It all begins with an idea.
For Example, Charcoal. And the start of something delicious.
- Atoka Table builds a Custom Charcoal Retort Kiln -
To work. Turning Sheet metal into Charcoal. Come along. The process - 130 hrs work over a period of 3 months. The Owner could not be happier with the results - and the taste off the grill.
Note: 32" rolled sheet stock, 30" diameter, one drum with lid, 1ea 4' x 8' x 1/8" sheet and the drop from rolling the cylinder process
Initial angle - 2 x 3/16 10' 4ea (two more sections were needed. 1x1/4" x10' bar stock (2 more were needed) One ea 10ft length 1/2" black pipe, 12 lbs .035 mig wire (not shown)
48" x 96" x 1/8" sheet stock cut into the necessary pieces for this project. Note the small triangular pieces set to the side - that's the scrap pile cut from the one 4' x 8' sheet. Circle cut out from the rings were diligently consumed else where during the build.
Hinge of 1/2 -13 threaded rod Nuts and 1/2" Black pipe segments
Cylindrical gas passage set directly on fire box sides
Ash pan peices are fitted and tacked into place
Ash pan fitted and ready to weld out
Retort sets on ash pan fully welded 2-sides
Arrangement without vent showing gas passage 200 + inch long From Fire box to stack (not yet mounted)
Vent/Pan arrangement
Upside down, Ash pan rails and draw bolts are fitted and aligned
Ash pan slides to the rear of Kiln
Vent arrangement allows for 1/3rd under-fire draft
Adjustable vent arrangement
Rear wheel/axel aligned and installed
Castor placement
Four wheels. Castors in front for mobility and storage out of the weather between uses.
Finally! the end rings and Top-edge are cut through so the Clam-shell Retort can be opened and oven-barrel installed
First Left side, The Right clam-shell arrangement opens
Cylinder splits open symmetrically for easy removal (or replacement) of standard oil drum used as Kiln oven
Gas passage weirs shown
Open end of Kiln Oven (A barrel lid seals the chamber
Back of Kiln "oven" clamped within symmetrical Gas passage weirs
Typical Fire proof seal
Extra stiff hinges mount Fire Box Doors
Fire box door seal experiment
top length-wise seal face - 1-1/2 Angle and 1/4 x 1" bar stock on opposite edge
Only needs latches and stack connection
First firing is tomorrow. I need to get the latches installed
drew up Lacth geometry solid and durable - first and on-line search
Sturdy Latch Geometry - buildable if necessary
Fitting latches and top seals and temporary but solid stack connection
Latches were available on-line. We'll give them a test run
Good view of top seal
About 10 Cubic Feet of space (Standard 55 gallon oil drum)- We pack it tight!!
Owner starts first burn-load
Rolling nicely. You'll need enough fuel for 6-7 hour continuous burn, should achieve 650-700 for 1/2 hour then drop precipitously
1/2 hour into a 6 - 6-1/2 hour burn. Note smoke from drum vent - it's a great sign
Fire holding nicely
Nice hot fire (Door only open to add more fuel)
Note plume injecting from drum into flames through 4 ea drilled 1/2" holes
product volume is nearly equal, weight is substantially lower Before and a After weight was not recorded.
Close up of cooled product. Hickory Charcoal ready for Grill or Forge
Rear fenders [ to deflect Heat }
heat deflection fenders add style... this thing needs racing stripes
Heat shield on casters
simple frame allows for removable stack
Stack slides over frame - without fasteners
200 CFM Under-Fire draft fan creates light positive pressure through the gas passage weirs
Bolts lock handle
Fire box integrity inspection
Modifications completed
Charcoal Kiln Ready to deliver