Transform your BBQ with a DIY Smoke Generator

Table of Contents:

1. Introduction
2. Why Use a Smoke Generator?
3. Materials and Tools Needed
4. Building the Two-Part Mold
5. Pouring the Aluminum
6. Cleaning and Finishing the Mold
7. Welding the Bottom Plate
8. Drilling Holes for Air Circulation
9. Creating the Jet for Smoke Generation
10. Painting the Smoke Generator
11. Testing and Adjusting the Smoke Generator
12. Conclusion

Building a Smoke Generator for Your Masterbuilt Smoker

If you are a fan of smoking meat and own a Masterbuilt smoker, you may want to consider building a smoke generator as an add-on for your smoker. A smoke generator allows you to produce ample amounts of smoke to enhance the flavor of your food. In this article, we will guide you through the process of building your own smoke generator, step by step.

Introduction

Smoking meat is a popular method of cooking that infuses delicious flavors into the food. A key element in the smoking process is the generation of smoke, which adds a distinct smoky taste to the meat. While some smokers come with built-in smoke generators, others may require an external smoke generator to achieve the desired results. If you own a Masterbuilt smoker and want to enhance your smoking experience, building a smoke generator specifically designed for your smoker is a great option.

Why Use a Smoke Generator?

Using a smoke generator in conjunction with your Masterbuilt smoker offers several advantages. Firstly, it allows you to have better control over the amount and intensity of smoke produced. This is especially beneficial for meats that require prolonged smoking periods. Additionally, a smoke generator ensures a consistent flow of smoke, eliminating the need for manual intervention to maintain smoke levels. With a smoke generator, you can achieve consistent and flavorful results every time you smoke your favorite meats.

Materials and Tools Needed

Before you begin building your smoke generator, gather the necessary materials and tools. Here's a list of what you'll need:

1. Aluminum foundry and mold-making materials
2. Pipe for smoke output
3. Metal cutting and grinding tools
4. Welding equipment
5. Drill and drill bits
6. Quarter-inch brake line for the jet
7. MIG tip and brass fitting
8. High-temperature paint for heat resistance

It's essential to have all the required materials and tools on hand before starting the construction process. This will ensure a smooth workflow and prevent unnecessary delays.

Building the Two-Part Mold

The first step in building a smoke generator is creating a two-part mold for the main body. The mold allows you to pour molten aluminum and create a custom-shaped smoke generator that fits perfectly with your Masterbuilt smoker. Use aluminum foundry materials to construct the mold and follow the instructions provided by the manufacturer. Make sure to create voids in the mold that correspond to the shape and size of the feet of your smoker.

Pouring the Aluminum

After constructing the mold, it's time to pour the molten aluminum to form the body of the smoke generator. Heat the aluminum in a foundry, ensuring it reaches the appropriate pouring temperature. With caution and using protective gear, pour the molten aluminum into the mold, filling it completely. Allow the aluminum to cool and solidify before proceeding to the next step.

Cleaning and Finishing the Mold

Once the aluminum has solidified, remove it from the mold and clean off any excess residue or rough edges. Use metal cutting and grinding tools to file and shape the smoke generator to fit the barrel of your Masterbuilt smoker. Take your time to achieve a precise fit, ensuring a seamless connection with the smoke output pipe.

Welding the Bottom Plate

To create the platform for the wood chips in the smoke generator, weld a bottom plate onto the body. Use an 8-inch plate and position it accordingly, allowing for enough space to attach a supporting foot without interference. Secure the plate in place with a temporary wooden block, adjusting the height to the desired position. Once properly aligned, tack weld the plate onto the body.

Drilling Holes for Air Circulation

Air circulation is essential for smoke generation. Drill two 5/16-inch holes in the bottom plate to provide adequate airflow for the wood chips to burn. These holes allow the necessary oxygen to reach the burning chips while ensuring a controlled and efficient smoke output.

Creating the Jet for Smoke Generation

To generate smoke effectively, you need to create a jet that regulates and controls the airflow. Use a piece of quarter-inch stainless steel brake line with threaded ends as the base for the jet. Attach a quarter-inch adapter to one end, allowing for flexibility in adjusting the size of the jet hole. This enables you to fine-tune the smoke output based on your preferences.

Painting the Smoke Generator

To protect the smoke generator from the elements and ensure longevity, apply a layer of high-temperature paint. Use barbecue paint or caliper paint, specifically designed to withstand temperatures up to 900 degrees Fahrenheit. Apply multiple coats for better durability and resistance to heat.

Testing and Adjusting the Smoke Generator

Before using the smoke generator with your Masterbuilt smoker, conduct a test to ensure optimal performance. Load dry hickory chips into the generator, ensuring they are evenly distributed. Attach an air source, such as an aquarium pump or compressor, to the input pipe and adjust the airflow to your desired level. Ignite the wood chips and observe the smoke output. Fine-tune the settings as necessary, experimenting with the jet hole size and airflow rate to achieve the desired smoke intensity.

Conclusion

Building a smoke generator for your Masterbuilt smoker enhances your smoking experience by providing a reliable and controlled source of smoke. By following the step-by-step process outlined in this article, you can create a custom smoke generator that perfectly fits your smoker and produces the desired amount and intensity of smoke. Enjoy the rich flavors and delicious taste that smoking adds to your favorite meats, and elevate your culinary skills to new heights.