What it takes to make the hottest BBQ smokers in the country
As we have noted in many issues of The Smoke Sheet, Texas-style barbecue continues to grow in popularity across the nation and worldwide. With this increase in popularity comes a greater demand for products and materials that are commonly associated with barbecue in Texas, including prime briskets, post oak wood, and offset smokers. With this increased demand, high-quality offset smokers come at a premium.
Mill Scale Metalworks is a company that builds custom offset smokers in Lockhart, Texas.
On my most recent trip to Texas, I had the opportunity to visit Mill Scale Metalworks, fabricators of custom offset smokers for commercial, competitive, and backyard use.
Mill Scale Metalworks was launched by brothers Matt and Caleb Johnson almost a year ago and the company has quickly made a huge impact on the barbecue world, creating large offset smokers for some of the biggest names in the industry, including Billy Durney of Hometown Bar-B-Que in Brooklyn, Banger’s Sausage House & Beer Garden in Austin, Dylan Taylor of Goldee’s in Ft. Worth, Brick Vault Brewery & BBQ in Marathon, Buck’s BBQ in Houston, and Holy Smoke BBQ of Sweden.
I met the two brothers at their shop out along a gravel road outside of Lockhart, Texas, where an assortment of salvaged old propane tanks of various shapes and sizes sit ready to be given new life as offset smokers.
Salvaged propane tanks are repurposed into offset smokers at Mill Scale Metalworks.
Inside, I was greeted first by Caleb, the quieter and more imposing of the two and was immediately confronted with the sight of a 1,000-gallon smoker with a giant smokestack towering over me. The smoker had recently been completed and would soon be on its way to a new owner in an undisclosed location.
Matt, the more outspoken of the brothers said hello and immediately began giving me details about the smoker’s unique smokestack and other design features. He also described the network of people across the state who find propane tanks for them. What were once discarded and given away freely, “are getting harder to come by,” Matt said.
Inside the Mill Scale shop, a 1,000-gallon offset is being readied for shipment to its owner.
Beyond the enormous size of the smoker, what struck me most was its raw, unpolished appearance. Large scratches across the doors of the smoker were not covered up or painted over but were left to give it a unique character.
Matt said that while they have the equipment and the ability to paint the smokers, they prefer the raw aesthetic and so far none of their customers have asked to have the smokers prettied up. Matt explained that they also leave the data plate on, which gives customers some idea of the history and origin of each propane tank.
Caleb and Matt Johnson, founders of Mill Scale Metalworks in Lockhart, Texas.
When I asked how they got started making smokers, Matt and Caleb described growing up in a small town in Texas, learning to build, fix, and tinker with things from their dad. They also talked about how their mother was from the Portuguese island of Madeira and always grew vegetables in the garden and made her own food from scratch.
“We didn’t really go out and eat fast food,” Matt said. Meals were an important time their family spent together, so perhaps it is no surprise that barbecue, itself a very communal type of cuisine, would resonate with the two brothers. They cook as often as they can and continue to expand their knowledge of live fire cooking. Matt said he doesn’t hesitate to pick up the phone and call up chefs and pitmasters if he has questions or wants to understand what it is his customers might be looking for.
Mill Scale has recently developed a line of 94-gallon offset smokers for backyard use.
They have recently expanded their custom products to include durable, high-quality 94-gallon offsets for backyard use in addition to the 500 and 1,000-gallon smokers used by commercial and competitive pitmasters. The base price for the backyard smoker is $4,150 while 1,000-gallon offsets start at $15,500. They have also been creating new products inspired by live fire cooking found in cuisines around the world, including Japanese yakitori grilling and South American asado cooking techniques.
Demand for their products is high, despite the fact that they are selective about who they work with. “It’s like a relationship -- we’re going to be associated with these people for years to come.” New customers currently are on a 2-year wait list. “The goal is to get that 2-year wait list down,” said Matt.
Caleb and Matt take time for a quick photo.
When I asked the obvious question about adding additional employees to help out, it was clear that Matt and Caleb were looking for someone who is not only skilled in welding but also as passionate about food and cooking as they are. In addition to the requisite skills and passion, anyone looking to join the team would need to have an incredible work ethic.
While Matt is able to occasionally travel to attend barbecue events and festivals, Caleb likes to stay busy back at the shop. “I’d rather just stay here and work,” he said. Both of the brothers admit that they prefer to lead private lives and only recently joined social media with the creation of Mill Scale. The raw esthetic of the smokers they build, the sparks from welding, and the final products being put to use with live fire cooking make for visually appealing photos on Instagram, many of which were shot by their friend Robert Jacob Lerma.
I am incredibly honored that Matt and Caleb gave me so much of their time and willingly shared so much about the business they are passionate about. I also look forward to seeing how Mill Scale continues to grow and shape the world of barbecue and live fire cooking in the years to come.
Ryan Cooper (BBQ Tourist)
Co-Founder, The Smoke Sheet
Here are the top recent barbecue news stories from around the country:
The Smoke Sheet co-founder Sean Ludwig grills up some healthy steaks. Read some great health-conscious barbecue tips from the Houston Chronicle this week.
While we featured a guest article recently on being , there are lots of other tips on how to navigate backyard barbecues with health in mind. Houston Chronicle dietitian Maddy Falivene writes that you can mindfully plan your plate, bring a healthy dish, and more.
If you’ve ever wanted to get more detail on how to best order brisket at barbecue joints, Robert Moss has a great new primer in Southern Living.
Barbecue is truly everywhere these days, and that includes Little Haiti in Miami, writes the Miami Herald. Partners Jean “BJ” Lucel and Wesley Bissaint have quickly grown their joint Bon Gout BBQ there and have become known for their Southern barbecue with a Haitian twist.
Charlotte, North Carolina will soon have a great new barbecue option called Noble Smoke, writes the Barbecue Bros. Given owner Jim Noble’s restaurant experience and a clear passion for barbecue, the Bros. think this will be a true destination barbecue joint.
The St. Louis area has a great new barbecue option with Beast Butcher & Block, which is a new location of the acclaimed Belleville restaurant Beast Craft BBQ Co. It opened last Saturday.
If you don’t have a smoker but still want to work some grill magic on ribs, Thrillist has a list of 17 tips from pitmasters to help you make ribs at home. When you’re working on your ribs and need some barbecue sauce to pair with them, also check out these 10 barbecue sauce recommendations from Men’s Health.
The Dallas Observer says that the new Joe Riscky’s Barbecue “is a win for Fort Worth barbecue fans in search of quality smoked meats.”
Three months after shutting its doors and filing for bankruptcy protection, Wilber’s Barbecue, one of North Carolina's oldest barbecue joints, is for sale.
J.C. Reid of the Houston Chronicle writes that Houston is now the center of the "barbecue taco revolution."
Finally, sad news from London: Pitt Cue, one of the top barbecue joints in London barbecue, has closed after eight years in business, according to Eater London.
Here are BBQ shows, podcasts, or books you should check out this week:
Watch: Meet the Kings and Queen of Kentucky Style BBQ - Zagat Documentaries
When it comes to distinct American regional style barbecue styles, the state of Kentucky doesn't get the same praise as Texas and North Carolina. But residents of The Bluegrass State know that amazing barbecue, especially mutton, awaits for anyone traveling through. Zagat visited a selection of local BBQ joints (including Old Hickory Bar-B-Q, Moonlite Bar-B-Que Inn, and R & S Barbecue) to speak with the hardworking families of these institutions to find out what makes Kentucky-style 'cue unique. Watch it here.
Listen: Craig Pascoe and Trae Welborn from Georgia BBQ Trails - Kevin’s BBQ Joints
In this episode, Kevin chats with Craig S. Pascoe and James “Trae” Welborn from Georgia BBQ Trails. Craig is a History professor at Georgia College and Trae is an assistant professor at the same college. They discuss both of their backgrounds and how they connected and grew their 'historical' barbecue relationship. They also talk about the Barbecue Nation exhibit at the Atlanta History Center and the genesis and growth of the Georgia BBQ Trails website (with the site’s web map created by The Smoke Sheet’s own BBQ Tourist). Lastly, they cover historic barbecue joints to visit throughout the great state of Georgia. Listen to the episode here.
Read: BBQ Culture in America - by Allan Detrich
Award-winning photographer and storm chaser Allan Detrich has criss-crossed the country over two decades taking photos of natural disasters and weather-related incidents. In between these adventures, he became enamored with seeking out the best in American barbecue. Detrich spent over 10 years taking photographs of the people, places, and food from the barbecue world. From the most famous pitmasters and revered barbecue restaurants in American to tiny, hidden gems and mom and pop joints, the book Barbecue Culture in America contains 200 pages of beautiful and striking photographs. Order it here.
The Giant National Capital Barbecue Battle takes place this weekend in Washington, D.C.
June 22-23: The Giant National Capital Barbecue Battle - Washington, D.C.
This June, historic Pennsylvania Avenue in Washington, D.C., will become the epicenter of barbecue perfection. The biggest part of the event is the Cooking Contest, which will feature big names like Myron Mixon, Tuffy Stone, and Moe Cason competing with teams from around the U.S. Also, lots of U.S. barbecue joints from will be there serving food and more than 30 bands will perform live on three stages. More info here.
July 5-7: I Love BBQ and Music Festival 2019 - Lake Placid, New York
This annual event in Lake Placid, New York attracts some of the best BBQ competitors in the country and continues to grow in popularity each year. Not only are there Kansas City Barbeque Society competitions happening on-site, but there are also lots of food and drink vendors for the public to eat and drink well while watching a ton of live music. More info here.
July 12-14: Windy City Smokeout BBQ & Country Music Festival - Chicago, Illinois
Get ready for beer, BBQ, and country tunes, because the Windy City Smokeout BBQ & Country Music Festival is returning to Chicago. The Windy City Smokeout is one of the largest barbecue festivals in the U.S. and this year it will feature 20 of the world’s best pitmasters and more than 15 musical acts. More info here.
July 13: South Sound BBQ Festival 2019 - Lacey, Washington
The South Sound BBQ Festival is one of the largest BBQ events for the Pacific Northwest. It will include a pro cook-off sanctioned by the Pacific Northwest BBQ Association plus an assortment of food vendors and non-food vendors from around the South Sound. There will be live entertainment, free kids activities, chicken wing eating contest, adult-only beer & wine garden, and much more. More info here.
August 17: Stumptown Beer Revival and BBQ Cook Off 2019 - Monte Rio, California
This event, which is also called the “Russian River Beer Revival & BBQ Cookoff,” features copious amounts of beer and barbecue. An entry fee includes beer, cider, and barbecue tastings for the duration of the day, along with live music and activities. More than 40 breweries and 30 barbecue teams will participate. More info here.
September 7: Pig Island NYC - Brooklyn, New York
For those that love all things pork, the 10th annual Pig Island NYC in Brooklyn will be a can’t-miss affair. Held outdoors at beautiful Erie Basin Park in Red Hook, this all-inclusive event will feature great food from top Northeastern pitmasters, plus a ton of beer, cider, and liquor. Buy tickets here.
September 12-15: American Royal World Series of Barbecue - Kansas City, Missouri
The American Royal is celebrating 40 years of competition barbecue in 2019. On top of a huge KCBS competition with teams from around the country, this signature Kansas City event includes public-facing activities, including incredible live music, delicious BBQ and local food, a full line up of kids activities, and a vendor fair authentic to Kansas City and BBQ enthusiasts. More info here.
Easy BBQ Grilled Chicken
For this week’s Recipe of the Week, we chose a simple recipe for BBQ Grilled Chicken from The Wolfe Pit. Almost everyone loves home cooked BBQ chicken and it doesn't get any more straightforward or tasty than this backyard classic. The recipe calls for a simple seasoning with salt and pepper before indirectly grilling with apple wood for a hint of smoky flavor. The chicken is then finished with a bottle of your favorite sauce for a quick and delicious dish that even novice cooks can master. View the recipe here.
If you’re not already subscribed to The Smoke Sheet, sign up here. Want to be featured in or sponsor this newsletter? Email us now!