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By AndrewW1977 in CookingBBQ & Grilling

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Introduction: Making a Vertical Smoker and Grill

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About: http://www.youtube.com/c/AndrewWorkshop More About AndrewW1977 »

In a previous Instructable I made a smoker from an old expansion tank. It came out awesome, so I figured I would try making a larger smoker but could double as a grill, inspired by Japanese Kamado cookers ("" looking bbqs). If you are not familiar with those types of cookers, they can be used as a smoker or grill.

The benefits of the kamado is they are incredibly efficient in their fuel use and they can grill at super high temperatures, mainly because it is made from ceramic. The ceramic construction is a good "" and I use that term lightly as where the true benefits of the kamado stand out is thermal mass. I own a smaller kamado and what I dislike about the one I have is the cooking surface area is small and hard to load fuel once lit, however what I really like is when smoking meat, it can maintain an even 250F for long periods of time and use little fuel and not produce much creosote. The downside is with that thermal mass, it takes a while for the cooker to cool down or if you need to lower the temperature, it can take a while.

From here forward, I will refer to this smoker and grill as the "".

So my criteria for this build is:

  • Must have an ample cooking surface.
  • Should be able to retain heat and be fuel efficient.
  • Fuel source will be charcoal.
  • Different levels of grates
  • Have an easy way to add charcoal even with food in the cooker.
  • Be able to smoke and grill.
  • Have multiple cooking grates.
  • Room for a water pan
  • Be able to cook pizzas at high heat.

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Step 1: Design and Video

I landed on an initial design dictated by the materials I have access too. My idea was to use mostly sheet metal for the "" and it would be insulated by clay or sand for the thermal mass. I decided that kitty litter which is clay would make a good substance for thermal mass and is easy to get. The shape would be a vertical box for simplicity but unlike the flimsy vertical smokers that can be purchased at Home Depot, my cooker would be made from thicker sheet metal. The only thing it would have in common is visually it would look very similar to a regular smoker.

Here are videos of the build and the cooker in use, the written instructions follow.

Step 2: Metal and Materials

Typical smokers and grills use 20 or 22 gauge sheet metal or thinner (at least the cheap ones) which is why they rust out and do not retain heat very well at all. The walls for the cooker in this build are 14 and 16 gauge sheet metal. The inside walls will be exposed to the most heat so they are constructed from 14 gauge and the outside walls will be 16 gauge to cut down on weight. The frame is made from 1""x1/8"" #9 steel expanded metal and 1""x1/8""x1"" square for 1 last update 2020/07/13 tubing and 1"" angle steel

  • Cooking Surfaces and Fire Basket: 3/4""x1"" steel mesh
  • Typical smokers and grills use 20 or 22 gauge sheet metal or thinner (at least the cheap ones) which is why they rust out and do not retain heat very well at all. The walls for the cooker in this build are 14 and 16 gauge sheet metal. The inside walls will be exposed to the most heat so they are constructed from 14 gauge and the outside walls will be 16 gauge to cut down on weight. The frame is made from 1""x1/8"" #9 steel expanded metal and 1""x1/8""x1"" square tubing and 1"" angle steel
  • Cooking Surfaces and Fire Basket: 3/4""x1"" steel mesh
  • Rabbit Brain Tanninghow to Rabbit Brain Tanning for Additional for 1 last update 2020/07/13 Materials:Additional Materials:

    • Heavy duty casters
    • Kitty Litter
    • Various hardware hinges
    • Misc bolts and nuts
    • BBQ Paint
    • BBQ Thermometer
    • Welding Chipping Hammer
    • Felt gasket material for BBQs (got mine from Amazon)

    Step 3: Tools

    This is a more advanced build as it requires the use of a welder. But anyone can learn to weld and this is a great project for anyone up for a challenge. I am by no means a great welder but I was able to build this.

    If you are looking to learn how to weld I would recommend getting a flux core wire feed welder as it''t want to weld you could modify the design and get away with bolting the whole thing together or using a tap to tap bolt threads in the frame.

    You will need but not limited too:

    • Welder
    • Mini Grinder
    • Grinding and Cutting Discs
    • Chipping Hammer
    • Welding magnets
    • Basic hand tools
    • Safety equipment (glasses, cotton long sleeve clothing, footwear, gloves)
    • Welding Rods: 7018 for the structure, 6013 for the sheet metal or thin parts of the smoker.

    A note about cutting discs, do not be tempted to buy cheap ones, they do not last and will disintegrate after a few uses. Buy quality bulk ones to save money, it will pay off in the long run and they are by far safer to use.

    Step 4: Making the Frame

    The frame is made from 1""x1/8""x19""

    Welding magnets were essential to help keep the whole box square. Also a template was made from some wood so two sides could be made and then they were welded together. Before welding anything I made sure to measure corner to corner and adjust as necessary to keeps things square as well. Ideally you would use a 3 position clamp but they are very expensive.

    Heavy duty casters were then welded to the bottom and reinforced with some angle steel.

    The top of the frame had some slots cut out, this is so the clay/kitty litter can be added after the fabrication.

    Step 5: Adding the Inside Walls and Top

    The inside walls are made from 14 gauge sheet metal.

    First the the right and left sides were tack welded in place then the back was welded in place. I welded in small sections, moving to different parts of the frame to minimize warping. Ideally two extra 1"" tubes should have been staggered vertically that would help keep the 1 last update 2020/07/13 warping down. First the the right and left sides were tack welded in place then the back was welded in place. I welded in small sections, moving to different parts of the frame to minimize warping. Ideally two extra 1"" tubes should have been staggered vertically that would help keep warping down.

    The outside walls are made from 16 gauge sheet metal. It had a hole cut so the tube for the rotisserie could be welded between the wall. The walls were then welded all the way around, this is optional and only necessary since I will be filling the walls with clay/kitty litter.

    Rabbit Brain Tanninghow to Rabbit Brain Tanning for For the ceiling some angle steel was welded so the sheet metal had a place to rest and then was welded in place.

    Step 6: Doors and Air Intake

    There are two doors for the cooker, the top the 1 last update 2020/07/13 one for access to the food and a bottom for checking on the fire.There are two doors for the cooker, the top one for access to the food and a bottom for checking on the fire.

    These are filled with kitty litter as well and the bottom door will also need an air intake that can be choked to control the fire.

    They are made from 1""x1/8"" steel bar stock then bolted to the doors.

    Step 7: Chimney

    Chimney is a 4""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step8""step""SIY9A66IPA1P713""step-title""mediaset""no-js-photoset""Outside Walls""https://cdn.instructables.com/FN7/WA94/IP8M8POR/FN7WA94IP8M8POR.LARGE.jpg?auto=webp&frame=1&height=300""Outside Walls""https://cdn.instructables.com/FO4/A0BI/IP8M8PPL/FO4A0BIIP8M8PPL.LARGE.jpg?auto=webp&frame=1&height=300""Outside Walls""https://cdn.instructables.com/F37/ULJV/IP8M8PP6/F37ULJVIP8M8PP6.LARGE.jpg?auto=webp&frame=1&height=300""Outside Walls""https://cdn.instructables.com/FQ7/6YY3/IP8M8PO5/FQ76YY3IP8M8PO5.LARGE.jpg?auto=webp&frame=1&height=300""Outside Walls""https://cdn.instructables.com/FTN/Y372/IP8M8PRJ/FTNY372IP8M8PRJ.LARGE.jpg?auto=webp&frame=1&height=300""Outside Walls""https://cdn.instructables.com/FG4/P70J/IP8M8PVD/FG4P70JIP8M8PVD.LARGE.jpg?auto=webp&frame=1&height=300""Outside Walls""https://cdn.instructables.com/FAE/FVFY/IP8M8PJV/FAEFVFYIP8M8PJV.LARGE.jpg?auto=webp&frame=1&height=300""step-body""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step9""step""S6X1EUWIPA1P7U8""step-title""mediaset""no-js-photoset""Installing Doors""https://cdn.instructables.com/F1C/H8R2/IP8M8QVT/F1CH8R2IP8M8QVT.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/F14/BKDZ/IP8M8PTM/F14BKDZIP8M8PTM.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FWM/6II8/IP8M8PTN/FWM6II8IP8M8PTN.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FEN/0M3F/IP8M8PUF/FEN0M3FIP8M8PUF.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FSX/X2R8/IP8M8PUG/FSXX2R8IP8M8PUG.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FEG/O3KN/IP8M8PUU/FEGO3KNIP8M8PUU.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FPR/6TPJ/IP8M8QP6/FPR6TPJIP8M8QP6.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FWX/NIJL/IP8M8PTO/FWXNIJLIP8M8PTO.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/F9L/0CCQ/IP8M8PZF/F9L0CCQIP8M8PZF.LARGE.jpg?auto=webp&frame=1&height=300""Installing Doors""https://cdn.instructables.com/FLA/BJWW/IP8M8PVH/FLABJWWIP8M8PVH.LARGE.jpg?auto=webp&frame=1&height=300""step-body""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step10""step""SS944ZCIO4JFHUZ""step-title""mediaset""no-js-photoset""Cooking Grates and Fire Basket""https://cdn.instructables.com/FQZ/IZ3W/IP8M8QRH/FQZIZ3WIP8M8QRH.LARGE.jpg?auto=webp&frame=1&height=300""Cooking Grates and Fire Basket""https://cdn.instructables.com/F24/GH5W/IP8M8Q1B/F24GH5WIP8M8Q1B.LARGE.jpg?auto=webp&frame=1&height=300""Cooking Grates and Fire Basket""https://cdn.instructables.com/F4Q/RKN8/IP8M8PY8/F4QRKN8IP8M8PY8.LARGE.jpg?auto=webp&frame=1&height=300""Cooking Grates and Fire Basket""https://cdn.instructables.com/FQA/0LY2/IP8M8QP0/FQA0LY2IP8M8QP0.LARGE.jpg?auto=webp&frame=1&height=300""Cooking Grates and Fire Basket""https://cdn.instructables.com/FBC/LOL1/IP8M8QP5/FBCLOL1IP8M8QP5.LARGE.jpg?auto=webp&frame=1&height=300""step-body""x1""x1"" bar stock welded around the outside for support.

    The fire basket is made from 3/4""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step11""step""SMA63OAIOCE6JB8""step-title""mediaset""no-js-photoset""Cooking Grate Supports""https://cdn.instructables.com/F7S/9OD7/IP8M8PV3/F7S9OD7IP8M8PV3.LARGE.jpg?auto=webp&frame=1&height=300""Cooking Grate Supports""https://cdn.instructables.com/FSO/NQ11/IP8M8PV1/FSONQ11IP8M8PV1.LARGE.jpg?auto=webp&frame=1&height=300""Cooking Grate Supports""https://cdn.instructables.com/F73/5D5N/IP8M8QP4/F735D5NIP8M8QP4.LARGE.jpg?auto=webp&frame=1&height=300""step-body""x1/8""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step12""step""SBCGVLKIOCE6JTM""step-title""mediaset""no-js-photoset""Removable Top and Filling the Walls""https://cdn.instructables.com/FMQ/NRT8/IP8M8Q17/FMQNRT8IP8M8Q17.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/FTL/KNW3/IP8M8QFC/FTLKNW3IP8M8QFC.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/F6D/4AWF/IP8M8QHV/F6D4AWFIP8M8QHV.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/FYP/EZNL/IP8M8QR6/FYPEZNLIP8M8QR6.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/FRL/IV5Q/IP8M8QR5/FRLIV5QIP8M8QR5.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/FF9/DX09/IP8M8QR9/FF9DX09IP8M8QR9.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/F2K/FU3B/IP8M8QHW/F2KFU3BIP8M8QHW.LARGE.jpg?auto=webp&frame=1&height=300""Removable Top and Filling the Walls""https://cdn.instructables.com/FUM/CWP6/IP8M8QKG/FUMCWP6IP8M8QKG.LARGE.jpg?auto=webp&frame=1&height=300""step-body""step-toolbar""stepBody""step-tip""step-question""step-comment""svg-pdf step-download download-pdf login-required verification-required""course""step13""step""S101GADIOCE6LS8""step-title""mediaset""no-js-photoset""Side Table""https://cdn.instructables.com/FWL/V1W2/IP8M8PCG/FWLV1W2IP8M8PCG.LARGE.jpg?auto=webp&frame=1&height=300""Side Table""https://cdn.instructables.com/FE8/T2G1/IP8M8QCS/FE8T2G1IP8M8QCS.LARGE.jpg?auto=webp&frame=1&height=300""Side Table""https://cdn.instructables.com/FP6/5U6B/IP8M8QEY/FP65U6BIP8M8QEY.LARGE.jpg?auto=webp&frame=1&height=300""Side Table""https://cdn.instructables.com/FUW/7AE1/IP8M8QNX/FUW7AE1IP8M8QNX.LARGE.jpg?auto=webp&frame=1&height=300""step-body"" round stock bent in a "". The hinges are some utility hinges. On the cooker some pieces of square tubing were welded and holes drilled so the round stock could rotate and fold. On the side table a "" was added so the round stock had a place to wedge and hold the table up. This is a very strong mechanism and works very well.

    Step 14: Grinding and Painting

    The whole cooker had the edges ground with a grinding wheel and then was polished with a flap disc and then scrubbed down with a scotch bright pad. High heat bbq paint was rolled on.

    The stick on nomex felt gasket was the 1 last update 2020/07/13 applied.The stick on nomex felt gasket was applied.

    A thermometer was added to the door. Ideally you want to install a few, so they are at different heights in the cooker as temperatures fluctuate in different parts of the cooker.

    Cooker was completely washed down and scrubbed with soap and steel wool to remove any traces of the welding and residual from the metal.

    Step 15: Finished Cooker

    The cooker is completed. I did some grilling and it worked perfectly, held temperature with no issue at all. I was able to bring it up to searing temps and it stayed. The air intake works great and allows for little or a lot of air flow.

    As a smoker the cooker functioned as expected, it held 250F and even with opening the doors to check on the meat it came back up to temperature quickly (1-2 minutes).

    Even made pizza's on it! 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