So I made a deal and this deal fell through. Below is a rough draft of what I start with when designing a smoker. Since every smoker I’ve built has Custom no two are the same. First I design chamber size for the clients needs then calculate fire box to support the main chamber. After this I design the stand that the whole unit mounts on. From pencil to paper this takes about 5 hours and that includes drafting up a cut list. See below
Keep in Mind
Keep in Mind there is a calculation require to create the correct heat and draft for perfect smoking. These dimensions may change .
After 8 hours of welding
Calc the smoke output size
to the main chamber
Main chamber smoke intake port 
28″ Chamber height 
40″ Chamber length 
Thank god for air cranes
weigh here is 300 lbs +
The main chamber will have 3 racks
zip open the offset collector 
add the collector 
square up the collector
Collector just about done – the collector basically collects the smoke
and exhaust’s it out the stack – since this is a reverse flow, offset and BBq design,
the BBq requires a cold air intake vent to allow the charcoal basket
that’s mount in the main chamber to burn
CNC hinges for a perfect fit 
I’m actually going to cut these down and show you the difference
list for tomorrow
No More Santa Maria Grill just a grilling station 
Tons of prep still to be done 
Getting the countertop squared up 
Side grill going in 
Dam reverse flow stack is in the way of the grill lid 
Grill in place and now making the lid 
working on the firebox door 
first fire box door failed so I’ll just male another one 
Grill lid in place 
Fire box door cut up, zapped together and hinges installed. 
Gauges mocked up 
both stacks in and welded up 
Offset side 
left side air intake control 
Still needs a fire box damper for air intake 
I’m Zipping this handle off and changing the handles 
Hickory Handles mocked up for stacks. Rick at Savvy Hammer will epoxy dip the handles once I’m finished with mock ups 
Front handle is at a 50 degree angle since the lid is so tall 
Fire box damper is in but the handle needs to be cut back. Door handle is installed. I won’t be using a lock on the door since the fit is super tight and you pretty much need to kick it closed and rip it open when feeding the charcoal to it.
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