Beavers Gravity Fed BBQ Build Log

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beaver
Posts: 361
Joined: Tue Mar 25, 2014 10:59 pm

Beavers Gravity Fed BBQ Build Log

Post by beaver » Tue Nov 10, 2015 12:29 am

So i Built a smoker

I thought that Aussie BBQ Forum may be interested in a Cabinet smoker im building at the moment.
the END goal is to build them in australia but at the moment im in the prototyping phase where a mate and i are making them as simple to build as possible.

For those interested these smokers are refered to "gravity fed smoker" or "stumps clone"
while i dont like the bbq i have designed being labeled a "stumps clone" i suppose there is no getting away from it.

The design considerations were as follows

- minimal labour (plan on braising the corners after tacking them in place to spee dup production)
- perform perfectly WITH or WITHOUT a draft fan controller
- Can take Lump charcoal as well as Heatbeads
- Revision 2 will have a smoke management lever
- "managable" weight (under 300kg)
- Gastronom standards (2x 1/1 gastronom pans side by side)
- Slam latch for easy opening/closing
- well sealed
- fully insulated


Here are a few of the cad/actual unit shots
Some cutting diagrams we send off to the laser cutters
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The first cad output of the smoker (early stages) to show the height
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door and some of the walls removed to show internal structure
Those are 1/1 gastronom pans inside so LOTS of room
Each pan holds about a 8kg brisket for an idea
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The expanded steel racks are done a little different to your traditional bbq, we are having them made out of 15mm/5mm bent steel instead of box steel to cut down labour
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Here you see the handle for moving around, the laser cut holders for the handle that also hold the latch for the slam latch handle.
we were lucky enough to find the cad drawing of the handles so not much work needed to be done there to work out the dimensions
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you can see here some more detail of the heat delivery tube coming out of the firebox.
we have not finished the drawing of the fire management plate but hope to complete that soon
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yup......my mate decided to sully the pictures. with the door its a PITA to create it out of box steel so instead angle iron is used and the plate steel is welded to the inside, it makes for a much faster manufacturing process as well as a nice flush door as opposed to box steel were the door is set out of the pit.
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machining a part on the slam latch because i bought the wrong height latch.....wont need to do this in the second revision

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a few pictures of our progress, the pit is built quite fast and easily made square. the front steel is 6mm plate which is used as the main structure as opposed to box for quick assembly
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2015-02-05 by Brett Robinson, on Flickr
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2015-02-05 (2) by Brett Robinson, on Flickr
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It's starting to make shape :)

Few updates

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Doors/hinges are on

Insulating the door
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Progress so far
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Few more things to do but its maybe one nights work off being able to be lit

Cutting fire grates
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We kind of went full retard on SS
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Hole cut for chimney
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Welding on the chimney
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Fire grate put into the firebox
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Cutting the chimney
https://vimeo.com/139529465

An update or 2
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Still to do

Seals
Finishing on racks (handles grinding and guides)
Thermometer
Heat management plate
Braising the edges to make air tight
Cover on chimney
Drainage hole and drip tray holder
Latch on firebox door
Prep/paint

She just got home. Im painting her now
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Seals, clean, season and burnin left
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for those whom werent following my instagram or facebook over the comp this happened

Reason

1. firebox leak was still present and i was unable to snuff the charcoal even after 24 hours
2. trailer at 100km forced air through firebox and re-ignighted embers
3. 50kg of heatbeads in the cooking chamber and 20kg in the chute ignighted

the CFA were fantastic and we understood that despite having 5L of water and 2x fire extinguishers it was not sufficient to put out the fire but only contain it.

Nothing was damaged
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Buccaneer
Posts: 565
Joined: Mon Jan 21, 2013 8:56 am

Re: Beavers Gravity Fed BBQ Build Log

Post by Buccaneer » Tue Nov 10, 2015 6:23 am

3things.
1) I am a fan and am confident you will get there, hope I can support you.

2) The welds looked a bit , um, erratic?

3) On the road to rehabilitation, there are many potholes called relapses! :lol:

:wink:

You will get there bro, carry on! :D
2015 Smokin In The City-Boarshank Redemption
Buccaneer, BeachBums, Alimac23, SilentBob!

beaver
Posts: 361
Joined: Tue Mar 25, 2014 10:59 pm

Post by beaver » Tue Nov 10, 2015 8:20 am

Cheers buc

In relation to the welds we were just trialing out a few fabrication methods. Neither of us are professional boiler makers.
There is a mix of braising, tig, mig, ss and plasma in there :)

The production model we have decided to go with folded steel to reduce welds, counter sunk hex for structural joins and for airtight joins (where its not folded) mig.

Welding on the new design will be reduced by more than 80%.
The finish will be a LOT more professional.
The unit will be able to be taken apart for warranty repair (if needed) or upgrades.
The build time / skilled labour needed will be reduced considerably.

With those changes wemay even be able to do a build to order in the early stages however i think we will likely build 10-20 units to save on cost with a small production run.

Sent from my SM-N915G using Tapatalk

Smokey
Posts: 5961
Joined: Fri Jun 26, 2009 5:47 pm
Location: Terranora- Tweed

Re: Beavers Gravity Fed BBQ Build Log

Post by Smokey » Tue Nov 10, 2015 10:10 am

Massive effort Brett, Hope it turns out a real goer.
If your not a boiler maker now, You soon will be :lol:
If trees screamed when we cut them down, We wouldn't. If they screamed all the time we would.
http://www.aussiecue.com.au

beaver
Posts: 361
Joined: Tue Mar 25, 2014 10:59 pm

Re: Beavers Gravity Fed BBQ Build Log

Post by beaver » Tue Nov 10, 2015 11:20 am

Smokey wrote:Massive effort Brett, Hope it turns out a real goer.
If your not a boiler maker now, You soon will be :lol:
trust me, im not getting into welding any time soon.
all welds on the revised design will be hidden as much as possible with the exception of a few. the few that are seen i would like to have TIG welded as i prefer the look


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