AIR HOLE CUTOUT COMPLETE 50
FIGURE 6-1.5 - VENT ATTACHED TO BARREL 51
FIGURE 6-1.6 - COMPLETED VENT 52
6-2 - OPTION 2 - BUILDING THE AIR INTAKE VENT 53
FIGURE 6-2.2 - DRILL HOLES ON TOP AND BOTTOM PIECES 54
FIGURE 6-2.3 - PLACING THE NUTS ON TOP AND BOTTOM PIECES. 54
FIGURE 6-2.4 - VENT DOOR COMPLETE 55
FIGURE 6-2.5 - COMPLETED AIR VENT 56
FIGURE 7-1.1 - FIRST COAT OF PAINT 57
FIGURE 7-1.2 - PAINTING COMPLETED AND DRYING 58
STEP 8 - PUTTING ON THE CASTERS 59
FIGURE 8-1.1 - CASTERS ON THE BARREL 59
STEP 9 - ADDING HARDWARE 60
STEP 9-1 - ADDING A LID HANDLE 60
FIGURE 9-1.1 - LID HANDLE 60
STEP 9-2 - ACCESS DOOR LATCH 61
FIGURE 9-2.1 - LATCH INSTALLED 61
STEP 9-3 - INSTALLING A DOOR KNOB 61
STEP 10 - INSTALLING THE FIRE BRICK 62
FIGURE 10-1.1 - FIRE BRICK LINED BOTTOM 62
FIGURE 10-1.2 - BRICK LAYOUT 63
FIGURE 10-1.3 - DOOR OPENING BRICK LAYOUT 64
FIGURE 10-1.4 - BRICKS MORTARED IN PLACE 65
STEP 11 - BUILDING THE FLAME SHIELD/HEAT DIFFUSER 66
FIGURE 11-1.1 - FLAME SHIELD/HEAT DIFFUSER 66
FIGURE 11-1.2 - FLAME SHIELD/HEAT DIFFUSER IN PLACE 67
STEP 12 - INSTALLING A GRATE 68
FIGURE 12-1.1 - HOLE PLACEMENT FOR GRATE SCREWS 68
FIGURE 12-1.2 - GRATE IN PLACE 69
STEP 13 - INSTALLING THERMOMETERS 70
FIGURE 13-1.1 - INSTANT READ THERMOMETER MOUNTING 71
FIGURE 13-1.2 - THERMOMETER PROBES IN PLACE 72
STEP 14 - BUILDING THE CHARCOAL CHUTE 73
FIGURE 14-1.1 - CHARCOAL CHUTE PARTS (THE 4’ TUBE HAS ALREADY BEEN CUT) 73
FIGURE 14-1.2 - CHUTE CONSTRUCTION COMPLETE 74
FIGURE 14-1.3 - CHUTE BOTTOM MODIFICATIONS 74
STEP 15 - BUILDING THE SIDE TABLES (OPTIONAL) 75
FIGURE 15-1.1 - SQUARE BASE DIMENSIONS 75
FIGURE 15-1.2 - COMPLETED SQUARE 76
FIGURE 15-1.3 - WASHER AND NUT IN PLACE 76
FIGURE 15-1.4 - SIDE TABLE DIMENSIONS 77
FIGURE 15-1.5 - COMPLETED SIDE TABLE 77
FIGURE 15-1.6 - SIDE TABLE BRACKET PLACEMENT 78
FIGURE 15-1.7 - TOP SLAT DIMENSIONS 79
FIGURE 15-1.8 - CORNER BRACE AND FIRST TOP SLAT 80
FIGURE 15-1.9 - SHOWS THE 2ND SLAT IN PLACE. 80
FIGURE 15-1.10 - TOP ALMOST COMPLETE 81
FIGURE 15-1.11 - TOP COMPLETE 82
STEP 16 - BUILDING THE CHARCOAL BASKET 83
PART LIST: 83
STEP 1 - BEND EXPANDED METAL TO MAKE BOTTOM AND SIDES OF CHARCOAL BASKET 84
STEP 2 - BEND AND CUT STEEL SHEET TO MAKE SIDES OF CHARCOAL BASKET 87
STEP 3 - DRILL HOLES IN STEEL SIDE PIECES 90
STEP 4 - ATTACHING STEEL SIDES TO EXPANDED METAL 90
SECTION 17 - ADDITIONAL EQUIPMENT, INFO AND ADD-ONS 93
CHARCOAL CHIMNEY - 93
CHAFFING DISH WARMER - 94
INSULATION - 95
BARREL COVER - 96
HOOKS - 97
SECTION 18 - SMOKIN’ BARREL OPERATION 98
SMOKIN’ BARREL OPERATION STEPS - 98
PRE BBQ - MEAT PREPARATION - 100
STEPS 1, 2, 3 - HEAT DIFFUSER, GRATE, AND PIT PROBE - 101
STEPS 4 - SETUP THE CHARCOAL BASKET - 102
STEP 4 CONTINUED - 103
STEPS 5 AND 6 - STARTING THE CHARCOAL CHIMNEY - 104
STEP 7 - DUMP CHARCOAL CHIMNEY INTO THE CHARCOAL BASKET- 105
STEP 8 - PUT THE LID ON THE BARREL - 106
STEP 9 - REGULATE THE TEMPERATURE - 107
STEPS 10 - START BBQ’N ! - 108
STEP 10 CONTINUED - RIBS AFTER A FEW HOURS 109
FINISHED BBQ RIBS - DON’T THOSE LOOK GOOD! 110