Smoke Chef Pellet Grill Parts: How to Assemble Each Correctly

Although there are a number of steps involved in assembling Smoke Chef pellet grill parts they are all fairly simple if you take care and follow the instructions outlined below. Learn how to assemble Smoke Chef pellet grill parts.

The Smoke Chef pellet grill assembly is best initiated with the grill legs.

Here is how leg assembly is done for the smoke chef pellet grill.

pellet grill

Leg Assembly

First, you must locate all four legs. Then fit the left front leg into the right front leg. Similarly, you must also fit the left rear leg in into the right rear leg.

Once the legs have been assembled as described above, you have to attach them to the bottom shelf. For this, you will need 8 ¼ – 20 x .59 bolts. Begin by aligning the holes within the caster legs bracket and the wheel legs with bottom shelf holes. The bolts must then be inserted through holes of all leg brackets and then through the bottom shelf holes. For now, you do not need to tighten the screws.

SideBar/Legs Assembly

The next step is to fasten the sidebars onto the legs.

For this you will have to make use of the 2 leg support brackets and 8 bolts. Since there are two sidebars, you will be making use of 2 x 4 = 8 bolts. You should then align the 4 holes located on each sidebar with the corresponding holes situated on the upper part of the leg assembly. For each sidebar, you will then have to insert four bolts into each hole. The sidebars will be located opposite to each other. Their job is to create a strong solid link between the two-leg assemblies, which at this point are not directly connected. Drive the bolts through the leg support bracket hole and then into the corresponding leg assembly hole. Tightening the screws at this point is not necessary.

Fastening Wheels and Caster onto the Base

Now it is time to connect the casters and wheels with the legs. The grill is supported by 2 casters and 2 wheels. Since it has a total of 4 wheels, it is a fairly mobile platform which will be easier to move than cumbersome and unwieldy grills that have only 2 wheels. Since there are two casters on one side, changing the direction of the grill while moving it is convenient.

You must take note of one important fact before mounting these wheels. In the axle holder located in the midpoint of each wheel, one end is longer compared to the other. First, align the longer end of the axle holder inside. When this is done, insert the wheel axle pin so that it goes through each wheel leg and wheel. An axle washer should then be kept on the adjacent side. Now pass the axle ‘R’ clip through the wheel axle pinhole.

You may then turn over the bottom shelf and assembled legs on one side to make it easier for you to screw on the wheels. Locate the open-end wrench provided with the grill. Use this implement to fasten casters on the two caster legs. Turn the hex nut located on the caster clockwise so that it travels into the threaded hole located on the leg tube bottom.

When the process outlined above is completed, position the bottom shelf/assembled legs upright. Hold and then press down the legs slightly to make sure that all casters and wheels touch the floor. Screw the bolts tight.

Mounting the Grill Barrel

You now have to mount the main grill body onto this leg assembly. For this, you will need bolts, spring washers, flat washers, and nuts. Four of each item is required to complete this step.

First, remove the grease pan and the porcelain grilling grates out of the grill. Keep the grill on the leg assembly. The 2 wheel legs must be placed at the opposite sides of the pellet hopper.

Align the holes of the grill with the legs. Then put one bolt each on each hole of the leg tubes and pass them through the main grill body. Place a spring washer and flat washer on all bolts within the grill. Place a nut over this combination and screw it tight.

Side Shelf Assembly

The next step involves fastening the side shelf assembly on the grill.

You simply need four bolts for this step. Tighten 2 bolts on the lower holes located towards the barrel’s left side. Leave out approximately ¼ inch of each screw. Making use of the 2 lower keyholes, align the side table onto the two bolts. Tighten 2 bolts from the outer part of the barrel onto top holes located on the side table. Make all 4 bolts tight.

Fastening the Lid Handle onto the Lid

In this step, you will have to fasten the lid handle on the lid.

First locate the heat shield, lid and lid handle. You will also need 2 spring washers, 2 flat washers and 2 bolts. Align the 2 holes located on the lid with corresponding holes placed on the lid handle. On each bolt, slide a flat washer and spring washer. The bolt must now be inserted in the head shield and passed through the lid. Turn the bolt into the handle till it is tight.

Smokestack and Cap Assembly

The smokestack and cap assembly is next on our list. To complete this step, you must find the smoke stack cap, smokestack, 3 nuts and 3 bolts.

Slide the smokestack over the circular opening located on the barrel. Fasten this smokestack in place on the barrel using 3 nuts and 3 bolts. You now need to screw the smoke stack cap in the clockwise direction onto the smokestack.

The smokestack is adjustable in nature so that smoke exiting the barrel can be controlled. While raising the cap, make sure that it does not go so high that it becomes detached from the smokestack.

Bucket/Grid/Heat Plate/Baffle Assembly

The final step involves setting up the bucket/grid/heat plate/baffle assembly.

Place the heat baffle on top of the firebox. Keep it on the locating brackets mounted on the inner barrel walls. Make sure that the notched legs on the baffle are pointing downwards on the locating brackets. Now keep the grease pan so that the long flange end connects with the grease pan support towards the left side of the grill. The short flange is must then be placed on the right side of the grill to complete the setup.

You should follow one recommendation for greater convenience. For easier cleanup ensure that you place aluminum foil on the grease drain pan. The foil ends and sides should be kept tight against the lower part of the grease pan.

Now place the grill grates on the back and front supports built for the grid. These supports run along the entire length of the cooking area. Put the grease bucket on the grease tube that is present towards the left of the barrel.

At this point, the pellet grill assembly now stands complete. You should then fire up the grill for the first time and season it prior to using it for making barbecue.

Testing the Grill and Seasoning It

Keeping the lid open, take the porcelain grid, heat baffle and grease out of the grill. The power switch should be kept in the OFF position. Insert the power cord into a properly grounded electrical outlet.

Open up the pellet hopper lid and find the auger. Ensuring that there are no external objects within the auger, turn on the power switch and observe the pellet hopper to make sure that the auger is working. Confirm that the draft inducer fan is blowing out air and without touching the ignitor rod ensure that it is getting heated. You can switch off the power after confirming that the ignitor rod is becoming hot.

Load the pellet hopper with hardwood pellets. Turn on the power switch and position the temperature dial to the HIGH setting. After pellets start dropping inside the firebox, turn off the power switch.

Now turn on the power switch again and set the temperature dial to SMOKE mode. Observe the pellets to make sure that they are set on fire. When flames are emitted from the firebox, turn off the power switch and allow the grill to cool.

You should then season the grill to make it ready for grilling. Turn on the power switch and set the temperature dial to the smoke mode. In around 2 minutes, smoke will start bellowing from the grill as the pellets burn. Shut the lid and keep the temperature dial at HIGH.

Keep the grill running for 45 minutes to season it. This procedure must be completed before anything is cooked on the grill.

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