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Offset Smoker Design

Pretaco

Pretaco

Yellow Skull
Joined
Feb 1, 2023
Member Number
6016
Messages
7
I want to build a small backyard offset smoker for myself and also as a prototype for sale.

Here is what I have so far:
20x40 main grill surface, expanded metal with slide out. Will add another slide out surface above main grill.
53 gallon sized smoke box, 22 gal firebox, 4" stack (24" tall).
1" insulation around firebox.
10 gauge construction for whole unit. Stack will be 16ga.

Obviously I have to add the hinges, handles, counterweight, shelves, frame and wheels.

Anybody got one about this size, what do you like / what would you change?
 

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I've done a ton of homework, just looking for real word opinions. But thanks for your help!:flipoff2:
 
Can you make one out of a barrel or old large propane tank?
 
I have a plasma table and want to build it different than all the propane smokers that are out there.
 
There are calculators out there online for all this stuff. I'd go bigger than you think you'll need.
 
1) Roll it instead of breaking if you can't find pipe or a tank, or at least put a peak in it. The issue is moisture that condenses on the flat portion will build up and drop on the meat in splats, no good. You don't want any flat portions over the grate.

2) Definity do reverse flow, move the stack add movable tuning plates.

3) I lowered my firebox even more on one of mine to aid with the reverse flow setup, I even frenched under a little.

4) Insulation is tough, I'm interested to hear your plan there? I'm a 100% stick burner so I typically have more heat than I want for TBS, so I've never found myself wanting insulation but I can see the advantage. Wind ends up being a much bigger factor IME, and I think that's mostly due to draft changes. Consider a surround to help with that.

5) Something I've always wanted to build but never have is a foot pedal to open the lid. Many times that would be handy.

6) A shelf and warming tray are nice features

7) Dedicated spot to hold the temperature logger, even just a dedicated cool vertical piece of steel for the magnet to stick to is good enough.

8) have a plan for a water tray location and access for filling. Make sure you've got a little room under the grates.
 
larboc said:
1) Roll it instead of breaking if you can't find pipe or a tank, or at least put a peak in it. The issue is moisture that condenses on the flat portion will build up and drop on the meat in splats, no good. You don't want any flat portions over the grate.
Click to expand...
I will look at adding a peak to the top.
larboc said:
2) Definity do reverse flow, move the stack add movable tuning plates.
Click to expand...
Reverse flow was going to be the next design, tried to keep is simple for the first.
larboc said:
3) I lowered my firebox even more on one of mine to aid with the reverse flow setup, I even frenched under a little.

4) Insulation is tough, I'm interested to hear your plan there? I'm a 100% stick burner so I typically have more heat than I want for TBS, so I've never found myself wanting insulation but I can see the advantage. Wind ends up being a much bigger factor IME, and I think that's mostly due to draft changes. Consider a surround to help with that.
Click to expand...
Double wall with 1" gap and rock wool or ceramic insulation blanket material. Most people have said the insulated firebox makes a big difference in holding the correct temps.
larboc said:
5) Something I've always wanted to build but never have is a foot pedal to open the lid. Many times that would be handy.

6) A shelf and warming tray are nice features

7) Dedicated spot to hold the temperature logger, even just a dedicated cool vertical piece of steel for the magnet to stick to is good enough.

8) have a plan for a water tray location and access for filling. Make sure you've got a little room under the grates.
Click to expand...
I will look closer at the water tray and temp logger locations, shelf and counterwieght system are later once this part is finalized.

Thanks for the help!
 
I would say firebrick in the firebox, would greatly improve the life of the firebox, temp control etc.

I'd also only do a reverse flow, can't see the reason not to.
 
Not pimping another site, but I would suggest going to Smokerbuilderu.net, as it is just dedicated to building pits.


On a pit that size, you are going to have trouble keeping the temps down... insulated box isnt going to help that.

Material thickness might be a bit small, unless you are targeting the sub-$1k market. Most built like this are 7ga atleast.
 
Reverse flow with at peak at the top for condensation purposes. It looks a little too star wars for my taste, but will cook more betterer...
I'll add the baffle and drain.
 

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LowDown said:
I get wanting to DIY but consider getting a 22" Webber Smokey Mountain. Awesome smoker, makes great traditional barbecue.
I have 3...love 'em.
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I've got a WSM and it has it's place, but even a COS is better if you're into stick burning than the WSM. Too hard to keep the heat right and smoke clear unless you're using charcoal, which is for bitches.
 
I don't like the lid on the Chiasson smoker. Needs more "reach in space".

Started smoking, with my Stepfather, at 15yrs. We used a military field cooker that was stripped out and shelves added. Small mesquite fire at the bottom. Water dish in the middle. Meats above. Made good smoked meats.

Bought a GMG DB in 2014. Did a side by side with a Traeger. Would never own a Traeger.

I wouldn't worry about insulation. Smoked from 4000k to 9000k. Temp wasn't a problem. Wind is a problem. Add more wood.

Yoder is one to look at. I like the steel they use. Build quality is good.

Now, I like this sign. Two of my three favorite states. Where do I get one?



Screenshot 2024-08-21 at 8.03.55 PM.png
 
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For years I’ve been sure I was going to build a reverse flow. I have pretty much all the CAD drawings drawn up ready to adjust based on the propane tank I end up with. A year or two I happened upon the 250 and 325 gallon tanks. Plate steel prices were/are dumb, so it’s been mothballed (like all my personal projects…). Now I happened upon 3 4x8 1/2” plates for the firebox. Over the years, I think I’ve scrapped the idea of a reverse flow, and it irritates me because I like to build shit, and RF sure seems cool from a builder perspective, but honestly, I like barbecue more. I’m going to stick with direct flow and lots of it.

Then again, I also scrapped my 20” diameter backyard idea and I’ll do a minimum of a 30”x72”+.
 
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Pt_Ranger_v8 said:
He has a yellow star... What have you done to support the site? :laughing:
Click to expand...


To be more constructive and ask real questions to help support:

  • What does your design bring to the market that isn't already there?
  • Do you have a novel design that has not been explored in this space?
  • Can you beat the Chinesium built contraptions on price point or materials?
  • Do you have the readies to build and fabricate many instances once the design works and is ready for sale?
  • Or, would these be custom builds by invoice (I.E. would you have stock ready to ship)?
  • Per above, if you have stock ready to ship, can you store it? Can you afford to sit on unpurchased inventory?
I applaud the effort; trust me on this - I was in a bad mood last night and should not have lashed out.

I would absolutely suggest that you build one and cook on it more than once before you post it for sale. It seems to me that the market is saturated with all sorts of smoker designs. You can spend hours days on youtube watching reviews of all the various designs; I am sure you're aware.
 
O, it doesn't look like you've got a lid on the firebox. Add that and a grate. I often cook lunch in the firebox.
 
Pretaco said:
Reverse flow with at peak at the top for condensation purposes. It looks a little too star wars for my taste, but will cook more betterer...
I'll add the baffle and drain.
Click to expand...

Shouldn't that stack be located higher in the smoke chamber? Same for the first design.

I get that you're trying to do this with a CNC plasma and a brake, but I think a pipe stack with a CNC cut flange welded to it would be a simpler solution that uses less material.

Something along the lines of...

1724328614014.png
 
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To add more ideas (complications) think about adding reliefs in the lid design for gasketing material. It makes a difference when it comes to keeping the heat and smoke INSIDE. Remember, everything choses the path of least resistance and there is no reason to go up the stack if it can sneak out directly.

I very much like the squared firebox design. I would cross-reference that shape with the dimensions of commonly available fire bricks (ie available at the big box stores or a favorite online ordering site) so that you just tell the end user what they need for the box

Since you are already doing the BBQ table thing, remember that the chef always needs more counter space - think about adding an option for a shelf to the design. That would obviously be an up-charge but I have never not wished I had too many flat spaces to drop something
 
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dwygrsshpr said:
To be more constructive and ask real questions to help support:

  • What does your design bring to the market that isn't already there?
  • Do you have a novel design that has not been explored in this space?
  • Can you beat the Chinesium built contraptions on price point or materials?
  • Do you have the readies to build and fabricate many instances once the design works and is ready for sale?
  • Or, would these be custom builds by invoice (I.E. would you have stock ready to ship)?
  • Per above, if you have stock ready to ship, can you store it? Can you afford to sit on unpurchased inventory?
I applaud the effort; trust me on this - I was in a bad mood last night and should not have lashed out.

I would absolutely suggest that you build one and cook on it more than once before you post it for sale. It seems to me that the market is saturated with all sorts of smoker designs. You can spend hours days on youtube watching reviews of all the various designs; I am sure you're aware.
Click to expand...
I'm trying to bring something in the range between the chinese made offsets and the recteq / custom ones I see on fb all the time.
You can't beat the chinese made on price, but definitely on material thickness an quality. I will have stock ready to ship as a base unit with custom options available, I have the space and money for inventory, albeit only 5-10 units to start with.
Yes, I'm building to a price point. If I wasn't the smoker would start at $4000 like most of the American made ones do.
My plan is exactly that; to build one and try it out.
Thanks to everybody for the advice.
 
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