How To Build A Smoker – Construction Materials

In order to make a comparison I will also compare and contrast with prototype No.1

My challenge was how to build a smoker out of the lowest cost construction materials that would do the job and to be as clear as possible I've put links here through to pictures at Amazon so you can get a good understanding. The vast majority of the construction has been made using the following:

• 5 ply plywood 3/8'' thick for the outer skin.
• A moisture resistant fire retardant board for the inner skin
• Softwood timber battens
• 4 casters
• ¾'' dowel – 2 lengths of 2'
• 4 Brass Hinges - brass doesn't rust.
• Velcro loop - Don't buy the self adhesive stuff. Gluing with PVA is much better.
• 3-Inch Barrel Bolt
• 2 Snap catches
• 6 x 3/4 Screws, Undercut Flat Head, Phillips Drive

In my first attempt learning how to build a smoker I used a thinner plywood and the result was quite a flimsy structure. Admittedly it didn't have the benefit of the additional inner skin but I still think 9mm or 3/8 thick is the optimum balance between weight and structural rigidity.

The timber battens proved successful and just the right thickness.

Why did I choose plywood? Because I thought that it would be the best material for external use. I considered MDF and also chipboard but felt that these materials would be destroyed at the first sign of rain. As a balance between cost, ease to work with and longevity, I think that it was still the right decision.

The fireproof board I used is branded and was made from calcium silicate. What's readily available where you are might vary but the factors I considered when making my choice were:-

I used ¼ inch (6mm) board for the inner skin but you might find that ½ inch (12mm) is easier to get hold of. To take account of this I've coded my technical drawings and produced a table to calculate the measurements based on the material combination that you choose. That way, my drawings and methods for how to build a smoker can be understood and followed no matter where you are in the world.

Panels For Fabrication

Rear Panel
Side Panels
Base Panel
Top Panel
Food Chamber Door
Firebox Door
Firebox Front Panel
Fabricating The Smoke Spreader

The Assembly Process:-

Phase 1 – The Outer Structure
Phase 2 – The Firebox Panels
Phase 3 – The 3 Front Panels

Addenda:-

Daisy Wheel – An Alternative Chimney Design
Preparing For A Remote Firebox (Cold Smoking)

Return To The Build Your Own Smoker Index
Barrel Smoker Plans

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