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Ok, now that the burner assembly and hose and regulator are all complete, it is time to get the front on. First a little preparation. A door needs to be installed to get at the hose later. You need to cut this before the front is installed if you want to do it the way I did, or else you will be cutting through the bottom of the smoker to get it done later. I cut the door most of the way out, leaving just a little piece until the hinges are on so everything stays aligned. After the 1 1/2" hinges are installed, I finish my cut. I will let the picture tell the story. [img]http://rp.smugmug.com/photos/94132359-M.jpg[/img] The hole above the door is for air to get to the burner assembly. I use a 4x10 floor diffuser (Also called floor registers) and you want to cut the hole so it is centered on the air intake to the burner. Measure twice, cut once, like my daddy used to say. That burner needs air. I remove the closable louvers in the diffuser so they can't be operated, it needs to be full open at all times. [img]http://rp.smugmug.com/photos/94132649-M.jpg[/img] Now the front can be installed. Just lay the smoker on it's back and lay that front in there, I glue and staple mine on and use the bisquit joiner again here too. Like I mentioned earlier, if you need or want to use the finish nails, or even screws, it can be done any way you see fit. Time to cut in a door to the smoker, the fun part. Got a good jig saw? You're gonna need it. First make a mark 2" in on the sides and down from the top. I have this handy straight edge that I use, and it is a perfect 2". (Don't go less than 2", you need to clear the dowel holders that you installed earlier, plus the 2" of plywood left around the edges gives it some strength. [img]http://rp.smugmug.com/photos/94133300-M.jpg[/img] [img]http://rp.smugmug.com/photos/94133405-M.jpg[/img] I like to make my door about 33" long. The 35" measurement you see in the picture is with the 2" at the top, so the door is actually 33". Make the door bigger and it will just be more weight for the hinges and more chance of warping. Make the corners rounded. That way you only have one starting point with the jigsaw. [img]http://rp.smugmug.com/photos/94133464-M.jpg[/img] My starting point is under the middle hinge, so it is nice and hidden. You can cut up and make the curve around the top, and then you will have to cut down and make the rest of the cut from that direction to get clearance for the jigsaw. You'll know what I mean when you get to this point. Install the 3" hinges before completing the cut to keep things aligned. [img]http://rp.smugmug.com/photos/94133645-M.jpg[/img] Just before making the final cut, install the handle and put a piece of wood through it just like this, or the door will fall in when the final cut is made. And it will be tough to draw back out. [img]http://rp.smugmug.com/photos/94133778-M.jpg[/img]
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