How to Build a DIY Reverse Flow Smoker At Home

Reverse flow smoker plans are a decent way to learn how to build a smoker. Smoke and heat are trapped in a chamber at the bottom of this type of smoker. Amazingly, they are easier to build than the typical vertical or offset smokers because they do not require you to have a chassis.

This post is about reverse flow smoker plans you can follow to make a cost-effective DIY smoker from scratch. You can build one from scratch if you somehow have a sense of carpentry. These projects may be just the thing you need if you want to improve your work ethic. You can also make all types of smoker including gas smoker, vertical smoker at your home instead of paying high price.

What Is A Reverse Flow Smoker?

Unlike conventional offset smokers, reverse flow smokers look very much like their conventional counterparts. The heat moves reversely for cooking food. You will finally get the food cooked from indirect heat.

A firebox box is present outside the cooking chamber. A baffle plate takes the smoke and heats it away from the firebox. Then, it goes in the opposite direction through the cooking chamber, so it is called a reverse flow smoker.

All the reverse-flow smokers have offset smokers, but all the offset smokers are not reverse-flow smokers. An offset smoker firebox and chimney are placed on opposite sides, while the reverse flow smokers are on the same sides.

The reverse flow smokers burn cleaner and provide reasonable temperature control. A reverse smoker cooks food from bottom to top, while an offset smoker cooks food from top to bottom.

The best advantage of such smokers is that they protect your food from overcooking. With this smoker, you can cook your food better because it gives reasonable temperature control. Besides, it also maintains temperature while adding fuel.

Homemade Reverse Flow Smoker Plans

Are you looking for vertical reverse flow smoker plans? And You are probably searching for free smoker plans but get disappointed. The information and instructions below about reverse flow offset smoker plans help you build a professional smoker.

Reverse Flow Smoker

Indirect heat is used in reverse-flow smokers to cook food. The excellent feature of reverse flow smokers that makes them ideal for other smokers is that it gives consistent and better results. It is because indirect heat cooks food evenly without leaving any streak.

Steps

• Tank preparation
• Fitting the reverse flow system
• Welding
• Installing the smoke stack
• Firebox
• The finished product

Building A Smoker Pit

Furthermore, reverse-flow smokers can maintain a more consistent temperature and produce more smoke than conventional smokers. Undoubtedly, reverse-flow smokers are generally more expensive than some other smokers, but worthy people realize there could be a cost compromise, but the quality is needed. 

Steps

• Tank preparation
• Fitting the reverse flow system
• Welding
• Installing the smoke stack
• Firebox
• The finished product

Reverse Flow BBQ Smoker Grill

An offset smoker uses reverse flow baffles to distribute heat, producing good results and minimizing flow. Such a design makes good results and minimizes spots on the finished product. Just like offset smokers, some reverse-flow smokers can be used for grilling. 

Steps 

• Scrap hunting
• Cook chamber plumbing
• Smoker box
• Finish, fire, and enjoy

An Old Water Boiler’s Reverse Flow Offset Smoker

Building your reverse flow smoker is relatively easy but requires some welding skills. The most crucial step during building is the construction of baffles. You can make baffles from expended metal or sheet metal, but ensure that you have welded them in place so that they will become airtight. 

Steps 

• The project
• Cleaning the boiler
• The cutting of the boiler and internal sanding
• The oven
• Bearing structure
• The chimneys
• Make it transportable
• The reverse flow system
• The cooking grill
• Indispensable accessories
• Protective coating

The R-BQ, Building A 120-Gallon Reverse Flow Offset Smoker.

You should think about building your smoke if you like smoked foods. Before you begin the process, there are a few things you need to keep in mind. First of all, decide what type of smoker you need. In reverse flow smokers, there are two major types: vertical and offset. Offset smokers use wood or charcoal as fuel and are traditional.

Building An Offset Reverse BBQ Smoker

On the other hand, vertical smokers are modern smokers and use gas or charcoal as fuel. After deciding which type of smoker you want to make, you need to gather all the essential tools.  

Homemade Tabletop Reverse Flow Smoker

For building an offset smoker, the vertical smoker can be made from bricks or blocks to create an offset smoker. At last, you need to choose the location for the smoker.

If you decide to smoke, choose an area away from buildings or other structures, as smoke can cause damage to both the people and the property. Considering these considerations, you’re ready to start building your smoker.

7 Steps Building Process for A Reverse Flow Smoker

There are so many types of reverse flow smokers available in the market. Vertical smokers are famous among them, costing up to $300. If you consider all the benefits you are receiving, this is not a bad deal at all. 

However, it will be a better option to purchase a smoker. But if you want to build your smoker, it’s a good idea. By doing this, you can buy each part separately, saving you a lot of cash. 

The problem is that it takes work to find blueprint reverse flow offset smoker plans. Only these plans will cost you around $100 and need improvement. Here you will get seven simple ways to build a slow reverse smoker.

Gather The Tools

Before going into the process, you need to gather all the parts and tools that you will need during the process. These parts and tools make things more accessible during the process. These are some must-have tools:

• Wire brush
• Mini grinder
• Safety Gear (Glasses, Face Shield, Gloves & Welding shield)
• Welders
• Chipping hammer
• Pilers

You will need these supplies as well:

• Shelf 
• High heat paint
• Wooden handle 
• Hinges
• Extended metal for cooking grate and fire brisket
• Vents 
• ‘Thermometer
• Smoke stacks
• Casters
• Baffle plate
• Angle iron for the frame
• Firebox

Having gathered all of the above, you can move forward with building your home.

Building The Cooking Chamber Body

Various types of cylinders can be used to make the cooking chamber. Any readily available item will do. However, the best option is to use a cylinder similar to the boiler’s expansion tank.

No matter what material you have, ensure that you have to make a place where you can keep your meat. After selecting the frame, weld the legs of the smoker with the frame.

To make a good balance, weld four legs on four different corners. After cutting the tank’s opening, keep the piece of metal you have created because you will need it for the chamber door. 

You should weld the hinges close to the opening you just created, and the door should be bolted to the hinges. Screw aluminum stocks all around the beginning. It keeps the door in place.

Building The Firebox

Building the firebox is the main procedure of this process. Identify the firebox’s size first. Your choice will depend on the size of the unit you are building. The right way to avoid upcoming potential problems is to make the firebox a little oversized. I recommend you make the firebox from 1/4″ steel.

Measure and get the measurement of a smoker box if you want to know its average size. After taking measurements, get the building set up. It will allow the firebox to maintain heat steadily and distribute heat evenly. The process of building the firebox is below:

• Make square-shaped box
• Attach sturdy hinges to the box’s door. 
• For ventilation, drill a few holes on the side. 
• To control these vents, weld bolts in the holes. 

By acting upon the above process, you can build a firebox quickly. If you make it removable, then it will be better. Generally, the firebox is heavy and very hard to move. Due to this reason, bolting the firebox to the smoker’s body is very helpful. It is all about building the firebox. Now, you can proceed further. 

Installing The Baffle Plate

After building the firebox, it is time to install the baffle plate. The baffle plate is part of the reverse flow smoker because of which they are known as reverse flow. It is a steel plate connected to the smoker’s body. The main objective of the baffle plate is to prevent the meat from direct heat. 

It is good to use a baffle sheet because it ensures that the food gets equal heat despite its position. However, you can use any sheet. It will cost only $1 or less than it. 

After buying the baffle plate, wash them thoroughly with soap. Then, make a slot inside the smoker for the baffle plate. The slot should be 20cm above the base. After ensuring that the baffle plate is placed over the slot, you can go through the following process.

Installing The Chimney 

You need to set up a chimney to give a path to smoke and heat so they can leave the smoker. Making the chimney from a 4″ ventilation pipe will be best. The chimney’s height should be lowered if you are constructing a vertical reverse flow smoker.

Final Touch

Your process is almost completed. In the end, install a thermometer and a fire basket in the smoker. The fire basket should be made of aluminum. The primary purpose of the fire basket is to hold hot coals. At the same time, the thermometer helps you to monitor the progress of the process. 

Test The Smoker

Now, you have made a vertical reverse flow smoker most easily. The step is to check the functioning of your smoker to see whether it is working well. For this, follow the steps given below:

• Fill the smoker with woods
• Light up the smoker and let it burn for a while
• Wait till it smokes up
• When the smoker reaches a temperature of around 260 degrees Fahrenheit, put meat on it. 

After 20 minutes, if you got fully cooked meat with a smokey taste, then it means that your smoker is perfectly prepared.

Do You Need A Reverse Flow Smoker? 

It is beneficial to have a 250-gallon reverse-flow smoker in your home, and you have decided to build one. It is wise to finalize everything after you know what you are doing. Therefore, you must understand why you do not need a reverse-flow smoker and why you need it. A quick discussion on the ups and downs of the reverse flow smoker are:

Pros

You can get many benefits from reverse-flow smokers. Some of them are as follows: 

• It distributes heat evenly in the smoker so that you will not need to flip your meat again and again
• Smoke is distributed, so each meat part gets a smokey flavor.
• Even if you add more wood or fuel to the smoker, the temperature does not get out of control.
• Once opened, reverse flow smokers retain more heat and return to their desired temperature faster.
• The reverse flow smoker comes with a metal plate that acts like a tray, so you do not need a separate water tray or grease with it. 
• The finished product obtained from the reverse flow smoker has more moisture as flavor the tray collects fats and oil and filters through.
• It is generally straightforward to construct a reverse-flow smoker.

Cons

• In the reverse flow smoker, removing the multi-function metal plate is impossible. For example, if you want to remove it to clean it, you cannot do that.
• As the reverse flow smoker forces smoke to change its direction, you might face issues controlling airflow. Sometimes, if you are not careful, it over-smokes the meat and gives it a bitter taste.
• It takes much time to reach the temperature of the BBQ pits or cooker.
• You need more wood or fuel to control the heat inside the reverse flow smoker.
• It is not possible to cannot control airflow in the reverse smoker. It will prove to be the biggest failure during cooking. 

Frequently Asked Questions

Final Words

One of the great things about building your smoker is that you can build it any way you want. These smokers use a refrigeration system for smoke generation and reverse flow for smoking. The benefits are multifold: no canning required, customization due to the electric smoke, automated temperature regulation, and all substantial cost savings compared to other commercially available units.