UDS build kits

[IrregularPulse]

I'll have to look into that. I am in Ohio and might know a guy.

 

[JohnTheBrewist]

The small flat rate box is 9"x11"x6" and the large box is 12"x12"x6". You might consider something like a 12x12X12 square fire box design with an expanded metal bottom. The 12" square base would be wired to the sides about 1.5" from the bottom, giving proper air space below and 10.5" high basket sides.

Considering five 12x12 pieces per kit, you'd get about 6 kits (plus 2 squares) per 4x8 sheet of expanded metal.

 

[dataz722]

The small flat rate box is 9"x11"x6" and the large box is 12"x12"x6". You might consider something like a 12x12X12 square fire box design with an expanded metal bottom. The 12" square base would be wired to the sides about 1.5" from the bottom, giving proper air space below and 10.5" high basket sides.

Considering five 12x12 pieces per kit, you'd get about 6 kits (plus 2 squares) per 4x8 sheet of expanded metal.

That is something I didn't even think about. I was just going to have two 24x12" pieces that would be bolted together then formed into a circel and then attached to a weber grate with the bailing wire or SS zipties. That is how I did mine and it works great but I would consider sending a prebuilt coal box if there was interest in it. Of course I would want to charge more for that since it would involve a considerable amount more work on my part.

 

[JohnTheBrewist]

Check what you metal supplier would charge to make the cuts for you, it might not be that bad. You wouldn't have to pre-build it, just give the the five squares and wire.

 

[dataz722]

Check what you metal supplier would charge to make the cuts for you, it might not be that bad. You wouldn't have to pre-build it, just give the the five squares and wire.

The place I am getting it from is just a wholesaler and wont do anything less than full 4x8 sheets and won't cut to order at all. I could get it from a place that will cut to order but the metal itself is much more expensive because I would be paying retail. I guess I could just have people build it themselves and just send precut.

What do you think would be easier for people to build, a round one where you just bend it in a circle and attach to a grate or the square one? I don't see it being much different. The cost would still be a little higher for the square one though since it would take more metal. Overall cost would go down for people though since they wouldn't have to get a normal charcoal grate too.


Thanks for all the advice.

 

[dataz722]

Menke, do you already have a UDS?

 

[JohnTheBrewist]

Menke, do you already have a UDS?

Yes. Just recently built. All this rain has kept me from being able to use it yet. I'm hoping to give an inaugural smoke this weekend.

It seems most people build the fire basket as you describe, I was just trying to find a way to reduce shipping costs and hassle by using the USPS Flat rate priority mail boxes, and still give your customer something easy to build.

They also have a 13 5/8" x 11 7/8" x 3 3/8" medium flat rate box that is only $10.70 to ship up to 70lbs.

 

[dataz722]

Yes. Just recently built. All this rain has kept me from being able to use it yet. I'm hoping to give an inaugural smoke this weekend.

It seems most people build the fire basket as you describe, I was just trying to find a way to reduce shipping costs and hassle by using the USPS Flat rate priority mail boxes, and still give your customer something easy to build.

They also have a 13 5/8" x 11 7/8" x 3 3/8" medium flat rate box that is only $10.70 to ship up to 70lbs.

I do like your idea and was wondering if you had one is that what you used? How well does it work? I am seriously considering going that route.

While it would take more metal it would mean that people wouldn't have to buy the grate and it would make shipping cheaper. I also wouldn't have to include as many bolts so that would cut the cost down some too.

 

[JohnTheBrewist]

My only concern is that it may be a little small. I think I still have some expanded metal lying around - time and weather permitting, I'll make one and try it out. I'll let you know how it goes.

 

[dataz722]

My only concern is that it may be a little small. I think I still have some expanded metal lying around - time and weather permitting, I'll make one and try it out. I'll let you know how it goes.

That and securely tying everything together without welding were my two biggest concerns. I am looking at metal zip ties now and even bulk they aren't cheap.

 

[IrregularPulse]

I like the idea of the square basket using all expanded steel, but would want something like that welded. I don't know how sturdy it's be with just wire ties. I'd stick with sending panels and leaving it to the customer to assemble. You could source a welder, but that'd only be profitable if you were going very large scale with this.

There's always silver solder as well.

 

[dataz722]

Actually I just figured it out and the square one would be a little over twice the volume of the round one.

 

[IrregularPulse]

So use smaller panels.

 

[dataz722]

I like the idea of the square basket using all expanded steel, but would want something like that welded. I don't know how sturdy it's be with just wire ties. I'd stick with sending panels and leaving it to the customer to assemble. You could source a welder, but that'd only be profitable if you were going very large scale with this.

There's always silver solder as well.

I have been wanting a welder anyway but can't really justify it for this. That would increase the cost of shipping too.

 

[Hugh_Jass]

<noob smoker alert>

There's no way to bolt together the expanded steel?

 

[dataz722]

So use smaller panels.

I wasn't saying it was a problem. I was actually worried that it might be too small but then I actually thought about it and realized it was bigger. Now my only concern with it is the stability. It would take quite a few zip ties and they aren't really cheap so bailing wire would be better from a cost point but probably not as strong and more difficult to assemble.

 

[dataz722]

<noob smoker alert>

There's no way to bolt together the expanded steel?

The way I was originally planning on doing it you would bolt together the two pieces but then would still have to use either zip ties or bailing wire to attach to the grate. With the box since all the connections would be at 90 degree angles bolts wouldn't really work unless you bent all the corners so they would overlap. I guess that could possibly be feasable but I think it is somethign that I would have to do before sending it out. In order to get nice bends it would have to be heated and then hammered on a form.

 

[JohnTheBrewist]

There must be something along the lines of hog rings that could just be squeezed together with a pair of pliers...

It doesn't have to be a tight fit, just as long as it doesn't come apart. The base would hold it relatively square.

 

[dataz722]

There must be something along the lines of hog rings that could just be squeezed together with a pair of pliers...

It doesn't have to be a tight fit, just as long as it doesn't come apart. The base would hold it relatively square.

Not a bad idea. Would probably be cheaper than the zip ties but more secure and easier than the wire. I'll see what I can find.

 

[JohnTheBrewist]

The way I was originally planning on doing it you would bolt together the two pieces but then would still have to use either zip ties or bailing wire to attach to the grate. With the box since all the connections would be at 90 degree angles bolts wouldn't really work unless you bent all the corners so they would overlap. I guess that could possibly be feasable but I think it is somethign that I would have to do before sending it out. In order to get nice bends it would have to be heated and then hammered on a form.

If you bent the sides, your square base would have to be smaller, forcing you to make more cuts, too.

 

[dataz722]

If you bent the sides, your square base would have to be smaller, forcing you to make more cuts, too.

True, but making the cuts wouldn't be a big deal. The time it would take the bend all the sides might be though.

 

[dataz722]

Looking into it further it looks like zip ties would be a cheaper option than bending and bolting. The best I have found so far for the zip ties would add about $6-$9 to the cost but would take less stainless hardware so would probably be able even.

I could do two options, one for a round and one for a square and probably keep the price the same.

 

[Hugh_Jass]

Let me know when you get some pricing together.

 

[dataz722]

Trying to get a really close idea tonight. I wanted it done earlier today but it is taking longer than I had initially thought.

 

[FoundersBrew]

Data, after building a few of these, I have found it most cost effective purchasing the full 4x8 sheet of expanded metal and cutting to desired size. I also have a welder and used it on some baskets, but, found that a simple coat hanger wire actually works better to tie it all together.

 

[dataz722]

Data, after building a few of these, I have found it most cost effective purchasing the full 4x8 sheet of expanded metal and cutting to desired size. I also have a welder and used it on some baskets, but, found that a simple coat hanger wire actually works better to tie it all together.

For many people that isn't really an option. I am trying to put together a DIY kit. I will be buying full sheets and cutting them down.

 

[dataz722]

Ok here is what I have so far. All hardware is either stainless or plain steel. Nothing is zinc coated/galvanized/hot dipped etc.

------------------------------QTY
Air control
3/4" 2" Nipples--------------3
2 Caps---------------------2
3/4" Ball Valve--------------1
Magnets for top------------5
Conduit nuts---------------6

Grate Mount
2" 1/4" 20 Bolts-------------3
1/4" nuts-------------------6

Round Fire Basket
Expanded Steel 24x12-------2
1" 1/4" 20 bolts-------------4
Nuts-----------------------8
Fender Washers-------------8
Fender Washers for base-----6
Nuts for base----------------6
3" 1/4" 20 bolt---------------3
Zip Ties/wire-----------------4

Square Basket
Expanded Steel 12x12--------5
Zip ties/Wire----------------24



I am looking at a price somewhere in the $40-$50 range. You would have your choice of which basket style you would prefer. It would also come with detailed instructions and I would probably make a video walkthrough too.

Thoughts?




Huge thanks to menkemoose and everyone else for their advice.

 

[bob1852]

Thoughts?

I'm not much of DIY'er at all - sightglass on the kettle, and weldless fittings on kettle/MLT, etc. is about all I've been good for.

I would be willing to pay for the kit with good instructions.

I'm willing to pay a little more for someone else to do the work.....

That's why I've never pursued a UDS; why do all that work when I can get something NIB for a few hundred...

 

[dataz722]

I'm not much of DIY'er at all - sightglass on the kettle, and weldless fittings on kettle/MLT, etc. is about all I've been good for.

I would be willing to pay for the kit with good instructions.

I'm willing to pay a little more for someone else to do the work.....

That's why I've never pursued a UDS; why do all that work when I can get something NIB for a few hundred...

I would be willing to build them complete to order but the only problem is that if you aren't local then shipping would kill you. I looked at shipping just an empty plain drum and it was $100 just to ship. Granted that was cross country and I wanted to get pretty much worst case, but it is still crazy.

With the kit all you would need for tools would be a drill, a step bit (I am looking into trying to get them wholesale but that won't be until I know this is going to be somewhat popular), a pair of pliers, and a wrench or socket set. Other than that you would need grates (homedepot, lowes, walmart, etc), a 55 gal drum, and a thermometer.

 

[integrator]

I'll have to let others comment on price but I think it's fair. I just found a place near Indy that has refurbished, unlined drums for $31 and new ones for $57. I'm trying to find out if they were food-grade on the used ones.

I'd probably be interested. I'm assuming I would need a thermometer? Anything else?