Reverse Flow Offset Smoker Plan – How To Build One On Your Own

Talk about the reverse flow smoker,  an innovative alternative to the conventional offset smokers. Do you know that regular offset smokers become heated near the firebox and cool elsewhere? A reverse flow smoker solves this. Ingeniously, it distributes heat and smoke evenly over the cooking surface. How, you ask? The baffle plate cleverly directs smoke and heat.

Due to its size and complexity, building a reverse flow offset smoker may seem daunting. You may question why you should make one. Cost comes first. Building a smoker is far cheaper than buying one. Materials and designs may be tailored to your needs and budget. Second, DIY is gratifying and entertaining. If you’re a barbecue fan, creating anything by hand, especially a smoker, is unmatched. 

I’ll help you choose materials and understand baffle plate, firebox, and smokestack components as we work together. Let’s simplify the process and construct your own reverse flow offset smoker. I promise, with the appropriate approach and a clear, step-by-step instruction, this task is possible and rewarding.

THINGS YOU NEED TO KNOW WHEN BUILDING A REVERSE FLOW OFFSET SMOKER

Ready to build a reverse flow offset smoker? It’s exciting and rewarding! Let’s make sure you have the right skills, tools, and materials.

Essential Skills

• Metalworking Knowledge: You’ll need to cut, weld, and shape metal. These are key for your smoker’s parts.
• Precision Measurement: Measure accurately. Even small mistakes can affect your smoker’s performance.
• Basic Design Understanding: Knowing design basics helps a lot. It’s crucial for setting up the smoker’s layout.

Required Tools

• Welding Equipment: For joining metal parts firmly.
• Metal Cutting Tools: Such as plasma cutters or angle grinders, for shaping steel.
• Measuring Tools: A tape measure, level, and protractor are your best friends here.
• Drill and Bits: Needed for installing gauges and making adjustments.

General Materials for All Parts

• Steel: Use regular, non-galvanized steel for durability and heat resistance.
• Insulation Materials: Keeps the firebox hot.
• Temperature Gauges: For keeping an eye on the heat.
• Wheels and Supports: Make your smoker easy to move.

Places to Acquire Materials

• Metal Supply Stores: Great for steel and tools.
• Hardware Stores: For general tools and supplies.
• Specialty Smoker Part Suppliers: Find specific parts like gauges here.
• Online Retailers: Handy for comparing prices and finding unique items.

Additional Tips

• Safety First: Always wear protective gear like gloves and goggles.
• Research and Plan: Get your smoker’s design down before starting.
• Seek Expert Advice: Don’t be shy to ask for help if you’re new to this.
• Be Prepared for Trial and Error: It’s a learning process. Adjust as needed.

With these pointers, you’re all set to create an awesome reverse flow offset smoker. It’ll bring delicious smoked flavors to your table for years!

REVERSE FLOW OFFSET SMOKER PLAN

A reverse flow offset smoker has a complicated structure, so we’ll dissect it part by part to explain its function, the general ideas behind it, and where to position it. After each part, you’ll get closer to the final product—the reverse flow smoker you long for for that ultimate smoky flavour.

1. Food Chamber

The food chamber is the primary area where the food is smoked. In a reverse flow offset smoker, it’s crucial because it’s where the smoke and heat circulate around the food, cooking it evenly.

Regular steel is the most recommended due to its availability and affordability. Avoid galvanized steel due to the risk of toxic gases at high temperatures.

The size depends on your needs. For backyard smoking, consider a chamber that can accommodate several racks of ribs or a couple of briskets. The vertical distance between shelves should be enough to fit large cuts of meat.

Ideally, it should have multiple grates at different levels to handle different types of meats and quantities.

The style can vary based on personal preference. The traditional round shape is popular for its even heat distribution.

Basic metalworking skills are needed to cut, weld, and assemble the chamber. Accurate measurement and alignment are crucial.

The chamber should be securely welded to ensure no smoke or heat escapes. Doors must be fitted properly for easy access and to maintain consistent temperature.

Steel suppliers or hardware stores would have the necessary materials. Pre-cut pieces may also be available.

If you’re looking for some more do-it-yourself (DIY) BBQ options, try building an offset smoker. It’s the easiest structure to construct, and it has its own unique set of benefits as well as concerns.

2. Firebox

The firebox is where the fire is made, generating heat and smoke for the food chamber.

About choosing materials, similar to the food chamber, regular steel is preferred. Size and insulation are more critical than material aesthetics.

A 50 cm x 50 cm x 60 cm (20″ x 20″ x 24″) firebox is adequate for most needs. It’s large enough to hold a fire but not so large as to be inefficient.

Another important part that requires skills in metalwork for constructing and insulating the box.

Should be attached to the side of the food chamber with an opening that allows heat and smoke to enter the chamber efficiently.

3. Smoke Stack

Smoke stack facilitates the flow of smoke and heat out of the chamber, crucial for maintaining temperature and smoke density.

You will just need the regular steel, with the emphasis on the diameter and height for proper draft.

The diameter and length should be proportionate to the size of the food chamber. For a backyard smoker, a stack around 10″ in diameter and 3 meters tall is usually sufficient.

You should have basic metalwork for attaching the stack and ensuring a smooth transition with minimal air flow resistance.

Once you have the smoke stack, position it at the top of the food chamber for standard smokers, or lower for reverse flow designs.

4. Baffle Plate

The baffle plate is essential in a reverse flow smoker. It directs the flow of heat and smoke under the plate and then back over the food, ensuring even temperature distribution. A baffle plate often looks like this:

The baffle plate is a big, flat piece of metal. It fits perfectly inside the smoker and goes along almost the whole length of the cooking area. Heat and smoke can move around the sides because it’s not as wide as the inside of the smoker.

Most of the time, it’s made of tough steel that can handle high temperatures. With its thickness, the metal keeps heat in and spreads it out evenly.

There are two popular styles for baffle plates: the long, straight baffle, and the slanting baffle. Here’s how you can build each:

Long, Straight Baffle Plate

Design Concept:

This baffle plate runs the entire length of the food chamber, lying flat and close to the bottom. It ensures that the smoke and heat are evenly distributed as they travel the length of the smoker before rising to cook the food.

Features a long, flat baffle plate running almost the length of the cooking chamber. This design forces smoke and heat to travel to the far end before reversing back over the food.

This design is widely popular among reverse flow smoker enthusiasts and is often seen in commercially available models.

Provides excellent heat distribution and smoke flow, resulting in more uniform cooking temperatures.

Building this type of smoker can be more challenging due to the need for precise measurements and effective heat and smoke channeling.

This type is ideal for serious barbecue enthusiasts and professionals who prioritize consistent cooking results and are willing to invest time in construction and maintenance.

Building Steps:

• Measure the length and width of your smoker’s food chamber.
• Cut a piece of heavy-duty steel to these measurements. Ensure it’s slightly narrower than the chamber to allow smoke and heat to flow around the edges.
• Place the baffle plate flat on the bottom of the food chamber, leaving equal space on each side for smoke and heat to pass.
• Weld the plate at each end to secure it in place, ensuring it’s level and flat.
• Make sure there is enough space for smoke and heat to circulate around both ends of the baffle plate.

Slanting Baffle Plate

Design Concept:

A slanting baffle plate is angled upwards from the firebox towards the opposite end of the smoker. This design helps in directing the heat upwards more efficiently, ensuring a more even distribution, especially towards the far end of the smoker.

Utilizes a slanting baffle plate with differently sized holes to redirect the flow of heat and smoke within the cooking chamber.

It is less common than the long baffle design in commercial reverse flow smokers, but it’s a viable alternative for custom builds.

The slanting baffle with perforations can help in distributing heat more evenly, but it might not be as effective as the long baffle in terms of overall temperature uniformity.

The construction of a slanting baffle smoker can be somewhat simpler than a long baffle design, as it requires less precise channeling of smoke and heat.

This method is better suited for hobbyists or home barbecue enthusiasts who are looking for a balance between efficient smoking and ease of construction.

Building Steps:

• Take measurements of the food chamber’s length and width.
• Cut a piece of heavy-duty steel according to these measurements. The width should taper slightly from one end to the other.
• Let’s form the angle, bend the steel plate so that it forms a gentle slope. The lower end should be near the firebox, and the higher end towards the opposite side of the smoker.
• Position the plate inside the food chamber. The lower end should be a few inches above the opening from the firebox, sloping upwards.
• Weld the plate at both ends, ensuring it’s firmly attached and the slope is maintained.
• Ensure the slope is gentle enough to allow heat and smoke to travel upwards but not too steep to hinder the flow.

Slanting baffles for reverse flow offset smokers are simpler and more beginner-friendly than lengthy baffles. Its design doesn’t need sophisticated planning like a lengthy baffle, making it simple. Unlike a lengthy baffle, the slanting baffle’s variable proportions don’t affect its operation if measurements are off. Additionally, the slanting baffle’s heat and smoke distribution holes are more forgiving in size and location. Due to the streamlined production and installation procedure, adjustments and modifications are easy. The slanting baffle requires less metalworking skills and makes creating a functioning smoker easier for DIYers and beginners.

5. Temperature Gauges

Temperature gauges are crucial for monitoring the cooking environment inside the smoker to ensure the food is smoked at the right temperature.

You might need a high-quality, heat-resistant gauges.

At least two gauges are recommended, one at each end of the food chamber, to monitor temperature variations.

Minimal; involves drilling holes and securely mounting the gauges.

Gauges should be mounted at grate level for the most accurate readings. Ensure they are easily readable.

6. Supports and Wheels for Mobility

Supports and wheels add stability and mobility to the smoker, making it easier to move and position.

You will need durable metals for support and high-quality, heat-resistant wheels.

Wheels should be large enough to handle the smoker’s weight and suitable for the terrain where it will be used.

Basic metalworking skills for attaching support and wheels.

Support should be welded to the bottom of the smoker for stability. Wheels are typically attached at the back for ease of movement.

MAKING THE MOST OF YOUR DIY REVERSE FLOW OFFSET SMOKER

Great job making a reverse flow offset smoker! It’s impressive, but utilising it properly is the pleasure. Let’s discuss how to make your DIY smoker operate as well as or better than commercial ones.

Accept the DIY Difference

First off, your handcrafted smoker is fantastic and unique. However, it may manage heat differently than store-bought smokers. Watch your fire and temperature for the ideal cook. Consider how your materials retain and transfer heat as they may differ from the experts’. Any small holes or leaks may be sealed quickly to boost efficiency.

Optimising Your Smoker

Before adding food, let your smoker heat up for optimal results. This is essential for even cooking. Maintaining the correct temperature and smoke level requires knowing your smoker’s airflow, including vents and dampers. Always use high-quality fuel for steady burning. You should have thermometers in various areas of your smoker to monitor temperature.

Caring for Your Smoker

DIY smokers need love and attention like classic cars. Check for wear and corrosion, particularly where you’ve welded pieces. Cleaning it after each usage keeps it in good condition. Cover it while not in use, particularly if your materials aren’t as heavy-duty as professional ones.
Treat doors, grates, and other moving components carefully. Since they may be weaker than commercial versions, hard handling might harm them.
To preserve the metal and increase cooking efficiency, season the smoker inside with cooking oil regularly.
 Be open to making modifications. Over time, you might find that certain tweaks can improve your smoker’s performance.