DIY Smoke Generator

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Post Options Post Options   Likes (0) Likes(0)   Quote got no boat Quote  Post ReplyReply Direct Link To This Post Posted: 18 Apr 2011 at 12:10pm
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Made a modification to my problematic smoker which may have fixed it. I stole farmer Browns idea of the baffle and pulled apart an old siv. Then I wrapped it around the inlet and outlet pipe of the smoke generator so there is a gap in the wood chips and it worked well, allowing you to adjust the pipes without pushing woodchips in and blocking them. Will have to give it a test this weekend to see how long it will burn for. Ran it for about an hour last night not probs.

If a 6 was a nine... I don't mind
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Post Options Post Options   Likes (0) Likes(0)   Quote MikeP Quote  Post ReplyReply Direct Link To This Post Posted: 11 May 2011 at 11:04pm
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This is a cool topic.  I had a go at makin a DIY smoker myself and I can tell you about a few of the
pitfalls.
Here's a photo of the smoke generator and the air pump.
Smoker and air pump
 
Here's another looking down the hopper.  There's a stainless mesh in the bottom and the hopper is about 60mm diameter.  You light it from underneath.
Looking down the hopper
The blue air line is 6mm diameter and the jet tube for the venturi is about 4mm diameter.
The smoker worked well for an hour or so and then the screen in the bottom clogged up with ash.
The smoke pipe also clogs up with tar and ash and needs to be cleaned between runs.
The efficiency of the venturi depends a lot on the relative diameter of the jet pipe and the outer pipe.  The inside hole in my jet pipe is only about 2mm diameter and the inside of the venturi pipe is about 15mm. 
So lessons learned so far:
You have to be able to get it apart for cleaning
You have to have somewhere for the ash to go
The diameters of the jet and venturi pipes matter more than the position but neither are that critical.
You can't turn it off so make it easy to remove from the smoker and tip the sawdust out.
The smoke may be cold but the smoke generator gets hot enough to burn you. take care!
Some ash comes out of the pipe so put the smoke generator at the bottom and don't put fish or flamable materials where the ash will blow onto it.
Alec's smoke canon is excellent value for money but how can you put a price on the satisfaction of doing it yourself!
 
Here are some photos of the smoker box I made.  It is made from 1 sheet of untreated 9mm ply and 40x18mm timber.  The dimensions were chosen to fit some racks I got from an old oven at the tip.  Because this is used with a cold smoke generator the heat required to cook the food comes from the top of one of those benchtop convection cookers.  These have a thermostat and a circulating fan and this one I picked up at the tip the same day I found the oven racks.  There is a tray that goes in the bottom to catch the drips (I bought the tray)
I have a digital thermometer that I use to watch the temperature.  I aim for around an hour at 90-100°C to cook a snapper or Kahawai.  I also have one of those wireless meat thermometer probes that I can stick inside the thickest part of the fish.  The fish is cooked when the internal temperature reaches 70°C.  But once you've done it a few times you don't need to bother with that. The last thing I cooked was 5 Kahawai at about 2kg each.  I brined them overnight in a 1/16 brine.  (2 cup salt, 2 cup brown sugar to 8 litres water)
 
 
 
"Sumfin Fishy"
Lotus 1900 (19 ft) with 135HP Mercury O/B
"My greatest fear is that, when I die, my wife will sell all my toys for what I said I paid for them".
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Post Options Post Options   Likes (0) Likes(0)   Quote tas-tackle Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 2011 at 2:17am
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Nice unit Mikep.... Nice project well done...and great innovation using the cooker unit...
Dont have the gear to weld so have one of Alec's units to put into a Kiwi smoker, which uses gas at the bottom for a heat source and a cast box to hold the sawdust... Bit of a pain doing a longer smoke having to open the door and work within the heat to replenish sawdust ...
I like the idea of my water bowl to cool the heat as it rises and with the new smoke generator, I should be able to set it up now and leave it for the duration... It works well as it is but I think it will simply work better now...  Will take pics when I have installed it...

http://www.tas-tackle.co.nz
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Post Options Post Options   Likes (0) Likes(0)   Quote got no boat Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 2011 at 11:18am
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Nice looking unit MikeP. Anyone know where I can get a stainless hopper like that from? I am using an old tin that is looking abit sad and wouldn't mind flashing it up a bit.
If a 6 was a nine... I don't mind
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Post Options Post Options   Likes (0) Likes(0)   Quote MikeP Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 2011 at 2:07pm
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Someone asked in a PM for details of where I got materials.
 
You can buy untreated ply at placemakers or Mitre 10 or any building materials supplier.  It is nothing special just CD grade.  The other timber is just 40x20mm pine, also from Placemakers.  I glued and screwed it with Gorilla glue and some stainless 6gx20 screws.
If you want something nicer looking then plyman or timpan have marine hardwood plywoods that have nice knot free appearance both sides and are not chemically treated.
The smoker shouldn't be going over 120°C and the ply handles those temperatures without any problems.
I ran it for a few hours with no food in it to "condition" it.

I made the hopper myself. If you haven't got the tools to make something like this then you should get the smoke cannon from  Alec (see earlier post) his price is very down to earth.
Cheers,
Mike
"Sumfin Fishy"
Lotus 1900 (19 ft) with 135HP Mercury O/B
"My greatest fear is that, when I die, my wife will sell all my toys for what I said I paid for them".
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Post Options Post Options   Likes (0) Likes(0)   Quote H8_4DS Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 2011 at 5:02pm
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WOW that smoker cabinet is great.

I think i will be building one at one stage. i already have one of those convection ovens in my spare room not doing much.

Do you think there would be enough heat produced from the motor to heat a bigger smoker> thinking at least twice the size

Cheers
Blair.


Also what size is the mesh in the bottom of your smoke cannon? If it was a bigger mesh size would it work any better?

I have one that my mate made up and it has a bowl on the base of it to catch the embers and ash.
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Post Options Post Options   Likes (0) Likes(0)   Quote got no boat Quote  Post ReplyReply Direct Link To This Post Posted: 12 May 2011 at 5:05pm
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It takes the fun out of it if you buy one. I have made one that works pretty well. Last smoke I did was about 8 hours of solid smoke but it doesn't look as nice as I would like due to not being able to get a propper hopper(cylinder) I have all the other parts but my hopper is actually a chivas regal tin.
If a 6 was a nine... I don't mind
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Post Options Post Options   Likes (0) Likes(0)   Quote MikeP Quote  Post ReplyReply Direct Link To This Post Posted: 13 May 2011 at 9:28pm
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The mesh is a 12x12 mesh (12 wires per inch) or about 2mm pitch
"Sumfin Fishy"
Lotus 1900 (19 ft) with 135HP Mercury O/B
"My greatest fear is that, when I die, my wife will sell all my toys for what I said I paid for them".
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Post Options Post Options   Likes (0) Likes(0)   Quote MikeP Quote  Post ReplyReply Direct Link To This Post Posted: 13 May 2011 at 9:36pm
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The convection oven is supposed to be 1100W.  It is fine for the size of my smokehouse.  It should be big enough for a plywood smoker twice the size provided you don't have too many air gaps.  One of the nice things about plywood is it is a poor heat conductor compared to a metal box.  at 100° the outside is barely warm to the touch.  So it takes much less power to heat it than a metal box would.  It's also safer where kids are running around.
"Sumfin Fishy"
Lotus 1900 (19 ft) with 135HP Mercury O/B
"My greatest fear is that, when I die, my wife will sell all my toys for what I said I paid for them".
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Post Options Post Options   Likes (0) Likes(0)   Quote Coochdog Quote  Post ReplyReply Direct Link To This Post Posted: 15 May 2011 at 3:26pm
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I eventualy bought a smoke generator off Alec after making my own.Had to constanly moniter my DIY unit as it would clog up with tar and stop burning.Alecs generator is awesome its done 3 smokes at about 6 hours each and only got a slight build up of tar.
Anyway what do you guys use to remove the tar build up??
Have tryed cleaning it with turps and a small brush what did not work.
Any ideas??
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Post Options Post Options   Likes (0) Likes(0)   Quote tas-tackle Quote  Post ReplyReply Direct Link To This Post Posted: 16 May 2011 at 12:02am
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Havent used mine yet but what about trying BBQ cleaner or oven cleaner...... spray on and then use small brush... wash with warm soapy water ....

http://www.tas-tackle.co.nz
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Originally posted by H8_4DS H8_4DS wrote:

WOW that smoker cabinet is great.

I think i will be building one at one stage. i already have one of those convection ovens in my spare room not doing much.

Do you think there would be enough heat produced from the motor to heat a bigger smoker> thinking at least twice the size

Cheers
Blair.


Also what size is the mesh in the bottom of your smoke cannon? If it was a bigger mesh size would it work any better?

I have one that my mate made up and it has a bowl on the base of it to catch the embers and ash.
 
 
 
COULD JUST GO GET A BRADLEY AND START SMOKINGWink OH BUT U DONT GET KEPPERS ON MULLET ANY WAY SO DOESNT MATTER HA HA HA GO THE SOFTYSLOL
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Post Options Post Options   Likes (0) Likes(0)   Quote H8_4DS Quote  Post ReplyReply Direct Link To This Post Posted: 22 May 2011 at 7:47pm
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Mullet is where its at.

And cant afford a Bradley, not with my major fuel bill on my boat
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Originally posted by H8_4DS H8_4DS wrote:

Mullet is where its at.

And cant afford a Bradley, not with my major fuel bill on my boat
 
NEED A FOURSTROKE DUDE WE GET OUT TO THE NOISES AND FURTHER ON MY BROS NEW RIG FOR 12 LITRES THERE AND BACK 5M SENATOR CENTRE CONSOLE AND A 70 HP MERC WE DONE TIARUA PINS FISHING FOR KINGS 3 WEEKS AGO PUT 6 HRS ON IT 37 NMILES FOR 27LITES RUNNING ALL DAY TURN OFF ONCE FOR LUNCH WICKED BUT 55 BUCKSClap
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Leave Maraetai ramp and to the Hole in Sargent. Back to the boat house at omana and back to the ramp is 23 litres. mind you we are doing just over 45 knots most of the time. only problem is that the hull dont like the chop to much. gotta be dead flat to do that sort of speed.
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Ok, so i had half an hour free on Thursday at work, so i decided to rummage thru my Steel collection(which is not that big, as i work for a plastics company) and found a few bits and pieces to make another smoke generator.

This was designed along the lines of a design, that John (*fisher*) emailed me. Thanks mate cause this one has worked the best so far.

Hopper is a bit of 2.5" chrome tube from an umbrella stand. Thick wall so it gets real hot once its been going for a while. The smoke tube is 32mm od pipe with a 9mm stainless venturi tube. Bottom of the hopper has a steel plate welded on with 10 or so holes so it can breathe.

Here are the pics of it.





And a couple of quick videos of it running. Was recorded at night so the video isnt that clear, but you can get the driftBig smile

http://www.youtube.com/watch?v=Sazc5sL6L-o

http://www.youtube.com/watch?v=jYSpCjWbfis

The second video is showing how much air there is being pulled thru the smoker. There is not alot of wood chips left in the hopper. The hopper is approx 350 mm long and it lasted about 1.5 hours when filled approx 2/3 full. Never had a problem of it going out either.

I started the air pump before i put the wood chips in. And lit it with a propane torch rather than a normal ciggie lighter or match. I think this gives it a bigger smouldering pile of chips rather than just a few on the outside.
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Post Options Post Options   Likes (0) Likes(0)   Quote tas-tackle Quote  Post ReplyReply Direct Link To This Post Posted: 30 May 2011 at 1:04am
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Yup Mate, I use a Butane torch unit just for this job....  good wee investment and can refill from cans from the supermarket...
http://www.trademe.co.nz/Antiques-collectables/Tobacco-related/Lighters/auction-380017728.htm
Nice one, and ya can keep the rain off at the same time... LOL



http://www.tas-tackle.co.nz
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Post Options Post Options   Likes (0) Likes(0)   Quote BritSteve Quote  Post ReplyReply Direct Link To This Post Posted: 24 Jun 2011 at 11:01pm
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Hi guys.

Sorry for posting on this thread from the UK as a first post but I have been following it as a guest. All my searching for a smoker like the one in the h8_4ds photos has left me with some simple but important questions. If anyone who has built one with a right angled air to smoke tube connection can answer these I would be grateful.

How are the two smaller tubes connected. Is the air tube just inserted into the smoke tube or is it shaped. How far does it extend into the tube. I don't see how it can suck from the fuel end and blow out the open end. There doesn't appear to be anywhere for a venturi effect to work.

Judging from the photos I assume the smoke tube does not pass far into the fuel tube. Is that correct?

Steve
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Post Options Post Options   Likes (0) Likes(0)   Quote H8_4DS Quote  Post ReplyReply Direct Link To This Post Posted: 25 Jun 2011 at 11:06am
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Hey Steve.

The air tube is blocked off at one end and a hole is drilled thru the side wall.


                       Air in from pump

                          [    ]
                          [    ]
                          [    ]
                          [    ]
---------------------[    ]------------------------------------------------------------------
                          [    ]                                                             Smoke-------------
                          [    ]                                                             Smoke------------------
                          [                                                                 Smoke-------------
                          [      Hole in air tube                                  Smoke-------------                                       
                          [    ]                                                             Smoke-------------
                          [    ]                                                             Smoke-------------
--------------------------------------------------------------------------------------------

Thats the most difficult thing to draw on my cellphone.


Basically the air goes thru the tube and out the hole and causes a vacuum and pulls the air and smoke past the air tube. then the smoke goes out the end and into your smoker.

Only thing i can say is make the air tube hole reassonably large. IE 4mm or so. I used a 2mm drill and have found that the resin from the wood smouldering, blocks the air hole and then you get a very poor amount of air flow.

Hope this helps

Blair




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Post Options Post Options   Likes (0) Likes(0)   Quote BritSteve Quote  Post ReplyReply Direct Link To This Post Posted: 26 Jun 2011 at 7:48am
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Thanks for the reply. It all makes sense now. The diagram is impressive if you did that on a phone and is appreciated.

Steve
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