I got tired of hearing about the Bayou Costco smoker so...

12ring

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Jan 27, 2015
Location
Albuquer...
I went ahead and built a smoker.

Around a year ago someone posted that Costco had a Bayou smoker that looked thick, well built and kept getting cheaper. I had never really thought that I wanted a stick burner but that crazy dude on here (Jason TQ) and some other guy (can’t remember who) made me want one bad.

I went on a mission trying to find one in my state and all 3 states that border NM. Nobody had one with in 10 hours. I wasn’t gonna drive 10 hours and nobody on here was biting on me sending them $ and buying me one to go pick up at a later date so I decided to build one instead.

I haven’t welded since high school 20 years ago but my buddy said he would lend me his Lincoln stick welder to use. I bought a grinder and started looking for material on the cheap. I had a few buddies on the look out as well so I scored a few freebies along the way. After I finished, I would say I’m in it for about $400-$500.

This is how it started. The cook chamber is 40” long and is 1/4” steel. The fire box is 19” long and 3/8” thick steel.

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Used a 4.5” grinder with a cut off wheel to make all my cuts except my hinges and handle brackets. I used a torch for that.


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I used some CAD (cardboard aided design) to design my plenum and stack.

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Plenum was a lot of work but I like it.

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Worked into the night many times because after work was some of the only time I could work on it.

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I don’t know how many pics I can attach at a time so I’ll post those 5 and finish up shortly after.



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Cut the FB door out.

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Welded up a heavy duty grate for the FB. Used 1/2” round bar welded to 1” angle iron.

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Used 1 1/2” square tubing to build my frame.

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Built my cooking rack.

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Took some time away from building to scout for and kill a bull. Man he tastes good too.

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Really nice work but we need more pics!
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I started off with bullet hinges and 2” door banding. I ended up cutting all that off, fabricating some hinges and using 1 1/2” banding. That sucked. I wasted a bunch of time doing that.

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Fabricated up some door handle brackets. I used some hollow pipe for a handle and welded on the ends and tapped them. Worked good.

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Decided to design the intake like this

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Grinder bit one day. I swear it was the only day I didn’t wear gloves and it got me.

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Assembled it all together then sent it to be sand blasted. It was during the holidays so they took forever. I was ok with it because i was busy chasing deer with my bow anyway.

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After sand blasting.

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POS harbor freight casters rated at 600 lbs bent so I cut them all off and bought some beefier ones.

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Better ones.

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Built a shelf and drilled a port for my thermometer wires. I made it big enough to fit a thermoworks smoke thermometer because I want that next.

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I decided the door was way to heavy so I built a counter balance.

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I messed up painting it. I used Rustoleum high heat flat but wasn’t sure if I liked how dull it was. I then painted the door with a semi gloss but didn’t like it the semi gloss after all. I lightly sanded it and tried to go over it with flat but I was 4-5 beers deep and I grabbed the semigloss AGAIN and put another coat of semigloss on it. At that point I lightly sanded it and hit it with flat but now it’s darker than the rest. I can’t wait to use it so it’s gonna have to do for now.

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I see elk antler for the FB handles.

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Over all I’m happy with how it turned out. I have a few buddies who helped so I owe them a big cook out and a lot of beer.



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I'm anxious to see her seasoned and producing some great Que. Nice work BTW.
 
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