Advice please - what to buy for first and hopefully last bbq smoker for family.

[LOOPERDOLLY]

First let me state this right upfront.  I don't easily part with my money, but when I do I buy stuff that will last a lifetime or two.  Presently, I'm in "need" of a bbq smoker for the family farm.  We raise and sell pigs/pork.  We'll use the bbq smoker mostly for the family and small gatherings with friends.  And once a year, we'll have a farm field day where we serve up some pork for ~ 50 to 100 people.   So 4-8 people regularly, and 50-100 people once a year.

I live in Minnesota.  So far, I've looked at Backwoods G2 party and fat boy. And read the website for Minnesota made a Backyard Bomber (do any of you have one of these?).  I am also impressed by Peoria Cookers design, as per their website. And Stumps.  But shipping costs may be a deal breaker. The Backwoods and Backyard  Bomber can be picked up locally by me.

My specs so far:
Preference is for charcoal and wood. Though I admit that my preference is rather uninformed.
Easy clean up. And say to operate ( we're newbies to low and slow outdoor smoking/cooking)
Rugged for leaving outside year round.
Fully insulated.
Not too much babysitting through the night when cooking.
Should last twenty years or more ( if possible)
Produce good smoked meat.

I would really appreciate any suggestions on size, type, brand.  Do u think I can get away with one smoker for both uses (family cook outs and annual big farm field day)?

Today we have a Ducane natural gas grill and a weber charcoal kettle.  We'll likely keep those for grilling. Both are 16 years old and going strong.

Cost matters but is not the primary factor.   Would like to stay well under $4k

Thoughts?

Regards,
looperdolly

[sparky]

gravity feed smokers, Humphreys smokers or fec 100.   

[teesquare]

It appears that you like the "cabinet" or "box" style smokers. They do offer a number of conveniences. I think I would look at:

1. WHERE the manufacturer is :- in relationship to you. If you have a maintenance or repair issue - freight can be a cost savings killer. SO - if there is  a manufacturer of a unit that
    you like near you - favor them. It is not THE reason to buy, but proximity counts.

2. Materials used: First - what kind of metals - outer shell stainless? What grade? Some stainless looks good initially - but will in fact rust. Ask for the grade of stainless used.
    Second - insulation - what kind an how thick? Industrial rock wool is the best available currently. Sprayed in foams are not long term stable with their R-values shifting with time             
    and heat. A chemistry issue that would put you to sleep - but I can back up what I am saying if you ned that information. Additionally - spray foam insulation limits the temp. that
    you can run the pit. It cannot take heat like rock wool. Still - there are manufacturers that use it, because they design pits to do "Low-and- Slow ONLY."
    Third- Interior metal used - should always be a food contact approved grade of stainless. the racks them selves - maybe not. They are easier to remove and clean.

3. Versatility: - Is this the only pit you will have? What will you need it to do? Will it be capable of running at the temps you may want? ( i.e. chicken as one example - you need a
    higher temp for skin that is palatable. If your pit can only run at say...max. temp 250F - you will have rubbery, nasty chicken skin - unless you have a second type of grill or pit to
    put the chicken in and crank up the heat in order to crisp the skin to an edible state. I know you are a hog farmer - but....do you really want to limit how you can cook and what
    you can cook?

4. Cost: - always a consideration. None of us are made of money after all....

5. Other cooker types to consider: - My number one answer is king be a pellet grill - based on your description of what you want from a grill. Why? You are cooking with wood. There
    are a great variety of wood pellets in flavor you can select from. It is thermostatically controlled. Some can cook as low as 160-170F for a REAL smoke generating cook and taste.
    Some can cook as high as 700+ degrees. Some are internally insulated ( at least the hood is ) Some can actually be controlled from your smart phone.  ( I cannot express to you
    the usefulness of this feature. I thought it was frivolous until I tried it...and now it gives me freedom to continue working, or sleeping or anything - and monitor meat and oven
    temp., and even change the temp, or turn the grill off - from anywhere that I have internet connection!!!
   
So - for my money - i would strongly urge that you look at better brand pellet grills, and buy an insulating blanket ( there are several resources for these - old welders blankets are
       but one of them ) and investigate the pellet grill manufacturers. We have 2 of them that are well loved and used  as sponsors here on LTBBQ. They are sponsors NOT because
       they were willing to write a check. They are sponsors because their products present a great advantage or value in a marketplace of some highly variable quality of products.

Hope this helps!

[Pappymn]

I agree with Tee, as he is old and wise. Consider a pellet grill. They produce great results and have a much shorter learning curve. I have a Mak 2 star. Rock solid for low and slow.

Memphis is also well regarded and made in Minnesota. Rec Tec also should be considered.

[sliding_billy]

Personally, I like the idea of a large insulated vertical (gravity fed).  I think shipping/delivery is going to be one of the major challenges.  I would seriously look at Craigslist where someone else has already absorbed that cost.  There isn't much that a good cleanup can't make pretty again, and with the amount you are going to be cooking I wouldn't expect the smoker to look showroom new for too long.  Besides the obvious choices (brand-wise), I would strongly recommend giving Shirley Fabrication as call.  Paul and Tyler are class act folks and fantastic builders.  Their following on the "Big BBQ Forum" is near cult-like.  There has never been a bad word spoken about them, and that is hard to accomplish when you do full custom and stock build work.  While reverse flow stick burners are their primary line, I have no doubt that if you can dream it up they can build it.

http://www.shirleyfabrication.com/

[Hub]

I've read and reread your post several times to make certain I'm seeing your need.  Where there is an inherent and perhaps illogical compromise is the difference between a cooker of any type that will gracefully generate enough heat and have enough space to cook for 50-100 people once a year vis-à-vis a cooker that will be very suitable for feeding a small group of family and friends the rest of the time.  This implies that 364 days a year a big cooker would be significantly underutilized and/or one day a year a "standard" sized cooker would be overtaxed.

What is missing that might aid in clarification is "what do you cook and when?"  Whole hogs, ribs, butts, shoulders, weenies, burgers, tofu lumps, slaughtered veggies, fatties, ABT's, briskets, etc. etc.

I can think of a few cookers that can approach this very broad spectrum of use, but not many.  And, I've owned every type and a lot of the brands over the years.  I've never had one last 20 years, either, but with low utilization and good maintenance and storage that might be possible for some really heavy-duty ones.

Thanks for a wonderful post and a real conundrum    -- there are some good answers getting started for you here and I don't disagree with any but I'd like a little more info to help me narrow down the field a bit.

Hub

[LostArrow]

For about $500 you can get a smoker with enough room to cook 80 lbs pork butt or 12-14 racks ribs.
Will last 20 years in the elements , is as easy a "Set -it- and forget it " smoker made !
Is easy to clean, & $500 includes an insulated cover.
It's made in America & Smoky will agree ....he has 2 or 3
A 22 in Weber WSM with an insulated jacket might just fit your needs!

[LOOPERDOLLY]

Thanks for the great responses.  You all are so generous with your time and knowledge. I see that It's not that easy to define specs, with no prior experience, but I'll try to apply logic and preferences , and we'll see if it points me towards a particular style and size of cooker...

Long lasting - my frame of reference is the Ducane gas grill and Weber charcoal grill that are going strong after 16 years.  So I figured if I'll be spending $1K to $4K on a bbq smoker, I should get quality and ruggedness that will last similar length of time.  So 20'years.  Maybe unrealistic or flawed logic?

Versatile Use - various cuts of pork (shoulder, ham, ribs, whole loin roasts, bratwurst) often, whole roasting chickens often, and various cuts of beef and chicken less frequently,  but NEVER whole hogs.   Hot dogs and  burgers would still be cooked on the weber grill. Likely steak too.

Small groups often (4-8) and annual large gathering for farm field day (over 50 people).  I would bias cooker selection to be great for the day to day use and be compromised  for the annual field day.  Maybe we'll call in for friends with cookers to help out on the field day...

I like the looks of the box or cabinet style cookers because I have assumed they are build like a tank and thus would be more likely to be a long lasting investment.  Admittedly,  this could be a false conclusion.  I also have assumed they will be simpler to operate and clean.  Feedback welcome.

I hadn't considered pellets but will study up on them after reading the good advice from you folks.

One scenario that I've been avoiding is to buy a drop in metal coal separator to convert the weber grill to a indirect heat smoker and start our learning using that simple low cost approach. My concern is that type of setup will more likely be difficult and provide discouraging results. Again, just an assumption. Did any of you start out this way?


Hoping to visit a bbq contest and look and learn about various equipment types that way too.  I think there will be one in August in MN.


Regards,  looperdolly

[Pappymn]

Thanks for the great responses.  You all are so generous with your time and knowledge. I see that It's not that easy to define specs, with no prior experience, but I'll try to apply logic and preferences , and we'll see if it points me towards a particular style and size of cooker...

Long lasting - my frame of reference is the Ducane gas grill and Weber charcoal grill that are going strong after 16 years.  So I figured if I'll be spending $1K to $4K on a bbq smoker, I should get quality and ruggedness that will last similar length of time.  So 20'years.  Maybe unrealistic or flawed logic?

Versatile Use - various cuts of pork (shoulder, ham, ribs, whole loin roasts, bratwurst) often, whole roasting chickens often, and various cuts of beef and chicken less frequently,  but NEVER whole hogs.   Hot dogs and  burgers would still be cooked on the weber grill. Likely steak too.

Small groups often (4-8) and annual large gathering for farm field day (over 50 people).  I would bias cooker selection to be great for the day to day use and be compromised  for the annual field day.  Maybe we'll call in for friends with cookers to help out on the field day...

I like the looks of the box or cabinet style cookers because I have assumed they are build like a tank and thus would be more likely to be a long lasting investment.  Admittedly,  this could be a false conclusion.  I also have assumed they will be simpler to operate and clean.  Feedback welcome.

I hadn't considered pellets but will study up on them after reading the good advice from you folks.

One scenario that I've been avoiding is to buy a drop in metal coal separator to convert the weber grill to a indirect heat smoker and start our learning using that simple low cost approach. My concern is that type of setup will more likely be difficult and provide discouraging results. Again, just an assumption. Did any of you start out this way?


Hoping to visit a bbq contest and look and learn about various equipment types that way too.  I think there will be one in August in MN.


Regards,  looperdolly

Yep. In the Sam's club parking lot in Woodbury.

[Hub]

I really admire the thoughtful approach you are taking.  Please read my two Pellet Cooker 101 articles here:  http://www.letstalkbbq.com/index.php?board=59.0
Then, when you start looking around art a contest, check out the FEC 100 or FEC 125.  These are actually commercial units but show up at most competitions.  Their best fit to your needs is VERSATILTY.  They'll cook small batches economically and are plenty powerful enough to feed a hundred using dense cuts like butts and briskets.  Combined with what you already own, they'll fit in nicely.  I'm leaning toward T's thoughtful post above.

Based on all the needs you've outlined so far, I think this is a good fit, but maxes out your budget.  Watch for good used ones on E-bay and Craigslist postings.  Keep us informed on your search    I've lost track of all the cookers I've been through to get to the ones I own and love today but it has been fun to get here.

Hub