If you want to know how to build a self-made pallet smoker, you’re in luck! Here is a detailed tutorial on how to get started building and smoking in no time.
Yes, with a stack of old pallets, less than $ 100 and a bit of work, we’ve built this really cool smokehouse. 3 “x 3” it is big enough to smoke an entire animal, or at least a few large bowls of meat and some sausages.
I love this project – I still wonder what you can do with recycled wood and how good it looks. We really wanted to make a big DIY smoker, but most of the plans we looked at showed you how to build a smokehouse that was too small and / or cost a lot of expensive material. We never found plans that really fit our needs. That’s why we finally made ourselves.
Our thoughts on home improvement plans were:
- Size – it had to be big enough to have many items at one time and to smoke large items
- costs– It had to be as cheap as possible and still smoke the meat well
- Skill level required – It had to be something that you could achieve with basic knowledge of woodworking
I do not know if you’ve ever smoked meat, but it’s a rewarding but time-consuming task. Since your meat is preserved for a long time and is therefore good, it makes the most sense to smoke a lot at once. After finding out how much wood we need for a decent sized smoker, we decided to use pallets. For less than $ 100, we’ve been able to put together this great smokehouse that can hold a ton of meat. Several smoking racks and a place to hang sausages. You can even hang a whole deer in it if you want.
Here are the supplies you need to get started and the instructions and video for this cool project:
What you need to build a homemade pallet smoker:
- 20-30 pallets, deconstructed (do you need pallets? Read this post to find free pallets, and this post to find the safest pallets for your project).
- 2 1/2 inch screws * You should choose a good outer screw, we have used plastic coated cover screws
- 1 1/4 inch screws
- Aluminum flashes
- Corrugated sheet for roof (4’x3 ‘) * This must be raw metal, not galvanized
- heavy tin foil
- Roll of aluminum sieve
- Handle (for door)
- Hinges (3)
Tools you need to build a smokehouse:
- Saber saw with bimetal blade (for disassembling pallets)
- Drill gun, preferably a cordless
- Drill 1/8 bit and countersunk head
- tape measure
- Metal / tin scissors
- Utility knife
- Skil saw or saw table
- safety goggles
- working gloves
Handyman: Accessories and tools you need for the project
Pictured are the deconstructed pallet pieces, both the palette fields (shown on the left) and the 2 × 4 pallet pieces, all of which are cut with the dimensions in our cut list.
Take a look at our project videos for this DIY smokehouse:
Step 1: Select your pallets and deconstruct them
There are some challenges when using free, recycled materials. The wood you receive is not constant, often very dry, sometimes warped. It splits easily. It’s far from perfect, but it’s free. You need 20-30 pallets for this project. We recommend that you spend some time looking for those who do not have too many broken fins and that the wood is not too warped. It’s fine if you do not or are unable to find perfect pallets (they do not exist). Your wood may be a bit warped, but that’s fine. Her smokehouse will not be perfect, but she smokes meat. You want a few more pallets than you think to get the best materials. Pallets are usually available in a range of 42 “-48” and 3 “x 3”. If you use palettes in this size range, you can create this. The 2 × 4 units of most pallets are usually 4 ‘- 5’ long and have recesses for a forklift. The cutouts are fine. If you wish, you can assemble two boards, which we will explain in more detail in our DIY smoker video.
Pallets come in many shapes and sizes. Each is a little different and some are in better shape than others.
Where can I get pallets? In our article you will learn where to get free pallets and recycled wood
How do you know if your pallets are safe? This tells you if a pallet is safe
Deconstruct your pallets. We recommend using a saber saw with a bimetallic blade that cuts nails. Trust me, that’s the easiest way. In our tutorial and video on the simple way to deconstruct a palette, you’ll find step-by-step instructions.
A saber saw with a bimetallic blade makes disassembly of the pallet much less work than a lever bar.
You place the blade under each blade and cut it so that you leave the 2 × 4 planks between the blades.
Step 2: Cut off the clean ends on board and cut underneath
Once you’ve deconstructed your palettes, you’ll need to make your cuts. Start with clean cuts at the ends of all of your pallet boards. You should just have to remove something. We have chosen our 3 ‘design to compensate for this wood loss from your pallets.
Cut these out 2x4s:
- (Part 1) 2 upper struts front and rear @ 33 “
- (Part 2) door frame 2 pieces @ 70 “
- (Part 3) Door frame 2 pieces @ 29 “
- (Part 4) wall frame front 2 pieces @ 6 ‘
- (Part 5) wall frame back 2 pieces @ 5 ‘6 “
- (Part 6) Rear frame 2 pieces @ 5’4 “1 × 1
- (Part 7) shelf rack 8 pieces @ 33 “
- (Part 8) shelf frame 8 pieces @ 32 ¾ “
- (Part 9) and 8 pieces à 30 ½ “
Cut these from pallet plates:
- (Part 10) Left side @ 36 ¼ “
- (Part 11) right side @ 34 ½ “
- (Part 12) Door @ 35 ¾ “
- (Part 13) Back @ 35 ¾ “
- (Part 14) Roof @ 38 “
- (Part 15) Vent cover 2 pieces from 18 “to 24”
- (Part 16) Lower Front Brace 1 Piece @ 36 “
- Corrugated Iron Roof 4 “x 3”
You want to make clean cuts on the ends of your pallet boards. You should not have to cut off too much from the ends.
If you remove the split ends of the wood, you should have a clean cut that looks like this.
PREDRILL AND COUNTERSINK SCREWS:
Depending on the condition of your wood, you must pre-drill and countersink ALL screws to ensure that the wood does not crack. We strongly recommend doing this when using reused wood.
Step 3: Design and secure the racks and frame for the left and right sides
You will create two side frames here that also have cross pieces that hold your racks. This handyman smoker uses a neat design – the racks make up the structure itself, and you can even easily adjust the frame heights in the design. The parts that hold the racks in place are the ribs that hold the frame in place. We marked 24 “, 36”, 44 “and 52” so we could place larger meat near the fire and smaller meat at a greater distance. You can even add hooks at the top for sausage if you have enough space to hang. The only important consideration is your fire box, which we put on 24 “. NOTE: Make sure your fire box fits under the 24 “brace. Adjust your shelves as needed. These dimensions are not fixed and can be placed at any height as long as you have enough space for your fire box.
Assemble and secure:
Take one (Part 4 – Front Wall Frame, 6 ‘) and (Part 5 – Rear Wall Frame, 5’ 6 ”) the floor and fasten 4 parts (Part 7 – Shelf Support, 33 ”) at 24 “, 36” “44” and 52 “If you attach parts 7 to part 5, leave a gap of 1 ½” for part 6. You will repeat the same steps for the second page, setting the frame for the right and left sides of your smoker
Measure and mark part 4 and part 5 at 24 ”, 36 ”, 44 ” and 52 ”. These dimensions are adjustable if you want your shelves to have a different height.
Place one of the parts 4 and 5 in each case and mark your dimensions at 24 “, 36”, 44 “and 52”.
You secure your rack supports (part 7, 4 pieces, 33 “for each side) with the four marked dimensions.
You should put the ends in the right corner to make sure your racks and smoker are on the same level.
You will attach four shelf supports (part 7, 33 “) on each side
We lowered our bolts before attaching these parts. We strongly advise you to do this so that your wood does not splinter.
Step 4: Build the frame for the door
Take parts 2 and 3 (part 2 – door frame, 2 pieces @ 70 “) and (part 3 – door frame, 2 pieces @ 29”) and screw them together to get a door. We used a homemade device so we could screw our screws in at a slight angle. Use four screws on each corner.
Take two of your 70-inch parts (Part 2) and two of your 29-inch parts (Part 3) and screw them to your door.
We used a homemade device to attach our screws at an angle to the frame.
The device allows us to draw in the screws at an angle. Use four screws on each side.
Our finished door frame looks like this.
Step 5: Lift the sides and door, then secure
Assemble the walls and door and temporarily bolt the door to the wall so you can hold it together.
Temporarily screw the door to the frame so you can hold it together.
Step 6: Cut the angle for the roof
Using a piece of panel against the top and left wall, draw a line to set the angle for the roof pitch, and cut off the excess to create the roof pitch.
Use a blackboard to draw a line for the roof angle. Cut along this line on both sides to make it even.
Screw Part 1 (Part 1 – Two (2) Front and Rear Top Struts @ 33 “) to the top of the front and rear walls.
Attach Part 1 (2 top 33 “front and rear struts) to the wall top along the angle you cut in Step 5.
Add Part 6 (Part 6- Rear Frame 2 Pieces @ 5’4 “1 × 1) to the back of the frame, screw it into Part 5 (Rear Wall Frame).
Place the rear frame (part 6) next to the back of the wall frame (part 5).
Attach the Rear Frame Part (Part 5) to the Wall Frame with Bolts (Part 6).
Step 9: Add fairing
Disguise. First, add the back cover from scratch. Repeat for the right and left sides.
Remove the door from the frame. Screw in the hinges and hook in the door. Leave at least half an inch at the bottom of the door.
Add panels to door and add panels last to roof.
NOTE: The right side is shorter so that the hinges have room to turn. In addition, the left side is longer, so that the door sits inside the panel.
From the ground up, add your panels to smoker’s sides.
Continue adding liners until you are at the top.
Repeat the cladding on the other side.
Step 10: Attach wood for roof
Screw the roofing material (Part 14 Roof @ 38 “) to make the roof.
Place roof panels (part 14) and secure with screws.
Screw the roofing material onto the roof so that it looks like this.
Step 11: Finish the door
Replace the door frame. Attach the hinges to one side of the door frame. Add pallet panels to the door. Attach the handle to the front of the door on the opposite side of the hinges.
Attach your door frame to the smoker and add hinges on one side.
Attach the pallet panels to the bottom of the door until you reach the top. Drill the vent holes and attach the handle to the door on the side opposite the hinges.
Step 12: Create racks
Screw rack parts together. (Part 8 – Shelf Frame 8 pieces @ 32 ¾ “) Fold the screen onto the rack. If you have two pages stapled, tighten the screen while stitching the other two sides together.
Screw together the rack frame parts (part 8,) to make your smoking racks.
Place a piece of screen over the rack to get the right size.
Cut the aluminum screen with your metal shavings to the desired size.
Attach the screen to each rack.
If you have two pages stapled, drag the screen as hard as possible while stapling.
Step 13: Cut ventilation holes
Select two panels from the door, one at the bottom and one at the top. Remove the plates, unscrew part 15 (Part 15 – Vent Cover 2 pieces @ 18 “to 24”) on the face and drill holes with a hole saw. Make sure there is enough space between the holes to allow them to be closed. Remove the screws and install a clamp to hold part 15 in place.
Step 14: Cover the inside with foil
Line the inside of the smokehouse with high-performance sheet metal foil. Make the structure as airtight as possible. Expect 2 to 3 rolls of film. Use a stapler to attach the foil to the walls.
NOTE: Do not use galvanized metal in the smokehouse as it is poisonous.
Cover the entire interior of the smoker with strong tin foil. Secure the foil with your stapler.
Put your racks in the smoker.
Imagine what you can smoke here.
Step 15: Attach the tin roof
Secure the box to the roof and secure with screws.
Your cut piece of sheet should fit well on the roof. Fix it with screws.
Step 16: Admire your finished smoker
Your DIY smoker is complete and ready to smoke meat!
Her smoker is complete and ready to smoke meat.
There you have it. Your own, handmade smoke house. Now to the boil!
Take a look at our step-by-step project videos:
How to Build a DIY Smoker: Part One
How to Build a DIY Smoker: Part Two
How to Build a DIY Smoker: Part Three
Will you build this homemade pallet smoker this weekend? Let us know in the comments below.
Like this? I am sure that you will LOVE:
This article was found on pioneersettler.com. Read the original article