Handles for Smoker

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Project by Karson posted 1358 days ago 2202 views 1 time favorited 18 comments Add to Favorites Watch

I was using my smoker last weekend and the handles started to fall off.

They were only about 10 years old, so I’m not sure why they started to fail. I broke the pieces off and kept a couple for measurements to make new ones.

I took a piece of 5/4 square Sapele that was cracked on one end but had about a 12” section that had no splits.

I turned it round on the lathe and kept it to as full a size i could get and keep it round. I split it on the bandsaw. Marked the holes and drilled through and used a forstner bit to cut for the head and the nut.

The bolt and nut were replaced with Stainless Steel. I mean when you’ve got all those bolts you need to use some of them up.

The replacement went fine and now I can keep my hand cool again. I used the finger nail clips to keep the nut from turning when tightening the bolt.

I smoked a turkey for the day after Thanksgiving. Walmart had fresh turkeys quite cheap after the holiday. I also smoked rib tips It was a great feast.

I smoked some additional rib tips the next day because i bought too many packages the first time. So we had smoked ribs and smoked turkey for a couple of days after the holiday.

I used Oak from a tree that died on my property a couple of years ago. That and some cherry wood pieces were the fuel for the fire.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

18 comments so far

View sedcokid's profile


2667 posts in 2222 days

#1 posted 1358 days ago

It is always good to keep things repaired, good job! What did you do buy out a hardware store with all those nuts and bolts you are a regular Sears and Roebucks aren’t you… ;)

Thanks for sharing

-- Chuck Emery, Michigan,

View Napaman's profile


5332 posts in 2701 days

#2 posted 1358 days ago

I was really trying to figure out what you meant when I read the project title in my e-mail…

Ahhhh…what a relief when I saw the picts…cool little project—-here is the important question——how many people would have just thrown the whole thing out with broken handles? That is why I love this place…

-- Matt--Proud LJ since 2007

View dbhost's profile


5378 posts in 1856 days

#3 posted 1358 days ago

My New Braunfels Smoker Bandera Smoker is ready for new tray slats. The handles are spun stainless wire so no problem there. Not sure if I ever posted it here, but a while back I did something similar for the plastic caster pockets that failed. I knocked them out of the legs, taper cut some replacements from glued up red oak, drilled the holes for the caster shaft, and drove them in place with a mallet… It works fantastically!

-- My workshop blog can be found at

View jack1's profile


1912 posts in 2651 days

#4 posted 1358 days ago

Now all you need is some of that high temp paint… Just like new.

-- jack -- ...measure once, curse twice!

View Karson's profile


34869 posts in 3024 days

#5 posted 1358 days ago

Jack1 That was in my mind. I’ve used it before on a BBQ and I think I’ll give it a try here. I need a new brace on one set of legs. it has a slight twist to the rear and I’d hate to have a load of food end up on the ground.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View Karson's profile


34869 posts in 3024 days

#6 posted 1358 days ago

Chuck: I got some of those boxes from my son as a birthday gift. I then went and bought 6 more of them. 3 for $100.00 with what ever they had inside. It was a lumberstore like HD and Lowes but was being pushed by the new guys coming into town.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware †

View PurpLev's profile


8476 posts in 2272 days

#7 posted 1358 days ago

looks and sounds delicious!

curious – any idea what the original handles were made of?

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View jockmike2's profile


10635 posts in 2870 days

#8 posted 1358 days ago

Smoked turkey and ribs sound awesome!! Nice replacements, and yes you do have quite the collection of nuts and bolts. Me too. Some I left in the boat and they got rusty. Wish I had a shot blast!! Nice to see a post. GB, mike

-- (You just have to please the man in the Mirror) Mike from Michigan -

View Lee A. Jesberger's profile

Lee A. Jesberger

6646 posts in 2603 days

#9 posted 1358 days ago

Gee Karson, you think you have enough nuts and bolts?

I’ve seen hardware stores with less!

Nice repair job, buddy.


-- by Lee A. Jesberger

View lew's profile


9989 posts in 2379 days

#10 posted 1358 days ago

Wow, what a hardware collection!!


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Bob #2's profile

Bob #2

3808 posts in 2645 days

#11 posted 1358 days ago

That’s thinking on your feet there Karson.
Goo job!

-- A mind, like a home, is furnished by its owner

View cajunpen's profile


14375 posts in 2690 days

#12 posted 1358 days ago

Karson, I wish I lived near you – you sound like someone that I could be great friends with. I got into smoking this year and have really enjoyed it. I quit smoking cigarettes and started smoking meat – the meat is a lot better for me.

-- Bill - "Suit yourself and let the rest be pleased."

View Chip's profile


1904 posts in 2716 days

#13 posted 1358 days ago

Nice fix Karson.

The hell with Woodcraft, I’m thinking a visit to your shop is in order… with the Cherokee. Just leave me alone in your shop for an hour or so and I’m bringing a list, checking it twice… hardware: check, Holly: check… and please don’t walk me to my car when I leave… you might notice the tires looking flatter. ;-)

-- Better to say nothing and be thought the fool... then to speak and erase all doubt!

View Knothead62's profile


2364 posts in 1585 days

#14 posted 1357 days ago

What?? Why did you burn oak and cherry? Do you know what you could have made from it? Shame! ;)

View Bob Kollman's profile

Bob Kollman

1796 posts in 1815 days

#15 posted 1357 days ago

Good save Karson, thats quite a good assortment of screws,

wish I had your collection of hardware!!!!

-- Bob Kenosha Wi.

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