Introduction : Cold Smoke Generator - Door
This is a follow on from the initial instruction on creating a vent for the smoke generator.
I have decided to break the instructions into a number of key parts which might just be useful components on their own. The circular door isn't something I have seen elsewhere and ended up much simpler to implement than you might think.
Step 1: Smoke Testing
This video shows the smoker during an initial test run to check that the door actually worked.
Step 2: Parts
The aim is to use a few consistent parts
- 5 x 4mm x 15mm long pop rivet;
- 1 x M6 10mm x 10mm square nut;
- 1 x M6 pan head machine screw x 30mm long (any head will do);
- 1 x 20mm diameter M6 Penny washer;
- 1 x M6 nylon lock;
- 1 x M6 nut;
- 2 x 15mm diameter M4 Penny washer (optional);
- 3 x M4 counter-sunk machine screw x 15mm long (any head will do);
- 5 x M4 nut;
- 2mm x 100mm x 100mm sheet aluminium;
- 2mm x 35mm x 35mm sheet steel or aluminium; and
- 1 x nylon plastic handle 172mm x 30mm x 40mm.
**A gas canister or anything else that needs a door**
Step 3: Tools
Think this is the minimum you will need
- 1 x drill (potentially electric);
- 1 x 100mm diameter hole saw (needs to be robust as cutting steel);
- 1 x 4mm drill bit;
- 1 x 6mm drill bit;
- 1 x angle grinder;
- 1 x slitting disc;
- 1 x hand file with flat blade;
- 1 x sharp scribe (sharpened nail worked);
- 1 x dividers or compass for drawing a circle; and
- 1 x clamp.
Step 4: Cut Out the Door
Cut out the shape
- As the aluminium is relatively soft, just use a sharpened scribe to drawn out the shape directly on the metal.
- Use the compass for dividers to scribe out the circle.
- No simple options for this, but I tend to use an angle grinder with a slitting disc to slice the metal off in successive passes and then file down the shape.
- Clamp the aluminium to a piece of wood or chipboard so you can cut through the metal against something flat.
- At this stage you only need to drill a 4mm hole at the centre.
I have added a PDF for the dimension and DXF file of the outline.
Step 5: Cut Out the Latch
Cut out the shape
- Clamp the aluminium/steel to a piece of wood or chipboard so you can cut through the metal against something flat.
- Drill the two 6mm holes.
Step 6: Drill Door Hole
Using the hole saw drill the door hole
- Take the cut canister circle.
- File off any rough edges.
Step 7: Door
Assemble the parts together to form the door
- Bolt the door to the canister circle together using the M4 bolts and nut.
- Line up the canister circle so that most curvature part lines up with one of the six holes.
- This will be where the door touches the cut canister circle.
- Otherwise when you fit the handle it will end up in a odd place.
Step 8: Retainer
To stop the door falling off
- Test fit the door.
- Drill two 4mm diameter holes at the perimeter.
- I aligned these with the lower diagonal rivets for aesthetics.
- Place the M4 nut onto each M4 machine screw.
- Pass through the hole in the canister.
- Tighten the internal M4 nut against the external nut.
At this stage you can adjust the length of screw sticking out of the canister, to improve the fit.
**Optionally you can add washers and further nuts if you have problems getting it to sit correctly in the hole**
Step 9: Finished
- Cut the handle in half.
- Place the square nut onto the M6 screw and tightened to the end.
- Pass the bolt through the handle hole.
- Slid on the penny washer.
- Pass the bolt through the assembled door.
- Tighten the M6 nylon lock bolt onto the M6 screw so the handle will just spin.
- Add the latch.
- Aligned the handle.
- I set it so that up was open and down was closed.
- The latch will need to be set in the opposite direction to the handle.
**Handle is a grab handle for a caravan, and looks similar to the BBQ manufactures ones**