|Project by Quixote||posted 413 days ago||3145 views||15 times favorited||8 comments|
Bourbon Whiskey Barrel BBQ Smoker
The first question I get from people is “Is that a still?” and after a few dozen others, they ask if I mind if they take a picture. In the first picture, the smoker has been at full temp of 225 f for about 5 hours. You can see a very light puff of smoke out the left stack. The operation is very efficient; the 4 hour mark used only about 2 pounds of charcoal. The food comes out very moist. In my other smokers, I have to foil wrap the food after a few hours to keep it from drying out, but not with this one. After 4 cook cycles, for around 24 hours of heated time, the barrel still has a distinctive bourbon smell that adds a great taste to the food.
In operation, I have a couple of inches of water in the bottom of the barrel, a Weber table top grill sits on its own legs inside the barrel. There is about a 4” clearance between the grill and the barrel, but I also have a heat shield formed from a piece of 14” wide aluminum flashing. I closed the bottom vents on the grill and drilled a 1” hole in the side of the base, flashing and barrel to accommodate the air intake pipe that you see on the bottom right. I use a small computer fan to add / regulate the intake air to control the temperature. Without the fan, the unit actually settles in at around 235 f with the intake non restricted. The bottle fed feature uses the factory bung hole, I simply wrap some aluminum foil around the neck of a small bottle, and with the cap off, it sips a small amount of additional flavor during the cooking process. I use foil pans to capture any drippings, so no food or sauce is left in the barrel. I drain and refill with a couple of inches of water between use t keep the wood swelled tight for a good seal.
With the lid open, the food grate sits on screws just above the closed grill. I reinforced the inside of the hinge plate for top and bottom. The hinge is a simple hinge with a built up foundation to keep it straight and lift slightly behind the back lip so I would not tear the felt gasket. The 1” copper pipes and elbow actually pull the exhaust from below the food grate. This keeps the heat and flavor in the top of the chamber where the food is cooking, and greatly reduces the amount of flow through that would have occurred if the vents were at the top. The copper pipe does have some condensing feature, so the unit recovers a lot of the moisture and drips back into the barrel. The wire whisks at the top also collect little drops of condensation and return to the pipe. They look nice, but are really a safety feature to keep eager observers from poking an eye on the copper exhaust. The handles are intentionally rough finished.
Repurposing a wood barrel was a little harder to do than I expected. I marked a level cut around the top, used a hand saw to get a straight cut across the barrel, but I was surprised at how much harder it was to cut the bourbon saturated oak. It had a tendency to bind up during the stroke. The other surprise that came from a fresh bourbon barrel was the power of the aroma. I was slightly concerned that the residual alcohol may have been flammable. This was after I welded the reinforcing rods to the barrel stays. My hinge foundation build was overkill. The next one will simply be a gate strap hinge without the added outside bracing, and I will use a couple of chains to limit the opening.
-- I don't make sawdust...I produce vast quantities of "Micro Mulch."