Day/Night 3
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| Construction of the Magnum Day/Night 3 |
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| This picture shows the main components of the magnum after Day 3. At this point, the magnum is only lacking cooking shelf brackets, mating flange gasket (fiberglass rope gasket between the flanges where the cooking chamber meets the kettle grill base) and door gasketing (high temp silicon caulk to seal doors.) By far the most difficult part of the construction so far was the fabrication and installation of the mating flange between the cooking chamber (top barrel) and the base/kettle grill bottom. The Inner flange was installed first by making a round ring of 1/8" x 1-1/2" steel bar stock, the diameter of the ring was determined by measuring the diameter of the kettle grill bottom several directions and taking a 'WAG' as to what would work. This flange was then set on the barrel head ring remaining (cooking chamber barrel upside down on the floor) and shimmed into place using 1/2" x 1-/12" to 2" long shims wedged between the bead and the flange. The flange was welded into place by running a weld bead along the top of each shim bridging from the flange to the bead. A 1/16" shim was required on the outside of the bead to ensure there was enough clearance to get the cooking chamber on and off the base (this is still a snug fit but that's a good thing at this point.) I hope to get some pictures of the finished bead taken when I install the rope gasket between the inside and outside flanges. The doors were fabricated by shearing 1/16" steel to 9" wide and then rolling to a radius slightly larger than the barrel radius. This allows the draw latch to pull the door closed tightly. | ||||||||||||||||||||||||||
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| Above is a view looking into the firebox door. You can see the top of the charcoal basket in the bottom of the opening and at the top of the opening is the baffle plate and drip pan. There is a 3/4" gap between the baffle plate and the bottom of the drip pan, both are 1/8" thick steel. Below is a close up view of the drip pan assembly specifically showing 1 of the 4 legs. The drip pan legs rest on the partial barrel head still remaining which is reinforced by the inner mating flange of the cooking chamber which is welded to both the bead of the barrel head and the head itself.. | ||||||||||||||||||||||||||
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| Final Asembly & Burn-In | ||||||||||||||||||||||||||
| Cooking on the Magnum | ||||||||||||||||||||||||||
| Engineering Sketches of the Magnum | ||||||||||||||||||||||||||
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