Smoker, Redneck style

[McGurk]

Thought I'd share the build of my first Smoker; an Ugly Drum Smoker (UDS). I've heard nothing but positives about them on another forum that specializes in smoking. They are cheap, relatively simple to build, easily customizable, hold temps with minimal fuel amazingly, and can turn out some PHENOMENAL meat. So I thought I'd take a stab at it as my gas grill is just not doing it for me anymore.

"Fresh Barrel"

First off, you start with a 55 gal drum. These work great because they are cheap and easy to find. Another popular choice for parts is to find a doner 22 1/2" Weber (or knockoff) kettle grill. You can use the grates and the lid from this to make your smoker. It isn't necessary, but I thought it made sense for my build.

"Burnt Barrel and Donor Kettle"

You need to clean the barrel out, burn it, and then wire brush it out to get any residue from any inner liner off, and get down it to bare metal. You need to get the top off to do the clean and burn whether it is a removable clamp-on lid or a rolled permanent lid. Mine was crimped and I used a cutting wheel on an angle grinder to go around the inside for removal. I popped the intake holes (we'll get into that later) and loaded her up with wood for a hot and long burn (4 hours).

"Inside after Burn, Before Cleaning"

After it cooled and was emptied, I used a braided wire cup brush on my angle grinder to finish the cleaning. I wiped it down inside with clean water, and did another quick grinding, and another wipedown. I also scrubbed down the outside with water and a rag as the paint was powdering due to the heat from the fire. After you do a final hosedown and wipe it dry (it rusts very fast), you will need to season the inside with some sort of oil or fat, just like you would a cast iron pan. I used butter flavor crisco as that is what I had, but many use lard, bacon grease, or vegetable oil.

"Coal Basket"

To hold the coals during the smoke, you'll need a coal basket. There are many ways to go about this with different materials, but the basics are to have it 10-16 inches across, and 6-12 inches tall. THen you need the bottom of it suspended 3" off the bottom of the barrel. I used a coal grate from the Weber grill, and then built it 6" up with expanded metal. It's not in the picture, but I used (3) bolts to get it off the bottom.

"Total Build during Seasoning"

This is how it looks without paint during the seasoning process. The things on the bottom are the air intakes. A basic setup uses (3) 3/4" black iron short threaded pipe n!pples. You then get caps for (2) of them and a ball valve for the third. The temp is then controlled using the amount of allowable intake controlled in this manner.

"Ball Valve"

Due to the cold winters, I switched things up a bit. I have (3) 3/4" intakes, all with caps, and a fourth intake that is 1" with a ball valve on it. Ignore my pathetic welding, please. I'm still learning!

"Inside, After Seasoning"

This is how it looks after seasoning. Notice the legs on the fire basket and the small amount of charcoal. I got this up to 400 degrees for a few hours with only this much. As I said, VERY efficient.

I still obviously have to get the racks in, and I want to paint it and put a different lid on it (you'll see!). I also need do my "grill mod" to get the basket up high for grilling, so more info and pix will follow!

[sweept]

Built myself one this winter. They are a blast to cook on!!!!!

[Big Dave2]

Great job McGurk! Looks perfect to me. Make sure you get some pictures of the first cook!

[Swimbait2009]

Looks great! Have you thought of cutting a door in by the fire box so you can add charcoal or wood without removing the lid, or is this not necessary?

[McGurk]

Looks great! Have you thought of cutting a door in by the fire box so you can add charcoal or wood without removing the lid, or is this not necessary?

Thanks for the comments! As far as the door, some people do add one when they have a desire for a wood burning smoker. When using charcoal or lump, there isn't a whole lot of need to add more during the smoke due to their efficiency (when they're made correctly). It's not unheard of to get 12-20 hours smokes out of (1) 18 lb bag of charcoal, which in most cases can be all held at once. The secret is ultra air intake control, and keeping the magic 220 degree temp.

I'm hoping to get some more done tomorrow night, and I'll post pix for you all. Hopefully some pix with food, too!

[Deitz Dittrich]

you could always invite us all over for dinner? 8-)

[McGurk]

Got some more work done on the UDS last night. You can now see how the racks mount and where a temp probe would go. It is recommended to use stainless steel hardware due to zinc plated hardware out-gassing at high temps (1600 degrees?). I don't think it's a huge deal, but I paid a bit more for it anyway so it won't rust. Plus the bling factor!

"Inside with Hardware"

Being I am using a Weber kettle lid, I can put 2 racks in here with one very close to the top. If you were to use a drum lid, you'd have to put the top rack down lower or omit it completely. The magic numbers for a standard 55 gal drum (34" tall inside) with a dome lid are as follows:

-Bottom of drum

-Bottom of charcoal basket 3" above that

-Lower rack 24" above that (27" from bottom of drum)

-Upper rack 6" above that (33" from bottom of drum)

"Inside with Racks in Place"

Not much to say here, but I used a folding Weber rack for access to the bottom rack, but I'm not sure how well it will work. I assume I'll have to pull the top rack to access the bottom one. The reason for using eyebolts on the bottom rack will become clear in the near future. I want to be able to use this as a standerd charcoal grill, also, so they will be the mounting points for the charcoal basket. You'll see soon.

"Full Length Shot"

This is the outside so you can see the relationship of the mounting points. The round thing is a thermometer with a 12" long probe.

This is to find the temp underneath the lower grate, which is the critical temp location of your smoking. It goes up to 700, but you are only interested in a range from 150-400 degrees realistically, and are aiming for 220 typically. A short probe will give you a side temp which is lower in temp than in the center, directly above the charcoal.

"Temp Probe Fitting"

This is how I mounted the probe, and is just a gas line fitting that I drilled out to accomodate the 1/8" diameter probe. Pretty simple.

Well, as it sits, it is a working smoker. I have a few more things I want to do to it (shelf, wheels, tool rack, temp gauge on lid, handles, paint, etc...)

but I may give it a run tonight with some simple appetizers. More to come!

[buddha]

That is really cool. Keep us posted.

[Big Dave2]

Lookin' good!

[CRAZYEYES]

I like it! I was thinking about doing something similar with a metal trashcan and my old weber style kmart grill that the legs rusted off of. I got the inspiration from one of those grilling shows where they use a 20 dollar trashcan from a hardware store.

[Jim Uran]

Nothing ugly about that!!!!! That will produce some good eats for sure.

[LABS4ME]

If the $20 trash can is a zinc plated trash can... me - myself? I would pass on using it. Zinc is a hazardous material... I know the internal temps should not reach the point of causing harm, but why risk it. No thanks... Pure steel for me. ie: 40 or 50 gal drum.

Good Luck!

Ken

[McGurk]

There's alot of back and forth about using zinc-plated cans and hardware and using galvanized anything when it comes to cooking. As far as I'm concerned, if there isn't fire directly touching the hardware/metal or within a foot of your heat source, it's probably OK, but you never know. It would be horrible to poison your guests, family, or yourself to save a few bucks.

[Big Dave2]

just make sure the trash can isn't galvinized.

[McGurk]

Weekend Update: Worked on it some more this weekend. Still haven't smoked with it, but I could if I had a day to babysit it. They are supposed to be pretty much "set it and forget it" after you get the feel for it, but I'm not there yet. Things I did- moved the main intake up higher (fat-man mod), added wheels, put an additional exhaust wheel and thermometer on the lid, and finished the charcoal basket.

"Centerfold Shot"

Here she is, as she sits now.

"Fat Man Mod"

Added an Elbow and 18" extension for the Main adjustable 1" intake. The valve handle is right at the Rack Temp Probe.

"Added Exhaust and Thermometer"

I took daisy wheel from my old donor kettle and mounted it on the lid with 4 new holes. I also grabbed a thermometer from a trashed grill (along with some Stainless Steel bling to be added later) and put her in on top. Also, note the wood handle. I took all of 5 minute with some sandpaper to get it cleaned up. It was pretty nasty before, and I'm going to stain and seal it before long.

"Wheels"

I used a wheel assembly from the donor Weber, and made a third leg from some scrap 1/16" stock. Works great, and free.

"Charcoal Basket"

This was made with the intent of using it as a grill, so that is why it looks as it does. You wouldn't need the "wings" otherwise, but the legs are necessary.

"Legs and Wings"

Closeup of the hanging assembly. The basket bottom is 3" above the bottom of the barrel.

"Mounted up High for Grilling"

"With a Rack"

[McGurk]

Did a second seasoning run (with the rest of the stick of Butter flavored Crisco) and was able to get over 400 degrees this time (only a hint over 300 deg last time). I also calibrated the 2 thermometers in boiling water, and really had to tweak the one in the lid. They should agree now, and read pretty accurately (I hope). Ready for food!

[Kylersk]

Very Nice McGurk! UDS is a great smoker! Very fuel efficient and easy to maintain temps with. You'll love it!

BTW, what HSOforum? Is it the Brethren?

Here's a pic of the one I made last year..

[McGurk]

You know it! I've learned a lot there, and am looking forward to the first cook with it. Looks like you've got a Stoker setup on yours, how's that working? Also, any tips on finding an elec dual probe thermometer on the cheap? Thanks!

[Kylersk]

Yup, custom built 'stoker'. It works great. No more restless nights worrying about the temp.

I picked up my dual prob thermometer (with wireless display) off of HSO-Classifieds. Seemed to be the cheapest. Cant remember the exact name of it though..

[Kylersk]

IT's a maverick ET-73, bought new off of the bay.

[sweept]

What is on your ball valve?

[Kylersk]

Computer fan that is tied into the temp controller. The fan cycles on and off forcing air into the smoker. This is how it controlls the temp. More air, more fire, hotter smoker.

[McGurk]

Hey Kyle, did you document a build over there? If so, what's your handle so I can look it up? Lot's of red drums over there!

[Kylersk]

McGurk, I go by same name and no, I didnt document my build. I think I have a few process pics though.. I'll see if I can find them..

[Big Dave2]

http://www.hotspotoutdoors.com/forum/ubb...ker#Post1833509

Here is Kylersk's thread about his UDS build.