I helped my brother-in-law build a reverse flow smoker because he is an avid outdoorsman and loves to cook food on the grill. I, on the other hand, am not as experienced in the great outdoors, so I was happy to help him out.

The first step was to gather all of the materials we would need. My brother-in-law already had a smoker, so we just needed to buy a few extra pieces. We picked up a metal barrel, some pipes and fittings, and a few other supplies from the hardware store.

The next step was to assemble the smoker. It was actually very easy to put together, thanks to the clear instructions that came with the parts. We just had to drill a few holes in the barrel and attach the pipes and fittings.

The final step was to season the smoker. We filled the barrel with applewood chips and lit them on fire. The smoker smelled amazing! We let it burn for a few hours until the chips were completely charred.

Now it was time to cook some food! We decided to make some smoked ribs. The ribs turned out absolutely delicious! The smoke from the smoker gave them a wonderfully smoky flavor that was unlike anything I had ever tasted before.

In this article, I will demonstrate the fundamental stages for building a reverse flow smoker. If you’re unfamiliar with a Reverse Flow Offset Smoker, it’s one in which the firebox is offset to one side of the cooking chamber and a steel baffle plate is used to divert the heat away from the meat.

This lets the meat soak up the smoke without being scorched by the grill.

This structure features both repurposed and brand-new metal components. The heavy steel required to construct the firebox will be the primary source of cost. Using thick steel means less fluctuation in temperature and less work for you to maintain.

DIY Reverse Flow Smoker Plans, Designs & Ideas

1. Reverse Flow Smoker

Reverse Flow Smoker
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A reverse flow smoker is a type of smoker that uses indirect heat to cook food. The main benefit of a reverse flow smoker over other smokers is that it produces more consistent results. This is because the indirect heat ensures that all the food is cooked evenly, without any hot or cold spots.

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2. Building a Smoker Pit

Building a Smoker Pit
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Other benefits of a reverse flow smoker include its ability to hold its temperature more consistent and its ability to produce more smoke. Reverse flow smokers are typically more expensive than other smokers, but many people feel that the benefits are worth the extra cost.

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3. Reverse Flow Bbq Smoker Grill

Reverse Flow Bbq Smoker Grill
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A reverse flow smoker is a type of offset smoker that uses a series of baffles to direct heat and smoke evenly across the cooking chamber. This design helps to minimize hot spots and produce more consistent results.

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4. Reverse Flow Offset Smoker From an Old Water Boiler

Reverse Flow Offset Smoker From an Old Water Boiler
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Building a reverse flow smoker is not difficult, but it does require some basic welding skills. The most important part of the build is constructing the baffles. These can be made from sheet metal or expanded metal, and they should be welded in place so that they are airtight. 

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5. How to Build a Reverse Flow Offset Smoker

How to Build a Reverse Flow Offset Smoker
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Once the baffles are in place, the smoker can be insulated and lined with firebrick before being fired up for the first time. With a little practice, anyone can build a reverse flow smoker that produces perfect smoked meats every time.

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6. The R-BQ, Building a 120-gallon Reverse Flow Offset Smoker

If you’re a fan of smoked foods, you may be thinking about building your own smoker. However, before you get started, there are a few things you need to consider. First, you’ll need to decide on the type of smoker you want to build. There are two main types: offset and vertical. Offset smokers are more traditional and typically use charcoal or wood as fuel.

7. Building an Offset Reverse BBQ Smoker

Vertical smokers, on the other hand, are more modern and can use either charcoal or gas as fuel. Once you’ve decided on the type of smoker you want to build, you’ll need to gather the necessary materials. 

8. Homemade Tabletop Reverse Flow Smoker

For an offset smoker, you’ll need heavy-duty steel sheets, while a vertical smoker can be constructed from cinder blocks or bricks. Finally, you’ll need to choose a location for your smoker. It’s important to choose a spot that’s away from any buildings or other structures, as smoke can be damaging to both people and property. With these things in mind, you’re ready to start building your very own smoker.

9. Reverse Flow Offset Smoker Build

10. Reverse Flow and Vertical Smoker Builds

11. Home-Made Reverse Flow Smoker

12. DIY Reverse Flow Smoker Build Air Tank

How to make a reverse flow smoker

The Parts Required:

  • Culinary Chamber
  • Firebox
  • Baffle Dish
  • Angle Iron Framing
  • Casters
  • Smoke Stack
  • Vents
  • Thermometer
  • Wooden Handle
  • Hinges
  • Shelf
  • Metal Expanded for Fire Basket and Cooking Grate
  • Extremely Hot Paint

Tools Required

  • Welder
  • Mini-Grinder
  • Pliers
  • Hammer
  • Wire Broom
  • Protective Gear

Steps for making reverse flow smoker

Step 1

Assemble all the parts

Step 2: Body of Cooking Chamber-

You can get as creative as you like; all you really need is a flat surface for the meat to sit on while it smokes. For mobility, I bolted wheels onto the frame I made out of legs. The door was made by chopping a hole in the tank and reusing the metal that was removed.

The door to the cooking chamber was welded onto hinges, and the chamber itself was bolted together. Since a smoker doesn’t become extremely hot, you can use some pure cotton as a gasket, but you can also use felt or silicone in its place.

Step 3: Firebox Construct

The hearth is crafted from 14 “using plate steel, which is hefty but can uniformly distribute heat and maintain a constant temperature, I fabricated a simple square box and welded on some strong hinges for the door.

You can kept things basic by building a square box and welded on some solid hinges for the door. On the side you can bore holes for air intake and welded on a bolt so a vent control could be installed.

The vent control is little more than some sheet metal. The handle for the firebox door is made from a chipping hammer, which is simple, inexpensive, and functional. The box’s latch was fabricated from a piece of scrap metal welded to the box’s side, a bar bolted to the door, and some washers and the handle from a chipping hammer.

It’s a pain to move or store the whole smoker only to get to the firebox, so I made it removable by welding a plate to the smoker’s base and then bolting on the firebox to that plate.

Step 4: Cooking Grid and Baffle Plate

The smoker’s body is made of plate steel that serves as a heat sink, an insulator, and a radiant heat source. It runs the length of the cooking chamber and is welded into place so that smoke and heat can travel from the firebox to the chimney.

Step 5: Chimney

The chimney is constructed from a 4 by 4 to vent the smoke and heat “a duct for air flow. The chimney was fastened to a flange that had been manufactured.

Step 6: Final Touches and Fire Basket

After placing the thermometers and creating the expanded-mesh fire basket, the room temperature was successfully measured. Hot coals will be contained in the fire basket.

Some aluminum was also fashioned into brackets for the cook chamber’s wooden door handle. The smoker should be washed thoroughly inside and out to remove any flux residue left over from welding, and then high-heat paint should be applied.

Step 7: Test Cooking

Turn on the smoker for the first time, let it heat up, and then discard the accumulated oils. You’re free to light up then! I made some fantastic short ribs here. Charcoal can be used as a fuel, and wood can be used for smoke in some methods.

Smoke can only be produced by adding more wood after the fire has burned down to embers. It’s difficult but well worth the effort to master.