500 propane tank Rf build with cabinet (Big Pappa Bill's Beast)

[walterkennison]

This is my first build,,, lol
So we go big,,,500 gallon tank.
first question, can we blow it up,,,
spend a couple of days pondering the possibilities, in the end. We pumped our CO2 from the mig for displacement and lit a match.
granted the tank has been open for months, and the smell gone for a couple of weeks, but apprehension makes for a safe bet.

spent some time marking out the doors and the firebox cutouts. and went to town with the 4.5 inch grinder,,,
that lasted about 5 minutes.
quick phone call and out comes the plasma cutter. Cutting was slow for the expected result,,, the quarter inch wall should cut easier than this.
well,,, it was 3/8 inch wall, and we horsed our way through all the door cutting.

We installed the hinges, before we cut the doors loose, making sure of a good positive alignment.
using a straight edge to align the hinges while tacking, kept everything straight and functioning
Our cuts aren't perfect neither is my welding skill.
but we are happy with the result. "it works"

[walterkennison]

Firebox cutout,,, lol
had to move the cut toward the end about 1 1/2 inches since the lap joint of the cylinder and the hemispherical end was 5/8 thick.
I havent made the cabinet cut yet, nor the stack hole. want to get the view of the firebox first.

Using the barrel hinges ,
The upper strip for sealing the door is located on the inside of the cooker.

door location,,, i did move the door top cut off center.
good or bad, I dont know but comfortable
it is taking a bit of doing, trial and error to locate the counterweight
balancing between the door opening far enough and balancing against the door closed weight.
I think ... "think" we go it.

kept the door handles simple,,
just a taper from 3 inch to 1 1/2 inch over 6 inch length,
oak for the wood but plan to get hickory later.
just drilled quarter holds in the closet pole dowel and lagged in with 3 inch lags.

removed a fitting at the top of the tank leaving over a 2 inch hole,
Patched with a cut piece of quarter inch plate and welded it in.

all the sanding marks you see, are the removal of the welding beads.
I am using lincoln brand .035 flux core,,,
surprised with the result
took some time, but was reminded to drag the weld. (avoids contamination during the welding process)

got lucky with the stack,,, local used steel supplier had some 14 gage stainless 6 inch pipe,,,leftovers!

Steel should be sheared and in next week for the firebox.
still thinking about adding an ash tray and log box

[Big T]

Looks like you're off to a great start!

[walterkennison]

Lots of grinding,,,
all the cuts
all the edges
all the welds

Today
Flapwheels are my best friend.

By the way,,, i do owe alot of thanks to my Eric, my brother for all his help, (he's the guy in the pics)

[walterkennison]

first build,,
hours with shopping about guestimated at 26
planning time not included

[ajfoxy]

Coming along nicely

[Rodcrafter]

Heck yeah!


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[Dirtytires]

Did you get the counterweight figured out? If not, you might consider adjusting the support angle. It seems like it needs to be tilted back a ways...

Making great progress...keep it up.

[walterkennison]

I did the numbers and tested the counterweight at 50 lbs,,, it'll work
door hinges were moved down about 8 inches so everything is a new trial,,,:)

The humble beginnings of a Beast.

building the firebox

My welding skills aren't perfect,, using Lincoln .035 flux core with a Hobart 210 welder.

getting better at welding,, but in a hundred years,,who'll care

used a latch for a trailer tailgate for the firebox door,,,, touch warped.. but will tune it in later

used 3/16 for the slide,,then 1/8 x1 and 1/4 square stock for for the guides

the exciting moment of marrying the chamber and firebox

Got the stack tacked in ,,, stainless,,, woohoo!
looking good,,, just need to weld up the bottom

its comming along,,, may have to wait till winter to add the cabinet,,, got plans for this in two weeks

[walterkennison]

so started the build on april 26,,,
any suggestions on expanded steel ,,, as is or flattened?

[walterkennison]

Oh,,, i am soooo amazed ,,,
it fit together and both level as they should be.

next is to do a burn on the chamber to get last of the propane smell out,,,,
then clean, and install the baffle.

[Cole]

That thing is a beast, keep posting

[Big T]

I prefer the flat expanded metal 3/4' 'X 9

[Pete Mazz]

Looks good!!!

[Rodcrafter]

Yeah what BigT said


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[walterkennison]

looking at the grates,, I may mix it up,,, i need at least 2 sheets of expanded,,,
the lower frames are 34x36,,, and non flattened would be less worry,,,just weld in without reinforcement..
then the middle is 30x36 and that could go one of each
then the uppers are 24x30 and keep those flat.
still deciding...
what do you see as the advantages of flattened?

[walterkennison]

I'll get a better pic of the firebox handle but am really happy with how it turned out

[Big T]

Either will work fine but I like the flat because it's easier to move things around. You can slide them over without having to lift them up where as the raised ex metal tends to grab and dig into the meat if you don't lift them completely off the grate.

[Dirtytires]

Ditto....go flat. Much easier to clean also.

[walterkennison]

I did end up with flat,,, good advice and reasons..

got the baffle fitted and getting ready to add the drain.
all the frames are made for the racks.
really want to add the cabinet above the firebox, but have an idea for building a corn roaster and funding is limited to one or the other.

baffle fitted

[Big T]

[McBroom]

I did end up with flat,,, good advice and reasons..

got the baffle fitted and getting ready to add the drain.
all the frames are made for the racks.
really want to add the cabinet above the firebox, but have an idea for building a corn roaster and funding is limited to one or the other.

beauty 21.jpg

My vote: Corn roaster


I Love My 2018 RAM 2500HD 4x4 Off Road 6.4L. USMC (ret)

[Rodcrafter]

I would vote for the cabinet.


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[ajfoxy]

[Dirtytires]

The cabinet can be used for every cook year round. Corn is only in season 6 weeks. No brainer....cabinet.