Smoker Rehab 2018

Posted on March 26, 2018 by Chase

Two years ago I pulled my old smoker out and gave it a complete overhaul. It needs a little help again. Nothing dramatic, but the paint is chipping up with rust blisters in places. Best to get to that before they become dramatic.

A heavy grit flap sander pad on my angle grinder did a good job of cleaning off the paint and exposing fresh metal. I think I used a wire brush last time, but this works a lot better. So much better in fact that it revealed a lot more bad paint than I had originally thought. I had sites all over the smoker that needed grinding and repainting.

Out came the high temp primer and paint. I basically ended up repainting 75% of the smoker. That was a lot more dramatic that I set out to do, but I figure it is a lot cheaper than having a rusted out smoker.

With it safe from the elements for a few more years I had one trick to install. I wanted to customize the front fold out table. I figured some kind of Florida BBQ sign was in order. I was going to make it look like a caution road sign, but then thought that would reflect poorly on my cooking. Watch out for this guy’s food!

I would historically use my mill to cut a stencil from thin plywood or hardboard. I haven’t used it in ages and need to spend a day on repairs and re-learning how to use it. Instead I tried to 3D print a stencil. It can make finer curves and lines anyways.

I sprayed the back with some light hold adhesive hoping that would keep spray paint from seeping under while letting me pick the stencil back up. I masked around it and sprayed away.

The edges weren’t as clear as I had hoped, so for the BBQ letters I sprayed more adhesive and make sure to rub it onto the grill table really hard. That probably would have gone ok, but I sprayed too much paint and it seeped under. Multiple lighter passes would have worked better. I used too much adhesive and it left residue on the table. I will wait a few days for the paint to really cure well before hitting it with a solvent. I also didn’t mask enough and got a little over spray on the grill.

Up close it has a lot of issues, but from afar it isn’t bad. All lessons learned for next time. Maybe in 2 more years when it needs another paint touch up I will have a better plan for branding it. The smoker will be 11 years old at that point!

Chicken Sausage

Posted on September 19, 2016 by Chase

The sausage maker strikes again. This time with a smaller load of chicken thighs.

I started with only 5 pounds of chicken thighs instead of 10+ pounds of meat like last time. The pieces were chopped up smaller this time, and I didn’t add any pork fat. This was just simple chicken, salt, pepper, and a little fresh rosemary from the garden.

Last time I was doing a lot of meat shoveling and stuffing, and ended up having to employ my lovely wife to help. I didn’t get many pictures as a result. This time my maker mom was in town. I figured out how to guide with one hand while I pressed with the other. Mom filled the hopper and took pictures.

I don’t know if it was the consistency difference, the smaller hunk size or what, but this batch went really smoothly. My diameter consistency needs help still, but I am improving. When all was said and done, we had two piles of lumpy but delicious looking sausage.

The batch with rosemary got grilled for dinner the same night as it was made. I don’t know if it should sit in the fridge a few nights for the flavors to meld or not, but this worked well. It was pretty tender and moist enough. Not as much as the brats were, but the fat content of this was a lot lower. A very delicious and cheap chicken sausage for the grill.

The second batch got smoked a few days later. It was also quite delicious. I am glad I didn’t use any white meat, the sausage was good, but could probably easily be dry if it were any leaner.

Easter Brisket

Posted on March 29, 2016 by Chase

Since my smoker renovation back in January I have been working to re-learn the process. The new controller holds everything at different temperatures than I am used to. Time to experiment! I had a lot of family over on Easter, and decided to skip the ham and go for an Easter brisket!

This badboy started off at 2am weighing in at over 13 pounds!

A lot of trimming later he was ready for some coarse salt and pepper rub down.

Trimmings

Off the little brisket goes to smoker school to learn to be tender and dark and delicious.

5 hours later I woke up and did a check. It was really far along. I started off with the setting of 275, but I know that the smoker runs a little colder in the center than the built in probe reads. Maybe using oak changed the setting. I lowered the temp to 225 and let it go for another 4 hours.

Our little brisket has graduated with a bachelors degree in deliciousness. Some post graduate school would do it well. All wrapped up in butcher paper it continued its studies in a cooler. Resting in a cooler is great, all the insulation keeps it hot for hours. We ate nearly 3 hours later, and it was still piping hot.

The bottom 1/8 to 1/4″ of the brisket was a little dry and hard, but the rest was pretty good. I am guessing this was due to the heat being too high at the outset. The fat was well rendered and melted in your mouth.

Over all it is a really tasty brisket, but there is always room for improvement. Next time, I will start at 250 and see how things run.

I couldn’t completely buck tradition. Sometimes you just really want ham for Easter. I stuck a little half ham in the smoker for the last few hours to warm it up and impart a little smoke. Oak and ham aren’t a perfect match, but it turned out well nonetheless.

Smoker Renoation

Posted on February 5, 2016 by Chase

My beloved smoker has fallen on hard times. I bought a traeger pellet fed smoker in the summer of 2009, and have done mountains of delicious meat in it ever since. All those years outside in florida have taken their toll.

The paint has faded and is rusting through in places, the outside is quite dirty, and a back leg has completely rusted through. I had to prop it up to keep the thing from rocking.

The inside doesn’t look much better. Surface rust is kind of unavoidable, but neglect had built up on the walls and in the bottom tub. I should really clean this thing out more.

My bad behavior aside, this thing is built like a tank. Even with all the years of outdoor use, I was able to pull all the screws out. There is a lot of surface rust, but nothing too deep except for the one back leg. I started to take everything apart and became even more enamored with my smoker’s build and design.

With all the parts pulled out and the mess cleaned up it was time to get everything back into shape.

Rebuild

I used a wire brush on my angle grinder to strip all the bad paint and rust. I started everything with flat black rustoleum grill paint. It covered everything but looked kind of bad. I was in the hardware store and noticed they have a semigloss. It matches the original paint job. I redid most of the parts with a primer, and gave everything another coat with the semi-gloss.

Once all the paint was down I started rebuilding. Some of the hardware got replaced, but most of it was actually in really good shape. The back leg was shortened and fitted with an aluminum extension. No more rusting off foot! I replaced the hot rod starter because it is hard to get to and didn’t cost much to replace.

Other upgrades happened along the way. They have a nice shelf that bolts in with the legs. It folds away when not in use, and sits nicely in line with the entrance so you can transfer to and from the smoker.

I pulled out the old controller that only had 3 heat settings. The new one reads the internal temperature and feeds in pellets accordingly. It has an autostart-up feature and a shutdown cycle that helps prevent soot. I also replaced the drip bucket because it was pretty nasty.

All in all it looks pretty good. Because I couldn’t get all the old paint off there is some odd texture, but it looks way better than when I started. Now that I have the primer and grill paint around I will make it a point to check every year or so for bad spots that need a touchup.

Lastly, the accessory I should have bought when I first got the grill. A cover! I don’t know how much longer the paint would have lasted with one, but it is worth a shot.

This smoker rocks. With a little more preventative maintenance than I had been doing I can hopefully look forward to another 6+ years of service. Delicious smoked meat posts to follow!

Kilted Craft Works

Let's make something!

Tag Archives: smoker