I build and sell my own smokers out of food-grade 55 gallon drums. They sit
vertically on the ground. The meat sets about 24 inches above the coals. I
buy the drums from a local juice company. They receive the juice concentrate
in these drums. These smokers need the lids to the drums as well to work
properly. I call them "Big Drum Smokers". It took me about 2 years to
perfect the design.

Initially, the coals were placed directly on the bottom of the drums. I
realized that the coals should get more air under them, so I designed a
charcoal grate to left them up off the bottom a few inches.
I had to figure the best size and amount of holes to use in the drum for
intake vents. That was very frustrating, but paid off after several changes.
I also designed a charcoal basket (ring) to set on the charcoal grate. This
extended the burn time and efficiency. I can get 12-16 hours burn time from
10-12 pounds of charcoal. I use 2-3 fist size chunks of wood on the
charcoal. I prefer to light the coals with a high output propane torch. I
also had to determine the size and amount of holes to put into the lid for
the exhaust vents. I mount 6 inch metal pull handles on top of the lids.

Unfortunately, I have been limited to selling these locally, because their
size exceeds UPS and FedEX normal shipping rates. They would cost as much to
ship as they cost to buy which is not very cost effective. I burn out the
drums with logs to remove any paint or coatings, then I brush off the
outside and repaint with high-temp Rustoleum spray paint.

Here are some links to pictures:

Early pictures of the Big Drum Smokers in progress

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1310780

Butts & Brisket in Big Drum Smokers #1

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311221

Butts & Brisket in Big Drum Smokers #2

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311236

Butts & Brisket in Big Drum Smokers #3

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311244

Butts & Brisket in Big Drum Smokers #4

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311254

Butts, Chicken & Ribs in Big Drum Smokers

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311370

Turkey Breasts & Babybacks in Big Drum Smokers

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311407

Beef Ribs, Pork Butts & Shoulders in Big Drum Smokers

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311460

Homemade Corned Beef in Big Drum Smokers

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311651

Homemade Pastrami in Big Drum Smokers

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311674

ABT's in Big Drum Smokers #1

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311717

ABT's in Big Drum Smokers #2

http://www.dotphoto.com/go.asp?l=Roc...BQ&AID=1311860

Rocky wrote:
> I build and sell my own smokers out of food-grade 55 gallon drums.
> They sit vertically on the ground. The meat sets about 24 inches
> above the coals. I buy the drums from a local juice company. They
> receive the juice concentrate in these drums. These smokers need the
> lids to the drums as well to work properly. I call them "Big Drum
> Smokers". It took me about 2 years to perfect the design.

How neat, Rocky. Congrats on your work. Is the temp controlled through fire
size, or do you have other methods?
Dave

Hi Dave,

The heat is mainly regulated by the size and quantity of the holes in the
bottom sides of the drum.

I started off using 1/2 inch diameter holes, then switched to 7/8 inch
holes. But then, when I decided to lift the coals up off the bottom of the
drum, the temp was too hot. So, I found some electrical punch-out tabs that
fit perfect to plug some of the holes. The drums that still had 1/2 inch
holes, I was able to plug the extra holes with hex head bolts.

The holes in the lid should definitely stay 1/2 inch though. I tried bigger
holes once and the temp jumped up to over 350 F.

I use eight 1/2 inch holes in the lid, and three 7/8 inch holes in the drum.

When I start the coals, I plug one of the 7/8 inch holes, leaving 2 open.
After about 1 hour, I plug 1 more hole, leaving 1 open. That usually keeps
the temp between 225 and 250. If the temp goes higher than 250, I keep only
1 hole open. If the temp drops below 225, I take out 1 plug and keep 2 open.
The temp stays very steady. I use an electronic polder type thermometer with
probe to check temps with. I just stick the end of the probe in one of the
exhaust vent holes in the lid. So, technically, you only really need two 7/8
inch holes in the drum, but I live in high altitude area over 3000 feet, so
I added a 3rd hole for people that might need extra ventilation. Otherwise,
just keep the 3rd hole plugged. It is quite a primitive temp control system,
but it works perfectly. It is the same with the drums with the 1/2 inch
holes. You just add or remove 2 or 3 of the hex head bolts to adjust temps.
The bigger holes work a bit better because there are less holes to mess
with.

With big pieces of meat like brisket, shoulders or butts...I usually turn
the meat after 4 hours, mop if desired, and let it go another 3 hours before
turning again. Each time you remove the lid, it kick-starts the coals and
unburnt pieces of wood again. This works especially well at around the 7 to
8 hour mark. With the lid off for about 5 minutes, it gives the coals enough
air to charge on for at least another 6 hours.

One very interesting thing about these smokers, is that the meat is always
done much faster than when using indirect heat. Briskets and butts rarely
ever take more than 8 hours. Occasionally they may take 9 hours, but several
times they have taken between 7 and 8 hours. I smoked an 18 pound whole pork
shoulder last week in one of these smokers, and it was done in 10-1/2 hours,
reading 195 degrees internal. The temp of the smoker stayed between 225 and
250 the entire time.

I love the meat from these smokers. After trying BBQ smoked over direct
heat, I rarely want to eat any smoked in an offset smoker. I used to think
the Q from my old Klose pit was the bomb, but then I tried it from these
simple smokers. I guess what those old timers said that run the BBQ joints
in texas and here in NC were right. You just can't get that taste unless the
meat is smoked directly over the coals. The key is to keep the meat at least
20 inches or higher from the coals. I try to keep mine at 2 feet, but 3 feet
is probably even better.

I use machine screws through the sides of the drums to support the charcoal
grate and cooking rack. I buy replacement Weber 22-1/2 inch kettle cooking
racks to use for these smokers. They fit perfectly in the drum like they
were built for them. I keep the cooking rack about 7 to 8 inches down from
the top of the drum. that way, you can fit even a big turkey in there.

You can fit 5 chickens or 4 if they are big. I turn the chickens after 2
hours, then back again in 1 hour. Two 15 pound turkeys, two 13 pound
briskets, two 15 pound shoulders, three 8-9 pound butts. I prefer to not
pack the meat too tight though. It is best to leave plenty of room for heat
and smoke to circulate all around the meat.

I like to start ribs in rib racks, then about half way through the cook I
remove them from the racks and layer or shingle them for the rest of the
cook, rotating every 30 minutes or so.

You can use less charcoal/wood for smaller cooks like chicken, ribs, or
turkey. I have successfully used only 5 pounds of charcoal for these shorter
cooks. The temp stays the same, you just don't get as many hours. No point
in wasting 12 pounds of charcoal on a 3-6 hour cook. You get about 6-8 hours
from 5 pounds of charcoal. I only use one nice chunk of wood for the shorter
cooks. You don't want to over smoke the ribs or chickens. You can blast the
brisket and shoulders and butts though. They seem to be better the more
smoke they get.


>
> How neat, Rocky. Congrats on your work. Is the temp controlled through
fire
> size, or do you have other methods?
> Dave
>
>

Hi Dave,

The heat is mainly regulated by the size and quantity of the holes in the
bottom sides of the drum.

I started off using 1/2 inch diameter holes, then switched to 7/8 inch
holes. But then, when I decided to lift the coals up off the bottom of the
drum, the temp was too hot. So, I found some electrical punch-out tabs that
fit perfect to plug some of the holes. The drums that still had 1/2 inch
holes, I was able to plug the extra holes with hex head bolts.

The holes in the lid should definitely stay 1/2 inch though. I tried bigger
holes once and the temp jumped up to over 350 F.

I use eight 1/2 inch holes in the lid, and three 7/8 inch holes in the drum.

When I start the coals, I plug one of the 7/8 inch holes, leaving 2 open.
After about 1 hour, I plug 1 more hole, leaving 1 open. That usually keeps
the temp between 225 and 250. If the temp goes higher than 250, I keep only
1 hole open. If the temp drops below 225, I take out 1 plug and keep 2 open.
The temp stays very steady. I use an electronic polder type thermometer with
probe to check temps with. I just stick the end of the probe in one of the
exhaust vent holes in the lid. So, technically, you only really need two 7/8
inch holes in the drum, but I live in high altitude area over 3000 feet, so
I added a 3rd hole for people that might need extra ventilation. Otherwise,
just keep the 3rd hole plugged. It is quite a primitive temp control system,
but it works perfectly. It is the same with the drums with the 1/2 inch
holes. You just add or remove 2 or 3 of the hex head bolts to adjust temps.
The bigger holes work a bit better because there are less holes to mess
with.

With big pieces of meat like brisket, shoulders or butts...I usually turn
the meat after 4 hours, mop if desired, and let it go another 3 hours before
turning again. Each time you remove the lid, it kick-starts the coals and
unburnt pieces of wood again. This works especially well at around the 7 to
8 hour mark. With the lid off for about 5 minutes, it gives the coals enough
air to charge on for at least another 6 hours.

One very interesting thing about these smokers, is that the meat is always
done much faster than when using indirect heat. Briskets and butts rarely
ever take more than 8 hours. Occasionally they may take 9 hours, but several
times they have taken between 7 and 8 hours. I smoked an 18 pound whole pork
shoulder last week in one of these smokers, and it was done in 10-1/2 hours,
reading 195 degrees internal. The temp of the smoker stayed between 225 and
250 the entire time.

I love the meat from these smokers. After trying BBQ smoked over direct
heat, I rarely want to eat any smoked in an offset smoker. I used to think
the Q from my old Klose pit was the bomb, but then I tried it from these
simple smokers. I guess what those old timers said that run the BBQ joints
in texas and here in NC were right. You just can't get that taste unless the
meat is smoked directly over the coals. The key is to keep the meat at least
20 inches or higher from the coals. I try to keep mine at 2 feet, but 3 feet
is probably even better.

I use machine screws through the sides of the drums to support the charcoal
grate and cooking rack. I buy replacement Weber 22-1/2 inch kettle cooking
racks to use for these smokers. They fit perfectly in the drum like they
were built for them. I keep the cooking rack about 7 to 8 inches down from
the top of the drum. that way, you can fit even a big turkey in there.

You can fit 5 chickens or 4 if they are big. I turn the chickens after 2
hours, then back again in 1 hour. Two 15 pound turkeys, two 13 pound
briskets, two 15 pound shoulders, three 8-9 pound butts. I prefer to not
pack the meat too tight though. It is best to leave plenty of room for heat
and smoke to circulate all around the meat.

I like to start ribs in rib racks, then about half way through the cook I
remove them from the racks and layer or shingle them for the rest of the
cook, rotating every 30 minutes or so.

You can use less charcoal/wood for smaller cooks like chicken, ribs, or
turkey. I have successfully used only 5 pounds of charcoal for these shorter
cooks. The temp stays the same, you just don't get as many hours. No point
in wasting 12 pounds of charcoal on a 3-6 hour cook. You get about 6-8 hours
from 5 pounds of charcoal. I only use one nice chunk of wood for the shorter
cooks. You don't want to over smoke the ribs or chickens. You can blast the
brisket and shoulders and butts though. They seem to be better the more
smoke they get.


>
> How neat, Rocky. Congrats on your work. Is the temp controlled through
fire
> size, or do you have other methods?
> Dave
>
>

Rocky wrote:

> I build and sell my own smokers out of food-grade 55 gallon drums. They sit
> vertically on the ground. The meat sets about 24 inches above the coals. I
> buy the drums from a local juice company. They receive the juice concentrate
> in these drums. These smokers need the lids to the drums as well to work
> properly. I call them "Big Drum Smokers". It took me about 2 years to
> perfect the design.

<snip>

Looks perfect!

--
Aloha,

Nathan Lau
San Jose, CA

#include <std.disclaimer>

"Rocky" > wrote in message
news:qhUIc.80173$Oq2.48618@attbi_s52...
> Hi Dave,
I guess what those old timers said that run the BBQ joints
> in texas and here in NC were right.

Where in NC?

And how much do you sell them for?

Nathan Lau > wrote in
:

> Rocky wrote:
>
>> I build and sell my own smokers out of food-grade 55 gallon drums.
>> They sit vertically on the ground. The meat sets about 24 inches
>> above the coals. I buy the drums from a local juice company. They
>> receive the juice concentrate in these drums. These smokers need the
>> lids to the drums as well to work properly. I call them "Big Drum
>> Smokers". It took me about 2 years to perfect the design.
>
> <snip>
>
> Looks perfect!
>


You sure know smokers!
I'm impressed.
--
StocksRus®

Hi Michael,

I live in western North Carolina near Hendersonville. About 30 minutes from
Asheville.

I charge $135 for 1 drum smoker, $130 each for 2, $125 each for 3, $120 each
for 4, $110 each for 5, $100 each for 10. I have 20 available right now.
Once those are gone, I will make another batch. You could easily resell them
for $175 to $200 each. Sell 3 and it will pay for yours.

I also have high-output propane torches for lighting the coals with for $25
each. Or you can order them from Harbor Freight. Sometimes they are on sale
for about $12.99 or $17.99 or $19.99, but they add on a handling fee as well
as shipping fee.

I don't recommend using lighter fluid to light the coals. You can add lit
coals from a charcoal chimney on top of unlit coals, but it is much, much
easier and less messy and faster to use a torch.

Cleanup with these smokers is super fast and easy!!

email me at if you want more information.


"Michael" > wrote in message
...
>
> "Rocky" > wrote in message
> news:qhUIc.80173$Oq2.48618@attbi_s52...
> > Hi Dave,
> I guess what those old timers said that run the BBQ joints
> > in texas and here in NC were right.
>
> Where in NC?
>
> And how much do you sell them for?
>
>
>

"Rocky" > wrote in message
news:RdVIc.45692$WX.38644@attbi_s51...
> Hi Michael,
>
> I live in western North Carolina near Hendersonville. About 30 minutes
from
> Asheville.

I live east of Charlotte and one of your BDS's wouldn't fit too well in the
Volvo.

Hi Michael,

If you take out the charcoal grate and ring, and take off the lid, it should
fit fine in the trunk laid down horizontally. You might need a couple bungee
cords to secure the trunk lid just in case it doesn't close completely.

I fit two 55 gallon drums at a time in the back of my old 2-door subaru
hatchback GL. Unfortunately, I didn't have my truck back then when I was
buying the drums used for the smokers, so I loaded 2 at a time per trip.

Do you have any friends or relatives that own a pickup truck?

I believe Charlotte is about 2 hours from here.


"Michael" > wrote in message
...
>
> "Rocky" > wrote in message
> news:RdVIc.45692$WX.38644@attbi_s51...
> > Hi Michael,
> >
> > I live in western North Carolina near Hendersonville. About 30 minutes
> from
> > Asheville.
>
> I live east of Charlotte and one of your BDS's wouldn't fit too well in
the
> Volvo.
>
>

Hi Michael,

If you take out the charcoal grate and ring, and take off the lid, it should
fit fine in the trunk laid down horizontally. You might need a couple bungee
cords to secure the trunk lid just in case it doesn't close completely.

I fit two 55 gallon drums at a time in the back of my old 2-door subaru
hatchback GL. Unfortunately, I didn't have my truck back then when I was
buying the drums used for the smokers, so I loaded 2 at a time per trip.

Do you have any friends or relatives that own a pickup truck?

I believe Charlotte is about 2 hours from here.


"Michael" > wrote in message
...
>
> "Rocky" > wrote in message
> news:RdVIc.45692$WX.38644@attbi_s51...
> > Hi Michael,
> >
> > I live in western North Carolina near Hendersonville. About 30 minutes
> from
> > Asheville.
>
> I live east of Charlotte and one of your BDS's wouldn't fit too well in
the
> Volvo.
>
>

"Rocky" > wrote in message
news:G2WIc.45915$WX.37692@attbi_s51...
> Hi Michael,
>
> If you take out the charcoal grate and ring, and take off the lid, it
should
> fit fine in the trunk laid down horizontally. You might need a couple
bungee
> cords to secure the trunk lid just in case it doesn't close completely.

My trunk stays full, traveling peddler, if I'm in Hendersonville.
>
> I fit two 55 gallon drums at a time in the back of my old 2-door subaru
> hatchback GL. Unfortunately, I didn't have my truck back then when I was
> buying the drums used for the smokers, so I loaded 2 at a time per trip.
>
> Do you have any friends or relatives that own a pickup truck?

Well, actually I own two but neither one of them would make it to
Hendersonvillw and back. One is a farm truck that never leaves the property
because it isn't even close to being street legal. The other might make it
but the gas bill is hard to imagine, F-250 w/ a 460 and a four barrel.

The F-250 isn't the dream vechicle to take on a four hour drive either.
Rides kinda rough when empty.

>
> I believe Charlotte is about 2 hours from here.

I'll keep your address handy as I borrow my uncle's pick up each year to get
piglets at Warren Wilson College in Swannanoa.

>
>
> "Michael" > wrote in message
> ...
> >
> > "Rocky" > wrote in message
> > news:RdVIc.45692$WX.38644@attbi_s51...
> > > Hi Michael,
> > >
> > > I live in western North Carolina near Hendersonville. About 30 minutes
> > from
> > > Asheville.
> >
> > I live east of Charlotte and one of your BDS's wouldn't fit too well in
> the
> > Volvo.
> >
> >
>
>

Michael wrote:

> "Rocky" > wrote in message
> news:G2WIc.45915$WX.37692@attbi_s51...
>
>>Hi Michael,
>>
>>If you take out the charcoal grate and ring, and take off the lid, it
>
> should
>
>>fit fine in the trunk laid down horizontally. You might need a couple
>
> bungee
>
>>cords to secure the trunk lid just in case it doesn't close completely.
>
>
> My trunk stays full, traveling peddler, if I'm in Hendersonville.
>
>>I fit two 55 gallon drums at a time in the back of my old 2-door subaru
>>hatchback GL. Unfortunately, I didn't have my truck back then when I was
>>buying the drums used for the smokers, so I loaded 2 at a time per trip.
>>
>>Do you have any friends or relatives that own a pickup truck?
>
>
> Well, actually I own two but neither one of them would make it to
> Hendersonvillw and back. One is a farm truck that never leaves the property
> because it isn't even close to being street legal. The other might make it
> but the gas bill is hard to imagine, F-250 w/ a 460 and a four barrel.
>
> The F-250 isn't the dream vechicle to take on a four hour drive either.
> Rides kinda rough when empty.
>
>
>>I believe Charlotte is about 2 hours from here.
>
>
> I'll keep your address handy as I borrow my uncle's pick up each year to get
> piglets at Warren Wilson College in Swannanoa.
>
>
>>
>>"Michael" > wrote in message
...
>>
>>>"Rocky" > wrote in message
>>>news:RdVIc.45692$WX.38644@attbi_s51...
>>>
>>>>Hi Michael,
>>>>
>>>>I live in western North Carolina near Hendersonville. About 30 minutes
>>>
>>>from
>>>
>>>>Asheville.
>>>
>>>I live east of Charlotte and one of your BDS's wouldn't fit too well in
>>
>>the
>>
>>>Volvo.
>>>
>>>
>>
>>
>
>

I use the same type cooker when I don't want to fire up the brick pit.
instead of holes drilled in the barrell, I have a hinged door to
regulate the draft. I got the barrel free and took it to a welding
shop. They cut it, put the rebar in it, and the expanded metal all for
$25...not a bad price! I simply cover the top with a piece of
cardboard. I have a second piece of expanded metal that I use in the
bottom of the grill to suspend the charcoal so that it will cook
hotter...just put 3 bricks under it to suspend the metal. The only time
I need to suspend the charcoal is if it's cold outside to generate more
heat. On a hot day, 10 lbs of charcoal will cook chickens or ribs for 4
hours.

You can see a couple of pix of mine at
http://webpages.charter.net/epeay/barrel1.jpg
http://webpages.charter.net/epeay/barrell2.jpg

Evans

Michael wrote:

> "Rocky" > wrote in message
> news:G2WIc.45915$WX.37692@attbi_s51...
>
>>Hi Michael,
>>
>>If you take out the charcoal grate and ring, and take off the lid, it
>
> should
>
>>fit fine in the trunk laid down horizontally. You might need a couple
>
> bungee
>
>>cords to secure the trunk lid just in case it doesn't close completely.
>
>
> My trunk stays full, traveling peddler, if I'm in Hendersonville.
>
>>I fit two 55 gallon drums at a time in the back of my old 2-door subaru
>>hatchback GL. Unfortunately, I didn't have my truck back then when I was
>>buying the drums used for the smokers, so I loaded 2 at a time per trip.
>>
>>Do you have any friends or relatives that own a pickup truck?
>
>
> Well, actually I own two but neither one of them would make it to
> Hendersonvillw and back. One is a farm truck that never leaves the property
> because it isn't even close to being street legal. The other might make it
> but the gas bill is hard to imagine, F-250 w/ a 460 and a four barrel.
>
> The F-250 isn't the dream vechicle to take on a four hour drive either.
> Rides kinda rough when empty.
>
>
>>I believe Charlotte is about 2 hours from here.
>
>
> I'll keep your address handy as I borrow my uncle's pick up each year to get
> piglets at Warren Wilson College in Swannanoa.
>
>
>>
>>"Michael" > wrote in message
...
>>
>>>"Rocky" > wrote in message
>>>news:RdVIc.45692$WX.38644@attbi_s51...
>>>
>>>>Hi Michael,
>>>>
>>>>I live in western North Carolina near Hendersonville. About 30 minutes
>>>
>>>from
>>>
>>>>Asheville.
>>>
>>>I live east of Charlotte and one of your BDS's wouldn't fit too well in
>>
>>the
>>
>>>Volvo.
>>>
>>>
>>
>>
>
>

I use the same type cooker when I don't want to fire up the brick pit.
instead of holes drilled in the barrell, I have a hinged door to
regulate the draft. I got the barrel free and took it to a welding
shop. They cut it, put the rebar in it, and the expanded metal all for
$25...not a bad price! I simply cover the top with a piece of
cardboard. I have a second piece of expanded metal that I use in the
bottom of the grill to suspend the charcoal so that it will cook
hotter...just put 3 bricks under it to suspend the metal. The only time
I need to suspend the charcoal is if it's cold outside to generate more
heat. On a hot day, 10 lbs of charcoal will cook chickens or ribs for 4
hours.

You can see a couple of pix of mine at
http://webpages.charter.net/epeay/barrel1.jpg
http://webpages.charter.net/epeay/barrell2.jpg

Evans

"MonopTN" > wrote in message
...
> Michael wrote:
>
> > "Rocky" > wrote in message
> > news:G2WIc.45915$WX.37692@attbi_s51...
> >
> >
> I use the same type cooker when I don't want to fire up the brick pit.
> instead of holes drilled in the barrell, I have a hinged door to
> regulate the draft. I got the barrel free and took it to a welding
> shop. They cut it, put the rebar in it, and the expanded metal all for
> $25...not a bad price! I simply cover the top with a piece of
> cardboard. I have a second piece of expanded metal that I use in the
> bottom of the grill to suspend the charcoal so that it will cook
> hotter...just put 3 bricks under it to suspend the metal. The only time
> I need to suspend the charcoal is if it's cold outside to generate more
> heat. On a hot day, 10 lbs of charcoal will cook chickens or ribs for 4
> hours.
Same idea I have. Firing up the pit is an effort and using the Weber sort
of limits you.