Ugly Drum Smoker Plans (UDS Build)

Ugly Drum Smoker Plans (UDS Build)
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A UDS is among the most cost effective smoker

For your money, you can't buy a better smoker than building your own Ugly Drum Smoker.
55-gallon

Can I interest you in a smoker you can easily build yourself which will be designed well enough to smoke food for upwards of 10 hours without the need for constant maintenance?

The UDS is a true set-it-and-forget-it style of smoker.

Don’t let the odd name turn you away: ugly drum smokers (UDS) are a simple barrel-drum structure and are one of the most versatile instruments out there, allowing barbecue fanatics to cook a variety of different meats to perfection, including brisket, turkey, ribs, prime ribs, and more. Before you dive right in, there are some important warnings you should be aware of.

This is a great #MeatGeek project with an insatiable drive for DIY tasks. You’ll need some specific tools, but if you're a hardcore DIY-er then you probably already have all the tools you need.

Although it might sound complicated, building one of these beasts is actually pretty easy for the average do it yourselfer.

Ugly Drum Smoker (UDS) Build

This walkthrough takes you through everything you need and how to assemble your very own UDS. The hardest part of the entire project is acquiring the 55 gallon drum -- even that isn't all that difficult -- more on this in a second.

The Super Easy Method

Should you decide that 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 Pit Barrel Cooker Co.

This kit shows up at your door with all the parts ready to be assembled...almost like Ikea furniture – it's okay, we won't tell.

The DIY Method

Before we get started, there are a lot of different ways to build a UDS. For example, some plans call for a welder, we swapped out that step and went a different route by building a charcoal basket fastened with u-bolts instead of welding it together. You can apply your own DIY-er knowledge and tweak these plans to make a UDS perfect for you.

Basic Project Overview

In a nutshell, it goes like this… get a 55-gallon drum, then strategically drill a bunch of holes into it. Build a charcoal basket and find a 22-inch grilling grate to place inside. Finally, attach some plumbing valves to work as the air inlets. And voilà you’ve got yourself a one of a kind ugly drum smoker. Insider secret… it’s not ugly at all. When you’re done you’ll see for yourself how awesome it is.

Ugly Drum Smoker parts

building-a-uds

Drum

55 Gallon Drum

drum for uds barrel
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 $75 or less for a new non-lined barrel.

CHARCOAL BASKET

  • Charcoal grate
  • Steel mesh - around 45 x 9 inches
  • Bolts (4" long), washers, nuts and lock nuts -   6 of each
  • U-bolts - 2 each

CHARCOAL BASKET: LEGS

leg assembly

CHARCOAL BASKET

parts for uds basket

ASSEMBLY

Handel & Grill Grate
  • Door handle -  at least 1 for the lid, but get 2 more to attach to the sides of the barrel for easier handling.
  • Standard grill grate 22.5” - get 2 (one for meat, one for a water pan)
grate and handle

AIR INTAKE

All parts are 3/4ths Inch
  • 3 Steel pipe nipples
  • 3 Steel pipe caps
  • 3 Conduit nuts
  • 1 Ball valve
uds build parts

CREATING THE BASKET – easy peasy

NO WELDER, NO PROBLEM

Some of us don't have access to a welder. Others, have no business operating one, myself included (the first basket I welded came out looking like a middle school shop project). I found this method online, and it is by far the easiest way to create a basket. Simple, yet practical. No welding required – it can be completed in under an hour (depending how long you spend on step 1).

basket inside ugly drum

Step 1 – Bend Ring

Bend a 45" x 9" sheet of expanded metal around a propane take. The propane tank is ideal, however, it still takes a bit of finesse.

ugly drum smoker basket
basket connect

Step 2 – Fasten Ring

Secure the cylinder with two bolts using washers and nuts.

creating ugly drum basket

Step 3 – Fasten Legs

Fasten the 4" bolts to the grate as shown.

basket completed for uds

Step 4 – Fasten Basket

Attached the basket you bended to the charcoal grate using the U-Bolt. Simple.

Drilling & Mounting The Assembly

Now we will prepare the drum for assembly in a few quick steps.

If you don’t already own a step bit, I can recommend this one which will set you back about $10 to $15. You can easily spend $60 on a good titanium bit at your local hardware store, but if you don’t plan on using it on the job site everyday the recommended one is perfectly fine. After all, we’re on a budget here.

The recommended bit goes from ¼ inch to 1 3/8. You’ll use ¼ inch for the holes that hold the cooking grate and handle.  1 inch will be perfect for the exhaust lid holes and the air intake at the bottom.

The Lid

Drill 8 evenly spaced 1 inch exhaust holes all the way around the lid.

drilling barrel lid

The handle

Mount the handle to the lid with four 1/4 inch holes (or however you see fit  based on your handle).

adding handle to lid

Grate supports

Measure about 7 inches from the top of your barrel and drill four 1/4 inch holes evenly spaced around the barrel with your step drill.

You’ll place the nuts and bolts in these holes to support the grilling grate.

holes for grate

Air Intake Valve/Holes

Drill three 1 inch holes evenly spaced, about 3 inches off the bottom. Two of these holes will hold the capped ¾ inch steel nipples and the third hole will hold the ball valve.

air holes

Optional - Create an additional area for increased functionally features

If you have a second grill grate you can work it into the bottom part of the barrel to provide a place for searing, dropping in a heat diffuser, water pan, drip pan, etc.

To add the second grate you'll be repeating the same steps you just completed in step 4. Measure 12 to 14 inches from the bottom and drill four 1/4 inch holes all the way around. 

You want to make sure this second grate will sit above the charcoal basket you made.  Double check the height before you start drilling these holes.

charcoal basket 5

Congrats, You've Built Your Own UDS Smoker

Now you're pretty much ready to go.

If you don't already own a leave-in thermometer check out our reviews for the latest Wi-Fi temp readers.  Alternatively, you can install a  traditional analog gauge by simply drilling a hole into the barrel.  I recommend passing on the standard gauges you'll find at a local store; they're never accurate. Go with the Tel-Tru BBQ Thermometer if installing an analog gauge -- temperature matters -- especially when smoking meat for 8+ hours.

thermometer on uds not working

Standard analog grill thermometers are almost always off.

Depending on your DIY-er drive, and how much beer you have left, you can paint your barrel before completing the final assembly. Make sure to use paint that is rated for 500+ degrees. You can even find paint specifically made for barbecues.  Feel free to have fun with pimping your UDS and making it totally your own custom creation.

Optional: Season your new UDS smoker

It’s always a good idea to season your new grill. To do this load your newly created charcoal basket (it should hold almost a full 20lbs bag of charcoal) with charcoal mixed with a few wood chunks for flavor. Leave a little room on top because we’ll be adding hot coals to the top.

load up uds basket

I wouldn't normally add this much wood, but for the seasoning I'm okay with barreling clouds of smoke

Load your chimney with about a dozen or two coals. Once there hot drop them on top of the charcoal basket that you loaded with coal and wood chunks.

Open all of the vents and put the lid on.

Now, for this seasoning you’ll want to cook something with a lot of fat (bacon, breakfast sausage, chorizo, etc.). Add the meat to the center of the grate.

Next, have fun discovering how your new UDS will keep the perfect temperature. Play around with the air intake regulator and the valve caps; covering and uncovering these capped ends with a magnet. If you have the charcoal going property you should be around a perfect 250°F. The best part of an Ugly Drum Smoker is you should remain at 250°F for upwards of 10 hours. The seasoning process should be completed after two hours, then, you’re ready for your first smoke!

Using your uds

BASICS TIPS FOR SMOKING W/AN UGLY DRUM SMOKER

As you know smokers are not grills. Don’t exceed 300 degrees F – smokers are ideal at lower temperatures. Any higher will result in scorching. You should also be aware that when you open the lid to the smoker, you should keep the exposure to the air as brief as possible, as too much oxygen may ignite at grease buildup that’s on the sides of the grill, so be sure to give it a thorough cleaning after each time.

Ugly Drum Smoker best Practice Tips

Lighting the UDS

There are a few different ways to light your UDS. If you’re inexperienced, it’s a good idea to wait at least one hour if not two for the temperature stabilize after ignition before you place meat inside. One method is simply using coals. Fill the basket nearly the top with charcoals, but don’t use any kind of self-lighting fire briquettes, because they contain petroleum and fluid that will give your meat an odd flower.

The most efficient way to ignite a UDS is to use a chimney lighter.

Some people prefer to use a fire starter cube instead of a chimney. Once your coals are lit up, all you need to do is add some wood chunks and wait a while for the temperature to stabilize.

Preparing to smoke

It’s important to control the temperature carefully and not let too much oxygen in. Depending on the model of the UDS, there are either a pair of ball valves or a sliding vent door, which you can open or close depending on whether you want to raise or lower the temperature.

When you first start adjusting the temperature using the vents, the charcoal will emit a thick white smoke. Wait for this to settle down before adding the meat! This can take about thirty minutes or longer. The ideal smoke has a thin, bluish appearance.

Once the white smoke disappears, open the lid and place your meat on the grates. At first you'll want to monitor the temperature to be sure it doesn't exceed the ideal smoking temperature of 225°F to 240°F.

Post smoke

After smoking, it’s important that you clean it out.

This technique is called “seasoning” a smoker and is designed to burn away any leftover oils, grime, or other materials. Take either vegetable oil or a cooking spray and apply it all over the inside of the drum. Light it up as usual and let it burn around 250°F for a few hours while the flames purify the inside. It’s advised to add some bacon to the grates to give the smoker a naturally delicious aroma and keep the air inside clean and smoky.

Once you’re all done either seasoning or just smoking, it’s important to carefully shut down the UDS. When it’s time to shut it down, all you have to do is close all the vents and wrap the chimney in heavy-duty aluminum foil. This will prevent air from flowing back in and fueling the fire, which will eventually extinguish itself due to a lack of exposure to oxygen. It’s pretty simple.

Just make sure that the next time you go to start up your smoker, you shake out any ashes from the coal basket and add fresh coals to the top of it.

So those are the basics of handling a smoker, but what’s the best technique for heating and smoking a proper rib? Of course, every rib smoking expert will have a slightly different technique that they prefer, but there is one method that is a tried-and-true favorite by beginners and experts alike. Read on for some instructions for this easy-to-manage smoking technique.

Smoking Ribs on a UDS

Tried-And-True 3-2-1 Smoking Method

Not sure how to make the most tender, juiciest smoked ribs? The so-called “3-2-1 method” is one of the most common techniques that people use to smoke their ribs.

This is a great smoking technique that is versatile enough to smoke almost any cut of pork ribs to perfection. All you need is your trusty smoker, a large sheet of aluminum foil, and your previous knowledge about how to smoke.

The idea is to smoke normally for 3 hours, cook 2 hours wrapped in heavy-duty foil to keep the moisture in, and 1 final hour while unwrapped.

During the first three hours the smoke is soaked into the meat as normal, while during the two wrapped hours, the ribs are steamed, allowing the moisture to soak in, making the meat much more tender to get that “fall-off-the-bone” effect. The last hour while it’s exposed to the heat allows the smoke to form that delicious crust on the surface.

Steps of the 3-2-1 Method:

  • Prep your rib cut as usual. Trim the fat, remove any stringy membranes, and apply a generous helping of a rub of your choice.
  • Place the meat with the bone side facing down in the smoker. Cook for three hours at 225 degrees F, which is 108 degrees C.
  • Wrap the ribs very tightly in heavy-duty foil. Double-fold if you need to. Place it back on the smoker with the bone side facing up. Smoke as usual for two hours.
  • Unwrap the ribs and place them with the bone side facing down to smoke for one hour. An optional step is to apply whatever sauce you want during the last half hour of cooking time.
  • An optional variation takes place at the step after the wrapped two hours. If you prefer, you can place the wrapped ribs into an oven or on a grill to finish off there.

2 Comments

  1. Lance September 24, 2018 Reply
    • Top Geek September 24, 2018 Reply

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