Drum smoker

A new, unlined 55-gallon steel drum with pipe intakes at the base, a charcoal basket on bolt legs, cooking grates on bolts, hanging rods and a lid with exhaust holes.

Default dimensions are shown below. Enable JavaScript to edit dimensions and inspect the 3D model.

Dimensions

drum Inside Diameter: 572 mm
drum Height: 851 mm
drum Wall: 1 mm
basket Diameter: 356 mm
basket Height: 229 mm
basket Leg: 76 mm
grate Diameter: 559 mm
grate Count: 2
top Grate Drop: 178 mm
lower Grate Height: 356 mm
bolts Per Grate: 4
intake Count: 3
intake Pipe Dn: 20
intake Hole: 25 mm
intake Height: 76 mm
exhaust Hole Count: 8
exhaust Hole: 25 mm
rod Count: 2
rod Diameter: 10 mm
thermometer Hole: 16 mm
bolt Diameter: 6 mm
basket Bolt Diameter: 8 mm
rod Stock Length: 1,000 mm
mesh Sheet: 305 mm, 1,219 mm
kerf: 2 mm

Shopping list

Quantities follow the dimensions above and have not been checked against a built example.

Quantity	Item	Note
Metal lengths
2 1000 mm lengths	mild-steel round bar10 mm × 10 mm section · 10 mm round bar2 cuts · 812 mm offcut in total	First-fit estimate with the entered saw kerf; the section and material are proposed, not a listed product.
Mesh and screen
1 sheet	expanded metal mesh305 mm × 1,219 mm	For the basket strip, 1168 × 229 mm.
Pipe and duct
1 valve	ball valve, 3/4 in pipe thread	On the front intake; the main air control.
2 caps	pipe caps, 3/4 in	For the other intakes.
3 nipples	pipe nipples, 3/4 in × 51 mm	Threaded or clamped through 25.4 mm holes.
Fixings and hardware
3 handles	handles	Two on the sides, one on the lid.
6 bolts	hex bolts, 6.4 × 16 mm, with nuts and washers	Two for each side handle and two for the lid handle. 1 nut and 1 washer each. Stainless or plain steel to suit the heat, not zinc-plated.
8 bolts	hex bolts, 6.4 × 30 mm, with nuts and washers	Grate supports through 6.4 mm holes. 1 nut and 1 washer each. Stainless or plain steel to suit the heat, not zinc-plated.
4 bolts	hex bolts, 7.9 × 100 mm, with nuts and washers	Basket legs through the charcoal grate, 76 mm off the floor. 2 nuts and 2 washers each. Stainless or plain steel to suit the heat, not zinc-plated.
2 bolts	hex bolts, 7.9 × 20 mm, with nuts and washers	For the basket seam. 1 nut and 2 washers each. Stainless or plain steel to suit the heat, not zinc-plated.
3 pieces	locknuts or large washers, 3/4 in	Inside the drum on each nipple.
14 hooks	S-hooks	About one per 75 mm of rod inside the drum.
2 U-bolts	U-bolts for the basket	Holds the ring to the charcoal grate; size them to the grate bars.
Bought parts
1 grate	charcoal grate, at least 376 mm across	The basket floor; the ring sits on it.
2 grates	cooking grates, 559 mm across	Rests on 4 bolts, 6.5 mm from the wall each side.
1 thermometer	dial thermometer	For a 16 mm hole; stem about 64 mm long. Check the hole against the thermometer you buy.
1 drum	open-head drum, 55 US gal, new and unlined	Drawn at 572 mm inside, 851 mm tall inside, 1.2 mm wall. Buy it new, unlined and food grade, and measure it before drilling.
Sealants and coatings
coating, amount not specified	high-heat paint for the outside	Burn out and paint only as the drum and paint makers instruct. Leave the inside unpainted.

Cutting plan

Stock allocation uses the model’s kerf rule and the default stock lengths. No piece is spliced to fit.

rod 1rod

1,000 mm

592 mm

Offcut 406 mm

rod 2rod

1,000 mm

592 mm

Offcut 406 mm

mesh 1

305 mm × 1,219 mm

229 mm × 1,168 mm

Placed one piece at a time with the entered kerf; not a nesting plan.

Cut list

Cut lengths and joints
Stock	Cut	Joint and angles
mesh	1,168 mm × 229 mm	cut 1,168 mm × 229 mm, roll into a ring with a 50 mm overlap and bolt the seam Ends 90° / 90°
rod	592 mm × 10 mm	cut square and file the ends; rests in two 12 mm holes with 25 mm outside each wall Ends 90° / 90°
rod	592 mm × 10 mm	cut square and file the ends; rests in two 12 mm holes with 25 mm outside each wall Ends 90° / 90°

Openings and fitted details

drill List

diameter: 6 mm
count: 14
uses: 4 top grate bolt, 4 lower grate bolt, 2 right handle bolt, 2 left handle bolt, 2 lid handle bolt

diameter: 12 mm
count: 4
uses: 2 hanging rod 1, 2 hanging rod 2

diameter: 16 mm
count: 1
uses: 1 thermometer

diameter: 25 mm
count: 11
uses: 1 air intake 1, 1 air intake 2, 1 air intake 3, 8 exhaust

holes

id: hole.grate-top.1
target id: drum.body
face: wall
use: top grate bolt
angle deg: 45
centre: 203 mm, 203 mm, 683 mm
direction: 0.707, 0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-top.2
target id: drum.body
face: wall
use: top grate bolt
angle deg: 135
centre: -203 mm, 203 mm, 683 mm
direction: -0.707, 0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-top.3
target id: drum.body
face: wall
use: top grate bolt
angle deg: 225
centre: -203 mm, -203 mm, 683 mm
direction: -0.707, -0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-top.4
target id: drum.body
face: wall
use: top grate bolt
angle deg: 315
centre: 203 mm, -203 mm, 683 mm
direction: 0.707, -0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-lower.1
target id: drum.body
face: wall
use: lower grate bolt
angle deg: 45
centre: 203 mm, 203 mm, 366 mm
direction: 0.707, 0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-lower.2
target id: drum.body
face: wall
use: lower grate bolt
angle deg: 135
centre: -203 mm, 203 mm, 366 mm
direction: -0.707, 0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-lower.3
target id: drum.body
face: wall
use: lower grate bolt
angle deg: 225
centre: -203 mm, -203 mm, 366 mm
direction: -0.707, -0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.grate-lower.4
target id: drum.body
face: wall
use: lower grate bolt
angle deg: 315
centre: 203 mm, -203 mm, 366 mm
direction: 0.707, -0.707, 0
diameter: 6 mm
depth: 1 mm

id: hole.intake.1
target id: drum.body
face: wall
use: air intake 1
angle deg: -90
centre: 0 mm, -287 mm, 89 mm
direction: 0, -1, 0
diameter: 25 mm
depth: 1 mm

id: hole.intake.2
target id: drum.body
face: wall
use: air intake 2
angle deg: 30
centre: 248 mm, 143 mm, 89 mm
direction: 0.866, 0.5, 0
diameter: 25 mm
depth: 1 mm

id: hole.intake.3
target id: drum.body
face: wall
use: air intake 3
angle deg: 150
centre: -248 mm, 143 mm, 89 mm
direction: -0.866, 0.5, 0
diameter: 25 mm
depth: 1 mm

id: hole.thermometer
target id: drum.body
face: wall
use: thermometer
angle deg: -90
centre: 0 mm, -287 mm, 746 mm
direction: 0, -1, 0
diameter: 16 mm
depth: 1 mm

id: hole.rod-1.right
target id: drum.body
face: wall
use: hanging rod 1
angle deg: -19.471
centre: 270 mm, -96 mm, 804 mm
direction: 0.943, -0.333, 0
diameter: 12 mm
depth: 1 mm

id: hole.rod-1.left
target id: drum.body
face: wall
use: hanging rod 1
angle deg: 199.471
centre: -270 mm, -96 mm, 804 mm
direction: -0.943, -0.333, 0
diameter: 12 mm
depth: 1 mm

id: hole.rod-2.right
target id: drum.body
face: wall
use: hanging rod 2
angle deg: 19.471
centre: 270 mm, 96 mm, 804 mm
direction: 0.943, 0.333, 0
diameter: 12 mm
depth: 1 mm

id: hole.rod-2.left
target id: drum.body
face: wall
use: hanging rod 2
angle deg: 160.529
centre: -270 mm, 96 mm, 804 mm
direction: -0.943, 0.333, 0
diameter: 12 mm
depth: 1 mm

id: hole.handle-right.1
target id: drum.body
face: wall
use: right handle bolt
angle deg: -10.068
centre: 282 mm, -50 mm, 614 mm
direction: 0.985, -0.175, 0
diameter: 6 mm
depth: 1 mm

id: hole.handle-right.2
target id: drum.body
face: wall
use: right handle bolt
angle deg: 10.068
centre: 282 mm, 50 mm, 614 mm
direction: 0.985, 0.175, 0
diameter: 6 mm
depth: 1 mm

id: hole.handle-left.1
target id: drum.body
face: wall
use: left handle bolt
angle deg: -169.932
centre: -282 mm, -50 mm, 614 mm
direction: -0.985, -0.175, 0
diameter: 6 mm
depth: 1 mm

id: hole.handle-left.2
target id: drum.body
face: wall
use: left handle bolt
angle deg: 169.932
centre: -282 mm, 50 mm, 614 mm
direction: -0.985, 0.175, 0
diameter: 6 mm
depth: 1 mm

id: hole.lid-handle.1
target id: lid.disc
face: lid
use: lid handle bolt
axis: z
centre: -50 mm, 0 mm, 865 mm
diameter: 6 mm
depth: 1 mm

id: hole.lid-handle.2
target id: lid.disc
face: lid
use: lid handle bolt
axis: z
centre: 50 mm, 0 mm, 865 mm
diameter: 6 mm
depth: 1 mm

id: hole.exhaust.1
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: 0 mm, 172 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.2
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: -121 mm, 121 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.3
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: -172 mm, 0 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.4
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: -121 mm, -121 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.5
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: -0 mm, -172 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.6
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: 121 mm, -121 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.7
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: 172 mm, -0 mm, 865 mm
diameter: 25 mm
depth: 1 mm

id: hole.exhaust.8
target id: lid.disc
face: lid
use: exhaust
axis: z
centre: 121 mm, 121 mm, 865 mm
diameter: 25 mm
depth: 1 mm

Parts

Parts and materials
Material	Size	Basis
handle	130 mm × 30 mm × 35 mm	bought handle; position marker
open head drum	574 mm × 574 mm × 864 mm	reference drum as entered; measure your own
open head drum	572 mm × 572 mm × 1 mm	reference drum as entered; the recess is drawn, not measured
drum lid	590 mm × 590 mm × 1 mm	reference lid drawn as a flat disc
drum closing ring	602 mm × 602 mm × 29 mm	reference closing ring envelope
charcoal grate	376 mm × 376 mm × 8 mm	bought round charcoal grate; the model reserves its size
expanded metal mesh	356 mm × 356 mm × 229 mm	proposal derived from the entered dimensions
hex bolt	8 mm × 8 mm × 100 mm	proposal derived from the entered dimensions
hex bolt	8 mm × 8 mm × 100 mm	proposal derived from the entered dimensions
hex bolt	8 mm × 8 mm × 100 mm	proposal derived from the entered dimensions
hex bolt	8 mm × 8 mm × 100 mm	proposal derived from the entered dimensions
hex bolt	8 mm × 20 mm × 8 mm	proposal derived from the entered dimensions
hex bolt	8 mm × 20 mm × 8 mm	proposal derived from the entered dimensions
U bolt	12 mm × 12 mm × 45 mm	proposal derived from the entered dimensions
U bolt	12 mm × 12 mm × 45 mm	proposal derived from the entered dimensions
cooking grate	559 mm × 559 mm × 10 mm	bought round grate as entered
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
cooking grate	559 mm × 559 mm × 10 mm	bought round grate as entered
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
hex bolt	28 mm × 28 mm × 6 mm	proposal derived from the entered dimensions
pipe nipple	27 mm × 51 mm × 27 mm	proposal derived from the entered dimensions
ball valve	41 mm × 60 mm × 41 mm	proposal derived from the entered dimensions
pipe nipple	58 mm × 49 mm × 27 mm	proposal derived from the entered dimensions
pipe cap	35 mm × 39 mm × 33 mm	proposal derived from the entered dimensions
pipe nipple	58 mm × 49 mm × 27 mm	proposal derived from the entered dimensions
pipe cap	35 mm × 39 mm × 33 mm	proposal derived from the entered dimensions
dial thermometer	76 mm × 25 mm × 76 mm	bought dial thermometer; dial and stem drawn as an envelope
dial thermometer	6 mm × 64 mm × 6 mm	proposal derived from the entered dimensions
mild steel round bar	592 mm × 10 mm × 10 mm	proposal derived from the entered dimensions
mild steel round bar	592 mm × 10 mm × 10 mm	proposal derived from the entered dimensions
handle	35 mm × 130 mm × 30 mm	bought handle; position marker
handle	35 mm × 130 mm × 30 mm	bought handle; position marker

Build steps and tools

Get the right drum
Buy a new, unlined, food-grade open-head drum. Measure its inside diameter, inside height and wall at the rim and enter them, with the grate you will use. Burn out any coating and paint the outside only as the drum and paint makers instruct.
Tape measure and pencil.
tape measuremarking pencil
Mark and drill the holes
Mark each hole from the drill list: intakes at the listed height round the base, grate bolts below the rim, the thermometer above the top grate, rod and handle holes near the top, and the exhaust ring and handle holes in the lid. Centre-punch, then drill small holes with a twist bit and open the large ones with a step bit or hole saw.
Drill/driver with twist bits; hole saw. A step bit and centre punch are not in the tool list.
drill driverdrill bithole saw
Fit the intakes and bolts
Thread a nipple through each intake hole with a locknut or large washer inside. Fit the ball valve on the front intake and caps on the others. Bolt in the grate supports, heads outside, with a washer and nut inside. Fit the side handles, the lid handle and the thermometer.
Screwdriver and pliers. Spanners and a pipe wrench are not in the tool list.
screwdriverpliers
Make the basket
Cut the expanded metal strip to the listed size, roll it into a ring and bolt the overlap. Stand the ring on the charcoal grate and hold it with the U-bolts. Fit the leg bolts through the grate with a nut and washer above and below, set to the listed height.
Mesh shears or wire cutters for light mesh; heavy mesh needs an angle grinder, which is not in the tool list.
shearswire cutterspliers
Cut the rods
Cut each hanging rod from round bar to its listed length and file the ends. Push them through their holes; take the top grate out before hanging food.
A saw that cuts steel bar, such as a hacksaw, and a file; neither is in the tool list by name.
saw
Check before use
Check the grates sit level on their bolts, the basket clears the intake nipples and the lid closes. Fire safety, where the drum stands, and the food process are yours to settle; the model gives no temperatures or times.
A physical check; the model covers geometry only.

Tools by operation

measure drum

Measure the inside diameter, inside height and wall of your drum, the grate and the pipe fittings, then mark every hole from the drill list.

requiredtape measuremarking pencil

alternativeruler

optionalsquare

drill holes

Centre-punch and drill the wall and lid holes: small ones with a twist bit, large ones with a step bit or hole saw. A step bit and a centre punch are not in the tool list.

requireddrill driverdrill bit

alternativehand drill

optionalhole sawclamp

unsuitablejigsaw

fit intakes

Thread the nipples through the intake holes with a locknut or large washer inside, then fit the ball valve and the caps. Pipe wrenches or spanners are not in the tool list.

requiredpliers

make basket

Cut the expanded metal strip, roll it into a ring, bolt the seam, fix the ring to the charcoal grate with U-bolts and fit the bolt legs.

requiredshearspliers

alternativewire cutters

optionalclamp

unsuitableutility knife

cut rods

Cut the hanging rods from round bar and file the ends smooth.

requiredsaw

optionalclamp

unsuitablemitre sawjigsaw

bolt in

Bolt in the grate supports, the handles, the lid handle and the thermometer.

requiredscrewdriverpliers

optionaldrill driver

paint outside

Paint the outside only, with a high-heat paint used as its maker instructs.

requiredpaint brush

optionalsander

Before you build

Use a new, unlined, food-grade drum. Burn it out and paint it only as the drum and paint makers instruct. Fire safety and the food process are on the builder; the model gives no smoking temperatures or times. Check the grate fit, bolt reach and every hole against your own drum before drilling.

Use a new, unlined, food-grade drum. Burn it out and paint it only as the drum and paint makers instruct. Fire safety and the food process are on the builder; the model gives no smoking temperatures or times. Check the grate fit, bolt reach and every hole against your own drum before drilling.
The drum, lid, closing ring and grates follow the entered sizes; the grates are plain discs. Wall and lid holes are cut in the fixed renders; the live view lists them in the drill list instead of drawing them. The expanded metal ring is a translucent surface. Valve, caps, thermometer and handles are envelopes or markers, not product shapes; nuts, washers and the rolling hoops of the drum are not drawn.
Drill 20 holes in the wall and 10 in the lid: 14 holes of 6 mm, 4 of 12 mm, 1 of 16 mm, 11 of 25 mm. Heights are measured from the drum floor inside and from the rim.
The top grate sits 178 mm below the rim and the lower one 356 mm above the floor. The basket top is 313 mm above the floor. With the grates out, the rods are 473 mm above the basket.
Fixed proposals: 20 mm of bolt under each grate edge, 51 mm nipples, the thermometer 50 mm above the top grate, rods 60 mm below the rim and side handles 250 mm below it.

What the 3D model leaves out

The drum, lid, closing ring and grates follow the entered sizes; the grates are plain discs. Wall and lid holes are cut in the fixed renders; the live view lists them in the drill list instead of drawing them. The expanded metal ring is a translucent surface. Valve, caps, thermometer and handles are envelopes or markers, not product shapes; nuts, washers and the rolling hoops of the drum are not drawn.

Taking the model apart separates parts for inspection; it is not an assembly order.

Dimension evidence and geometric checks

basis: Layout and defaults from published builds (S2 to S6); drum sizes from S1 and S7; pipe sizes from S8; thermometer hole from S9; hanging rods from S10; mesh sheet size from S11. Bolt lengths, heights no source gives, and the handle, rod and thermometer positions are proposals.
drum: Use a new, unlined, food-grade drum (S2, S5, S6). Burn it out and paint it only as the drum and paint makers instruct.
food process: None stated. The model gives no smoking temperatures or times.

unique ids: Yes
part count: 37
cut count: 3
stock count: 3
grate fits drum: Yes
grate bolts reach under grate: Yes
basket clears intakes: Yes
exhaust not tighter than intake: Yes
wall holes apart: Yes
rods above top grate: Yes
limits: Geometric checks only. No fit, strength, fire safety, airflow or food process has been tested.

Reference renders

Fixed views of the original proposal. They do not change with your dimensions.

Drum smoker · Assembled · original proposal — Assembled

Drum smoker · Disassembled · original proposal — Disassembled

Drum smoker · Inside, wall and lid hidden · original proposal — Inside, wall and lid hidden

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