I have read through this ENTIRE thread, and am in the process of building an 18.5" LBE. Thanks Villa! While I have been able to arrive at most of my design choices by reading previous posts, I guess I still have two questions to clear up. These have probably been covered at some point, but I skimmed a bit when topics like Brian May came up; )
1. Where is optimum placement of the lid side-vent, relative to the existing Weber factory lid-vent? Should I cut the side-vent so it is on the lid-edge closest to the factory vent, to pull all oven air to the same side of the lid? Or, cut the lid side-vent on the opposite side from the Weber factory lid-vent to potentially allow for some adjustment of air running over the kiln shelf, if the top is getting too much heat. From everything I have gathered, adequate top-heat is the name of the game with the LBE, so I don't anticipate this being an issue, but "dialability" in a design is always nice to have. Either way, I want to preserve the ability to use the Weber factory lid-vent in my design.
2. While aluminum foil seems to do a good job of heat reflection, I have been considering the idea of lining the egg with aluminum flashing, or possiblly copper flashing. I have access to a MIG welder, and like the idea of tack-welding in thicker guage aluminum/copper flashing instead of using foil. It would look cleaner, as foil wouldn't overlap onto the outside the of the oven, and the thicker guage metal would probably last longer. I am also attracted to the idea of opening the LBE and seeing it lined with copper, partly for asthetics, but also for it's metal properties. If I went this route, I would also fashion an air deflector for the lid out of copper as well. Does this sound like a good idea? Can you think of any drawbacks with the idea or either metal, in particular? I am not on a super tight budget, everything has gone great so far, so at this point, I want my LBE to be a Ferrari. I am a believer in the conductive benefit of lining the inside with Aluminum or some other conductive surface liner, so I will be including this design feature either way.
Any feedback is greatly appreciated. Thanks to all for your contributions to this thread. You have provided hours of incredibly inspiring reading. I can't wait to get cooking. I've felt handcuffed by my crappy kitchen oven for long enough!