Hondo
TM
MODEL 03207225
Assembly Instructions
Rev. 03-28-03
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CAUTION ! This unit is heavy.
CARBON MONOXIDE HAZARD
Burning charcoal inside can kill you.
It gives off carbon monoxide, which
has no odor.
NEVER burn charcoal inside homes,
vehicles or tents.
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Tools needed: 2 adjustable wrenches,
a flat screwdriver and hammer.
DO NOT assemble without a helper.
CAUTION!
Read and follow all Safety
! !
Statements, Warnings,
Assembly Instructions and
Use & Care directions before
attempting to assemble and cook.
CAUTION!
Some parts may contain
sharp edges. Wear
protective gloves as
necessary.
STOP!
Missing a part?
No Need To Go Back To
Call Our Help Line
The Store!
The store where you made your purchase
does not stock parts for this item.
If you need parts,
whether they are missing or damaged,
call the Customer Service
toll free Help Line.
Call us and we will gladly ship the
part you need
FREE OF CHARGE.
55700208 Smoke Chamber Kit 1
55700209 Firebox Kit 1
55700210 Wood handle Kit 2
55700211 Logo Plate Kit 1
55700212 Axle Kit 1
1-800-232-3398
55700213 Wheel Kit 2
55700214 Leg Brace Kit 2
55700215 Smokestack Kit 1
55700216 Short Leg Kit 2
55700217 Long Leg Kit 2
55700218 Knockout Cover Kit 1
55700219 Door Latch Kit 1
55700220 Butterfly Damper Kit 2
42000012 Hardware Bag 1
PARTS LIST
40002811 Fire Grate Set (3 ea) 1
40009916 SC Grate Set (2 ea) 1
40009925 FB Grate (1 ea) 1
46030090 Wood Rack 1
44830150 Grease Can Holder 1
42802812 Wire Front Shelf 1
GET A HELPER ! This unit is heavy and may require a second
person for lifting and moving.
Pick a suitable location to work. Open the carton and slit the
corners to open like the illustration at the right. This will give you a
protective work surface upon which to start the assembly of your
new smoker.
Hardware parts list and descriptions are listed on next to last page.
For steps 1 through 8, do not tighten bolts until all parts are assembled and attached to smoke chamber.
STEP 1. Build two leg assemblies. Do this by sliding a
long leg and short leg together as shown.
LONG LEG
SHORT LEG
STEP 3. Place the wood rack hooks into the holes
provided in each end of leg assembly as shown. Now
swing wood rack up so it is perpendicular to the floor.
STEP 2. Attach 1 leg brace to the outside of each end
of one leg assembly using 10-24 x 1 3/4” screws and
10-24 flange nuts.
LEG BRACE
STEP 4. Now with the aid of a helper, take the second leg
assembly, making sure that the two short legs on each
assembly are on the same end, and hook the wood rack
holes on the legs onto the wood rack hooks.
Swing the leg
assembly over
so that it is
parallel to the
opposite leg
assembly.
STEP 5. Attach the loose end of the leg brace to the
corresponding leg. Turn the leg frame assembly upside
down in preparation for axle and wheel attachment.
STEP 7. Turn the leg frame assembly on end
with the wheels on the floor to attach the
smoker chamber. Slide the smoker chamber up
against the frame aligning the four holes in the
legs with the four holes in the bottom of the
body. The smoker chamber should be standing
up on the solid end cap.
STEP 6. Using a hammer, knock one plastic axle cap
onto one end of the axle. Slide one wheel onto axle.
Slide the axle through the holes in both of the short legs.
Slide on the other wheel and tap on a plastic wheel cap
to secure the axle.
STEP 8. Bolt chamber to leg assembly
using 4 1/4-20 x 2” Combo Truss Head
Screws and 4 flange nuts.
TIGHTEN ALL BOLTS AT THIS TIME.
STEP 9. Align the heat passage bolt pattern on the firebox with the heat passage bolt pattern on the smoker
chamber. The firebox should sit slightly offset from the smoker chamber. Bolt together using 6 1/4-20 x 3/4” hex
head bolts, 12 1/4” flat washers, and 6 1/4-20 flange nuts.
Washer
Body
Flange Nut
WITH THE AID OF YOUR HELPER, STAND THE UNIT ON IT’S LEGS AT THIS TIME.
STEP 10. Install butterfly damper on the backside of the barn door with the pin through the opening at the bottom
of the door. Secure by using a 1/4-20” x 3/4” hex bolt, a 1/4” flat washer and a 1/4” reversible lock nut on the inside
of the barn door. Tighten just enough to where the butterfly damper can be easily opened and closed.
Reversible lock nuts are identified
by a small rectangular indentation
on the side of the nut.
STEP 11. Install barn door latch using 1/4-20 x 3/4” hex
bolt, 1/4” flat washer, and a 1/4-20 reversible lock nut.
Tighten so the latch can move freely.
STEP 12. From inside the smoke chamber, slide the
smokestack up through the large hole at the right-rear of
smoke chamber. Align the bolt holes and secure using 2
1/4-20 x 3/4” hex bolts from outside the unit and 2 1/4-20
flange nuts from inside of unit.
STEP 13. Install smoke stack damper by sliding damper
over pin on smoke stack. Secure by tapping a 3/8” PAL
nut on top with a hammer.
STEP 15. Install grill support bolts in all four holes on the
back of the smoker chamber. Use 4 10-24 x 1” Combo
Truss Head screws and 4 10-24 flange nuts.
STEP 14. Attach a wood handle to smoke chamber door
using 2 1/4-20 x 3” bolts, 2 aluminum sleeves, and 2 1/420 flange nuts as shown below. Repeat steps for firebox
door handle.
STEP 16. Front Shelf Installation. Insert ends of wire
shelf into 4 aligning holes as shown. After inserting the
ends of the wire shelf into the holes, tilt the shelf fully
upright and push the ends all the way into holes and then
bring the wire shelf down to the horizontal position. Install
1/4” chrome plugs in second hole from each end of
smoke chamber.
STEP 17. Install 13/16” chrome plug in temperature
gauge hole in smoke chamber lid if you have not
purchased the optional Model 3000 temperature gauge
(12503000).(To order call 1-800-232-3398).
STEP 18. Install the grease can wire clip. From below
the unit push the wire clip up through the large hole and
then pull down so that the tip of the wire clip goes down
through the smaller hole.
A 12 oz. tin can (i.e. soup can or vegetable can) will fit
nicely into clip to collect grease.
STEP 19. Install die cast logo plate by inserting the pins
on logo plate through the two holes in the lower right
corner of smoke chamber door. Secure in place by
slipping the Tennerman clips over the protruding pins
and pushing them until they are snug against the inside
surface of door.
STEP 21. Diamond Fire TM plate (24810036) installation
(FOR UNITS WITHOUT DIAMOND FIRE ACCESSORY
(22504850)).
STEP 20. If you wish to grill in the smoke chamber,
insert BOTH wire fire grates into the smoke chamber
and place them on the bottom of the cooking chamber
to build your fire on. Insert the two porcelain cooking
grills into the smoke chamber and rest them on the
protruding grill support bolts.
Firebox fire grate installation for smoking: Insert a
wire fire grate into the firebox through the barn door
opening and rest it on the bottom of the firebox
chamber. When smoking food, do not put a cooking
Locate the 2 3/32” x 2 11/16” cover plate in the hardware
grate in the firebox.
box. At the bottom right end of the firebox are the holes
for the Diamond Fire Propane igniter accessory (not
included). Align the two holes in the cover plate with the
holes on each side of the large hole in the firebox.
Secure using 2 #8-32 x 1/2” combo pan head screws and
2 #8-32 keps nuts.
Firebox cooking grill If you wish to use the firebox to grill with, you will need to install 4 10-24 x 1” Combo truss
head screws and 4 #10-24 flange nuts into the 4 holes provided in the firebox. Use the smallest of the three
cooking grates in the firebox.
Firebox cooking grill installation Insert porcelain cooking grill into fire box as shown.
HONDO SMOKER HARDWARE (not to scale)
20 10-24 Flange Nut 16 1/4”-20 Flange Nut
2 11/64” Logo Plate Clip 1 13/16” dia. Chrome Button Plug
1 3/8” PAL Nut 10 1/4-20 x 3/4” Hex Head Machine Screw
4 1/4-20 x 3” Combo Truss Head Screw 2 1/4-20 Reversible Lock Nut
Small Indentation
on side of nut
8
10-24 x 1” Combo Truss Head Screw 4 1/4-20 x 2” Combo Truss Head Screw
2 8/32 x 1/2” Combo Pan Head Screw 2 8/32 Keps Nut
8 10-24 x 1 3/4” Combo Truss Head Screw 2 .281 Chrome Button Plug
14 1/4” Flat Washer 4 .400” dia x 1.125” Aluminum Spacer
2 Axle Cap 2 1 3/8” Leg Cap
Parts diagrams ARE NOT actual size.
Use ruler to determine correct size
1/16”
1/8”
1/4”
1/2”
1”
1” 2” 3”
Preparing and using your SMOKER / GRILL
Before cooking with your unit, the following steps should be closely followed to both cure the finish and season the interior
steel. Failure to properly follow these steps may damage the finish and/or impart metallic flavors to your first foods.
1. Brush all interior surfaces including grills and grates with vegetable cooking oil.
2. Build a small fire on the fire grate, being sure not to lay coals against the walls.
3. Close lid. (Position butterfly and smokestack damper approximately at one quarter opening.) This burn should be
sustained for at least two hours, the longer the better. Then, begin increasing temperature by opening the butterfly and
smokestack damper half-way and adding more charcoal. Your smoker is now ready for use.
Rust can appear on the inside of your smoker / grill. Maintaining a light coat of vegetable oil on interior surfaces will aid in
the protection of your unit. Exterior surfaces of unit may need occasional touch up. We recommend the use of a
commercially available black high temperature spray paint. NEVER PAINT THE INTERIOR OF THE UNIT !
GRILLING
Wood is recommended, however charcoal or a combination of both may be used as the fuel source for grilling, with the
fuel source placed and ignited on the fire grate. Do not build too large a fire. We recommend starting a fire with no more
than 4 pounds of charcoal and adding more as needed during cooking. After allowing the fire to burn down, place the
cooking grill in the unit. Failure to read and follow instructions for lighting charcoal may result in serious personal injury
and/or property damage.
GRILL MAINTENANCE
Frequency of cleanup is determined by how much the unit is used. Make sure coals are completely extinguished before
cleaning inside of unit. Inside surfaces may be cleaned with a strong solution of detergent and water applied with a scrub
brush. Thoroughly rinse with water and allow to air dry before using again.
SMOKING AND SLOW COOKING
If using unit as a smoker or slow cooker, build your fire on top of the fire grate in the firebox. Either charcoal or wood may
be used, but wood is the recommended fuel for it’s rate of burn and the flavor it imparts to the food being cooked. Most
seasoned hardwoods are good for smoking such as hickory, mesquite, pecan, oak, and many other fruit woods. The
firebox will accommodate most split fireplace size logs (16”). Bark should be avoided or burned off first as it contains a
high acid content and imparts an acidic flavor.
After allowing the fire to burn down, close the doors and control the temperature and smoke with the dampers located on
the firebox and atop the smokestack. Smoke is contained within these chambers which will reduce burn while imparting
more smoke flavor. Do not operate the unit with temperatures exceeding 450 degrees in the smoke chamber. Place the
food in the smoke chamber and monitor the temperature. Cooking and smoking are taking place using indirect heat.
There is no need to worry about a grease fire flare-up ruining the food. Do not place food within 6” of the opening from the
firebox into the smoke chamber. A general rule of thumb for cooking is about 1 hour per pound for smoking large cuts of
meat. Refer to a cook book for specific cuts of meats. A maintained temperature of between 225 degrees and 275
degrees will provide the best results for most cuts of meat. Limit the number of times you open the smoke chamber door
as this will allow heat to escape and extend the cooking time.
LIMITED WARRANTY
New Braunfels Smoker Company warrants the Smoker/Grill for replacement or repair of parts and or workmanship for a period of 3 months. New
Braunfels Smoker Company warrants to the original Smoker/Grill owner repair or replacement of the cooking chamber only,should “burn-out” or
“rust-through” occur for a period of 1 year. Paint is not warranted and will require touch-up.
These limited warranties are made exclusively to the original customer presenting proof of purchase. These warranties are limited to noncommercial usage. Any returned goods must be clearly marked with a New Braunfels Smoker Company Return Authorization Number and
shipped prepaid. These limited warranties do not cover normal wear and tear, damages resulting from abuse or mis-use. This warranty excludes
incidental or consequential cost due to damage or losses to persons or property of any nature.
NOTICE: Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied
warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have
other legal rights which may vary from state to state.
TOLL FREE 1.800.232.3398
Visit our web site at www.nbsmoker.com
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