Another Little Blue Egg

I made this smoker after viewing little blue egg instructions online several years ago. The initial post I am no longer able to locate. I suspect that it may have been Nigel but I am not certain. His latest plans may have been a redesign as well, at any rate I would like to thank the initial poster and Nigel as well for there work and effort, they are the posters that motivated me to show my plans. I am simply offering an alternative design for those interested in making there own smokers.  I would urge anyone to modify and develop there own design and post it as well. Thanks and good luck.


Caution............ This design poses the risk of serious burns as with any charcoal starter tube would. Take adequate precautions to protect hands when handling, use heat proof gloves. Protect children from potential injury by isolating or guarding the unit from accidentally being touched.

These are the pots that I purchased at Lowes, a short one for the top and a tall one for the body. 12.5 ID at the top.

 

 

Here are the parts that I initially started with. Charcoal starter for the heat source with handle removed, metal bowl for the top vent adjustment, handles for the top, thermometer for top, I also purchased a small table top charcoal grill to use as a water pan support, flue cap as an  end cap for the charcoal starter base, 1/8" x 1/2 mild steel band to use inside the starter tube to control height of charcoal grate. 

                                                This is assembled view.

 

 

 

This is the top before drilling a hole to insert threaded rod that allows adjustment of bowl for air flow. Two nuts and washers secure the rod to the top as in next photo. I think I used 1/4 threaded rod so I could adapt it to the knob I had on hand for the bowl adjustment.

 Here is an inside shot of the rod secured to the lid.

This is the hole cut through the base of pot to allow the starter tube to pass through. The body of the table top grill is set into the pot. I trimmed the center out to accept the grate as a water pan support, this later proved to be a big mistake as the heat expanded the ring and cracked the pot. I should have cut down the side to allow the ring to expand.

 Here is the tube inserted through the hole in the base.

I cut a purchased BBQ grate and adapted it to rest onto the top of the table top grill. I used a felt padding to protect and seal the top to base resting surface.

 An outside view of the starter tube slid inside the pot base. The clamping method I initially used (shown here) I abandoned in favor of a revised tube I will show below.

 The initial tryout proved to work just fine, I was able to hold 225-275 degree temp range by adjusting air flow.

       These are up to date photos, with revisions.

This is after 3-4 years of use. I mounted it on my old Weber that I also modified to smoke on as well.

 I cut the old support ring to allow more even air flow and bypass the ring expansion issue.

This shows what I used for clamping the tube in place. I used two chimney flue trim rings, one inside and one on the outside bottom. Sandwiched between these is a length of flue pipe cut down the length and cut also at the top one inch tabs spaced 1/2 to 1 in apart 1 in deep that will be bent over at a 90 deg to lock the adjustment tube between the trim rings. I had to secure the trim rings to each other with 1/4 in bolts and nuts.

I also mounted a clamping band to lock the tube in place using rivets.

This is a view of the tube with the adjustable charcoal support in place as well as the end cap removed. I used screws and slots to secure the end cap by twisting the cap to remove.

I cut a strip of sheet metal to use as a sleeve to slide up and down to adjust airflow.

 I made a stacking ring to contain food and allow stacking. This prevents food from falling out when turning for more even cooking.

This size pot is OK for a small family of three but had I been able to find larger pots I would have preferred 16 in or larger diameter ID.
I've done brisket,turkey legs (cured and smoked like Disney world), ribs, rib tips, whole chickens, whole hams all with excellent results.

Notes: The smoker may be lit by sliding the starter tube out and loading it with charcoal and wood chunks as you would a typical charcoal starter then sliding it back into the smoker and locking it to the desired height. Then using paper or a propane torch to light the charcoal from below before sealing with the end cap. After 1-2 hrs you will notice the temp is settling to 200 or so, I then unclasp the tube and set it on a fireproof surface and top with fresh charcoal and wood then reinstall and clamp using heavy fireproof gloves (like welders gloves).

Caution!!!! When reloading the tube, fireproof and heatproof gloves must be used or you will be seriously burned by the starter tube, this is the only drawback to this smoker. double walled tubing could be used but I chose to go with single wall  if you have children that may touch the smoker I would take adequate precautions to avoid injury.