DougGuy
04-12-2017, 09:08 PM
I have been a home coffee roaster for about 6 years now, I started off with the bottom of a West Bend Stir Crazy popcorn popper which you strip the guts out of and leave only the motor, and you replace the plastic actuator shaft with one made of metal from a 1/4" drive extension. The heating unit is the top of a Galloping Gourmet tabletop convection oven, and it will roast 1lb of coffee in about 17 minutes or so, and for $35 bucks invested? Heh IT ROCKS!!
I could run it in late fall and roast enough coffee to last me until spring so I didn't have to roast in cold temps but it didn't really go fast enough and the beans come out fairly unevenly roasted. This isn't such a bad thing because some of the beans have the flavors of a medium roast, and other darker beans have that baker's chocolate aroma and flavor so it's a complex set of tastes and smells that come from this roast so the inefficiency of the "Turbo Crazy" roaster isn't unliveable.
The new roaster is born of wanting to reduce roasting time by increasing capacity and also to even out the finished roasts. Now... I have been watching fleabay for a couple of years, and the cost of a roaster that will handle even 1kg or 2lbs of beans is ASTRONOMICAL! Even a hobby built, semi-professional roaster built on the Ronco 4000 rotisserie oven can run you into a couple of thousand dollars!
So.. After doing some research and speaking with the very fine craftsman that sells these high quality semi professional home built roasters on ebay, (he himself roasts his own coffee, in a 2lb drum, in a Char Grill gas grill) I decided to abandon plans I had to convert a Craigslisted Ronco rotisserie oven, and move on to a gas grill with a rotating drum.
The spark that started the fire was this Sunbeam Model 340 grill on Craigslist for $45, and when I saw how high the arch in the lid was (makes for a larger drum = more capacity) and then saw the size of the flame around the burner, I knew this one could be made to work so I lit out and got the grill, drew up some plans, ordered the perforated stainless steel sheet for the drum, sourced out some scrap 16ga stainless for the cone and the nozzle was a scrap piece of 3" tubing I took home from a big stainless pipe job in a pharmaceutical plant...
I will update the post as progress is made but if you google BBQ coffee roaster you will find countless hundreds of youtube vids, construction plans, photo essays of home built units, etc.. Here is mine. I can roast and enjoy the best coffees in the world, for about $5/lb on average, Starsucks can KISS my hind side..
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Front640_zps65xqmqqs.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Front640_zps65xqmqqs.jpg.html)
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Side640_zpsvfmve7ms.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Side640_zpsvfmve7ms.jpg.html)
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbream%20Burner%20Lit640_zpstpzacjxl.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbream%20Burner%20Lit640_zpstpzacjxl.jpg.html)
Material laid out ready for cutting and fabrication:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Layout640_zpslreg9k2o.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Layout640_zpslreg9k2o.jpg.html)
After splicing together the perforated sheet metal (VERY tedious work I might add too!) with the TiG welder, it was rolled rather crudely around an oxygen bottle with ratchet straps and eventually bent the rest of the way in a small home brew brake press, which also rolled the cone most of the way and I am able to force it into the final fitment for welding..
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Rolled640_zpssnr9p4yp.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Rolled640_zpssnr9p4yp.jpg.html)
TiG welding the pieces of the cone:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Outside%20Cone_zpsvw0qqad9.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Outside%20Cone_zpsvw0qqad9.jpg.h tml)
Attaching the nozzle to create the "Tin Man's Hat"
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Tin%20Mans%20Hat640_zps53pxnxyy. jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Tin%20Mans%20Hat640_zps53pxnxyy. jpg.html)
Drum fitted together, laying in grill to check placement, ready for welding:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Side%20View640_z pspebrw5pm.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Side%20View640_z pspebrw5pm.jpg.html)
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Angle%20View640_ zpszge1e1lb.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Angle%20View640_ zpszge1e1lb.jpg.html)
Bottom of drum showing drive connection, a Craftsman 1/2" socket cut off and welded:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Bottom640_zpsmhwilf1z.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Bottom640_zpsmhwilf1z.jpg .html)
I could run it in late fall and roast enough coffee to last me until spring so I didn't have to roast in cold temps but it didn't really go fast enough and the beans come out fairly unevenly roasted. This isn't such a bad thing because some of the beans have the flavors of a medium roast, and other darker beans have that baker's chocolate aroma and flavor so it's a complex set of tastes and smells that come from this roast so the inefficiency of the "Turbo Crazy" roaster isn't unliveable.
The new roaster is born of wanting to reduce roasting time by increasing capacity and also to even out the finished roasts. Now... I have been watching fleabay for a couple of years, and the cost of a roaster that will handle even 1kg or 2lbs of beans is ASTRONOMICAL! Even a hobby built, semi-professional roaster built on the Ronco 4000 rotisserie oven can run you into a couple of thousand dollars!
So.. After doing some research and speaking with the very fine craftsman that sells these high quality semi professional home built roasters on ebay, (he himself roasts his own coffee, in a 2lb drum, in a Char Grill gas grill) I decided to abandon plans I had to convert a Craigslisted Ronco rotisserie oven, and move on to a gas grill with a rotating drum.
The spark that started the fire was this Sunbeam Model 340 grill on Craigslist for $45, and when I saw how high the arch in the lid was (makes for a larger drum = more capacity) and then saw the size of the flame around the burner, I knew this one could be made to work so I lit out and got the grill, drew up some plans, ordered the perforated stainless steel sheet for the drum, sourced out some scrap 16ga stainless for the cone and the nozzle was a scrap piece of 3" tubing I took home from a big stainless pipe job in a pharmaceutical plant...
I will update the post as progress is made but if you google BBQ coffee roaster you will find countless hundreds of youtube vids, construction plans, photo essays of home built units, etc.. Here is mine. I can roast and enjoy the best coffees in the world, for about $5/lb on average, Starsucks can KISS my hind side..
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Front640_zps65xqmqqs.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Front640_zps65xqmqqs.jpg.html)
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Side640_zpsvfmve7ms.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Side640_zpsvfmve7ms.jpg.html)
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbream%20Burner%20Lit640_zpstpzacjxl.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbream%20Burner%20Lit640_zpstpzacjxl.jpg.html)
Material laid out ready for cutting and fabrication:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Layout640_zpslreg9k2o.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Layout640_zpslreg9k2o.jpg.html)
After splicing together the perforated sheet metal (VERY tedious work I might add too!) with the TiG welder, it was rolled rather crudely around an oxygen bottle with ratchet straps and eventually bent the rest of the way in a small home brew brake press, which also rolled the cone most of the way and I am able to force it into the final fitment for welding..
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Rolled640_zpssnr9p4yp.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Rolled640_zpssnr9p4yp.jpg.html)
TiG welding the pieces of the cone:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Outside%20Cone_zpsvw0qqad9.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Outside%20Cone_zpsvw0qqad9.jpg.h tml)
Attaching the nozzle to create the "Tin Man's Hat"
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Tin%20Mans%20Hat640_zps53pxnxyy. jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Tin%20Mans%20Hat640_zps53pxnxyy. jpg.html)
Drum fitted together, laying in grill to check placement, ready for welding:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Side%20View640_z pspebrw5pm.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Side%20View640_z pspebrw5pm.jpg.html)
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Angle%20View640_ zpszge1e1lb.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Laying%20Angle%20View640_ zpszge1e1lb.jpg.html)
Bottom of drum showing drive connection, a Craftsman 1/2" socket cut off and welded:
http://i1202.photobucket.com/albums/bb374/DougGuy/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Bottom640_zpsmhwilf1z.jpg (http://s1202.photobucket.com/user/DougGuy/media/Coffee%20Roasting/Sunbeam%20Gas%20Grill%20Roaster/Sunbeam%20Grill%20Drum%20Bottom640_zpsmhwilf1z.jpg .html)