Welcome to the SmokerBuilder Podcast with Frank Cox, the BBQ Pit Engineer (@smokerbuilder), your guide to designing, fabricating, and mastering BBQ smokers.

In this episode, Frank tackles a hot topic from SmokerBuilderU.com member Greg Rose: Do you really need bracing on cook chamber doors for a 250-gallon propane smoker build? 

Drawing from years of experience, Frank explains why top builders like Moberg skip bracing and how propane tank construction—like submersible arc welding and seam welds—affects your build. 

He reveals his proven strategy: cut the firebox and collector holes first, weld them up, and save the doors for last to minimize spring and movement.

Frank also shares practical fixes for door alignment, using affordable tools like a Harbor Freight porta power or chain hoist, and even simple round bar or turnbuckles for reinforcement. 

With real-world examples—like his 500-gallon split door build for Matt Gerlach—Frank demystifies smoker fabrication tolerances (think 3/16-inch max play) and encourages builders not to sweat the small stuff. 

Whether you’re new to propane tank smokers or a seasoned pit master, this episode delivers actionable BBQ pit engineering tips to perfect your craft. 

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