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Grill Talk => Weber Grill Forum (Grills, Accessories) => Topic started by: ChadRex on July 14, 2013, 09:14:52 AM

Title: ChadRex's SJS Mini WSM ( with images)
Post by: ChadRex on July 14, 2013, 09:14:52 AM
After reading all the posts and reviews for the Smokey Joe Silver Mini WSM mods, I decided to go for it.
The hardest part was locating the right Steamer pot that would fit the base and lid of my Smokey Joe Silver.
I finally found the right pot, Hispanic markets seem to be the way to go. No crimping!

Here is Parts List I tried to include part/SKU #'s and prices.

Miscellaneous Tools Needed:

Some the small hardware I already had in my tool box (the stainless hex nuts and washers)
I did have to purchase a Jig Saw $59.00 and metal cutting sheers $12.00 at Home Depot, I didn't have these in my tool collection & sure I will need them for other projects so the cost of this will not be included in the overall total cost of my Mini WSM project. I realised I didn't need the jig saw the tin snips would have done the job fine. However cutting the Expanded metal for the charcoal grate was much easier with the Jig saw, using tin snips on expanded metal take more time and effort.

VMI 32 Qt Steam Pot-

(http://images61.fotki.com/v444/photos/3/650943/9034968/20130629_212546-vi.jpg)

Purchased at Best Way Hispanic Super Market- for $16.34 (tax included)
Lid fits perfectly and the pot sits snug in kettle,cooking grate fits nicely in steamer ridge very stable .
Distributed by VM International
1241 E Watson Center Rd
Carson CA 90745
(310)952-9000

Charcoal Grate and cooking grate stop Bolts

Temp Gauge Grommet

Expanded Metal Charcoal Basket

Water/Drip/Diffuser -Still searching for a suitable Water/drip Pan

Damper/Vent Handle- Lower
I was fortunate enough to have the damper control rod from a 1 touch cleaning system kit I ordered a few years ago hoping to upgrade my 22.5 " 1980's Weber kettle (It didn't quite fit my 22.5 " I am glad I kept the parts)   hopefully the diameter of the Damper handle isn't too big should be Ok
*Large Ash Catcher- 9"ALU Pie pan .99

Finishing ( Painting /Sanding)
Still considering my options for painting/ finishing. My 6 year old son is helping with the design,our thoughts are for anodized Blue Flames with orange tips or 2-tone Orange flames on Anodized Blue Surface, with the dampers, grill legs painted to match. I will NOT be painting the SJS kettle, it has a good finish and the black looks good.
Norton Metal Sand paper Assorted Pack- $5.97 HD SKU135-534

VHT Engine Enamel up to 550 F ( VHtpaint.com/CariD or TCP global



Estimated Total Cost of this project= $87.16 (Based on purchasing the above items listed) My cost was more around 75.00 not including the SJS.

I will do my best to document the steps and update posts.
Mahalo to all for feedback, replies and suggestions
Title: Bottom Damper Handle / Ash Catcher Mod
Post by: ChadRex on July 14, 2013, 09:34:27 AM
Lower Damper Handle and Ash Catcher Mod

(http://images55.fotki.com/v1618/photos/3/650943/9034968/20130701_195841-vi.jpg)

Replaced bottom tiny ash catcher with a larger 9" Round Aluminum Pie Tin from .99 Store.
(http://images56.fotki.com/v713/photos/3/650943/9034968/20130701_200722-vi.jpg)

Added markings on ash catcher to indicate damper open and closed positions.

Added a Top Damper/vent handle used a stainless steel T-Knob drawer pull

Top Cooking Grate: I decided I only needed to add mounts to support 1 cooking grate. I will set my lower grate in the indentation of the steamer pot, Weber SJS cooking grate model#7431- fits perfectly.

(http://images49.fotki.com/v571/photos/3/650943/9034968/20130702_201323-vi.jpg)

Temp Gauge Grommet : to pass a leave in temperature probe at top cooking grate level
I chose this location so the probe would sit just above the cooking grate. it turns out it sits right at grate level. The grommet mounts flush to the inside of the steamer pot. (Notice the lower cooking grate resting in the steamer pot steamer indentation ridge)

(http://images59.fotki.com/v222/photos/3/650943/9034968/20130703_210954-vi.jpg)

(http://images59.fotki.com/v111/photos/3/650943/9034968/20130703_210634-vi.jpg)

Charcoal Basket: and Ash damper cover
Many folks understand that with the Smokey Joe Silver has always had an issue with ashes clogging the lower vent, choking off air flow and preventing stable consistent heat.  By adding damper handle it makes getting in there to clean out the ashes easier. Another modification is to add a charcoal basket this accomplishes a couple things 1st. it contains the charcoal/heat source in the center of the kettle, also allows more coals to be added and helps with easier clean-up.
If you do nothing more than add a Lower damper handle, Charcoal basket and Damper hole Cover, you will develop a renewed interest and see huge improvements in the function, use and performance of your Weber Smokey Joe.

3"high Expanded Metal Charcoal Basket.
You will need a couple pairs of needle nose pliers and some patience when attaching the EM to the grate. This  proved to be challenging. Alternatively if you are a skilled welder - this can be a breeze.

(http://images108.fotki.com/v1629/photos/3/650943/9034968/20130702_211723-vi.jpg)

(http://images50.fotki.com/v1557/photos/3/650943/9034968/20130704_223829-vi.jpg)

Ash Can damper cover: The serves to block the ashes from falling and clogging the damper holes.

Picture below shows my Charcoal Basket and the Damper Hole Cover.

(http://images108.fotki.com/v613/photos/3/650943/9034968/20130704_223735-vi.jpg)

Permanent Mounted Thermometer.

Excuse the messy garage: Photo below shows finished SMJ Mini WSM  all  that is left is the paint.

(http://images46.fotki.com/v284/photos/3/650943/9034968/20130704_183540-vi.jpg)

Finishing /Painting
My 6 year old son is helping with the design,our thoughts are for 2-tone Orange flames on Anodized Blue Surface, with the dampers, grill legs painted to match. I will NOT be painting the SJS kettle, it has a good finish and the black looks good.


I have painted a few coats of Anodized Blue (inspired by another forums' members' ), "MAC's Blue Mini Mod" He did a much better job of painting his, I was going for that look as my base coating... I fell way short...
I regret to admit my painting skills are sub standard and nothing compared to the other paint jobs on others' WSM mini builds. Part of it could be the anodized type paint. I know I prepped the surface properly. I need more practice spray painting even coats.
I still have to add orange/yellow flames and a clear coat finish. Hopefully I can complete it to my 6 year old sons standards. He wanted blue with hot wheels style flames..
We shall see.

The table it's sitting on is an IKEA SKOGHAL side table for $14.99, I added a Weber tool holder and I plan on staining & adding a protective varnish. It is very stable & perfect for my Mini.
I was also considering getting IKEA Applaro wheeled outdoor wooden serving cart (http://"http://www.ikea.com/us/en/catalog/products/00208533/")  It has a shelf on bottom to store grill tools, hooks to hang tools or lid, and even a place to put paper towels. looks perfect for the mini smoker set up.

All thats left is a few more coats of Blue on the legs and  adding flames followed by 3-4 coats of clear coat.

I will post in the next couple of weeks.

Please keep in mind this project was inspired by Others' innovation and ideas. This post was simply to pay it forward as others have helped me..  I encourage anyone considering this to go for it it is an easy project that turns the Smokey Joe into a very functional sharp looking smoker, with out modifying the Smokey Joe. The best of both. 

(http://images51.fotki.com/v748/photos/3/650943/9034968/20130709_192047-vi.jpg)

Mahalo, -Happy Smoking[/list]
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: LightningBoldtz on July 14, 2013, 10:13:56 AM
very nice, I have an extra handle if I do a 2nd WSM I may have to try that.
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: addicted-to-smoke on July 14, 2013, 10:18:27 AM
Thanks for this detailed write-up. I'll be checking it out over the next few days. Being able to convert my Smokey Joe to a small smoker is something I want to do someday.
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: G$ on July 14, 2013, 10:21:36 AM
Thanks Chadrex for the write up.  Al though I am not a mini sj smoker user, many are, and your detailed write up will help countless folks!
Title: ChadRex's SJS Mini WSM ( with images)
Post by: Craig on July 14, 2013, 10:26:54 AM
Great instructional and nice mini buildup. I've thought of doing the one touch lever mod and now that I see yours, I am definitely doing this.
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: glrasmussen on July 14, 2013, 10:41:43 AM
Very nice job!
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: dwnthehatch on July 14, 2013, 11:26:39 AM
Great write up! Be careful with the galvanized steel wire. Galvanized steel should never be used for cookware or food storage since this may lead to zinc poisoning (aka heavy metal poisoning). Exposure to high levels of zinc can cause lethargy, dizziness, nausea, fever, diarrhea, irritability, muscular stiffness and pain, loss of appetite, and reversible pancreatic and neurological damage.
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: G$ on July 14, 2013, 11:34:26 AM
I missed the galvanized bit.  I agree I would not use galvanized in my charcoal cooker.  No need to.
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: ChadRex on July 14, 2013, 12:01:28 PM
Quote from: dwnthehatch on July 14, 2013, 11:26:39 AM
Great write up! Be careful with the galvanized steel wire. Galvanized steel should never be used for cookware or food storage since this may lead to zinc poisoning (aka heavy metal poisoning). Exposure to high levels of zinc can cause lethargy, dizziness, nausea, fever, diarrhea, irritability, muscular stiffness and pain, loss of appetite, and reversible pancreatic and neurological damage.

Thanks for the Tips, I opted to use 16-5-Gauge-Rebar-Tie-Wire (http://www.homedepot.com/p/Weyerhaeuser-400-ft-16-5-Gauge-Rebar-Tie-Wire-05337/202094311#.UeMD3uQ4vgc)

I was not aware of the harmful risks of galvanized wire.
Huge Mahalo!  I have edited my posts to eliminate the galvanized wire

The re-bar tie-wire was easier to work with. If I can i will try to get a friend to spot weld before my first cook.
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: ChadRex on July 14, 2013, 01:04:54 PM
Quote from: addicted-to-smoke on July 14, 2013, 10:18:27 AM
Thanks for this detailed write-up. I'll be checking it out over the next few days. Being able to convert my Smokey Joe to a small smoker is something I want to do someday.

You will not regret it. The project is easy to do.. and it really improves the function of Smokey Joe..
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: Red Kettle Rich on July 14, 2013, 01:46:05 PM
It doesn't hurt the SJ, the tamale pot will never be the same though 8)
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: 1911Ron on July 14, 2013, 01:55:32 PM
Nice detailed write up!  Only problem i see is it's to clean ;D
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: LFLSTD138 on August 04, 2018, 07:12:42 AM
I want to see how well it smokes
Title: Re: ChadRex's SJS Mini WSM ( with images)
Post by: HoosierKettle on August 04, 2018, 07:46:29 AM
Old thread but mine works fantastic. Great little portable smoker that sips fuel.


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Title: ChadRex's SJS Mini WSM ( with images)
Post by: HoosierKettle on August 04, 2018, 07:49:24 AM
Mini WSM appreciation thread
http://weberkettleclub.com/forums/index.php?topic=36357


Sent from my iPhone using Weber Kettle Club mobile app (https://siteowners.tapatalk.com/byo/displayAndDownloadByoApp?rid=91018)
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