Part 2 of series of articles on barbecue I'm writing for the Montecristo Social Club includes a tutorial on building a Little Brown Egg. My design incorporated elements from three others.
These are component pieces.
BRUCE’S “SMOKEY THE EGG” PARTS LIST
18.5” heavy-rimmed unglazed terra cotta planter
18” terra cotta low Italian bowl planter (
http://www.koopmansgardenworks.com/product_p/lb-18.htm)
Weber Smokey Joe kettle grill
18” Weber kettle replacement cooking grate (made for a 22.5” grill)
Charbroil replacement grill thermometer (with 2-inch-long probe)
Two 6 ½” heavy duty door pulls
Five machine screws, nuts (size #12-24 x 1”), lock washers and fender washers (size 3/16”)
¾” pellet stove replacement gasket kit
Aluminum sheet metal
12” terra cotta saucer
Pyrex pie plate
CONSTRUCTION
NOTE: When drilling terra cotta, use a bit made for ceramics, drill slowly, and gradually pour a stream of water over the hole while drilling to prevent cracking. A 3/16” bit is required for installing the bottom vent control and door pulls, and a ¼” bit for the thermometer.
1. Make aluminum vent controls. Bend an L-shape strip for the top. For the bottom, cut a piece in the shape of a mailbox flag, ensuring the square is wide enough to cover the planter’s drain hole and the handle is about 15 inches long. Drill a hole in one corner of the square. I also put a layer of furnace tape along the rims of the two planters to protect against chipping.
2. Install the bottom vent control. Turn the planter upside down and place the flag near the drain hole, ensuring it completely covers it when rotated into position. Drill and bolt into place. Turn the planter over, shim it on bricks or scrap lumber, and adjust the vent so the hole is completely covered. Make a mark on the handle where it touches the edge of the base. Adjust to the halfway open and fully open positions and make additional marks.
3. Install the gasket. Measure enough material to cover the circumference of the planter rim and fashion a loop. Duct tape the ends together and tape in place on the rim. Ensure the gasket also covers the rim of the lid and adjust as necessary.
4. Assemble the innards. From the Smokey Joe, place the legs flat inside the base planter around the drain hole and top with the ash catcher. Open the vent on the bottom half of the kettle bowl, insert into the planter (it will settle one-third down), and add its two grates. The replacement cooking grate nestles inside the gasket and the lid completes the egg.
5. Prepare the lid. Turn the bowl upside down and drill holes on the flat bottom for the door pulls and bolt them down. Drill another for the thermometer and insert it.
Here's what the finished egg looks like. (The original Brinkman thermometer I bought was a dud and was replaced with a Charbroil.)
Open the vents fully before using. Light charcoal inside the kettle bowl. When the flames subside, add wood chips (optional) and replace the kettle’s top grate. Add the saucer and Pyrex pan filled with water to provide indirect heat and moisture. Replace the cooking grate and lid, and allow the unit to get to temperature before adding food. Control the heat by opening or closing the bottom vent; the top vent should always be at least half open. If using the egg to bake pizza, omit the saucer and water pan and put a baking stone on the cooking grate.
Two weekends ago, the egg made its debut at my 20th anniversary party, hickory-smoking some eye of round roasts.