Are you looking for a smoker you can build yourself, designed to smoke food for upwards of 12 hours without constant maintenance?
The Ugly Drum Smoker is a true set-it-and-forget-it style of smoker built from a 55-gallon drum. It’s the same concept behind the Pit Barrel Cooker, our winner for the "Best Smoker Under $500". Despite its raw appearance, if you value function over form, this smoker delivers. Its efficient design produces exceptional BBQ, and its vertical layout promotes efficient heat circulation, similar to a convection oven.
For your money, you can't get a better smoker than by building your own Ugly Drum Smoker from a 55-gallon drum.
An Ugly Drum Smoker (UDS) is great at maintaining steady temperatures over long cooks. I find myself using my drum smoker more often than my traditional smokers, mostly because I have two of them, and well, I'm often at camp, and nothing travels better than the UDS.
Beef—It's What's for Dinner...
Why build an Ugly Drum Smoker? Aside from attracting cows into your camp, there are several benefits to building a UDS:
- Efficiency: The vertical design helps maintain steady temperatures.
- Ease of Use: Set it and forget it—just load the charcoal and go.
- Portability: Great for campsites and tailgating.
- Cost-Effective: Build a high-quality smoker at a fraction of the cost.
Overview: Building an Ugly Drum Smoker
Your journey begins with finding right drum. The best choice is a new, unlined 55-gallon steel drum. If you're using a previously-used drum, it's critical to ensure it only held food-grade materials and to burn it out thoroughly to remove any coatings or residues before getting started.
Here’s a quick look at what’s involved in the build:
1. Gathering Your Parts: You'll need specific hardware for airflow control, cooking grates, and a charcoal basket. This includes ball valves, pipe nipples, bolts, expanded metal, and a steel lid.
2. Drilling and Cutting: The main task involves drilling holes for your air intakes at the bottom of the drum and a hole for your exhaust on the lid. You’ll also drill holes to mount your cooking grates.
3. Assembling the Components: This step involves fitting your air intake valves, installing the exhaust pipe, and bolting in the grate supports. You'll construct a charcoal basket from expanded metal, which will sit at the bottom of your smoker.
4. Seasoning Your Smoker: Before you cook any food, you'll need to season the smoker by running a hot fire inside it. This burns off any remaining machine oils and creates a protective layer inside the drum to prevent rust.
Now, let's jump into the detailed steps, right after this word from our sponsor...
Easiest Way to Get a Drum Smoker...
If you like the idea of owning a UDS but don’t want to get your hands dirty, there’s a kit you can buy from Amazon or the Pit Barrel Cooker Co. directly. The kit arrives at your door with all the parts ready to be assembled...almost like Ikea furniture—it’s okay, we won’t tell.
Pit Barrel cooker
by pit barrel cooker co.
Overall Rating: 4.4/5
UDS Construction Tutorial
There are a few ways to tackle this project, and several plans call for welding. We’re here to show you a different, no-weld approach. By using some clever hardware like U-bolts to assemble the charcoal basket, you can build a top-notch smoker without ever striking an arc.
Here’s how to turn that 55-gallon drum into your new favorite cooker.
Ugly Drum Smoker Parts
The Drum
Look for a new non-lined barrel. While you can use a torch and some elbow grease to remove any possible toxic liners, it's easier to purchase a non-lined barrel. You can find them on eBay or other various online marketplaces.
Expect to pay about $100 or less for a new non-lined barrel.
Charcoal Basket w/ Legs
Charcoal Basket
- Charcoal Grate (1)
- Steal Mesh Expanded Metal (45" x 9") (1)
- Bolts (1"x5/16) (2)
- Nuts (5/16") (4)
- Washers (5/16") (4)
- U-bolt (2)
Charcoal Basket Legs
- Hex Bolts 3 1/2" - 4" (4)
- Nuts (4)
- Lock Nut (4)
- Washer (8)
Assemble (No Weld) Charcoal Basket
1 - Bend Ring
2 - Fasten Ring
3 - Fasten Legs
4 - Fasten Basket
Bend Ring: Bend a 45" x 9" sheet of expanded metal around a propane tank.
Fasten Ring: Secure the cylinder with two bolts using washers and nuts.
Fasten Legs: Attach 4" bolts to the grate.
Fasten Basket: Attach the basket to the charcoal grate using U-bolts.
Drum for Assembly
The Lid
The Handle
Grate Support
Air Intake
Optional Grate
2.A The Lid
Drill 8 evenly spaced 1-inch exhaust holes around the lid.
Note: Airflow will dictate how hot or cool your barrel smoker runs. The size and amount of holes should closely follow this guide for 55-gallon drums. If you don’t already own a step bit, I recommend this one ($15).
2.B The Handle
Mount your handle to the lid with 1/4 inch holes (or whatever size makes sense for the size of the handle/bolts you have).
2.C Grate Supports
Measure about 7" from the top of the barrel and drill four 1/4" holes evenly spaced around the barrel. Theses holes will hold the bolts that support your grate.
2.D Air Intake / Valve
Drill three 1" holes evenly spaced, about 3" to 4" from the bottom. Two of these holes will hold capped ¾" steel nipples, and the third hole will hold the ball valve.
Optional Feature
If you have a second grill grate, you can add it 12 to 14 inches from the bottom for searing or holding a heat diffuser, water pan, or drip pan.
Note: Be sure to drop your charcoal basket in to measure placement for this second grate. Holes for this second lower grate should be about 8" to 10" above the top of the charcoal basket.
That's It Folks...
CONGRATULATIONS
Certificate of Completion
This certifies that ____________________ has successfully fabricated their very own custom Ugly Drum Smoker (UDS).
Your dedication and craftsmanship have resulted in a unique and functional outdoor cooking masterpiece. Enjoy the delicious flavors that will come from your hard work and creativity.
How to Upgrade Your UDS
Temperature Control: To get the best out of your UDS, consider installing a traditional analog gauge or a Wi-Fi temp reader for precise temperature monitoring. A well-constructed drum smoker can reach high temperatures, but when the lid is on it should run consistently around 250 - 280°F which is good for low-and-slow cooking.
Customization: Go wild with your creativity—use heat-resistant paint that's rated for 500+°F to give your UDS a personal touch. Who said smokers can't be fashionable? Keep in mind, you're barrel smoker will reach high temps when fuel remains in the basket and the lid off.
Seasoning: Start off right by seasoning your new UDS smoker. Load the charcoal basket with a mix of charcoal and wood chunks. Light it by dumping in a chimney (about 20 brackets) of hot charcoal on top of your basket of loaded fuel. Leave your lid off and vents open - after about 20 minutes you should be above 500+°F. Now you're ready to season. Throw in some seasoning grease or something fatty like bacon to coat the interior. It’s like giving your smoker a spa day.
Fuel Choices: Your choice of fuel can impact your smoking experience. Lump charcoal burns hotter and cleaner, making it a great choice for quick heats, while briquettes provide a more consistent burn for those long, lazy smoke sessions. So, whether you're a lump lover or briquette believer, choose what suits your style.
Starting Your Session Right: When it comes to achieving that ideal smoking temperature, don’t go loading your basket with a full chimney of charcoal right away. Instead, fill up your basket with your preferred fuel, then sneak away about 15 briquettes or 8 wood chunks to place in a chimney. Light those bad boys up and wait until they’re about 40% ignited—think glowing, not flaming. Once you hit that sweet spot, dump the lit fuel from the chimney onto the unlit stuff in your basket. Leave the lid off for about three minutes to let everything mingle and start heating up. Then place your lid on. Remember to set your vent properly. Using this method will avoid you starting with a flaming inferno that requires a long wait time for temps to drop to a cool 250 - 280°F .
If you're looking to skip on securing your own drum and the entire DIY process, consider purchasing the premanufactured Pit Barrel Cooker.
While the Pit Barrel Cooker it's smaller than a 55-gallon drum -- well, it's smaller than a 55-gallon drum meaning -- its easier to load up and maneuver. Plus you don't have to mess around with dialing in your vents and air holes. The Pit Barrel comes ready to roll out-of-the-box. Ideal for those who prefer convenience over DIY.
Thanks for the dimensions and the info, really helps. I am building UDS and have a question regarding inside of barrel, I got a used one for the right price (FREE) and it has some rusty build up and I was wondering if you think it will burn off or if sand blasting it would be worth it?
Wheel brush should do the trick.
I am going to attempt this project myself. I see a lot of food grade barrels for sale for like $10.00 around me. My question is this: with a food grade barrel, do you need to do anything to the inside?
I always recommend treating your barrel unless you’re certain there is no liner or some type of rust treatment. My guess is there is some type of liner in your $10 food grade barrel and it will need to burned or sandblasted out. The cheapest method is purchasing a propane weed burner torch ($20) to heat up the liner/treatment and scrub it off.
I have done the burn out on my barrel. I do have another question: the Black Steel Pipe Nipple. Should I use 3/4″ inch X Closed or Pipe that a measurement (3/4″ X 1″ or 2″?)
You’re going to want a snug fit on this. Go with the 3/4″ x1″ nipple; thread the nipple into the ball valve, stick it through the hole, thread the nut on the inside of the barrel.
How long do the rods to hang the meats need to be?
If you’re placing rods in for hanging meat, the hooks should be anywhere from 3 to 6 inches (depending on where you drilled in the holes for your rods). The idea is to make sure when you hang your meat, say like a brisket, the bottom isn’t hanging out in the coals.
Going to build this barrel , Thanks
Ok. I’m going for this. Where do I put the thermostat…?
it should be placed close to where your food grates are
would be my thought thats where they are on my offset stick smoker
Thanks
How do you install hanging rod’s and hooks like the manufactured pit barrel has?
I’ll stick to my WSMS, which is actually the best smoker under $500, I don’t cook in trash cans.
Actually it’s a drum. And you can get them in stainless steel brand new…. You dumb ass.
Enjoy spending $500 clown. Do the work and have more pride in it. That’s why we are here.
exactly !
I really enjoyed this web site.
Thank you for sharing your knowledge.
Anytime! Thanks for letting us know.
One if the three best ‘vids’ I chose for guidance in my project…I did it a little different, following the Popular Mechanics version, which employs 4 air intake valves…I liked your diagrams & simple directions…My 2 mesquite-smoked turkey halves (laid on the grill) came out perfect after around 4 hours…I turned ’em over after 3 hrs., & was able to slip a few more wood chunks through the slots on either side of the grill into the fire basket…I also have an open 2″ vent pipe plugged into the standard barrel lid cap hole, besides the open 3/4″ ball valves…
Thanks for the info!…JB
What is a good recipe for a dry sweet rub
Thanks for sharing your knowledge. Very informative article on building a UDS.
I’m using a Weber Kettle (23 inch or so) lid as the lid for my UDSs. Go to Horror Fright, and get a cheap aluminum 4 foot “yardstick.” You’ll need more than one. Cut it to length, and wrap it inside at the top. It needs to stick up about 1/2 inch or so. Yes, you can get aluminum sheet metal strips at Homer’s place. HF’s cost less! If you make more than the one, save the leftover pieces of “yardstick” for the next one.
Wrap it around, at the top. The kettle lid fits on, perfectly. You now have more room above the top grate.
new here, but FYI, a 22″ weber grill with the fold up side flaps for adding coal or smoke chunks, fits a 22″ barrel perfectly. Around $30 at Lowes Lumber and hardware or prob anywhere they sell Weber products..
Just sayin.