I’ve been wanting to build a smoke shack for quite a while – ok about a year. I want to make my own bacon and smoke sausages which will expand my repertoire beyond bratwurst.  Cold smoking is smoking under 90F, preferably a little cooler than that. With that in mind there are a few other considerations:

  • I don’t have room for a permanent installation. Living in the western Chicago burbs, my season for cold smoking  will run from October to April.
  •  It needs to be relatively inexpensive (I’ve done this for about $150)
  • I want it to be attractive – no little metal store bought box costing twice as much for me!
  • I am not a carpenter! The finished product is not perfect or even perfectly square, but it should work
  • It needs to be relatively small. I’m not doing any half hogs. The finished smoke box itself is about 24″x 36″ x40″
  • I used no plans, just built it from what I thought

A trip to the big box store for:

  • Plywood
  • Wheels
  • Aluminum duct work (this will conduct heat out of the smoke)
  • An assortment of 2×2’s, 2×4’s, 1×2’s 1×3’s
  • Unfinished pine tongue and groove paneling
  • Hardware – handles, latches. etc…

    • DAY 1
    The first step was to put the wheels on the base.
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    Next, add some 2×4’s to make a shallow box. Notice I left room for 2×2 uprights in the corners.
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    Add the uprights, and braces for the shelf which will form the bottom of the smoke chamber.
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    Here is the bottom in place, as well as the rest of the basic box framed up. Notice I did put a pitch on it so the roof will drain.
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    DAY 2

    Next, I added framing for the door. I also added supports for the rack using 1×2’s with notches to hold rebar supports and metal shelf. The re-bar and the shelf are removable. I needed to be sure I could get them through the door opening.
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    I added some 2×4 bracing to attach rod supports (for a closet) to be able hang food items. The bracing will also give me something more to attach the paneling to.
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    With that, it was time to start “skinning” the smoker with the tongue & groove pine. Each part was cut to measure to ensure a tight fit. This was so far the most time consuming part of the project.
    Here the sides are done.
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    At this point the battery on my nailer died. While it recharged, I messed around with the smoke delivery system. I used “real” duct tape to attach an elbow on this roof flange which will sit over the fire box.
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    My initial plan was to use flexible aluminum duct work to route the smoke, It proved too fragile. I’ll have to rethink it.
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    Here you can see that I left the bottom of the back open to allow easy access to the smoke routing system. A little trim work makes it more attractive and finished looking.
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    Next I made the door and put the paneling on the front of the shack. The paneling is very thin and fragile so I needed to brace it to make it more rigid.DSC02893

    Here we are with the door installed. I added latches to keep it shut was well as a nice handle. Looks like an outhouse! Notice the shot with the door open, the door overlaps the door frame, hopefully creating a seal.
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    I put in about 10 hours on Day 2. (I’ll be doing penance in honey-do’s).

    So what’s left?

    • Roof
    • Smoke stack installation
    • Rebuilding the smoke delivery system
    • Thermometer installation
    • Test run
    • BACON!

    Until next time, Eat Well & Keep Digging!

    Click here for part two!