ChadRex's SJS Mini WSM ( with images)

[ChadRex]

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:

• Jig Saw with fine metal cutting blade or Metal Cutting Sheers (AKA: Tin Snips, Aviation snips)
• Measuring Tape
• String 16" (To measure distance between grate mounting bolts)
• Scratch Awl - To mark/pre-drill
• Goof Off - Paint prep wipes: clean residue off Aluminum Stock pot (mine had label adhesive)
• metal File or 150 grit metal sand paper: To sand off the sharp edges/burs from cutting bottom off and drilling holes
• Extra fine steel wool and paint prep wipes for preppeing Aluminum pot surface for painting
• 1/4 inch metal drill bit: for grate mounting bolts
• 3/8 metal drill bit for mounted thermometer and temp. gauge grommet
• Church key can opener or 3/4 inch drill bit to drill holes in vent damper cover can

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-



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

• 1/4x3/4 Stainless Hex bolts x6 - @.36 - $2.16
• Weber plated steel Smokey Joe cooking grate model 7431 - $7.49 Home Depot SKU 150-748
• 1/4 stainless steel Cap Nut x 6 @1.18 each $7.08 HD SKU 762-132
• 1/4 stainless steel lock washer 6 pack $1.18 each HD SKU 517-275
• 1/4 stainless steel hex nut 4 pac x2 @$1.18 each $2.36 HD SKU 307-319

Temp Gauge Grommet

• Made with Westinghouse brass lighting fixture parts found in Home Depot lighting section.
• 1/8-IP Zinc-Plated Nipples (8-Pack) need the 1/2" size- $2.97 HD SKU # 215-872
• Brass Plated Nuts and Washers (6-Pack) $1.57 HD SKU # 217-360
• 1/8-IP Brass Caps (2-Pack) - $1.98 HD SKU# 215-910

Expanded Metal Charcoal Basket

• Still contemplating on this design Flared vs standard 3" deep
• Expanded Sheet Metal plain 24x12 x 1 -$9.37 HD SKU 474-584
• Weyerhaeuser 16.5 Gauge-Rebar-Tie-Wire ( to connect coal basket & attach to coal grate) -$3.98 HD SKU#572-365

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

• looking for a stainless 9"x 2" deep cake pan, that will cut trimmed to sit on the steamer ridge/lip.
• Found a deep stainless Steel bowl at 99 Cent Store & some 9" alumn round cake pans 3 @ .99 - $2.99-
• In a pinch I have 9" round cake pan i can use (I raided my wife's baking supply hoard of pots and pans.)

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

• VHT Engine Enamel Paints Heat resistant up to 550 F. (can be found at auto parts retailers or online at TCP Global or CariD
• Gloss Clear High Temp Engine & Drivetrain Coating VHT SP145 $6.98
• VHT Paint Application and drying instructions

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

[ChadRex]

I started my Smokey Joe Silver Mini WSM build on 6/30.

Lower Damper Handle and Ash Catcher Mod

• Bent damper tabs up to 90 degree, drilled 1/4" holes in center of tabs
• Added a damper/vent handle  to the bottom damper vent on my SJS (from a One-Touch cleaning Kit bent slightly to fit)
• held in place with a 5/16 e-clip

Replaced bottom tiny ash catcher with a larger 9" Round Aluminum Pie Tin from .99 Store.


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.

• I drilled 3  1/4" Holes at 4" down from top of steamer (Measured from under pot lip) & 14 .5 " apart
• (3 x 1/4" stainless hex bolts with lock nuts, attached cap nuts on outside.
• measured the circumference of the pot divided into thirds/ took a string aprox 14 .5" in length to mark location of holes
• 1/4x3/4 Stainless Hex bolts x6 - @.36 - $2.16
• 1/4 stainless steel Cap Nut x 6 @1.18 each $7.08 HD SKU 762-132
• 1/4 stainless steel lock washer 6 pack $1.18 each HD SKU 517-275
• 1/4 stainless steel hex nut 4 pac x2 @$1.18 each $2.36 HD SKU 307-319
• Weber plated steel Smokey Joe cooking grate model#7431 - $7.49 Home Depot SKU 150-748

Temp Gauge Grommet : to pass a leave in temperature probe at top cooking grate level

• Made with Westinghouse brass lighting fixture parts found in Home Depot lighting section.
• 1/8-IP Zinc-Plated Nipples (8-Pack) need the 1/2" size- $2.97 HD SKU # 215-872
• Brass Plated Nuts and Washers (6-Pack) $1.57 HD SKU # 217-360
• 1/8-IP Brass Caps (2-Pack) - $1.98 HD SKU# 215-910
• Drilled a 3/8" hole aprox. 5" down from top of steamer pot ( measured from under lip) centered between handle

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)





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.

• Cut 3 12"x 3.5" sections from single sheet of Expanded Metal, ( used a Jig saw Aviation snips will work also.)
• Cut 10 3/4 circumference piece for charcoal grate bottom.
• Expanded Sheet Metal plain 24x12 x 1 -$9.37 HD SKU 474-584
• I used Weyerhaeuser 16.5 Gauge-Rebar Tie-Wire to connect coal basket & attach to coal grate
• Aprox. Measurements: Width 10 3/4  Height 3 3/8 (Mine was closer to 3" high the circumference was= charcoal grate

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.





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

• A Tuna or Chicken can no higher than 2 inches with holes cut out on top edge for airflow
• I used a 28 oz. tuna can/ Costco chicken cans work well for this too

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



Permanent Mounted Thermometer.

• I usedWeber Thermometer #70180
• Drilled 3/8" hole just below cooking grate

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



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.

• Prepped using Norton Metal Sand paper Assorted Pack- $5.97 HD SKU135-534 / Extra fine steel wool also works
• Duplicolor Prep-wipes Found mine at Auto Zone for about $3.00
• Wash with dish dish soap/ water, rinse well  and dry completely
• Used VHT Engine Enamel Paints Heat resistant up to 550 F. (can be found at auto parts retailers or online at TCP Global or CariD
• 3 coats of Anondized Color coat SP451 =Anodized Blue $8.98
• Gloss Clear High Temp Engine & Drivetrain Coating VHT SP145 $6.98
• VHT Paint Application and drying instructions

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  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. 



Mahalo, -Happy Smoking[/list]

[LightningBoldtz]

very nice, I have an extra handle if I do a 2nd WSM I may have to try that.

[addicted-to-smoke]

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.

[G$]

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!

[Craig]

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.

[glrasmussen]

Very nice job!

[dwnthehatch]

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.

[G$]

I missed the galvanized bit.  I agree I would not use galvanized in my charcoal cooker.  No need to.

[ChadRex]

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

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.

[ChadRex]

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..

[Red Kettle Rich]

It doesn't hurt the SJ, the tamale pot will never be the same though

[1911Ron]

Nice detailed write up!  Only problem i see is it's to clean

[LFLSTD138]

I want to see how well it smokes

[HoosierKettle]

Old thread but mine works fantastic. Great little portable smoker that sips fuel.


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