5 Prep the Barrel

Use a 55-gallon food-grade drum with an open head. (Some drums are treated with epoxy to prevent rust, but meat smoked in such a barrel is toxic.) You can buy a new drum at an industrial-supply store for $150 or less or a used one online for a mere $20. Make sure that the drum and lid are untreated, and buff their insides with a scouring pad or fine sandpaper.

Mark an 11½-inch-diameter circle centered on the lid. Using a step bit, drill eight equally spaced ½-inch holes around the circle. Thread a ¼-inch pipe plug into each hole. Place the handle assembly on the lid. Mark the four bolt locations; drill them with the step bit. Bolt the handle to the lid.

Mark the hole locations for the air intakes, grill supports, and thermometer. Start each hole with a center punch, and bore the 1-inch intake holes with a step bit. Test each one by threading in a ¾-inch close nipple. Using a ¼-inch bit, drill the grill-support holes. The hole size you make for the thermometer depends on the model.

Add the air intakes by placing the close nipple into each hole and rotating the assembly. Align the intakes vertically, mark the U-bolt locations, drill on the marks, and slip a faceplate on either side of the barrel wall. Then tighten the nuts on the U-bolt. Secure the air intakes at the barrel's base by threading the pipe locknuts onto the close nipples. Create grill supports using the ¼-inch bolts, washers, and nuts. Attach the thermometer with its included nut.