Pellet Pro® Hopper Assembly on the

Pellet Pro® Hopper Assembly
on the “Ugly Drum Smoker”
Instruction Manual
*PLEASE NOTE:
This is not a complete kit. The 55 gallon drum, racks
and rack fastenings, and legs must be purchased separately from your
local hardware store. Only the Pellet Pro® Pellet Hopper assembly
and hopper brackets are included. This manual is a DIY guide to
building your own Pellet Pro® Ugly Drum Smoker.
Step 1: Cutting the Opening for the Pellet Hopper
Take your Pellet Pro® Hopper Template (which is included) and tape it securely to
the side of your 55 gal drum so that the top hole is 10 inches from the bottom of
the drum. As shown in the picture, draw a line across the top 2 holes over the tape
to square off the template. Making sure that the template is level, drill (8) 5/16
holes which are shown on the template.
Then cut out the hopper opening shown by the picture with the dotted lines. The
easiest way to do this is to tape off the edges where you will cut and use a cutoff
tool or saber saw to cut the line as straight as possible. Once the opening has been
cut, it’s time to move onto attaching the legs.
10”
Step 2: Attaching the Legs
Since the circumference of the 55gal drum is 6 feet, cut a 18” inch long piece of
string and use it to measure out the (4) segments on the bottom outer edge of the
drum.
Once they are marked, take a piece of tape
and extend the marked spot inward about
2 inches as shown. Then, drill an
appropriate size hole where the new marks
were made. For the legs, we used wheels,
but 4 bolts, nuts, and washers work fine as
well.
*The barrel needs to be 4” off the ground
to ensure proper airflow for the hopper
assembly.
Step 3: Attaching the Grate Brackets and Hooks
Mark off 2 spots with a piece of tape, the 1st
8” from the top and the 2nd 16” from the top.
Then use a 2 foot piece of string to make the
other marks across the barrel, making sure
that the measurements are correct from the
top of the barrel.
Drill ¼” holes for each mark and attach the
brackets to the inside of the drum. We used
1” angle brackets, ¼”-20 x ½” nuts and bolts.
At the same time, if you find handles that you
would like to attach, this would be the time to
do so.
Now that your brackets are in place, take a strip of tape and place it 4” down from
the top of the drum and mark off (4) spots 4” from each other. We used #10-16 ½
self-tapping screws. In addition, we used the same hook underneath the lid in
order for the lid to hang off the side of the drum.
Step 4: Attaching the Pellet Pro® Hopper
Take the hopper brackets and attach them to the outside of the drum with a Philips
screwdriver and a 7/16” wrench. Make sure the side of the bracket at about 120° is
bolted to the drum with the square side outward. After your brackets are in place,
slide the hopper assembly into the drum and use a 10mm wrench to attach the
hopper to the brackets with the 10mm bolts provided Once hopper is secured to the
drum, drill a hole in the back of the drum and attach a compression fitting that will
allow the RTD probe to slide in and out. (The size of the hole depends upon the
size of the compression fitting you obtain.) Then connect your RTD wires.
Hopper Legs
This Kit also includes (2) hopper legs which are to be attached from the inside of
the hopper on the bottom. These legs have about a 3 inch adjustment length which
are then attached to the hopper by the thumb screws included.
Step 5: Attaching the heat diffuser brackets
Buy a set of 4- 3” L-brackets and
4- 8-20 x ½” screws at your local
hardware store.
Once the hopper has been
attached to the drum, remove the
4- 6-20 x ½” screws located on top
of the burn pot.
Arrange the (4) L–brackets as
shown and replace screws with
the 8-20 x ½” screws.
Place the heat diffuser on top of
the L brackets. You can also use
any 10” X 10” piece of 13 gauge
steel for your diffuser.
Step 6: Making the Lid
We drilled 6 additional 1” holes and
attached a 12” long steel pipe which
provided good airflow. Now you can
always add an adjustable vent using a flat
piece of steel or magnet, although it may
not be necessary due to the temperature
controlled RTD which monitors the
temperature. It is a must for providing
ventilation holes because there could be a
possibility of the pellet burner going out
since the drum would retain all of its
heat.
Again: This is our version of the Pellet Pro® Ugly Drum Pellet Smoker and
does not come as a full kit. It will be your choice as to what drum to use and
how it is fabricated. However, we do provide a parts list for our version.
Our Pellet Pro® Pellet Hopper assembly can be fitted to any existing 55gal
Ugly Drum Smoker by using the mounting brackets and template which are
provided. Thanks!!!
For ordering or more information go to: www.smokedaddyinc.com
Or call us at:
(847) 336-1329
Pellet Pro® Ugly Drum Smoker Parts List
 (1) Clean 55 gal drum
 (2) 22” grill grates (Weber)
 (4) 5/8” x 5” bolts or wheels of the same height
 (6) 5/8” x 2” fender washers
 (6) 5/8 -11 nuts
 (4) 3” L-brackets
 (4) # 8-20x ½ self-tapping screws
 (6) 1” angle brackets
 (6) ¼”-20 x ½” bolts
 (6) ¼”-20 nuts
 (1) roll masking tape
 (5) hooks
 (10) #10-16 x ½” self-tapping screws
 (1) 10”x10” 13ga steel or Heat diffuser